C-5AtomizerTestInstruction.pdf.pdf

2G-GTCP165-13-9

WP 004 00

REFERENCE MATERIAL REQUIRED

Publication Number Publication Title 1-1A-9 Aerospace Metals, General Data, and Usage 1-1A-8 Aircraft and Missile Repair Structural Hardware 1-1-2 Corrosion Prevention and Control for Aerospace Equipment 2G-1-2 OO-ALC General Cleaning Instructions 2G-GTCP165-13-1 General Information, Deport Maintenance Manual MIL-P-116 Methods of Preservation-Packaging 33B-1-1 Nondestructive Inspection Methods 34W4-1-5 Welding Theory and Application

APPLICABLE TCTOs

NONE

CONSUMABLE MATERIALS

NOTE

Index numbers are for reference to master consumable list in WP 003 00. All references to consumables in text will be preceded by 46. (Example: Oil (46-33)) For OO-ALC, when cleaning parts, refer to TO 2G-1-2.

Nomenclature Specification/Part No. CAGE Code Abrasive Paper (400- and 600-Grit) P-P-101 (3) Calibration Fluid (18) MIL-C-7024, Type II Cloth, Cleaning (23) MIL-C-85043, Type II Flexwrap (35) AE272-6 Lockwire (42) MS20995C32 Lubricant, Dry Film (44) MIL-PRF-46010 Rod, Weld (67) TI-6AL-4V (AMS4954) Solvent, Dry Cleaning (81) P-D-680, Type III

APPLICABLE SUPPORT EQUIPMENT

Part Number Nomenclature Figure Number IC848 Test Stand, Fuel Accessories (Test Stand) J020 (Catalog) Band-It, Pok-Kit Tool (Band-It) Figure 1, 1 281450-1 Tester Assembly, Fuel Atomizer (Tester Assembly) Figure 1, 3 284761-1-1 Adapter Assembly, Fuel Atomizer Nozzle (Adapter As- Figure 1, 2 sembly) 164101-100 Test Stand Figure 1, 4 201307204 Holding Fixture Figure 1, 5

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OO-MAN-2014-02751

Figure 1,5

TO 2G-GTCP165-13-9

Figure 2. Tangential Fuel Manifold Assembly - Disassembly (Sheet 1 of 2)

Figure 2. Tangential Fuel Manifold Assembly - Disassembly (Sheet 2)

d. Clean remaining parts using cleaning cloth (13-23)5. CLEANING.

dipped in dry cleaning solvent (13-81).

a. Clean nozzles (Figure 2, 4 and Figure 3, 5) using

6. INSPECTION.dry cleaning solvent (13-81) or equivalent and apply filtered, compressed air regulated at 150 to

6.1 General Inspection Requirements.30 psig.

a. Visually inspect parts for cracks, nicks, dents,b. Cleaning also may be done by ultrasonic cleaning.

wear, corrosion, burrs, carbon buildup, buckling,

c. For carbon removal on nozzles refer to TO collapsing, burned areas, and looseness. No dam- 2G-GTCP165-13-5. age, corrosion or carbon buildup allowed.

(1) If cracks are suspected, perform nondestructive WARNING inspection in accordance with TO 33B-1-1.

(2) If corrosion is present, corrosion treat part in

• Use approved personal protective equipment accordance with TO 1-1-691.

(goggles and face shield) when using dry cleaning solvent. b. Visually inspect threaded parts for stripped, galled or crossed threads. No damage allowed.• Use dry cleaning solvent in a well-ventilated area. Avoid excessive skin contact or pro- c. Replace parts that do not meet inspection longed inhalation of vapor. Do not use near requirements.

open flame or in area where high tempera-tures prevail. 6.2 Specific Inspection Requirements. See Table 1.

Figure 3. Axial Fuel Manifold Assemblies - Disassembly (Sheet 1 of 2)

Figure 3. Axial Fuel Manifold Assemblies - Disassembly (Sheet 2)

7.4 Repair Sockets (Figure 2, 8 and 16 and Figure 3,7. REPAIR.

9 and 17). Repair damaged threads on sockets (Figure 2,

7.1 Minor Nicks and Burrs. Lightly rework minor nicks 8 and 16, and Figure 3, 9 and 17) using a 3/8-32 NEF 3B tap.and burrs using abrasive paper (13-3).

