This leaf issued with A.L. No. 17 AP.2850A, Vol. II, Part 3, Sect. 5 October, 1946 CHAPTER 1 GENERAL INSTRUCTIONS ON REPAIR OF SECONDARY-SURFACE OIL COOLERS LIST OF CONTENTS Para Para. General— Repair of cases and external fttings— Introduction 1 General 38 Classification of repairs 4 Testing after repair— Tools and equipment required 6 General oe 40 Parts and materials required .. 8 Washing... : 41 Cheek fer loose solder 2 Preliminary cleaning and inspecting — Weight check... 43 First visual inspection 8 First internal air pressure test 44 De-greasing and cleaning |). 10 High temperature stressing 4 ‘Hot water wash n Second internal air pressure test... 46 Tnternal air pressure test 12 Hot pressure test 7 Locating "matrix and wbo-pate Cold pressure test : Pry Teaks “4 High temperature stressing 1.) 49 Locating leaks in the case 18 Third internal air pressure test 80 Flow testing : 19 Stand-by period 51 Second visual inspection moat Repeat tests : 52 Flow test ae) Matrix repairs— Casing test Do 34 Brief description of secondary-surface Interchangeability test and final set descrintion 2 a inspection. es aes ee 8S Suitable repair methods 2 Failure to paso tests sn 8 Piagging Tab itbout removal ‘i Fitting identification plate 1) 57 28 Preservative treatment — Blanking-of ends of tubes 30 ‘General. 58 Solder-loading minor surface ieaks |. 31 Taternal or fluid channels 88 Tube to tuberplate leaks 32 ‘Outside case 60 Sludging of oil passages aM External or air channels 61 LIST OF ILLUSTRATIONS Fie. Fig. Sectional view of secondary-surface oil Venting in a blanked-off end tube... 4 cooler matrix ' Solder-loading @ surface leak in matrix 5 Plugging 2 tube without removing end oe 2 Repairing tube to tube-plate leak with- planking-off ends of a tube C8 ‘out removing end tank " GENERAL Introduction 1, Therepair instructions in this Chapter are applicable to all makes and types of secondary- surface oil cooler, and are a guide to the procedure to be adopted when undertaking the following operations:— (1) Preliminary cleaning and testing. (2) Matrix repairs. (8) Repair of cases and external fittings. (4) Testing after repair. (5) Preservation. 2. The following chapters of this Section supplement the instructions given here and contain any additional information which may be needed when dismantling, repairing and re-assembling particular makes and types of secondary-surface oil coolers.3, There is a marked similarity between secondary-surface oil coolers and secondary- surface coolant radiators, and some of the information required when repairing oil coolers of this type is already to be found in Sect. 3 of this publication. Cross-reference to that Section is, therefore, made on occasion to avoid unnecessary repetition. Classification of repairs 4. No exact classification of repairs is practicable, but it should be noted that the informa- tion throughout is confined to repair methods which can be undertaken in Repair Units with the tools and equipment listed in para. 6. The extent of the repair which can be effected by these methads is generally as follows:— (1) Repair of leaks in tubes and tube-plates by blanking off damaged tubes or by approved methods of sealing. {2) Repair of minor damage to cases and external fittings by patching. (8) Repair of damage fo cases and external fittings by fitting new parts and/or sub-assemblies. 5. The information does not include the complete reconditioning of secondary-surface oil coolers, which is dealt with in Part 4 of this Volume. Tools and equipment required 6. The following tools and equipment are required for the repair operations dealt with in this Section :-— (1) Oil flow test equipment. (2) De-greasing and de-sludging equipment, incorporating a pump which will ensure the ete eculation of the Megreasing and de-shudging solutions through the internal passages of the oil cooler. (3) A high-temperature glycerine bath, fitted with an armoured glass guard to protect operators. (4) Baths of a size to permit coolers to be completely immersed in water, with compressed air supply to enable air-under-water pressure tests to be made. Air lines should be fitted with accurate gauges and efficient water traps. (5) Baths of similar size to (4) for washing complete oil coolers in hot and cold water. (6) A number of adjustable gas/air blowpipes, some of which must be capable of producing a long and extremely fine concentrated flame not exceeding } in. dia. (Soldering irons are not, as a general rule, suitable for the repair of oil coolers.) (7) The usual hand tools and sheet metal worker's tools. 7.