Fuel_oil_Released_7J1-96-3.pdf

T.O. 7J1-96-3

TECHNICAL MANUAL

OVERHAUL WITH

ILLUSTRATED PARTS BREAKDOWN

FUEL, LUBE, HYDRAULIC OIL COOLER

PART NO. CONTROL DWG NO.

70018-000 1583M13P02

(Hughes Treitler Manufacturing Corporation) (GE Aircraft Engines)

(ATOS)

Contract No.

F33657-88-C-2189

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and U.S. DoD contractors only, Critical Technology, 15 January 2014. Refer other requests for this document to AFLCMC/LPSBBA, Tinker AFB, Oklahoma 73145-3031.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violation of these export-control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of the contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

15 MAY 2005 CHANGE 3 - 15 JANUARY 2014

BASIC AND ALL CHANGES HAVE BEEN

MERGED TO MAKE THIS A COMPLETE

PUBLICATION

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . . 15 May 2005 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 1 April 2011

Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 15 June 2011 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . 15 January 2014

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 58, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - ii iii iv Blank v vi Blank 1-1 - 1-3 1-4 Blank 2-1 2-2 3-1 3-2 Blank 4-1 4-2 Blank 5-1 5-2 - 5-5 5-6 Blank 6-1 6-2 Blank 7-1 7-2 - 7-14 7-15 7-16 7-17 7-18 - 7-20 7-21 7-22 Blank 8-1 8-2 Blank 9-1 - 9-4 9-5 9-6 A-1 Added A-2 Blank

*Zero in this column indicates an original page

A Change 3 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

INTRODUCTION.......................................................iii 7.3 Troubleshooting ........................................7-17

7.4 Preservation...............................................7-21

SAFETY SUMMARY.................................................v 8 TABLE OF LIMITS.................................................8-1

8.1 General........................................................8-1 1 GENERAL INFORMATION...................................1-1 8.2 Torque Values.............................................8-1

1.1 General........................................................1-1 9 ILLUSTRATED PARTS BREAKDOWN...............9-1

1.2 Purpose........................................................1-1

1.3 Description..................................................1-1

SECTION I FOREWORD .....................................9-11.4 Leading Particulars .....................................1-1

2 SPECIAL TOOLS, TEST EQUIPMENT, 9.1 General........................................................9-1 AND CONSUMABLE MATERIALS ................2-1 9.2 Models Covered..........................................9-1

9.3 Finding Part Numbers, Illustra-

2.1 General........................................................2-1 tion, Description ....................................9-1

2.2 Special Tools and Test Equip- 9.3.1 Maintenance Parts List ...............................9-1 ment........................................................2-1 9.3.2 Figure and Index Number Col-

2.3 Consumable Materials ................................2-1 umn.........................................................9-1

9.3.3 Part Number Column .................................9-1 3 DISASSEMBLY .......................................................3-1 9.3.4 CAGE Column ...........................................9-2

9.3.5 Description Column....................................9-2

3.1 GENERAL..................................................3-1 9.3.6 Units Per Assembly Column......................9-2

3.2 UNPACKING.............................................3-1 9.3.7 Usable on Code Column ............................9-2

3.3 EXTERIOR CLEANING...........................3-1 9.3.8 Source, Maintenance, and Recov-

3.4 DISASSEMBLY.........................................3-1 erability (SMR) Code Column .............9-3

9.4 Similar Assemblies .....................................9-3 4 CLEANING ..............................................................4-1 9.5 Quick Change Units/Repair Parts

Kits .........................................................9-3

4.1 General........................................................4-1 9.6 Sheet Number Explanation.........................9-3

4.2 Cleaning ......................................................4-1 9.7 Usable on Codes.........................................9-3

9.8 Source, Maintenance, and Recov-5 INSPECTION, REPAIR, AND RE-erability (SMR) Codes...........................9-3PLACEMENT ......................................................5-1

9.9 Electrostatic Discharge Sensitive

(ESDS) Parts ..........................................9-35.1 General........................................................5-1

9.10 Parts Standardization ..................................9-35.2 Inspection....................................................5-1

9.11 Commercial and Government En-5.3 Repair..........................................................5-1 tity (CAGE) ...........................................9-35.4 Replacement................................................5-4

SECTION II MAINTENANCE PARTS6 ASSEMBLY..............................................................6-1

LIST......................................................................9-4

6.1 General........................................................6-1

6.2 Lubrication..................................................6-1 A ITEM UNIQUE IDENTIFICATION

6.3 Assembly.....................................................6-1 (IUID) SUPPORTING INFORMA-

TION....................................................................A-17 TESTING ..................................................................7-1

A.1 IUID Supplemental Information ...............A-17.1 General........................................................7-1

