e. Inspect

Figure 9-78. Aftercooler and Intake Manifolds (Sheet 2 of 2)

Figure 9-79. Tightening Sequence, Aftercooler Housing Covers

TM-9-6115-604-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 Kw. 1 Phase-2 Wire 1 Phase -3 Wire 3 Phase -4 Wire 120. 120/240 and 120/208 Volts Manual
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TM 9-6115-604-34 NAVFAC P-8-633-34 CAUTION To avoid damaging the cores, apply air pressure gradually and do not exceed a pressure of 30 psi (207 kPa). (2) Reverse flush the cores (30) thoroughly. Allow the core to fill with water, and flush, using short bursts of air pressure. Apply the air pressure gradually, and allow the core to fill with water between each burst. Continue the flushing procedure until all traces of rust and scale have been removed. This will be evident by dear water flowing from the inlet tube. e. Inspect. NOTE In the following procedure, repair or replace specific parts as instructed. Repair or replace all other parts in accordance with step g, below. (1) Check all capscrews and threaded holes for damaged or stripped threads. Repair slight thread damage by chasing with a tap set. Repair stripped holes in accordance with paragraph 2-12. Replace stripped capscrews. (2) Check the outlet connections (14, Figure 9-78), inlet connections (20), adapter connections (17), transfer tube (21), and transfer housing (25) for cracks, warped gasket surfaces, or damaged packing grooves. Replace any defective parts. (3) Visually inspect the air crossover housings (4), crossover connections (9), and tubes (7) for cracks, and warped or damaged gasket or packing surfaces. If cracks or porosity is suspected, check with dye penetrant, MIL-1-25135, in accordance with MIL-1-6866. Replace cracked or porous components. (4) Check the covers (28) for damaged or warped gasket surfaces. Check for cracks and porosity using dye penetrant, MIL-1-25135, in accordance with MIL-1-6866. (5) Check the housing (34) for damaged or warped gasket surfaces. Check for cracks and porosity using dye penetrant, MIL-1-25135, in accordance with MIL-1-6866. (6) Check the plates (36) and supports (40) for cracks. (7) Check the cores (30) as follows: (a) Check for bent fins, and bent or damaged gasket surfaces. (b) Check the inlet and outlet tubes for dents and out-of-roundness. Check the soldered joints for corrosion. (c) Check the core tubes for soundness and evidence of internal corrosion. Press lightly against the tube wall; tubes that dent or penetrate easily have been eaten away by internal corrosion. f. Test the aftercooler cores (30, Figure 9-78) as follows: (1) Plug or block off either the inlet or outlet tube, and attach a regulated air supply to the other tube. CAUTION To avoid damaging or permanently distorting the core, do not exceed an air pressure of 15 psi (103 kPa). (2) Immerse the core in a water tank and pressurize the core to 10 psi (69 kPa). Escaping air bubbles will show the location of any leak points. g. Repair. (1) Repair slightly warped or nicked gasket surfaces on the air crossover housings (4, Figure 9-78) and crossover connections (9) using a flat mill file. Replace the crossovers or connections i they are badly warped. (2) Refinish a warped gasket surface on the covers (28) or housing (34) using a surface grinder. (3) Replace the crossover housings (4), covers (28), or housing (34), i porosity or cracks extend through the capscrew holes. (4) Repair acceptable cracks or porosity in the crossover housings (4), covers (28), or housing (34) by welding in accordance with MIL-STD-248. 9-136

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