¥ Reference should be made to Sect. 1, Chap. 1, for fuller details of these items of equipment. Parts and materials required 8. The following parts and materials will be required for the repair operations and tests described in this chapter. In addition, spares provisioned for the repair of particular makes and types of cooler are listed in the appropriate chapters. All lists are included as a guide only, and when any item is requisitioned, reference should be made to the appropriate section of A.P.1086 which may include supplementary information. Stores Detail Ref. No. Nomenclature or Spec. Remarks 33C/547 _Trichlorethylene Commercial For use in de-greasing and de-sludging tanks 33C/836 Overseas 33C/620 Carbon tetrachloride . 33C/288 Solution, soldering Spec. DTD.8I For use in flux baths 30B/1214 Solder, tinman’s, grade “ For all soldering operations unless otherwise stated 30B/283 Solder, silver For use when specifiedThis leaf issued with A.L. No. 17 A.P.2850A, Vol, II, Part 3, Sect. 5, Chap, 1 October, 1946 Stores Detail Ref. No. Nomenclature or Spec. Remarks 38C/1_ Hydrochloric acid Commercial For _use in cleansing bath after repair (2% solution) 33C/245 Glycerine Spec. DTD.233 For use in high-temperature glycerine bath Primers, Universal Type U.P.10:— For use with For use as undercoat when Dark grey Spec. DTD.63A finishing repaired coolers 338/647 1 gal. containers 5 gal. containers— 338/648 lome 338/649 Overseas Light grey:— 388/650 1 gal. containers 5 gal. containers— 338/651 fome 338/652 Overseas 344/32 Oil, lubricating, Type No. 1 Spec. DTD.109 For flow tests or DTD.2472B Enamel, cellulose, Aerodyne ‘Spec. DTD.63A For final finish of repaired 338/306 1 gal. containers coolers 5 gal. containers— 338/504 ‘Overseas 33B/101 Paint, dark gre For oil and petrol resisting 1 gal. containers final finish 33B/102 2 gal. containers 5 gal. containers— 338/572 ‘Overseas 328/795 Paper, waxed, primary wrap cS.1998 For piickagin szpaos Paper, ted, double-faced meee 328/793 Tape,’ self-adhesive, W/P fabric, CS.2191 : in. wide PRELIMINARY CLEANING AND INSPECTING First visual inspect 9, Before any attempt is made at repair, the complete oil cooler should be thoroughly cleaned externally and carefully inspected to determine the extent of the repair work necessary and to decide whether it is advisable to undertake it. This decision must depend upon the facilities at the disposal of the Repair Unit concerned, the availability of replacement, and the urgency with which the particular component is required for service. ‘De-greasing and cleaning 10. The cooler should be thoroughly cleaned internally and externally by immersion in the de-greasing tank and by pumping the detergent through the oil cooler in the reverse direction to that of oil flow. The cooler should afterwards be scrubbed until all oil, paint and dirt are removed. (De-greasing and cleaning are of the utmost importance, first to ensure that leaks and other faults are revealed by subsequent tests, and secondly, to make sure that soldering and other repair operations are successfully completed.) Warning—When caustic soda is used as a detergent, any aluminium fitings must be removed from the assembly before it is placed in the de-greasing tank. Hot water wash 11, The oil cooler should be immersed in the hot water bath and washed thoroughly to remove the de-greasing solution. The temperature of the water should be approximately 180° F.Internal air pressure test 12. To locate leaks in the matrix or case, the cooler should be immersed in water and internal. air pressure applied. For this purpose an air ine or foot pump should be connected by a suitable adapter to one of the branch pipes of the cooler, all other openings in the cooler being sealed. If the cooler is part of a composite assembly, adequate support should be provided to prevent distortion at points which are normally strengthened by the presence of other units. Air pressure should be built up gradually, and the maximum pressure permissible for the cooler concerned must not be exceeded. This pressure, which varies with diferent types of oil cote, is given on the data plate of each cooler. After the test has been completed, the air pressure should be reduced gradually. The temperature of the water is not material to the test, but it is usually held to about 40° C. for the comfort of the operator. 13. Leaks will be indicated by the presence of air bubbles, but care is necessary to trace their exact position, The following notes will be helpful in locating defects during this test. Locating matrix: and tube-plate leaks 14. Place the oil cooler in the test tank in a horizontal position and completely immerse it. Build up air pressure gradually. If a leak becomes evident, lower the air pressure to avoid excessive disturbance of the water, and mark the approximate position of the defect on the face of the matrix. This can be done by attaching a piece of soft iron wire to the tube immediately over the point from which the bubbles are rising. 