7.5 Repair Coupling (Figure 2, 14, and Figure 3,

7.2 Repair Body Assemblies (Figure 2, 3 and 13). 15). Repair damaged threads on coupling (Figure 2, 14 and Figure 3, 15) using a 3/8-24 tap and die.

CAUTION

7.6 Repair Bodies (Figure 3, 3 and 14). Repair dam-

aged threads on bodies (3 and 14) using using a 1/4-32

Make certain all metal particles are removed NEF 2A tap.

from all parts after repairing threads to prevent

7.7 Repair Shroud (Figure 3, 4). Repair damagedcontamination of fuel system.

threads on shroud (4) using a 9/16-24 NEF 2B tap.

Repair damaged threads on body assemblies (3 and 13) using a 1/4-32 NEF 2A tap. 7.8 Repair Nozzle (Figure 3, 5). Repair damaged threads on nozzles (5) using a 1/4-32 NEF 2A die.

7.3 Repair Nozzle (Figure 2, 4). Repair damaged

threads on nozzles (4) using a 1/4-32 NEF 2A die.

8. ASSEMBLY & TEST.

8.1 General Assembly Instructions.

a. Use extreme care to prevent dirt, dust or foreign particles from entering parts or assembled unit.

(1) Should any foreign particle be dropped into unit during assembly, stop assembly.

(2) Find and remove particle before continuing assembly.

(3) For protection, cover openings.

(4) When leaving assemblies during assembly, cover all openings.

b. Ensure all parts are cleaned.

c. Lockwire parts, noted during disassembly, after assembly.

d. Never use extreme force to assemble parts.

e. Replace any damaged part found during assembly.

f. After assembly, package manifold assemblies in accordance with Specification MIL-P-116 to prevent damage.

8.2 Assemble Tangential Fuel Manifold

Assembly, part No. 892405-1.

CAUTION

Extreme care shall be used not to intermix the tangential and axial fuel nozzles (Figure 2 and 5, Figure 3, 5). The nozzles are identified by etching on the wrenching flat. Intermixing the nozzles can cause the turbine engine to malfunction and overheat, damage to the turbine section may result.

Do not install nozzles (Figure 2, 4) or washers (5) into body assemblies (3 and 13) until after pressure test of the manifold portion of the assembly, (step i.)

Before installing tangential fuel manifold assembly, make certain all shrouds (each cups 10) are centered with nozzle tip 4 (see Figure 7).

When building manifold assembly (p/n 892405-1), new hoses (698488-4 & 698488-

5) may come preassemble with sleeves (Figure 1, 9)that are shrunk to fit hose (10).

Inspect sleeve for tears or other possible defects. If sleeves are in good condition, clamps (6) are not required to secure hose.

This does not apply to any repaired hoses or assemblies that use flex wrap and RTV.

Clamps must be used when flex wrap (9) and RTV are used.

a. Install sleeves (9) on hoses (10) and position clamps (6). Do not tighten clamps (6) until after step o.

b. Alternate method of installing sleeves (9).

(1) Install flexwrap (13-35) one and one-half to two turns maximum on hoses (10) and position clamps (6).

(2) Do not tighten clamps (6) until after step o.

c. Install sleeve (17) on hose (18) and position clamp (6). Do not tighten clamp (6) until after step o.

d. Alternate method of installing sleeve (17).

(1) Install flexwrap (13-35) one and one-half to two turns maximum on hose (18) and position clamp (6).

(2) Do not tighten clamp (6) until after step o.

e. Install sleeve (15) and screw coupling (14) into socket (16).

f. Apply dry film lubricant (13-44) on adapters (2 and 12), install sleeves (7) and screw adapters (2 and 12) into sockets (8).

g. Position adapter (12) on body assembly (13) and adapter (2) on body assembly (3).

h. Press pins (1and 11) through holes in adapters (2 and 12) and recessed portion of body assemblies (3 and 13) to secure.

i. Pressure test fuel manifolds.

(1) Install unserviceable nozzles (Figure 2, 4) with tips welded/brazed closed in body assemblies (3 and 13).

(2) Leak check fuel manifolds by capping all openings and placing under water. Apply clean regulated air of 300 (5) psig to fuel manifolds.

Fuel manifolds shall hold pressure for 5 minutes with no leakage. If any leakage is noted, mark area.

(3) Remove unserviceable nozzles (4) installed in step (1).

