Attachment_0003_COLD_START_DEPOT_LEVEL.pdf

APPLICATION REVISIONS

NEXT ASSY USED ON LTR DESCRIPTION APPROVED

AVDS-1790-8CR

ENGINE

− PRODUCT BASELINE

ECP W1415R1

KAM

NOTES:

1. APPLICABLE STANDARDS/SPECIFICATIONS

A. ASME Y14.100-2004

B. ASME Y14.5M-1994

2. PACKAGE THE PRINTED DOCUMENT IN A WATER-SEALABLE CONTAINER AND APPLY THE

FOLLOWING MARKINGS IN ACCORDANCE WITH MIL-STD-129;

INSTALLATION OF THE COLD START ENHANCEMENT IN THE

AVDS-1790-8CR ENGINE.

DISTRIBUTION STATEMENT A.

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED.

COPYRIGHT © 2014 BAE SYSTEMS LAND AND ARMAMENTS L.P.

PMIC A CONTRACT NUMBER

W56HZV-07-C-0256

CONTRACTOR

BAE SYSTEMS LAND &

ARMAMENTS L.P.

U.S. COMBAT SYSTEMS

BAE Systems Land and Armaments L.P U.S. Combat Systems

YORK, PA 17408

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN INCHES

TOLERANCES ON

2 PLACES 3 PLACES

COLD START ENHANCEMENT

DEPOT LEVEL INSTALLATION

DESIGN ASSUR CONF MGR DRAWN BY

KAM

DATE (YR-MO-DA)

14-09-05

MANUFACTURING PROD

ASSUR

CHECKER

ENGINEER

FUNCTION DESIGN DRAWING APPROVAL-CUSTOMER

SIZE

A

CAGE

06085

DRAWING NO

12544294

MATERIALS WELDING DESIGN APPROVAL- CUSTOMER

SCALE NONE UNIT WT LB SHEET 1 of 20

Page 2 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

DEPARTMENT OF THE ARMY

HEADQUARTERS, UNITED STATES ARMY

WASHINGTON, DC 20380-0001

NORMAL

03 SEPTEMBER 2014

INSTALLATION OF THE COLD WEATHER START ENHANCEMENT

IN THE AVDS 1790 8CR ENGINE

1. Purpose. This enhancement improves the intake manifold flame heater system for Starting Main Engine in cold weather at temperatures between 32°F and -25°F (0°C and -32°C).

2. Technical Manuals Affected

DMWR 9-2815-247 dated 01 June 2006

3. Major Item Affected

Nomenclature NSN Part Number CAGEC Serial no.

range

ENGINE, Diesel With Container

2815-01-414-6821 12366412 06085 NA

4. Materiel Affected

a. Materiel Required

Nomenclature NSN Part Number CAGEC Qty

ASSEMBLY, Nozzle 4730-01-611-0963 E8CR130-0630 02978 2

EXCITER, Ignition 2920-01-611-1041 E8CR128-023 02978 2

COVER, Electrical 5935-01-214-0797 MS25042-10DA 96906 1

CLAMP, Loop 5340-00-833-3049 MS21333-127 80205 1

SCREW, Assembled Washer 5306-00-741-4584 7414584 19207 1

TUBE, Cross 4730-01-630-8944 E8CR130-068 02978 1

WASHER, Flat 5310-00-167-0820 NAS1149F0563P 80205 1

b. Bulk and Consumable Materiel

SEALING COMPOUND 8030-01-510-4844 54505 (or equivalent) 05972 AR

WIRE, Nonelectrical 9525-00-355-6072 MS20995NC40 80205 AR

Page 3 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

c. Mandatory Replacement Parts

NUT, Self-Locking 5310-00-982-4912 MS21045-5 96906 4

NUT, Self-Locking 5310-00-877-5797 MS21044N3 80205 1

d. Material Discarded. Parts no longer required will be disposed of in accordance with AR 710-2 and local standard operating procedures. The following table lists parts that are removed and discarded.