15. A close visual examination, preferably with an under-water inspection lamp held below the matrix, will usually enable the actual leak to be seen, If not, the cooler should be gradually tited out of the water until air bubbles cease to appear. A check should then be made, alternately lowering and raising the cooler, until the exact point at which the leak ceases to become apparent is found. Now measure the distance trom the edge of the cooler case to the surface of the water. This measurement, laid off from the edge of the case into the interior of the matrix, will indicate the point on the wall of the tube at which the leak has occurred. 16. If a matrix has serious leak, the escape of air at high pressure may agitate the water to an extent which will prevent the discovery of other and smaller defects. The test should, therefore, be repeated after such a leak has been repaired. 17.__ Air bubbles appearing from the top, bottom or sides of the matrix during these tests may indicate leaks either in the ends of the tubes themselves, in the tube-plate, or at the joint between the tube-plate and the tanks or case. It may not be possible definitely to locate the trouble until a certain amount of stripping down has been done, and for this purpose reference should be made to the specific {information in the following chapters dealing with the components concerne Locating leaks in the case 18. External leaks in the tanks or case may arise from loose rivets or tie bolts, from cracks in the case or fittings, or from faulty joints at such points as pipe flanges. Tinned portions of the case are particularly liable to fracture, and special attention should, therefore, be paid to the area around soldered-on fittings, such as channels, data plates and brackets. Dents may give rise to cracks and should be carefully examined for abrasions on the surface. When a leak is elusive, it is often helpful to raise and lower the air pressure alternately, meanwhile tapping the suspected area with a soft-faced mallet. Flow testing 19. If overheating has been reported and no obvious cause of unsatisfactory service is apparent the oil cooler should be flow-tested with the correct flow-testing equipment. Test equipment for this purpose is described and illustrated, and the procedure for flow-testing explained, in Sect. 1, Chap. 1 20. Failure of the cooler to give the required rate of flow under test may indicate restriction or blockage of oil passages, caused by sludging or by the presence of other foreign matter. The remedial measures for these faults should be applied and if these do not result in any improve- ment in the fiow reading, a structural defect is to be suspected.This leaf issued with A.L. No. 17 A.P.2850A, Vol. II, Part 3, Sect. 5, Chap. 1 October, 1946 Second visual inspection 21. When all leaks have been located and marked, a close visual inspection should be made of the general condition of the cooler. Damage to inlet and outlet pipes, brackets, channels, and other external fittings should be noted and a decision made as to whether it can be repaired by patching or made good by fitting a new component. MATRIX REPAIRS Brief description of secondary-surface oil cooler matrix 22. Fig. 1 shows the construction of a typical secondary-surface oil cooler matrix. The matrix is similar in principle to that of a secondary-surface coolant radiator (see Sect. 3), but normally has only a single row of tubes. The tubes are arranged edge-on to the slip-stream, and may be disposed vertically or horizontally. They are spaced approximately yy in, between centres, and are fitted into gill plates, the latter being stamped out to fit over the tubes and spaced at about 12 to an inch, (It will be seen that the pitch of the tubes and gill plates is somewhat closer than in a secondary-surface radiator.) The length of the tubes, and their number, vary according to the size of the oil cooler and the matrix area required, cut nate ensonareo. Fig. 1.—Sectional view of secondary-surface oil cooler matrix 23, Fitted internally along the length of each tube is a perforated and corrugated strip of sheet copper, which acts as a stiffener and forms seven flow channels within each tube. 24, The ends of the tubes are fitted into flanged tube-plates, to which the top and bottom tanks of the cooler are soldered when the cooler is assembled. Tubes, gill plates and tube-plates are tinned before assembly, and the complete matrix is solder-dipped after assembly.25, An oil cooler normally embodies two separate matrix Sections assembled in the manner described, one on the inlet side and the other on the outlet side. The flow is similar to that of a secondary-surface radiator, hot oil entering an inlet tank fitted at one end of the inlet side matrix, flowing through the tubes of that section to a common bottom tank, and then passing across the tank and:through the tubes of the other matrix section to the outlet tank and outlet connec- tion. This type of cooler is not usually fitted with a by-pass jacket, flow being diverted as, necessary before cold oil reaches the cooler. 