7.2 Testing.........................................................7-1

Change 2 i

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Tricooler - Overall View ................................ 1-2 7-8 Lube Oil, Hydraulic Oil, and Fuel Cir- 1-2 Tricooler - Schematic ..................................... 1-3 cuit Pressure-Drop Tests - Typical 2-1 Special Tools - Overall View......................... 2-2 Test Connections........................................ 7-8 5-1 Tricooler - Dimensional Inspection................ 5-3 7-9 Hydraulic Oil Circuit Pressure-Drop 5-2 Tricooler - Blend Area ................................... 5-5 Test - Test Connections ........................... 7-10 5-3 Tricooler - Blend Limits................................. 5-5 7-10 Lube Oil Circuit Proof-Pressure Test - 7-1 Lube Bypass Valve Leakage, Cracking, Test Connections...................................... 7-11 and Reseating Test - Test Connec- 7-11 Hydraulic Oil Circuit Proof-Pressure tions ............................................................ 7-2 Test - Test Connections ........................... 7-14

7-2 Lube Bypass Valve Full-Flow Test - 7-12 Fuel Circuit Pressure-Drop Test - Test Test Connections........................................ 7-3 Connections .............................................. 7-16

7-3 Lube Bypass Valve Test - Typical Test 7-13 Fuel Circuit Proof-Pressure Test - Lube Connections ................................................ 7-3 Oil Circuit Air Purge Test Connec-

7-4 Hydraulic Bypass Valve Leakage, tions .......................................................... 7-18 Cracking, and Reseating Test - Test 7-14 Fuel Circuit Proof-Pressure Test - Hy- Connections ................................................ 7-4 draulic Oil Circuit Air Purge Test

7-5 Hydraulic Bypass Valve Full-Flow Test Connections .............................................. 7-19

- Test Connections ..................................... 7-5 7-15 Fuel Circuit Proof-Pressure Test - Test

7-6 Hydraulic Bypass Valve Test - Typical Connections .............................................. 7-20 Test Connections........................................ 7-6 7-16 Fuel Circuit Proof-Pressure Test - Typi-

7-7 Lube Oil Circuit Pressure-Drop Test - cal Test Connections................................ 7-21 Test Connections........................................ 7-7 9-1 Tricooler - Exploded View............................. 9-5

9-2 Shipping Parts - View .................................... 9-6 A-1 IUID Identification Plate Location................ A-1

LIST OF TABLES

Number Title Page Number Title Page

1-1 Leading Particulars ......................................... 1-1 5-2 Nondestructive Inspection - Fluores- 2-1 Special Tools and Test Equipment ................ 2-1 cent - Penetrant .......................................... 5-3 2-2 Consumable Materials .................................... 2-2 A-1 Item Unique Identification (IUID) Re- 5-1 Inspection ........................................................ 5-1 quired Information .................................... A-1 5-1 Inspection ........................................................ 5-2 ii Change 2

INTRODUCTION

PPM Pounds per minute1. PURPOSE.

PSID Pounds per square inch differential SMR Source, Maintenance, and Recovera-This technical manual provides information required for bilityoverhaul and testing of the fuel, lube, hydraulic oil cooler Symbol Title(hereafter called the tricooler) The cooler is manufactured

- Alternateby Hughes Treitler Manufacturing Corporation, 300 Endo

Boulevard, Garden City, NY 11530-6708 (CAGE 12536) & And for use on GE aircraft engines. °F Degrees Fahrenheit

2. SCOPE. 5. LIST OF REFERENCED PUBLICATIONS.

Chapter 1 through Chapter 8 of this manual provide over- Referenced publications are as follows:

haul and test procedures, and Chapter 9 contains the IPB. A table of contents provides chapter, paragraph title, and page number to help find information. A list of illustrations and List of Related Publications a list of tables provide the number, title, and page number of illustrations and tables. Publication Number Publication Title

MCRL-1 USAF Master Cross Refer-3. CHANGES TO TECHNICAL ORDER (TO).

ence List

Recommendations for changes to this TO shall be submit- 00-5-1 AF Technical Order System ted by an AFTO FORM 22 in accordance with the technical

00-25-195 AF Technical Order Systemorder improvement reporting system outlined in TO 00-5-1.

Source, Maintenance, and Re-The AFTO Form 22, block 2, shall be addressed to: OC-coverability Coding of AirALC/LPARP Tinker AFB OK 73145-3031.

Force Weapons, Systems, and

4. ABBREVIATIONS AND SYMBOLS. Equipments

1-1-691 Aircraft Weapons SystemAbbreviations and symbols used in this manual are in Cleaning and Corrosion Con-accordance with MIL-STD-12, Abbreviations for Use on trolDrawings, and in Specifications, Standards, and Technical

Documents, except as follows: 33B-1-1 Nondestructive Inspection MethodsAbbreviation Definition

33D4-6-668-1 Lube Accessory Test StandAP Attaching part Hg Mercury 33D4-6-670-1 Fuel Accessory Test Stand ml Milliliter 1TL32-6670-1 Fuel Accessory Test Stand OOL Out-of-limits

Change 1 iii/(iv blank)

SAFETY SUMMARY

1. DEFINITIONS. • KEEP AWAY FROM LIVE CIRCUITS: Operating personnel shall think safety at all times. Do not replace

The following definitions apply to WARNINGS, CAU- components or make adjustments inside equipment with the TIONS, and NOTES found throughout this publication. electrical supply turned ON. Under certain conditions, danger may exist even when power control is in the OFF position due to charges retained by capacitors. To avoid

WARNING injuries, always remove power, discharge, and ground a circuit before touching. Adhere to all lock out/tag out requirements.An operational or maintenance procedure, prac-tice, condition, statement, etc. which if not • RESUSCITATION: Personnel working with or near strictly observed, could result in injury to or dangerous voltage shall be trained in modern methods of death of personnel. resuscitation. Information and training sources may be obtained from Director of Base Medical Services.