(4) Repair or replace fuel manifolds if requirement in step (2) is not met. 12

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j. Flow and spray test new or used nozzles (4).

(1) Using IC848 test stand, 281450-1 tester assem-bly, and 284761-1-1 adapter assembly, flow fluid through nozzles (4) at 100 (±2) psig.

(2) Flow from nozzles (4) shall be 6.8 (±0.3) pph.

(3) Nozzles (4) shall have spray angles of 70 (±5) degrees as shown in Figure 5.

(4) Any of the following are cause for rejection of the nozzles (Figure 2, 4).

(a) Spitting.

(b) Dribbling.

(c) Bubbling.

(d) Fluctuation.

(e) Discontinuity of cone.

(f) Solid stream in cone.

k. Install washers (5) with tab of washers on flat of body assemblies (3 and 13).

l. Install nozzles (4) in body assemblies (3 and 13).

m. Tighten nozzles (4) and torque to 40 inch-pounds.

n. Using IC848 test stand or 281450-1 tester assembly or 284021-1-1 test set assembly or equivalent test equipment, having filtered fuel, perform spray test on the completely assembled fuel manifold assemblies.

(1) Apply 100 psi fuel pressure to the complete manifold assembly and inspect manifold assem-bly for leakage between the nozzle tips and each manifold body. If leakage is observed replace nozzle tip and repeat this step.

(2) Any of the following are causes for rejection of nozzle tips (4) including the patterns in Figure 5.

(a) Spitting.

(b) Dribbling.

(c) Bubbling.

(d) Fluctuation.

(e) Discontinuity of cone.

(f) Solid stream in cone.

(3) Replace nozzle tip (4) if requirements in step n.

is not met.

(4) Repeat step n. if any nozzle tips (4) are replaced.

o. Bend two small tabs of washers (5) against flats of nozzles (4) and bend remaining tab against body assemblies (3 and 13).

p. Replace nozzle assemblies (Figure 2, 3 and 13) if requirements in step n. is not met and repeat step n.

q. Using J020 band-it, secure clamps (6).

14 Change 1

8.3 Assemble Axial Fuel Manifold Assemblies

(899178-11 & 899178-12).

CAUTION

Extreme care shall be used not to intermix the tangential and axial fuel nozzles (Figure 2, 4 and Figure 3, 5). The nozzles are identified by etching on the wrenching flat. Intermixing the nozzles can cause the turbine engine to malfunction and overheat damage to the turbine section may result.

Do not install shrouds (4), nozzles (5) or washers (6) into bodies (3 and 14) or lockwire bodies until after pressure test of the manifold portion of the assembly, (step g.).

When building manifold assembly (part No.

899178-11), new hoses (698488-3 & 698488-1) may come preassemble with sleeves (Figure 1, 9) that are shrunk to fit hose (10). Inspect sleeve for tears or other possible defects. If sleeves are in good condition, clamps (6) are not required to secure hose. This does not apply to any repaired hoses or assemblies that use flex wrap and RTV. Clamps must be used when flex wrap (9) and RTV are used.

a. Install sleeves (10 and 18) on hoses (11 and 19) and position clamps (7). Do not tighten clamps (7) until after pressure test.

When building manifold assembly (part No. 899178- 12), new hoses (698488-2, 698488-6) may come preassembled with sleeves (10) that are shrunk to fit hose (11). Inspect sleeve for tears or other possible defects. If sleeves are in good condition, clamps (7) are not required to secure hose. This does not apply to any repaired hoses or assemblies that use flex wrap and RTV. Clamps must be used when flex wrap (10) and RTV are used.

b. Alternate method of installing sleeves (10 and 18).

(1) Install flexwrap (13-35) one and one-half to two turns maximum on hoses (11 and 19) and position clamps (7).

(2) Do not tighten clamps (7) until after step q.

c. Install sleeve (16) and screw coupling (15) into socket (17).

d. Apply dry film lubricant (13-44) on adapters (2 and 13), install sleeves (8) and screw adapters (2 and

13) into sockets (9).

e. Position adapter (13) on body (14) and adapter (2) on body (3).

f. Press pins (1 and 12) through holes in adapters (2 and 13) and recessed portion of bodies (3 and 14) to secure.

Change 1 14.1/(14.2 blank)

Figure 5. Nozzle Test Spray Patterns

g. Leak Check fuel manifolds.