26. The end tubes in matrices of this type tend to distort or burst more easily than those which are strengthened by the main body of the matrix structure. The outer tubes are, therefore, usually blanked off from the oil flow. Such “dead” tubes are perforated to vent all flow channels, and to prevent air or water from becoming trapped, should any find its way into the tubes, ‘owing to defective plugging. Suitable repair methods 27. Secondary-surface oil cooler matrices are not stripped down in the course of repair and it is not possible to remove tubes or to.insert new tubes. Extensive damage, therefore, necessi- tates the removal of tanks and other sub-assemblies and the fitting of new matrix sections, instructions for which are given in subsequent chapters dealing with individual makes and t of oil cooler. Where damage is of a relatively minor character, however, much may be done to maintain the serviceability of the components by blanking off damaged tubes and by solder- locking leaks, and as most oil coolers are of the single row type, with all tubes easily accessible, such repairs present less difficulty than where secondary-surface radiators are concerned. Instructions for effecting such repairs are given in the following paragraphs. ‘Note—The blanking off of damaged tubes is permissible up to a maximum of 5 per cent. of the total number of tubes in any one matrix, providing that the oil cooler so repaired afterwards complies with the flow test requirements for repaired oil coolers. SECTION SHoWnNC TUBE Gir neancy THROUGH BEND THS PART OF TUBE ‘WARDS TO PROVIDE A CLEAR ACCESS FOR SOLDERING. IL ‘Fig. 2.—Plugging a tube without removing end tanks Plugging tobes without removal of tanks 28. Defective tubes can be blanked off without the removal of end tanks and without other dismantling, by the following method:— (1) Locate the defective tube by air-under-water pressure tests, as explained in para, 12-17This leaf issued with A.L. No. 17 A,P.2850A, Vol. II, Part 3, Sect. 5, Chap. 1 October, 1946 (2) Using a thin hacksaw blade, which can be insetted between the gill plates and the adjacent cooling tube, cut nearly through the affected tube, at a point close to the tube-plate (see fig. 2). ‘Note—On no account must a tube be completely severed when effecting this repair, as to do so will set up strain which will deform the tube-plate and lead to failure of adjacent tubes. (3) Bend the wall of the tube inward immediately above the cut, as shown in the sectional sketch in the same figure, and, through the hole thus formed, thoroughly clean and tin the inside of the tube below the cut. Using a thin, carefuily-controlled blowpipe flame, solder should then be fed into this portion of the tube until it is completely blocked. (4) Invert the oil cooler and repeat these operations to block the other end of the damaged tube. 29. Internal air pressure tests should be carefully applied to ensure that both ends of the tube have been effectually blocked and that other joints in the vicinity have not run during the operation. The cooler should then be thoroughly cleansed to remove flux, dried, and finally tested in accordance with the instructions in para, 41-57. TUBE TO BE KNOCKED OVER AND SEALED WITH SOLDER 7 x" DIA. HOLES AT APPROX. 3” PITCH Fig. 3.—Blanking-off ends of a tube Fig, 4.—Venting in a blanked-off end tube Blanking-off ends of tubes 30. This method entails the removal of the top and bottom tanks of the oil cooler and is usually adopted when the case components as well as the matrix have suffered damage, and considerable dismantling of the cooler is, therefore, necessary. After removing the tanks in accordance with the instructions on the dismantling of various makes and types of oil cooler in following chapters of this Section, the repair should be effected as follows:— (1) Knock over both ends of the defective tube, as shown in fig. 3, and thoroughly seal with solder. (2) Perforate the plugged tube to prevent the accumulation of air or water in the “dead”” tube, The tube must be so punctured that all the separate flow channels formed by the corrugations of the internal stiffener are vented. B ALT)(8) Apply an air-under-water pressure test to ensure that the defective tube has been completely sealed. This can be done before re-assembling the tanks by soldering a sheet brass jacket round the