CAUTION • LUBRICATING OIL/FUEL: Lubricating oil/fuel in liquid, vapor, or mist form is flammable, irritating to the skin and respiratory tract, and poisonous in the digestiveAn operational or maintenance procedure, prac-tract. Remove saturated clothing, wash skin well, do nottice, condition. statement, etc. which if not swallow liquid, and do not breathe mist and vapors.strictly observed, could result in damage to or destruction of equipment or loss of mission • PERSONAL PROTECTIVE EQUIPMENT: Weareffectiveness.

protective clothing/equipment (gloves, apron, eye protec-tion, etc. approved for materials, procedures, and tools

NOTE being used. Contact supervisor for guidance. If necessary, the Bioenvironmental Engineer or Base Safety Office shall

An essential operational or maintenance proce- be contacted for guidance.

dure, condition, or statement which shall be highlighted. • COMPRESSED AIR: Air pressure used in work area for cleaning or drying operations shall be regulated to 30

2. GENERAL PRECAUTIONS. PSI or less. Use approved safety equipment (goggles/face shield) to prevent injury to eyes. Do not direct jet of The following are general safety precautions that are not compressed air at self or other personnel; or so that refuse related to any specific procedure and therefore do not is blown onto adjacent work station. If additional air appear elsewhere in this publication. These are precautions pressure is required to dislodge foreign materials from that personnel shall understand and apply during the vari- parts, ensure that approved safety equipment is worn.

ous phases of equipment operation and maintenance. Ensure air pressure is not detrimental or damaging to the parts before applying high-pressured jets of air.• DO NOT SERVICE OR ADJUST ALONE: Do not attempt internal service or adjustment of equipment unless • DANGEROUS PRESSURES: Pressure system pre-another person capable of rendering aid and resuscitation is cautions apply to all ranges of pressure. Care shall be taken present. during testing to ensure that all test connections are proper and tight before applying pressure to the test setup; all• DO NOT WEAR JEWELRY: Remove rings, system components shall be compatible with pressureswatches, and other metallic objects which may cause shock applied. Personnel shall be protected by a safety shield oror burn hazards.

located at a distance sufficient to prevent injury.

• FINGER RINGS: Snagged finger rings have caused many serious injuries. Unless specifically allowed by shop safety procedures, remove finger rings during all mainte-nance activity.

v/(vi blank)

CHAPTER 1

GENERAL INFORMATION

1.1 GENERAL. 1.4 LEADING PARTICULARS.

This chapter provides purpose, description, and leading Leading particulars for the tricooler are listed in Table 1-1.

particulars for the tricooler (Figure 1-1).

1.2 PURPOSE. Table 1-1. Leading Particulars

The purpose of the tricooler is to cool engine lube oil and Characteristics Specificationsengine hydraulic oil by heat transfer to engine fuel.

Dimensions:

1.3 DESCRIPTION. Overall length 12.77 inches

Width 5.90 inchesThe tricooler (Figure 1-1) is a parallel fin type heat exchanger. The engine lube oil enters the tricooler through Height 4.35 inches a removable lube bypass valve. The lube bypass valve will Capacities:

bypass lube oil from the lube oil inlet to the lube oil outlet

Lube oil circuit 800 ccin the event of lube oil temperature reduction or heat Hydraulic oil circuit 150 ccexchanger blockage. The engine hydraulic oil enters the tricooler through a removable hydraulic bypass valve. The Fuel circuit 400 cc hydraulic bypass valve will bypass hydraulic oil from the Weight (dry) 9.60 LB maximum hydraulic oil inlet to the hydraulic oil outlet in the event of

Fuel specification JP-4, JP-5, and JP-8hydraulic oil temperature reduction or heat exchanger Oil specification MIL-L-7808blockage. A schematic of the tricooler is provided in

Figure 1-2. Number of fuel passes One

Type of flow Counterflow

1-1

Figure 1-1. Tricooler - Overall View

1-2

Figure 1-2. Tricooler - Schematic

1-3/(1-4 blank)

CHAPTER 2

SPECIAL TOOLS, TEST EQUIPMENT, AND CONSUMABLE MATERIALS

2.1 GENERAL. 2.2 SPECIAL TOOLS AND TEST EQUIPMENT.

This chapter provides special tools, test equipment, and Special tools and test equipment required are listed in consumable materials required for tricooler maintenance. Table 2-1 and illustrated in Figure 2-1.