BOLT, Assembled 5306-00-042-5828 425828 97403 2

BOLT, Assembled 5306-00-741-4584 7414584 19207 3

BRACKET 4820-00-423-3869 11684101 19207 1

CHECK VALVE 4820-01-434-5427 E8DR130-033 02978 2

CHECK VALVE 4820-00-467-2578 11684097 19207 1

CLAMP 5340-00-843-7826 MS21333-68 96906 1

CLAMP 5340-00-764-7051 MS21333-69 96906 1

CLAMP 5340-00-659-9514 MS21333-70 80205 8

CLAMP 5340-00-091-3790 MS21333-72 80205 1

CLAMP 5340-00-989-9222 MS21333-74 80205 2

CLAMP 5340-00-050-2740 MS21333-75 80205 4

CLAMP 5340-00-922-6300 MS21333-77 80205 1

CLAMP 5340-00-922-6301 MS21333-79 96906 1

CLAMP 5340-00-057-3034 MS21333-110 80205 2

COUPLING 4730-00-930-7776 2-2 130139C 81343 1

ELBOW 4730-00-204-1272 2-2 140239C 81343 3

ELBOW 4730-00-647-3207 2N1287 19207 1

ELBOW 4730-01-026-1848 10921622-2 19207 1

GROMMET 5325-01-492-8991 MS35489-97S 96906 1

HOSE ASSEMBLY 4720-01-434-5426 E8CR130-0410 02978 2

HOSE ASSEMBLY 4720-01-543-6441 E8CR130-046 02978 1

IGNITER 2920-00-770-1641 305001 0AFLA 2

NIPPLE 4730-00-825-7304 MS51501A4 96906 2

NOZZLE 2910-01-041-3370 12254278 19207 2

Page 4 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

NUT, Self-Locking 5310-00-877-5797 MS21044N3 80205 11

SCREW, Machine 5305-00-436-6754 MS35226-67 96906 11

SOLENOID 4810-00-974-7605 V5J21735 81978 1

TEE 4730-00-522-1909 MS51512A4 96906 1

TUBE ASSEMBLY 4710-01-434-5425 E8DR108-0030 02978 1

TUBE, Cross 4730-01-433-8146 E8CR130-008 02978 1

TUBE, Metal 4730-01-434-1495 E8CR108-0040 02978 1

WASHER, Flat 5310-00-167-0818 NAS1149F0363P 80205 2

WASHER, Lock 5310-00-637-9541 MS35338-46 80205 14

5. Special Instructions. The cold start enhancement is being incorporated into new production engines. There is also a field enhancement that is only a partial conversion. Therefore containerized engines at depot may have a complete enhancement, partial enhancement, or no enhancement applied.

a. New production engines – No actions are required. These engines may be identified by the absence of a flywheel end fuel return solenoid.

b. Original configuration engines – These engines will not have the cold start enhancement installed and all procedures are required.

c. Engines with field enhancement – Engines with a field-applied enhancement can be identified by the absence of fuel return lines and fittings to the flywheel end solenoid. A plug in the solenoid replaces return lines and fittings. Only partial conversion is required for these engines. These engines will have new ignition exciters (P/N E8CR128-023) and new nozzle assemblies (P/N E8CR130-0630). New ignition exciters and nozzle assemblies must be retained for re-installation.

6. Procedures

a. Remove and Install Ignition Units

NOTE

Determine configuration of ignition exciters before disassembly. If ignition exciter part number is E8CR128-023, retain for installation.

If ignition exciter part number is other than E8CR128-023 or unobtainable; discard ignition exciter.

(1) Disconnect two lead conduits (Figure 1, Items 1 and 7) from left and right bank ignition exciters (Figure 1, Items 8 and 16).

(2) Disconnect wiring harness 3W202 wire 530B (Figure 1, Items 6 and 10) from left and right bank ignition exciters (Figure 1, Items 8 and 16).

(3) Remove four self-locking nuts (Figure 1, Items 4 and 14), four flat washers (Figure 1, Items 3 and 13), four screws (Figure 1, Items 9 and 15), four clamps (Figure 1, Items 5 and 11), and two ignition exciters (Figure 1, Items 8 and 16) from two brackets (Figure 1, Items 2 and 12).

Discard ignition exciters (P/N 7062198) and self-locking nuts.

Page 5 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

Ensure ignition exciter part number E8CR128-023 is installed, new or retained.