matrix, making the joint on the flange of the tube-plates and thus enclosing the matrix in a temporary air- and water-tight casing. A suitable air-line connection should be fitted to the jacket, so that air pressure can be applied to the air side of the matrix. With the jacketed matrix immersed in water, air bubbles forming around the plugging at the ends of the damaged tube will indicate that itis not effectively sealed, and more solder should be applied. Only low test pressures, generally not exceed- ing 5 Ib. per sq. in., can be used with this temporary arrangement, but higher pressures can be applied if the jacket is supported by a heavy frame bolted round the matrix. (4) When satisfied that the damaged tube is effectively blanked off, remove the temporary jacket and carefully re-assemble the tank. (5) Thoroughly cleanse the cooler to remove all traces of flux; dry, and apply all final tests in accordance with the instructions in para. 41-57. Solder-loading minor surface Jeaks 31. This method of repair can be employed provided that the damage is of a minor character and is confined to either face of the matrix. It does not necessitate any dismantling of the oil cooler. (1) Cut two small strips of 16 or 18 s.w.c. aluminium, as shown at A in fig. 5. The strips should be 1 in. wide and approximately 1} in. longer than the damaged portion of the tube. With a hacksaw, cut a series of slots, approximately § in, long, along the edge of each strip, the slots being spaced to suit the pitch of the matrix gill (usually twelve to an inch). Fig. 6.—Solder-loading a surtace leak in matrixThis leaf issued with A.L. No. 17 A.P.2850A, Vol. 11, Part 3, Sect. 5, Chap. 1 October, 1946 (2) Thoroughly clean and flux the defective area. (3) Fit the slotted strips of aluminium over the gill plates on either side of the damaged tube, equally disposed on either side of the damage, as shown at Bin fig. 5. The bottom edge of each strip should be in contact with the damaged tube, and the tops approxi- mately } in. apart, forming a Vee. (4) Using a fine blowpipe flame, feed solder into the Vee formed by the aluminium strips to the level of the edges of the gill plates, completely covering and sealing the leak, as shown at C. (6) Remove the aluminium strips and clean off surplus solder from the vicinity of the repair. Apply internal air pressure tests to the maximum figure called for on the data, plate of the cooler concerned, and examine carefully to ensure that the repair is sound, following by thorough cleansing to remove flux, drying, and final testing, as explained in detail in para. 41-57. Tube to tube-plate leaks 32, Leaks may occur owing to the breakdown of the soldered joints at the points where the tube-ends pass through the tube-plates. Where possible these should be repaired without dismantling the cooler, and such leaks may usually be “caught” in the following manner:— (1) Locate the leaking joint by air-under-water pressure tests, as explained in para. 12-17. (2) Arrange the cooler with the defect at the bottom and clean the joint as thoroughly as possible. Apply flux, and, using a very long and thin blowpipe flame, build up solder all round the faulty joint, as illustrated in fig. 6. The key to success in this operation is the use of a suitably-adjusted and controlled flame, which must be thin enough to operate in the confined space between the tube-plate and the adjacent gill without burning the metal or over-heating other joints in the vicinity. (8) Test the soundness of the repair by immersing the oil cooler in water and applying internal Fig. 6.—Repairing tube to tube-plate air pressure to the maximum figure called for Teak without removing end tank on the data plate of the cooler concerned. (4) Thoroughly cleanse the cooler to remove all traces of flux; dry, and apply final tests in accordance with the instructions in para, 41-57. 33. If the leak does not respond to this treatment it is necessary to remove the tank and build up solder around the end of the tube projecting beyond the tube-plate. The end of the tube and the surface of the tube-plate in the vicinity of the faulty joint should be thoroughly cleaned, special care being taken to remove deposits which may have become trapped between the tube and the tube-plate. Flux should then be applied liberally, and the joint heavily tinned and bodied up to form a fillet all round the tube. The soundness of the repair should be tested before re-fitting the tank by applying an air-under-water pressure test in the manner described in para. 80 (3), and the cooler should then be thoroughly washed and tested as described in para. 41-57. Sludging of oil passages 34. During the life of an oil cooler, sludge is liable to be deposited in the oil passages. The deposition is progressive, and although the heat transfer from the oil to the tubes is hardly affected at all, the passages for the oil become reduced in size and offer increasing resistance to the oil flow. Ultimately, the pressure drop across the oil cooler becomes so great that the relief valve lifts and by-passes the cooler, with consequent soaring of oil temperatures. cunt35. The trouble is more likely to occur on secondary-surface coolers than on those of the tubular type, as the oil velocity is usually lower in the former and less scouring action therefore occurs between the oil and the surfaces with which it comes into contact. 