Equivalent items may be used if the recommended tool, test

2.3 CONSUMABLE MATERIALS.equipment, or consumable material is not available.

Consumable materials are listed in Table 2-2.

Table 2-1. Special Tools and Test Equipment

Figure 2-1 Tool/Equipment Index Number Nomenclature Use and Application

11578-006 Overhaul tool set, consisting of the (5C6254G01) following:

T60018-007 1 Hydraulic bypass valve test block Testing hydraulic bypass valve *M83248/1-905 Preformed packing *M83248/1-010 Preformed packing

T60018-008 2 Lube bypass valve test block Testing lube bypass valve *M83248/1-916 Preformed packing *M83248/1-021 Preformed packing

3C3966G05 Lube accessory test stand Testing

3C3970G05 Fuel accessory test stand Testing

3C3970G05-OC001 Fuel accessory test stand Testing

268667 Flushing stand Cleaning tricooler interior

* Not part of tool, but required for tool use.

Change 1 2-1

Figure 2-1. Special Tools - Overall View

Table 2-2. Consumable Materials

Nomenclature Specification or Part Number CAGE General use Brush, nylon H-B-643 Cleaning

Cloth, cleaning CCC-C-46 Cleaning, repair

Fluid, calibrating MIL-C-7024, Type II Testing

Gloves, cotton MIL-G-3866 Repair

Material, chemical conversion MIL-C-81706 Repair

Oil, lubricating MIL-L-7808 Assembly, testing, and preservation

Pad, scouring L-P-0050 Cleaning, repair

Paper, abrasive A-A-1049, 800-grit Repair

Petrolatum W-P-236 Assembly

Primer, epoxy waterborne MIL-P-85582, Type I, Class II Replacement

Solvent, dry-cleaning P-D-680, Type III Cleaning, repair

Stone, sharpening, extra fine grit SS-S-736 Repair

Wire, safety MS209950-C32 Assembly

2-2

CHAPTER 7

TESTING

7.1 GENERAL.

This chapter provides procedures for testing, troubleshoot-ing, and preserving the tricooler. The tests in this chapter are performed after assembly to ensure that the tricooler will operate satisfactorily. If the tricooler fails to meet requirements of applicable tests in this chapter, refer to troubleshooting table, then to Chapter 3 and Chapter 5 for applicable disassembly and repair procedures, After assem-bly, repeat checkout test procedures in this chapter. All steps apply unless specified by part number.

7.2 TESTING.

The following paragraphs provide procedures for perform-ing operational acceptance tests of the tricooler. Refer to Table 2-1 for a list of special tools and test equipment.

a. Test Conditions and Test Setup. Proceed as follows:

WARNING

• Calibration fluid, MIL-C-7024, is flamma-ble and toxic to skin, eyes, and respiratory tract. Skin and eye protection is required.

Use in a well-ventilated area.

• Lubricating oil, MIL-L-7808, is toxic to skin, eyes, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Use in a well-ventilated area.

(1) Perform all tests using calibrating fluid, MIL-C- 7024, or lubricating oil, MIL-L-7808, filtered to at least a 10 micron level.

(2) Maintain ambient air temperature at 55 to 90°F.

(3) Maintain test fluid temperature at 70 to 100°F.

(4) Maintain barometric pressure at 25.5-30.5 inches of mercury (Hg).

(5) Continually monitor external surfaces for leaks during tests.

(6) The 3C3970G05 fuel accessory test stand, or equivalent, can be used to test the fuel Chapter 7 of the tricooler. However, other typical test setups can also be used. Refer to T.O. 33D4-6- 670-1 or 1TL32-6670-1 for identification of fittings, hoses, and test connection ports.

(7) If using 3C3970G05 fuel accessory test stand, 713ZA Pegasus controller shall be set to mode

2. If using 3C3970G05-OC001 fuel accessory test stand, choose appropriate menu on the HMI touch screen.

(8) The 3C3966G05 lube accessory test stand, or equivalent, can be used to test the lube oil and hydraulic oil chapters of the tricooler. However, other typical test setups can also be used. Refer to T.O. 33D4-6-668-1 for identification of fit-tings, hoses, and test connection ports.

(9) If tricooler fails tests, replace tricooler.

b. Lube Bypass Valve Test. Proceed as follows:

(1) Install preformed packings (7 and 8, Figure 9-1) on lube bypass valve (6). Install valve in T60018-008 lube bypass valve test block.

Torque the valve to 150-175 in-lb.

(2) Connect T60018-008 lube bypass valve test block to 3C3966G05 lube accessory test stand (Figure 7-1). Figure 7-3 shows a typical test setup and is for reference only.

(3) Select A6*, VALVE HYD OIL COOLER BYPASS, on Micro-Flo 100.