(1) Install unserviceable nozzles (5) with tips welded/brazed closed in bodies (3 and 14).

Torque to 50-70 in-lbs.

(2) Leak check fuel manifolds by capping all openings and placing under water. Apply clean regulated air of 300 (5) psig to fuel manifolds. Fuel manifolds shall hold pressure for 5 minutes with no leakage. If any leakage is noted, mark area.

(3) Remove unserviceable nozzles (5) installed in step (1).

(4) Repair or replace fuel manifolds if requirement of step (2) is not met.

h. Flow and spray test new or used nozzles (Figure 3, 5).

Testing of nozzles shall occur normally built up as assemblies in manifolds. Individual nozzle testing is used as needed when the parts are suspect of non-compliance.

(1) Using 164101-100 or IC848 test stand, 281450-1 tester assembly and 284761-1-1 adapter assembly, flow fluid through nozzles

(5) at 100 (2) psig.

(2) Flow from nozzles (5) shall be 17 (0.5) pph.

(3) Nozzles (5) shall have angles of 70 (5) degrees as shown in Figure 5.

(4) Any of the following are cause for rejection of the nozzles (Figure 3, 5).

(a) Splitting.

(b) Dribbling.

(c) Bubbling.

(d) Fluctuation.

(e) Discontinuity of cone.

(f) Solid stream in cone.

i. Center tab B of washers (Figure 6, 6) on flats of bodies (3 and 14).

j. Install and tighten nozzles (Figure 6, 5) and torque to 50-70 inch-pounds.

k. Using 164101-100 test stand or IC848 test stand, and 281450-1 tester assembly using calibration fluid (13-18). Perform spray test on the fully assembled fuel manifold assemblies at 100 (2) psig.

(1) Apply 100 psi fuel pressure to the complete manifold assembly and inspect manifold assembly for leakage between the nozzle tips and each manifold body. If leakage is observed replace nozzle tip and repeat this step.

(2) Any of the following are causes for rejection of nozzle tips (5) including the patterns in Figure 5.

(a) Splitting.

(b) Dribbling.

(c) Bubbling.

(d) Fluctuation.

(e) Discontinuity of cone.

(f) Solid stream in cone.

l. Replace nozzle tip (5) if requirements in step k. is not met.

m. Repeat step k. if any nozzle tips (5) are replaced.

n. Bend tab A of washer (6) against two flats of nozzles (5) and into slots in bodies (3 and 14) as shown.

o. Install shrouds (4) on bodies (Figure 3, 3 and 14) hand tighten.

(1) Assemble manifolds with shrouds (968742-3), hand tighten only at this step.

(2) Rest manifold on holding fixture.

(3) Install a section of fuel emission hose per SAE 30R7 which is approximately 12 to 18 inches long to the bottom end of 5 out of 6 shrouds.

For manifold 899178-11 or 899178-12, attach sections of hole to ends of each nozzle shroud.

(4) Using 164101-100 test stand or 281450-1 tester assembly or 284021-1-1 test set assembly, and fixture 201307204, having filtered fuel (46- 18), perform spray test on the completely assembled fuel manifold assemblies. Turn on fluid through nozzle to ensure flow of fluid through nozzles (5) is 100 (2) psig. Angle at each nozzle shall be 70 (±5) degrees.

(5) Any of the following are causes for rejection of nozzle tips (5) including the patterns in Figure 5.

(a) Splitting.

(b) Dribbling.

(c) Bubbling.

(d) Fluctuation. 16

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(e) Discontinuity of cone.

(f) Solid stream in cone.

(6) Remove and replace the hoses on each shroud or nozzle tip until each spray pattern is verifiably good. Remove and replace the nozzles and shrouds as needed to obtain good spray patterns.

p. Following testing, torque shrouds to 60-65 inch-pounds using caution to minimize twisting of stem portion of body assemblies. Use appropriate tooling as needed to prevent damage to the body assemblies preventing twisting and distortion of body assembly.

NOTE

Do not run or twist lockwire over surface C.

q. Lockwire shrouds with (13-43).

r. Using J020 band-it. Secure clamps (7).

16.1/(16.2 blank)

Figure 6. Installation of Key Washers and Lockwire on Axial Fuel Manifold Assembly

Figure 7. Views of Centered Tangential Body With Shroud (Cup)

9. TEST.

Testing is integrated with assembly section of TO.

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