36. Sludge deposition in oil coolers has proved difficult to combat and investigation is proceeding at the present time to determine how best it can be prevented or how the accumulated material can be efficiently removed. The circulation of detergents, including trichlorethylene, through the fluid channels of the cooler at considerable pressures is a method which has yielded good results. 37. .Some success has been obtained by flushing with tractor vaporising oil (Stores Ref. 34A/41). This liquid has a greater solvent action then either flushing oil, paraffin, or aviation fuel. If it is not available, M.T. petrol should be used, this being preferable to aviation fuel. Whenever oil overheating’ troubles are reported, and’ special de-sludging equipment is not available, flushing in this manner should be tried before other repairs are undertaken, REPAIR OF CASES AND EXTERNAL FITTINGS General 38. The instructions given in Sect. 3, Chap. 1, on the repair of minor damage to the cases and external fittings of secondary-surface radiators apply equally to secondary-surface oil coolers, and reference should be made to that chapter for information on the following subjects : (1) Rivet leaks (para. 49-51). (2) Cracks and holes in tanks and cases (para. 54-65). (3) Dents in tanks and cases (para. 66-71). (4) Repair of channels (para. 75-77). (5) Repair of brackets and lugs (para. 78-80). (©) Repair of inlet and outlet pipes (para. 81-85). 39, Where faults cannot be repaired by these methods they may be rectified by fitting new parts and/or sub-assemblies. The following chapters of this Section contain instructions for dismantling typical oil coolers and re-assembling with new parts. TESTING AFTER REPAIR General 40. After any repair has been undertaken the oil cooler must be thoroughly cleansed to remove soldering solution from the internal and external surfaces of the oil cooler, and then tested, The washing and testing procedure should be as described in the following paragraphs. ‘Washing 41. The washing process should be such that every trace of soldering solution is removed from all surfaces of the cooler in order to minimise the danger of corrosion. This should be done by immersing the oil cooler in an aqueous solution of hydrochloric acid (hydrochloric acid 14- 24 per cent.) at a temperature of approximately 40" C., alter fushing the cooler internally with a similar solution. The oil cooler should then be thoroughly washed and flushed with cold water. The water should be thrown away after each wash and must not be re-circulated through the cooler. The washing process should be such that a minimum velocity of 1 ft. per second for acid or alkaline solutions and 0-3 ft. per second for the final water wash is maintained through the cooler for not less than 5 minutes in each instance. These precautions should be taken as soon as possible and in no instances more than half-an-hour after the completion of the repair. Check for loose solder 42, Test for the presence of loose solder by shaking the cooler. If the movement of loose solder is heard, the particles of solder should be removed as far as possible by inverting and shaking the cooler so that the pieces drop through the inlet or outlet pipes. Weight check 43. The complete cooler must be weighed empty and dry and the weight must be within the limits specified on the approved drawing.35 The trouble is more likely to occur on secondary-surface coolers than on those of the tubular type, as the oil velocity is usually lower in the former and less scouring action therefore ‘occurs between the oil and the surfaces with which it comes into contact. 36. Sludge deposition in oil coolers has proved difficult to combat and investigation is proceeding at the present time to determine how best it can be prevented or how the accumulated Material can be efficiently removed. The circulation of detergents, including trichlorethylene, through the fluid channels of the cooler at considerable pressures is a method which has yielded good results. 