(a) Leakage Test. Proceed as follows:

1 Press 733AA boost pump ON pushbutton.

2 Turn 242GE and 242GK valves CCW to set 38-42 pounds per square inch differen-tial (psid) as read on Micro-Flo 100.

3 Measure leakage at outlet port of T60018- 008 lube bypass valve test block, using graduated cylinder, Leakage shall not exceed 150 cc/minute. If leakage is out-of-limits (OOL) shut down test stand, dis-card lube bypass valve (6, Figure 9-1) and test new valve in test block.

4 Proceed to cracking pressure test.

Change 3 7-1

Figure 7-1. Lube Bypass Valve Leakage, Cracking, and Reseating Test - Test Connections

(b) Cracking Pressure Test. Proceed as follows:

NOTE

NOTE

Sudden flow decrease at the T60018-008 lube

Sudden flow increase at the T60018-008 lube bypass valve test block outlet port indicates bypass valve test block outlet port indicates the reseating of the lube bypass valve poppet.

lube bypass valve has reached cracking

2 Slowly turn 242GK valve CW until lubepressure.

bypass valve poppet reseats. Reseating

1 Turn 242GK valve slowly CCW until occurs when the flow from the T60018-cracking pressure is obtained. Cracking 008 lube bypass valve test block outlet pressure occurs when the flow from the port decreases suddenly.

T60018-008 lube bypass valve test block

3 Record reseating pressure. Leakage shalloutlet port increases suddenly.

not exceed 150 cc/minute at 36-40 psid.

2 Record cracking pressure. Cracking pres- 4 Turn 242GK valve CW, then proceed tosure shall not exceed 47 psid, as read on full-flow test.Micro-Flo 100.

(d) Full-Flow Test. Proceed as follows:3 Proceed to reseat leakage test.

1 Connect T60018-008 lube bypass valve(c) Reseat Leakage Test. Proceed as follows:

test block outlet port to test stand

1 Turn 242GK valve CCW to obtain full (Figure 7-2).

flow.

2 Turn 242GE valve fully CW.

3 Turn 242GK and 290CB valves CCW, until 56-60 psid is obtained, as read on Micro-Flo 100.

7-2

Figure 7-2. Lube Bypass Valve Full-Flow Test - Test Connections

Figure 7-3. Lube Bypass Valve Test - Typical Test Connections

7-3

4 Record outlet flow. Outlet flow shall be (1) Install preformed packings (2 and 3) on hydrau-

9.85 gpm minimum, as read on Micro-Flo lic bypass valve (4) Install valve in T60018-007

100. hydraulic bypass valve test block. Torque the valve to 150-175 in-lb.

5 Turn 242GK valve fully CW. Ensure

242GE valve is fully CW. (2) Connect T60018-007 hydraulic bypass valve test block to 3C3966G05 lube accessory test

6 Turn 242GE valve CCW to bleed pressure stand (Figure 7-4). Figure 7-6 shows a typical to 0 psid, as read on Micro-Flo 100, then test setup and is for reference only.

turn valve fully CW.

(3) Select A6*, VALVE HYD OIL COOLER 7 Press 733AA boost pump OFF BYPASS, on Micro-Flo 100.

pushbutton.

(a) Leakage Test. Proceed as follows:

8 Disconnect T60018-008 lube bypass valve test block from test stand, 1 Press 733AA boost pump ON pushbutton.

9 Remove lube bypass valve (6, Figure 9-1) 2 Turn 242GE and 242GK valves CCW to from T60018-008 lube bypass valve test set 24-26 psid, as read on Micro-Flo 100.

block.

3 Measure leakage at outlet port of T60018- 10 Remove and discard preformed packings 007 hydraulic bypass valve test block, (7 and 8) from lube bypass valve (6). using graduated cylinder. Leakage shall not exceed 50 cc/minute. If leakage is

11 Install new preformed packings (7 and 8) OOL, shut down test stand, discard on lube bypass valve (6) then install valve hydraulic bypass valve (4, Figure 9-1) and in tricooler. Torque the valve to 150-175 test new valve in test block.

in-lb.

4 Proceed to cracking pressure test.

c. Hydraulic Bypass Valve Test. Proceed as follows:

Figure 7-4. Hydraulic Bypass Valve Leakage, Cracking, and Reseating Test - Test Connections

7-4

Figure 7-5. Hydraulic Bypass Valve Full-Flow Test - Test Connections

(b) Cracking Pressure Test. Proceed as follows:

NOTE

NOTE

Sudden flow decrease at the T60018-007

Sudden flow increase at T60018-007 hydraulic hydraulic bypass valve test block outlet port bypass valve test block outlet port indicates the indicates reseating of the hydraulic bypass hydraulic bypass valve has reached cracking valve poppet.

pressure.

2 Slowly turn 242GK valve CW until 1 Turn 242GK valve slowly CCW until hydraulic bypass valve poppet reseats.

cracking pressure is obtained. Cracking Reseating occurs when the flow from the pressure occurs when the flow from the T60018-007 hydraulic bypass valve test T60018-007 hydraulic bypass valve test block outlet port decreases suddenly.

block outlet port increases suddenly.

