(2)
Install unions (7) on heat exchanger inlet and outlet fittings. Lubricate with assembly lube or hydraulic fluid.
CAUTION: EXERCISE CARE TO PREVENT IMPURITIES FROM ENTERING HYDRAULIC SYSTEM.
(3)
Remove protective caps from hydraulic lines and connect to unions.
500
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G. Install fuel tank access panel. Refer to Chapter 28, Fuel Tank Access Panels - R/I.
H. Service hydraulic reservoirs. Refer to Chapter 12, Hydraulic Fluid Servicing.
I. Refuel fuel tank No. 1 to a minimum of 250 gallons of fuel. Refer to Chapter 12, Servicing.
NOTE: Normally 250 gallons of fuel is required in the No. 1 fuel tank to provide adequate hydraulic fluid cooling.
J. Pressurize hydraulic system A by motoring either engine. Refer to 71-09-100, Power Plant (JT8D) - Operating Procedures.
K. Check heat exchanger fittings for signs of leakage.
L. Check fuel tank for leakage in areas reworked by heat exchanger removal and installation. Refer to Chapter 28, Fuel System.
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SYSTEM A HYDRAULIC FLUID HEAT EXCHANGER - REMOVAL/INSTALLATION
EFFECTIVITY
Airplanes with S271N401-X Heat Exchanger
1. General
A. A heat exchanger is installed in the bottom of No. 1 wing tank. A container will be necessary to catch any fluid when removing the heat exchanger. Should any fluid spill on the airplane, the affected area must be decontaminated (Ref 12-40-00).
2. Equipment and Materials
A. Skydrol Assembly Lube - MCS 352 or Hydraulic Fluid - BMS 3-11 (Ref 20-30-20)
3. Prepare for Removal
A. If flaps are not extended, pressurize hydraulic system B and operate flap handle to ten degree position. Depressurize hydraulic system A (Ref 29-11-00 MP).
B. Depressurize applicable hydraulic reservoir(s) (Ref 29-09-300 MP).
C. Open the following circuit breakers (P6):
(1)
FLIGHT CONTROL SHUT-OFF VALVES BAT STDBY RUDDER
(2)
FLIGHT CONTROL SHUT-OFF VALVES FLAP
(3)
ALTERNATE TRAILING EDGE FLAP DRIVE AC
(4)
HYDRAULIC SYSTEM ELEC HYD PUMP CONT SYS A
D. Defuel applicable wing fuel tank and remove fuel tank access panel No. 1 (Ref 28-23-0, Defueling).
E. Prepare fuel tank for entering (Ref 28-10-0 MP, Purging and Entry).
WARNING: FUEL TANK IS HAZARDOUS AREA. KNOW PRECAUTIONS BEFORE ENTERING FUEL TANK, OR INJURY TO PERSONNEL AND DAMAGE TO AIRPLANE MAY RESULT.
4. Remove Heat Exchanger (Fig. 401)
A. Disconnect and cap heat exchanger inlet and outlet lines at rear spar.
B. Remove unions, bulkhead nuts and washers. Discard O-rings.
C. Remove electrical bonding jumper from wing tank stringer.
D. Remove heat exchanger mounting bolts and washers. Retain laminated washers for
installation.
E. Loosen heat exchanger fittings from rear spar.
NOTE: Do not use material harder than 2024-T3 aluminum for removing sealant.
F. Remove heat exchanger through tank access opening.
5. Install Heat Exchanger (Fig. 401)
A. Insert O-rings in grooves of heat exchanger fittings.
Feb 20/85 29-11-52 Page 401
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System A Hydraulic Fluid Heat Exchanger Installation 500
29-11-52 Figure 401 Feb 20/85
Page 402
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
B. Pass heat exchanger through wing tank access opening with the inlet and outlet ports going through opening first.
C. Enter fuel tank and position inlet and outlet fittings so they enter the holes in rear spar.
NOTE: Ensure that O-rings are properly seated, and that sealing surfaces on the rear spar are clean and free from flaws. Apply assembly lube or hydraulic fluid to all O-rings and fittings to facilitate installation.
D. Install one phenolic washer (BACW10P361LA, 0.020 inch thick) under each lug of heat exchanger.
E. Install mounting bolts and washers hand tight.
F. At the rear spar, install bulkhead washers and nuts. Tighten bulkhead nuts and lockwire.
G. Check gap at each heat exchanger mounting lug, between phenolic washer and heat exchanger. If gap is greater than 0.010 inch, remove phenolic washer, measure gap and fill with washers in combination from the following table.
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