137. .Some success has been obtained by flushing with tractor vaporising oil (Stores Ref. 344/41). This liquid has a greater solvent action then either flushing oil, paraffin, or aviation fuel. If it is not available, M.T. petrol should be used, this being preferable to aviation fuel. Whenever oil overheating’ troubles are reported, and’ special de-sludging equipment is not available, flushing in this manner should be tried before other repairs are undertaken. REPAIR OF CASES AND EXTERNAL FITTINGS General 38. The instructions given in Sect. 3, Chap. 1, on the repair of minor damage to the cases and external fittings of secondary-surface radiators apply equally to secondary-surface oil coolers, and reference should be made to that chapter for information on the following subjects:— (1) Rivet leaks (para. 49-51). (2) Cracks and holes in tanks and cases (para. 54-65). (8) Dents in tanks and cases (para. 66-71). (4) Repair of channels (para. 75-77). (6) Repair of brackets and lugs (para. 78-80). (©) Repair of inlet and outlet pipes (para. 81-85). 39. Where faults cannot be repaired by these methods they may be rectified by fitting new parts and/or sub-assemblies. The following chapters of this Section contain instructions for dismantling typical oil coolers and re-assembling with new parts. TESTING AFTER REPAIR General 40, After any repair has been undertaken the oil cooler must be thoroughly cleansed to remove soldering solution from the internal and external surfaces of the oil cooler, and then tested. The washing and testing procedure should be as described in the following paragraphs. ‘Washing 41. The washing process should be such that every trace of soldering solution is removed from all surfaces of the cooler in order to minimise the danger of corrosion. This should be done by immersing the oil cooler in an aqueous solution of hydrochloric acid (hydrochloric acid 13- 24 per cent.), at a temperature of approximately 40° C., after fiushing the cooler internally with a similar solution. The oil cooler should then be thoroughly washed and flushed with cold water. ‘The water should be thrown away after each wash and must not be re-circulated through the cooler. The washing process should be such that a minimum velocity of 1 ft. per second for acid or alkaline solutions and 0-3 ft. per second for the final water wash is maintained through the cooler for not less than 5 minutes in each instance. These precautions should be taken as soon as possible and in no instances more than half-an-hour after the completion of the repair. Check for loose solder 42. Test for the presence of loose solder by shaking the cooler. If the movement of loose solder is heard, the particles of solder should be removed as far as possible by inverting and shaking the cooler so that the pieces drop through the inlet or outlet pipes. ‘Weight check 43. The complete cooler must be weighed empty and dry and the weight must be within the limits specified on the approved drawing,This leaf issued with A.L. No. 17 A.P.2850A, Vol. II, Part 3, Sect. 5, Chap. 1 October, 1946 First internal air pressure test 44, For this test the oil cooler is to be immersed in water at a temperature of approximately 40° C., and air applied internally at the pressure called for on the data plate affixed to the cooler, or at 70 Ib. per sq. in., whichever is the greater. This test pressure must be maintained for five minutes without leakage. Note—Precautions should be taken to ensure that high-pressure air used during tests after repair is reasonably free from moisture; for this purpose an efficient water trap should be used in the pipe-line. The air line should be connected to either the inlet or outlet pipe of the oil cooler by a suitable adapter, all other openings being plugged. A regulator should be fitted to the air line to allow gradual application, and oil coolers which are part of composite assemblies should be adequately supported at points which are normally strengthened by the presence of other units. High temperature stressing 45, The cooler should next be immersed in glycerine (Stores Ref. 33C/245) at a temperature of 190°C. fora period of five minutes, The interior should be vented to atmosphere by fitting a stand pipe to one branch pipe, all other openings being sealed. After immersion allow the cooler to drain and cool quickly, and wash with water externally. ‘Second internal air pressure test 46, Thoroughly dry the cooler internally and repeat the test described in para. 44. ‘Hot pressure test 47. Immerse the cooler in glycerine at a temperature of 130° C. and apply air internally for not less than five minutes at the pressure indicated on the data plate or at 70 Ib. per sq. in., whichever is the greater. Warning—An armoured glass guard should be positioned over the bath to protect the operators in the event of the oil cooler