3 Record reseating pressure, Leakage shall 2 Record cracking pressure. Cracking pres- not exceed 50 cc/minute at 25-30 psid.

sure shall not exceed 200 psid, as read on 4 Turn 242GK valve CW, then proceed toMicro-Flo 100.

full-flow test.

3 Proceed to reseat leakage test.

(d) Full-Flow Test. Proceed as follows:

(c) Reseat Leakage Test. Proceed as follows:

1 Connect T60018-007 hydraulic bypass 1 Turn 242GK valve CCW to obtain full valve test block outlet port to test stand flow. (Figure 7-5).

2 Turn 242GE valve fully CW.

3 Press 733AB hydraulic supply pump #2 ON pushbutton.

7-5

Figure 7-6. Hydraulic Bypass Valve Test - Typical Test Connections

4 Turn 242GK and 290CB valves CCW, 12 Install new preformed packings (2 and 3) until 190-200 psid is obtained, as read on on hydraulic bypass valve (4) then install Micro-Flo 100. valve in tricooler. Torque the valve to 60-

90 in-lb.

5 Record outlet flow. Outlet flow shall be

3.5 gpm minimum, as read on Micro-Flo d. Lube Oil Circuit Pressure-Drop Test. Proceed as

100. follows:

6 Turn 242GK and 290CB valves fully CW. (1) Select BO*, FUEL/LUBE/HYD COOLER, as Ensure 242GE valve is fully CW. read on Micro-Flo 100.

7 Press 733AA boost pump and 733AB (2) Connect tricooler to 3C3966G05 lube accessory hydraulic supply pump #2 OFF test stand (Figure 7-7). Figure 7-8 shows a pushbutton. typical test setup and is for reference only.

8 Turn 242GE valve CCW to bleed pressure (3) Press 733AA boost pump ON pushbutton.

to 0 psid, as read on Micro-Flo 100, then

(4) Ensure 242GE valve is fully CW.turn valve fully CW.

(5) Turn 242GK valve fully CCW.9 Disconnect T60018-007 hydraulic bypass valve test block from test stand.

(6) Slowly turn 290CB valve CCW until 9.9-10.1 gpm is obtained, as read on Micro-Flo 100.10 Remove hydraulic bypass valve (4, Figure 9-1) from T60018-007 hydraulic

(7) Open 210CR and 210CQ bleed valves. Shakebypass valve test block.

tricooler until air is purged from lube oil circuit, as observed in bleed valve indicators. Close11 Remove and discard preformed packings bleed valves.(2 and 3) from hydraulic bypass valve (4).

(8) Ensure 9.9-10.1 gpm is indicated on Micro-Flo 100.

7-6

Figure 7-7. Lube Oil Circuit Pressure-Drop Test - Test Connections

7-7

Figure 7-8. Lube Oil, Hydraulic Oil, and Fuel Circuit Pressure-Drop Tests - Typical Test Connections

7-8

(9) Record lube oil circuit pressure drop. Pressure (10) Disconnect tricooler from test stand.

drop shall be 26 psid maximum.

(11) Install gaskets (3, Figure 9-2) and sealing caps

(10) Turn 290CB valve fully CW. Turn 242GK fully (2). Secure caps, using screws (1). Torque the

CW. screws to 24-27 in-lb.

(11) Press 733AA boost pump OFF pushbutton. f. Lube Oil Circuit Proof-Pressure Test. Proceed as follows:

(12) Disconnect tricooler from test stand.

(1) Select BO*. FUEL/LUB/HYD COOLER, on

(13) Install gaskets (3, Figure 9-2) and sealing caps Micro-Flo 100.

(2). Secure caps, using screws (1). Torque the screws to 24-27 in-lb. (2) Connect tricooler to 3C3966G05 lube accessory test stand (Figure 7-10, sheet 1). Sheet 2 shows

e. Hydraulic Oil Circuit Pressure - Drop Test. Pro- a typical test setup and is for reference only.

ceed as follows:

(3) Turn 2920Q HYDRAULIC IN port valve fully

(1) Connect tricooler to 3C3966G05 lube accessory CW (part of test setup).

test stand (Figure 7-9). Figure 7-8 shows a typical test setup and is for reference only. (4) Turn 2920Q FUEL IN port valve CCW (part of test setup).

(2) Press 733AA boost pump ON pushbutton.

(5) Press 733AA boost pump ON pushbutton.

(3) Ensure 242GE valve is fully CW.

(6) Slowly turn 242GC valve CCW until FUEL

(4) Slowly turn 242GK valve CCW until 3.4-3.6 OUT standpipe manometer is about two-thirds gpm is obtained, as read on Micro-Flo 100. full, then turn 242GC valve fully CW.

(5) Open 210CS and 210CT bleed valves. Shake (7) Tilt and shake tricooler until air is purged from tricooler until air is purged from hydraulic oil fuel circuit, and observed in FUEL OUT stand-circuit, as observed in bleed valve indicators. pipe manometer.

Close bleed valves.

(8) Turn 2920Q FUEL IN port valve fully CW (part

(6) Ensure 3.4-3.6 gpm is indicated on Micro-Flo of test setup).

