This leaf issued with A.L. No. 16 A.P.2850A, Vol. IL, Part 8, Sect. 4 September, 1946 CHAPTER 5 INSTRUCTIONS FOR REPAIR OF SERCK TUBULAR OIL COOLERS LIST OF CONTENTS Para. Para, Introduction ee eae aD Thermometer adaptor tube... 8 Serck oil cooler WS.9041 "(Stores Repairs to case and external fittings 9 ‘Ref. 278/2445)— Cracks in brazing between baffle and Brief description 4 case See 10 Parts and materials, 5 Data for testing ul Repairs to tube-block | 6 LIST OF ILLUSTRATIONS Fig. Fig. Serck oil cooler WS.9041 ... .-.“T__ Repairing cracks in brazing between baile ‘and case (Serck oil cooler WS.9041) .. Introduction 1, Serck tubular oil coolers are similar in principle to other oil coolers of the tubular type, the tube-block, or core, being an assembly of round copper tubes, the ends of which are swaged ‘out to form true hexagons. ‘The tubes are bonded together by dipping their end expansions in flux and solder baths. The tube-block is usually divided into sections, or passes, by baffles having ports at alternate ends, so that oil entering one section is compelled to flow along the entire length of the tubes before entering the next pass. The tube-block assembly is normally mounted in a case consisting of an inner and an outer shell which form a passage round the block through which the flow of oil can be directed when the oil in the tube-block is at a low temperature. The coolers are made in a variety of sizes and shapes to suit the different requirements of the aircraft and power plants for which they are designed, and are described in greater detail in Vol. I, Sect. 4, Chap. 5 of this publication. 2, When undertaking repairs reference should first be made to Chap. 1 of this section, which gives general instructions on the cleaning, inspection, repair and final testing of tubular oil coolers. ‘The information in this chapter is supplementary to the foregoing, and provides any additional instructions necessary when repairing Serck tubular oil coolers, 3. The coolers are identified by the makers’ part numbers and by Stores ‘Ref, numbers, as given on the identification plate affixed to each cooler. SERCK OIL COOLER WS.9041 (Stores Ref, 27B/2445) Brief description The complete assembly of the Serck oil cooler WS.9041 (see fg. 1) consists of a rectangular matrix divided into ten main sections (73) by nine baffle plates (9); an external by-pass or warming jacket (7), comprising inner and outer shells; mounting channels (4); inlet pipe (2); outlet pipe (2); by-pass inlet pipe (3); a thermometer adaptor tube (9) soldered into the matrix at 8; and a § in, B.S.P. screwed drain plug located at the bottom of the outer casing. Oil flow through the cooler is controled by a thermostatic valve installed as a separate unit between the engine scavenge pump and the cooler, the valve directing the oil through the appropriate pipe-lines of the engine lubrication system to the by-pass connection on the cooler, or to the inlet branch of the cooler. according to temperature conditions. Oil entering the cooler by the by-pass connection flows round the external jacket and emerges at the outlet pipe without entering the matrix. That c catia)Fig, 1.—Serek oil cooler WS.9041 INLET Pere ouTLeT Pe BY-PASS INLET PIPE MOUNTING CHANNELS BAFFLE PLATE aFFLe PORTS EXTERNAL JACKET THERMOMETER TUBE HOUSING Key 9 THERMOMETER ADAPTOR TUBE 0 PORT IN ADAPTOR TUBE SEALING WASHER BLANKING CAP MATRIX SUB-ASSEMBLY HALF-ROUNO TUBES HEXAGONALENDED TURES PENTAGONALENDED TUBESThis leaf issued with A.L. No. 16 AP2850A, Vol. II, Part 8, Sect. 4, Chap, 5 September, 1946 directed to the inlet pipe flows horizontally through the ten passes of the matrix, its path being controlled by the baffle plates which have ports at alternate ends (6), and completes its circuit of the cooler via the upper half of the external jacket to the cooler outlet. Parts and materials 5. The following is a list of parts and sub-assemblies which may be renewed when this cooler is repaired:— Key Ref. Stores Detail or No. Ref. No. Nomenclature No. off Part No. (fig. 