failing while under pressure. Other precautions should be taken as specified in the note to para. 44. Cold pressure test 48, Completely fill the cooler with water (at approximately room temperature) and apply air pressure for five minutes at the appropriate pressure as stated in para. 44. The air line should be connected to either the inlet or outlet of the cooler, and all other openings should be sealed. ‘High temperature stressing 49. Repeat the test described in para. 45. Third internal air pressure test 50. Repeat the test described in para. 44. Note—If during any of the above tests leakage should develop in the unit and-a repair is effected, the unit must be washed and subjected to the full series of tests detailed in para. 41-55. Stand-by period 51. The oil cooler must be stored empty after the above tests for a minimum period of eight hours. Repeat tests 52. Subsequent to the lapse of the stand-by period, the cooler should be subjected to the following repeat tests:— (1) Cold pressure test as detailed in para. 48. (2) One immersion in the high temperature glycerine bath as detailed in para. 45 (3) Air-under-water pressure test as detailed in para. 44.Flow test 53. After the tests described in para. 42-52 have been completed the repaired cooler must be flow tested, using flow test equipment of an approved type such as that described in Sect. 1, Chap. 1, which also explains the method of making the test. For repaired oil coolers under the required conditions, a minimum flow of not less than 92 per cent. of that called for on the data plate of the oil cooler concerned is permissible. Casing test $4. When a repair has been made to the casing of an oil cooler which contains a pre-heating jacket, or when the matrix has been removed from such a cooler, the cooler should be air-tested before the matrix is again sealed into the casing. For this test the port between the jacket and the matrix should be Sealed and the pressure applied internally to the jacket in such a manner that any leakage from the jacket is detected. ‘The result may be considered satisfactory if the casing, immersed in water at a temperature of approximately 40° C., shows no sign of leakage after five minutes application of the casing test pressure called for on the approved drawings (not less than 5 1b. per sq. in.). Interchangeability test and final inspection 55. Check the leading measurements, as called for on the approved drawing, to ensure that no permanent distortion has taken place in excess of the specified limits. Check inlet and outlet pipes to ensure that they are free from obstruction. Remove any solder found on screw threads. Pipes which are required to enter rubber or rubber-substitute tubing should be tinned over the length of entry, and well-rounded to prevent damage to the joint. Failure to pass tests 56. If an oil cooler fails to pass any one of the tests called for in para. 41-55, it should be submitted to further examination and an effort should be made to remedy the defect. All tests must then be repeated. A cooler which cannot be repaired to a condition enabling it to pass all tests should not be returned to service. Fitting identification plate 57. Each repaired oil cooler should be identified by means of a small brass plate soldered on. to the case in close proximity to the maker’s original identification plate. The plate should bear the word “REPAIRED”, with sufficient information to identify the Repair Unit responsible for the repair. PRESERVATIVE TREATMENT General 58. After repair, secondary-surface oil coolers and other heat transfer equipment of the same type should be subjected to the preservative treatment described in the following paragraphs. Internal or fuid channels 59. To minimise corrosion of the internal or finid channels the components should be thoroughly dried internally, preferably in an oven at a temperature of approximately 100° C ‘The interior of the component should then be sealed by fitting air- and liquid-tight sealing caps of approved design to all branch pipes. Outside case 60. The external surfaces of the shell or case should be protected by an approved process. A suitable treatment for the majority of components consists of the following:— (i) One coat of universal primer, Type U.P.10, dark grey (Stores Ref. 338/647, 648 or 649) or light grey (Stores Ref. 338/650, 651 or 652). (ii) A final top coat of cellulose enamel paint (Stores Ref. 338/206), In some instances an oil- and petrol-resisting paint such as Stores Ref. 338/101 may be used as a final finish. Nole—The matrix must remain entirely free from any added finish External or air channels 61. The external surfaces of the matrix should be flushed with water and thoroughly dried. Poors ME2210/61708 147 2625 CRP Gp.t