(4) Install two ignition exciters (Figure 1, Items 8 and 16) (new/retained P/N E8CR128-023) to two brackets (Figure 1, Items 2 and 12) and attach with four clamps (Figure 1, Items 5 and 11), four screws (Figure 1, Items 9 and 15), four flat washers (Figure 1, Items 3 and 13), and four new self-locking nuts (Figure 1, Items 4 and 14) (P/N MS21045-5).

(5) Connect two lead conduits (Figure 1, Items 1 and 7) to left and right bank ignition exciters (Figure 1, Items 8 and 16).

(6) Connect wiring harness 3W202 wire 530B (Figure 1, Items 6 and 10) to left and right bank ignition exciters (Figure 1, Items 8 and 16).

Figure 1. Ignition Exciter Removal and Installation.

Page 6 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

b. Fuel Line Return Hose Assembly and Clamps Removal

NOTE

Hardware will vary based on multiple engine configurations.

(1) Remove nut (Figure 2, Item 4), two lockwashers (Figure 2, Item 5), screw (Figure 2, Item 1) and three clamps (Figure 2, Items 2 and 3) from fuel drain hose (Figure 2, Item 12) and attached hose assemblies at location ‘A’. Discard lockwashers, nut and clamp (Figure 2, Item 2).

(2) Re-attach two clamps (Figure 2, Item 10) and attached hose assemblies with screw (Figure 2, Item 1) and new lock nut (Figure 2, Item 11) (P/N MS21044N3) at location ‘D’.

(3) Remove six nuts (Figure 2, Item 9), 12 lockwashers (Figure 2, Item 7), six screws (Figure 2, Item 8) and 12 clamps (Figure 2, Item 6) from fuel drain hose assembly (Figure 2, Item

12) and attached hose assembly at locations ‘B’ and ‘C’. Discard all hardware .

Figure 2. Fuel Line Return Hose Clamp Removal.

Page 7 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

c. Verify Left Bank Nozzle Assembly Configuration

NOTE

Verify configuration of nozzle assemblies is required before replacing or discarding.

Configuration of nozzle assembly (Figure 3, Item 1) can be verified by presence of side fuel return line port in nozzle assembly. If side fuel return line port exists in nozzle assembly, discard. Install new/retained nozzle assembly (P/N E8CR130-0630) during procedures below.

Figure 3. Side Fuel Return Line Port Nozzle Assembly Verification.

d. Remove and Install Left Bank Hose Assemblies and Nozzle Assembly

Hardware and components in Step (1) may not be installed on engine due to variation in engine configurations.

(1) Disconnect two fuel return hose assemblies (Figure 4, Items 14 and 19) and remove related components (Figure 4, Items 1, 4, 5, 13, 15, 16, 17, 18, and 26) that connect nozzle assembly (Figure 4, Item 11) to solenoid valve (Figure 4, Item 3). Discard components (Figure 4, Items 1, 4, 5, 13, 14, 15, 16, 17, 18, 19, and 26).

(2) Disconnect hose assembly (Figure 4, Item 6) from adapter (Figure 4, Item 7).

Page 8 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

Field enhancement may have already been applied.

Check may have already been removed.

Verification of nozzle assembly configuration is required before removing.

(3) Remove adapter (Figure 4, Item 7), check valve (Figure 4, Item 8) if equipped, pipe bushing (Figure 4, Item 9), elbow (Figure 4, Item 10) and nozzle assembly (Figure 4, Item 11) from housing (Figure 4, Item 12). Discard check valve if equipped and verified nozzle assembly.

NOTE

Hardware and components in Steps (4) through (6) may not be installed on engine due to variation in engine configurations.

(4) Disconnect fuel return hose assembly (Figure 4, Item 22) and remove elbow (Figure 4, Item 2), check valve (Figure 4, Item 28), elbow (Figure 4, Item 27), hose assembly (Figure 4, Item 22), grommet (Figure 4, Item 21), and elbow (Figure 4, Item 20). Discard all parts.

(5) Remove two screws (Figure 4, Item 23), two flat washers (Figure 4, Item 24), and solenoid (Figure 4, Item 3) from bracket (Figure 4, Item 29). Discard screws, flat washers, and solenoid.

(6) Remove three screws (Figure 4, Item 25) and bracket (Figure 4, Item 29). Discard all parts.