1) Tubes, double-expansion, 5-25 mm. x 230 mm:— Hexagon 2034 ws.9922 16 Pentagon 487 wS.9922 16 Half-round 16 WS.9922 4 Matrix sub-assembly 1 WS.9431 13, Thermometer tube 1 WS.9672 9 Thermometer tube blanking cap 1 WS.6336 12 Thermometer tube sealing washer 1 WS.6337 u Drain plug 1 WS.5028 Drain plug washer 1 WS.5029 Drain plug lock plate 1 WS.5030 ‘Repairs to tube-block 6. It is important to note that all joints in this tube-block are made with a high melting- point solder consisting of 1 per cent. tin, 1} per cent. silver and 97} per cent. lead, and the same alley is employed for bonding the matrix sections to the shell and bafile plates. A solder of similar composition must be used for repairs as otherwise it will be impossible to obtain properly fused and efficient joints. 7. Apart from this difference, the methods of effecting repairs to the tube-block assembly are the same as those described in Chap. 1, to which reference should be made as follows:— (1) For instructions on repairing minor surface leaks (para. 28-32). (2) For instructions on removing tube-block sections, and’ assembling and fitting new sections (para, 33-48). ‘Thermometer adaptor tube 8. Cooling tubes are omitted from the section of matrix at the extreme outboard end of the cooler (8 in jig. 1) to accommodate the thermometer adaptor tube (9). The adaptor tube must be fitted with the open end towards the rear of the cooler, as illustrated, and the rectangular port (Z0) in the side of the tube must face inward to permit flow of oil into the tube. The tube should be firmly soldered into the matrix by sweating the shoulder at each end of the tube to the flats of the hexagonal ends of surrounding cooling tubes, gaps being filled in with half-round tubes to ensure complete packing and bonding. The sealing washer (21) and blanking cap (J2) should then be fitted to the thermometer adaptor tube. Repairs to case and external fittings 9. The inner and outer shells of the cooler with the baffle plates and all external fittings must be treated as an integral unit for normal repair purposes, as all the components are hard- soldered or brazed and riveted in position and cannot be removed and refitted when the inner and outer shells have been finally assembled. Repairs are, therefore, confined to the rectifica- tion of minor damage without dismantling. The methods of effecting such repairs described in Chap. 1 of this Section are applicable to this cooler, and reference should be made to that chapter as follows:— (1) For instructions on the repair of rivet leaks (para. 49-50) (2) For instructions on the repair of splits and cracks in the case and channels (para, 52-59 and para, 68-70) (3) For instructions on the removal of dents (para. 63-64 and para. 66-67).Cracks in brazing between baffle and case 10. By-passing may occur because of the development of cracks in the brazing between the baffle plates and inner case (see jig. 2). This fault should be rectified as follows:— (1) Remove the section of tube-block necessary to obtain access to the faulty joint, (2) Thoroughly clean and tin the cracked brazing along its entire length. Tin a length of } in. dia. brass wire, 9 in, long, and thoroughly sweat the wire into position along the entire length of brazing (J) (3) Remove the half-tube from the corner of the tube-block section which will be adjacent to the repair (2), fit the block and sweat into position. Any gap remaining between the wire and tube-block should be filled with solder. Fig. 2.—Repairing cracks in brazing between baffle and ease (Serok oil cooler W8.9041) Data for testing 11. After any repair has been executed the cooler must be thoroughly cleaned to remove flux, dried, and tested in accordance with the detailed instructions in Chap. 1 of this Section. ‘The figures called for in the tests are as follows:— (1) Pressure tests to a maximum of 120 Ib. per sq. in, (2) High temperature stressing at 130°C. (8) Oil flow test at 6-9 gall. per min. (4) Weight (empty): 72 1b. minimum, 76 Ib. maximum. uioo1 mas27/G1776 47 2628 CAP Gp.t