100.

(9) Tighten FUEL OUT standpipe manometer.

(7) Record hydraulic oil circuit pressure drop. Pres- Mark fluid level in standpipe manometer.

sure drop shall be 48 psid maximum.

(10) Turn 2920Q HYDRAULIC IN port valve CCW

(8) Turn 242GK valve fully CW. (part of test setup).

(9) Press 733AA boost pump OFF pushbutton.

7-9

Figure 7-9. Hydraulic Oil Circuit Pressure-Drop Test - Test Connections

7-10

Figure 7-10. Lube Oil Circuit Proof-Pressure Test - Test Connections (Sheet 1 of 2)

7-11

Figure 7-10. Lube Oil Circuit Proof-Pressure Test - Test Connections (Sheet 2)

(11) Slowly turn 242GC valve CCW until HYDRAULIC OUT standpipe manometer is

WARNINGabout two-thirds full, then turn 242GC valve fully CW.

Air remaining in tricooler may have explosive(12) Tilt and shake tricooler until air is purged from potential. Tricooler shall be purged of airhydraulic circuit, and observed in HYDRAU-before pressurizing. Failure to purge air canLIC OUT standpipe manometer.

result in injury or death.

(13) Turn 2920Q HYDRAULIC IN port valve CW

(18) Turn 250DA and 290EB regulators CW until(part of test setup).

600-625 psig is obtained, as read on Micro-Flo

100. Maintain pressure for 5 minutes. There(14) Tighten HYDRAULIC OUT standpipe manom-shall be no evidence of external or internaleter. Mark fluid level in standpipe manometer.

leakage from tricooler. There shall be no change

(15) Turn 200CC selector valve to OPEN position. in standpipe manometer fluid level displacement or distortion of tricooler during last minute of

(16) Turn 250DA and 290EB regulators CW until 50 test.

psig is obtained, as read on Micro-Flo 100.

(19) Turn 250DA and 290EB regulators fully CCW

(17) Open 210CJ bleed valve until air is purged from to reduce to 0 psig, as read on Micro-Flo 100.

lube oil circuit, as observed in bleed valve indicator. Close bleed valve. (20) Press 733AA boost pump OFF pushbutton.

(21) Disconnect tricooler from test stand.

g. Hydraulic Oil Circuit Proof-Pressure Test. Proceed as follows:

7-12

(1) Select BO*, FUEL/LUB/HYD COOLER, on (12) Tilt and shake tricooler until air is purged from Micro-Flo 100. lube circuit, and observed in LUBE OUT stand-pipe manometer.

(2) Connect tricooler to 3C3966G05 lube accessory test stand (Figure 7-11, sheet 1). Sheet 2 shows (13) Turn 2920Q LUBE IN port valve CW (part of a typical test setup and is for reference only. test setup).

(3) Turn 2920Q LUBE IN port valve is fully CW (14) Tighten LUBE OUT standpipe manometer.

(part of test setup). Mark fluid level in standpipe manometer.

(4) Turn 2920Q FUEL IN port valve CCW (part of (15) Turn 200CC selector valve to OPEN position.

test setup).

(16) Turn 250DA and 290EB regulators CW until 50

(5) Press 733AA boost pump ON pushbutton. psig is obtained, as read on Micro-Flo 100.

(6) Slowly turn 242GC valve CCW until FUEL (17) Open 210CJ bleed valve until air is purged from OUT standpipe manometer is about two-thirds hydraulic oil circuit, as observed in bleed valve full, then turn 242GC valve fully CW. indicator. Close bleed valve.

(7) Tilt and shake tricooler until air is purged from WARNINGfuel circuit, and observed in FUEL OUT stand-pipe manometer.

Air remaining in tricooler may have explosive(8) Turn 2920Q FUEL IN port valve fully CW (part potential. Tricooler shall be purged of airof test setup).

before pressurizing. Failure to purge air can

(9) Tighten FUEL OUT standpipe manometer. result in injury or death.

Mark fluid level in standpipe manometer.

(18) Turn 250DA and 290EB regulators CW until

(10) Turn 2920Q LUBE IN port valve CCW (part of 375-400 psig is obtained, as read on Micro-Flo test setup). 100. Maintain pressure for 5 minutes. There shall be no evidence of external or internal

(11) Slowly turn 242GC valve CCW until LUBE leakage from tricooler. There shall be no change OUT standpipe manometer is about two-thirds in standpipe manometer fluid level displacement full, then turn 242GC valve fully CW. or distortion of tricooler during last minute of test.

7-13

Figure 7-11. Hydraulic Oil Circuit Proof-Pressure Test - Test Connections (Sheet 1 of 2)

7-14

Figure 7-11. Hydraulic Oil Circuit Proof-Pressure Test - Test Connections (Sheet 2) observed in bleed valve indicators. Close bleed

(19) Turn 250DA and 290EB regulators fully CCW valves.

to reduce to 0 psig, as read on Micro-Flo 100.