Figure 4. Left Bank Manifold Heater Removal.

Page 9 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

(7) Apply sealing compound (54505) to all male pipe threads.

(8) Install nozzle assembly (Figure 5, Item 6) (new/retained, P/N E8CR130-0630) to housing (Figure 5, Item 5).

(9) Install elbow (Figure 5, Item 1) to nozzle assembly (Figure 5, Item 6).

(10) Install pipe bushing (Figure 5, Item 2) to the elbow (Figure 5, Item 1).

(11) Install adapter (Figure 5, Item 3) to pipe bushing (Figure 5, Item 2).

(12) Connect the hose assembly (Figure 5, Item 4) to adapter (Figure 5, Item 3).

Figure 5. Left Bank Manifold Heater Installation.

Page 10 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

e. Verify Right Bank Nozzle Assembly Configuration

NOTE

Verify nozzle assembly configuration before replacing or discarding.

Configuration of nozzle assembly (Figure 6, Item 1) can be verified by presence of side fuel return line port in nozzle assembly. If side fuel return line port exists in nozzle assembly, discard. Install new/retained nozzle assembly (P/N E8CR130-0630) during procedures below.

Figure 6. Side Fuel Return Line Port Nozzle Assembly Verification.

Page 11 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

f. Remove and Install Right Bank Hose Assemblies and Nozzle Assembly

NOTE

Hardware and components in Step (1) may not be installed on engine due to variation in engine configurations.

(1) Disconnect fuel return hose assemblies (Figure 7, Items 2 and 13) and remove related components (Figure 7, Items 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 14, and 15) that connect to nozzle assembly (Figure 7, Item 17). Discard components (Figure 7, Items 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, and 15).

(2) Disconnect hose assembly (Figure 7, Item 1) from adapter (Figure 7, Item 21).

NOTE

Field enhancement may have already been applied.

Check may have already been removed.

Verification of nozzle assembly configuration is required before removing.

(3) Remove adapter (Figure 7, Item 21), check valve (Figure 7, Item 20) if equipped, pipe bushing (Figure 7, Item 19), elbow (Figure 7, Item 18), and nozzle assembly (Figure 7, Item 17) from housing (Figure 7, Item 16). Discard check valve if equipped and verified nozzle assembly.

Figure 7. Right Bank Manifold Heater Removal.

Page 12 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

(4) Apply sealing compound (54505) to all male pipe threads.

(5) Install nozzle assembly (new/retained, P/N E8CR130-0630) to housing (Figure 8, Item 6).

(6) Install elbow (Figure 8, Item 4) to nozzle (Figure 8, Item 5).

(7) Install pipe bushing (Figure 8, Item 3) to the elbow (Figure 8, Item 4).

(8) Install adapter (Figure 8, Item 2) to pipe bushing (Figure 8, Item 3).

(9) Connect the hose assembly (Figure 8, Item 1) to adapter (Figure 8, Item 2).

Figure 8. Right Bank Manifold Heater Installation.

Page 13 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

g. Remove and Install Cross Tube Fitting

(1) Remove adapter (Figure 9, Item 5) from cross tube (Figure 9, Item 2).

(2) Disconnect fuel lines (Figure 9, Items 1, 3, and 4) from cross tube (Figure 9, Item 2).

(3) Remove nut (Figure 9, Item 6) from cross tube (Figure 9, Item 2) and remove cross tube (Figure 9, Item 2) from engine shroud. Discard cross tube.

NOTE

New cross tube (P/N E8CR130-068) does not have bottom port connection for discarded manifold heater fuel return line. Cross tube (P/N E8CR130-008) in engine overhaul kit (P/N 57K4483) may be superseded by (P/N E8CR130-068). Ensure new cross tube (P/N E8CR130-068) is installed.

(4) Install new cross tube (Figure 9, Item 2) (P/N E8CR130-068) through engine shroud and secure with nut (Figure 9, Item 6).

(5) Apply sealing compound (54505) to cross tube (Figure 9, Item 2) and install fuel lines (Figure 9, Items 1, 3, and 4).

(6) Install adapter (Figure 9, Item 5) in new cross tube (Figure 9, Item 2).

Figure 9. Fuel Return Cross Tube Removal and Installation.

Page 14 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

h. Install Wiring Harness Cap

(1) Connect protective cap (Figure 10, Item 1) (P/N MS25042-10DA) to wiring harness 3W202 wire 530B (Figure 10, Item 6).

(2) Secure protective cap lanyard (Figure 10, Item 5) to wiring harness 3W202 wire 530B (Figure 10, Item 6) with two wraps of non-electrical wire (MS20995NC40).

(3) Install clamp (Figure 10, Item 2) (P/N MS21333-127) and secure wiring harness 3W202 wire 530B (Figure 10, Item 6) with flat washer (Figure 10, Item 3) (P/N NAS1149F0563P) and assembled screw (Figure 10, Item 4) (P/N 7414584).

Figure 10. Protective Cap Installation.

Page 15 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

7. DMWR Update

MANIFOLD HEATER ASSEMBLIES (LEFT AND RIGHT BANK), SOLENOID 0037 00

VALVE AND HEATER PUMP, LINES AND ASSOCIATED PARTS

THIS WORK PACKAGE COVERS:

Removal, Disassembly, Cleaning, Inspection, Assembly, Installation, Test, Final Inspection

INITIAL SETUP:

Maintenance Level Reference Depot TM 9-2350-292-13&P

WP 0004 00

WP 0050-00

WP 0053-00

WP 0054 00

WP 0055 00

WP 0056 00

REMOVAL

Refer to TM 9-2350-292-13&P for procedures to remove Manifold Heater Assemblies (Left and Right Bank).

Refer to TM 9-2350-292-13&P to remove Manifold Heater Pump, Lines, Solenoid Valve and associated parts.

DISASSEMBLY

Refer to TM 9-2350-292-13&P for procedures to disassemble Manifold Heater Assemblies (Left and Right

Bank). Refer to TM 9-2350-292-13&P disassemble Manifold Heater Pump, Lines, Solenoid Valve and associated parts.

CLEANING

Refer to WP 0004 00 for general cleaning procedures.

INSPECTION

Inspect components not covered by an Overhaul Inspection Procedure (OIP) in accordance with WP 0004 00.

Refer to TM 9-2350-292-13&P for exploded view of Manifold Heater Assemblies (Left and Right Bank), Manifold Heater Pump, Lines, Solenoid Valve and Associated Parts.

Page 16 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

Table 1. List of Mandatory Replacement Parts

ITE

M

NO

PART NUMBER NSN NOMENCLATURE CAGEC

1* E9AR131-213 5330-01-433-5824 Gasket 02978 2 MS8005E860A 4720-01-433-3034 Hose Assembly, Nonmetallic 96906 3 ED89D 2920-00-711-5829 Spark Plug 01212

4* AMS-HH-G-101 TY1

STJ

5310-01-444-9183 Gasket 81648

5 MS3367-1-9 5975-00-074-2072 Strap, Tiedown, Electrical 96906 6 MS21045-5 5310-00-982-4912 Nut, Self-locking, Hexagon 96906 7 MS21044N3 5310-00-877-5797 Nut, Self-locking, Hexagon 80205 8 MS35489-97S 5325-01-492-8991 Grommet, Nonmetallic 96906 9 MS35335-33 5310-00-209-0786 Washer, Lock 93906

10 MS8005E1000B-REV 4720-01-465-2555 Hose Assembly, Nonmetallic 96906 11 MS8005E076B 4720-01-439-0582 Hose Assembly, Nonmetallic 96906 12 MS8005E074A 4720-01-448-0708 Hose Assembly, Nonmetallic 96906 13 7062196-1 6150-00-410-1975 Lead and Conduit Assembly 02978 14 MS8005E053A 4720-01-438-8832 Hose Assembly, Nonmetallic 96906 15 MS8005E081A 4720-01-438-7675 Hose Assembly, Nonmetallic 96906 16 MS35338-44 5310-00-582-5965 Washer, Lock 80205 17 E9AR130-077 5340-01-439-3762 Pad, Cushioning 02978 18 E9AR130-078 5310-01-439-3761 Pad, Cushioning 02978