(5) Ensure 198.5-201.5 ppm is indicated on Micro-

(20) Press 733AA boost pump OFF pushbutton. Flo 100.

(21) Disconnect tricooler from test stand. (6) Record fuel circuit pressure drop. Pressure drop shall be 95 psid maximum.

h. Fuel Circuit Pressure-Drop Test. Proceed as follows: (7) Turn 242GA valve fully CW and 290CA regula-tor fully CCW.

(1) Connect tricooler to fuel accessory test stand

(Figure 7-12). Figure 7-8 shows a typical test (8) Press 733CB low pressure pump OFF setup and is for reference only. pushbutton.

(2) Press 733CB low pressure pump ON (9) Disconnect tricooler from test stand.

pushbutton.

(10) (10) Install gaskets (3, Figure 9-2) and sealing

(3) Slowly turn 242GA valve CCW and 290CA caps (2.) Secure caps, using screws (1). Torque regulator CW, until 198.5-201.5 pounds per the screws to 24-27 in-lb.

minute (ppm) is obtained.

(4) Open 210CL and 210CM bleed valves. Shake tricooler until air is purged from fuel circuit, as

Change 1 7-15

Figure 7-12. Fuel Circuit Pressure-Drop Test - Test Connections

7-16

h. Fuel Circuit Proof-Pressure Test. Proceed as (13) Cap HYD IN port. Install standpipe manometer follows: on HYD OUT port.

(1) Connect tricooler to fuel accessory test stand (14) Connect tricooler to fuel accessory test stand (Figure 7-13). Figure 7-16 shows a typical test (Figure 7-15). Figure 7-16 shows a typical test setup and is for reference only. setup and is for reference only.

(2) Cap the FUEL IN and FUEL OUT ports. (15) Set 200CA selector valve to OPEN position.

(3) Press 733CB low pressure pump ON (16) Turn 290DA regulator CW to set 2,200 psig, as pushbutton. read on 079KA gage.

(4) Set 195-200 ppm, as read on 539KB, using (17) Turn 250FA regulator CW to set 2070-2095 242GA valve (CCW) and 290CA regulator psig, as read on 539BA. Hold for 5 minutes.

(CW). There shall be no evidence of external or inter-nal leakage from tricooler. There shall be no

(5) Open 210CL and 210CM bleed valves. Shake change in standpipe manometer fluid level dis-tricooler until air is purged from lube circuit, as placement or distortion of tricooler during last observed in bleed valve indicators. Close bleed minute of test.

valves.

(18) Turn 250FA regulator fully CCW.

(6) Turn 242GA valve fully CW and 290CA regula-tor fully CCW. (19) Turn 290DA regulator fully CCW.

(7) Press 733CB low pressure pump OFF (20) Turn 250FA regulator CW to bleed pressure to 0 pushbutton. psig, as read on 079KA gage, then turn regulator fully CCW.

(8) Disconnect test connections from LUBE IN and

LUBE OUT ports. (21) Disconnect tricooler from test stand.

(9) Cap LUBE IN port. Install standpipe manometer 7.3 TROUBLESHOOTING.

on LUBE OUT port.

Table 7-1 lists troubles that may be encountered during

(10) Connect tricooler to fuel accessory test stand testing, along with probable causes and suggested

(Figure 7-14). Figure 7-16 shows a typical test remedies.

setup and is for reference only.

(11) Perform substeps (3) through (7).

(12) Disconnect test connections from HYD IN and HYD OUT ports.

Change 1 7-17

Figure 7-13. Fuel Circuit Proof-Pressure Test - Lube Oil Circuit Air Purge Test Connections

7-18

Figure 7-14. Fuel Circuit Proof-Pressure Test - Hydraulic Oil Circuit Air Purge Test Connections

7-19

Figure 7-15. Fuel Circuit Proof-Pressure Test - Test Connections

7-20

Figure 7-16. Fuel Circuit Proof-Pressure Test - Typical Test Connections

7.4 PRESERVATION.

Preserve tricooler as follows:

a. Remove shipping parts (paragraph 3.2).

WARNING

Lubricating oil, MIL-L-7808, is toxic to skin, eyes, and respiratory tract. Skin and eye protec-tion is required. Avoid repeated or prolonged contact. Use in a well-ventilated area.

b. Flush lube oil, hydraulic oil, and fuel passages, using lubricating oil, MIL-L-7808, until oil is flow-ing from each port. Lubricating oil shall be filtered to at least a 10 micron level.

c. Drain excess lubricating oil, MIL-L-7808, from tricooler.

d. Install gaskets (3, Figure 9-2) and sealing caps (2).

Secure with screws (1). Torque the screws to 24-27 in-lb.

Table 7-1. Troubleshooting

Trouble Probable cause Corrective action Leakage Valves not properly torqued Torque valves

Damaged preformed packings Disassemble tricooler and replace preformed packings

Damaged tricooler housing Replace tricooler housing

Low flow Restriction in fuel or oil passages Clean (paragraph 4.2)

Change 3 7-21/(7-22 blank)

II MAINTENANCE PARTS LIST