*PART OF KIT 57K3591

Table 2. Components Requiring Overhaul Inspection

COMPONENT PART NUMBER OIP

Housing 654112-2 Table 12 Housing 654112-1 Table 12 Lead and Conduit Assembly 7062196-1 Table 10 Nozzle Assembly, Flame Heater E8CR130-0630 Table 8 Ignition Unit, Manifold E8CR128-023 Table 9 Pump, Fuel, Electrical 655401 Table 11

Table 3. Components Requiring Visual Inspection

COMPONENT PART NUMBER VISUAL

Plate, Mounting E9AR128-019 Table 7 Bracket, Mounting E9AR130-0710 Table 6 Bracket, Angle 11684100 Table 5 Clamp, Loop 10865374 Table 4

Table 4. Visual Inspection Procedures for Clamp, Loop – 10865374

QA

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracked, broken, or bent clamp Visual None allowed 2 Torn or deteriorated rubber cushion Visual None allowed

Table 5. Visual Inspection Procedures for Bracket, Angle – 11684100

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracks Visual None allowed 2 Bent or distorted Visual None allowed 3 Base metal exposed through protective finish Visual None allowed

Page 17 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

Table 6. Visual Inspection Procedure for Bracket, Mounting – E9AR130-0710

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracks Visual None allowed 2 Bent or distorted Visual None allowed 3 Base metal exposed through protective

Table 7. Visual Inspection Procedures for Plate, Mounting – E9AR128-019

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracks Visual None allowed 2 Bent or distorted Visual None allowed 3 Base metal exposed through protective

Table 8. Overhaul Inspection Procedure for Nozzle Assembly, Flame Heater – E8CR130-0630, OIP E8CR130-0630

QA

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracks Visual None allowed 2 Damaged threads Visual None allowed 3 Damaged filter Visual None allowed 4 A Plugged of damaged nozzle Visual None allowed 5 Spray angle Measure 75o ±5o 6 Flow rate Measure 29.0/32.0 cc/min. at

100 psig using DF2 or equivalent

Table 9. Overhaul Inspection Procedures for Ignition

Unit, Manifold – E8CR128-023, OIP E8CR128-023

QA

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracks, dents, or other damage Visual None allowed 2 Damaged threads Visual None allowed 3 Function check. Connect lead 7062196-1 to spark plug ED89D and energize with 10 V dc

Electrical Test

Must fire spark plug

4 Visibility of warning plate and name plate on ends of unit

Visual Must be visible and legible

Page 18 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

Table 10. Overhaul Inspection Procedures for Lead, Electrical – 7062196-1, OIP 7062196-1

QA

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracks, dents, or other damage Visual None allowed 2 Missing, damaged or brittle insulation Visual None allowed 3 Loose or missing terminals Visual None allowed 4 Broken solder joints Visual Must be unbroken 5 Missing label Visual None allowed 6 Insulation resistance check with high voltage tester Electrical Test

Resistance between conductor and shielding not less than 500 megohms at 15 kV dc.

7 Damaged threads Visual None allowed 8 Function check connect to spark plug

ED89D and ignition unit E8CR128-023 Electrical Test

Must show no indication of electrical leakage

Table 11. Overhaul Inspection Procedures for Pump, Fuel, Electrical – 655401, OIP 655401

QA

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracks, dents, or other damage Visual None allowed 2 Damaged threads Visual None allowed 3 Leakage sign Visual None allowed 4 Flow check Measure Pump must flow 3

GPH at 14 V dc minimum

Table 12. Overhaul Inspection Procedures for Housing – 654112-1 and 654112-2, OIP 654112

QA

REQ

NO.

REF

LTR

CHARACTERISTIC

INSP

METHOD

REQUISITE

1 Cracks Visual None allowed 2 Scratches, nicks, or gouges on contact surfaces Visual None allowed

3 Damaged threads (3 places) Visual None allowed 4 A Warped flange Measure Must be flat within

0.0020 inch

Page 19 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294

ASSEMBLY

Refer to TM 9-2350-292-13&P for assembly procedures.

INSTALLATION

Refer to TM 9-2350-292-13&P for installation procedures.

TEST

Refer to Final Inspection (WP 0050 00).

FINAL INSPECTION

Refer to Final Inspection (WP 0050 00).

END OF WORK PACKAGE

Page 20 of 20 Distribution Unlimited – See Title Sheet for Distribution Statement 12544294