Seal Dynamics

13780 McCormick Drive Tampa, Florida 33626

Engineering Report Number: SD3062011INSTL Revision: IR

Initial Released Date: 04/26/2011

Seal Dynamics New Product Development Group 13780 McCormick Drive Tampa, FL 33626

Page 1 of 8

Installation Instructions

APU Oil Filler Valve Kit used on Honeywell Model GTCP36-280[D] APU

installed in Boeing MD-88 Series Aircraft

Report Number: SD3062011INSTL Revision: IR, Dated 04/26/2011

Seal Dynamics

13780 McCormick Drive Tampa, Florida 33626

Engineering Report Number: SD3062011INSTL Revision: IR

Initial Released Date: 04/26/2011

Seal Dynamics New Product Development Group 13780 McCormick Drive Tampa, FL 33626

Page 2 of 8

Log of Revisions

Revision Description Date Approval

Seal Dynamics

13780 McCormick Drive Tampa, Florida 33626

Engineering Report Number: SD3062011INSTL Revision: IR

Initial Released Date: 04/26/2011

Seal Dynamics New Product Development Group 13780 McCormick Drive Tampa, FL 33626

Page 3 of 8

Table of Contents

Revision Log 2 Table of Contents 3 1.0 Scope 4 2.0 General Description 4 3.0 Distribution 4 4.0 Reference Publications 4 5.0 Work Instructions 4

Seal Dynamics

13780 McCormick Drive Tampa, Florida 33626

Engineering Report Number: SD3062011INSTL Revision: IR

Initial Released Date: 04/26/2011

Seal Dynamics New Product Development Group 13780 McCormick Drive Tampa, FL 33626

Page 4 of 8

1.0 Scope This report covers Work Instructions for the Installation of Seal Dynamics APU Oil Filler Valve Kit on Honeywell Model GTCP36-280[D] APU installed in Boeing MD-88 aircraft. Existing installation instructions for the APU are not affected by this modification and remain valid for use. 2.0 General Description Seal Dynamics part number SD92001-3 is an oil filler valve kit which replaces an existing oil filler neck and cap on Honeywell Model GTCP36-280[D] APU. An oil fill housing, part number 3863058-5 or 3863058-6 (post SB GTCP36-49-7628) is attached to the APU gearbox and provides a fill port used for oil servicing and includes an oil level sight gage. The Seal Dynamics oil filler valve provides an internal spring loaded poppet valve which helps prevent oil and oil fumes from escaping. 3.0 Distribution This document is an integral part of the STC and PMA data package for the installation of the APU oil filler valve on Honeywell Model GTCP36-280[D] APU installed in Boeing MD-88 aircraft. Seal Dynamics will furnish at least one complete copy of this document to the aircraft operator at the time of the PMA issuance. Seal Dynamics will authorize the aircraft operator to make this document available to any person required to comply with any of the terms contained in this document. 4.0 Reference Publications Applicable to Honeywell APU Model GTCP36-280[D]

Honeywell Component Maintenance Manual 49-26-49

Honeywell Illustrated Parts Catalog 49-26-45

Honeywell Maintenance Manual 49-26-47

Honeywell Service Bulletin GTCP36-49-7628 5.0 Work Instructions NOTE: The standard configuration of the Oil Fill Housing Assembly uses a cast housing part number 3863058-5. There is a significant quantity of assemblies in the fleet which were manufactured under Minor Deviation and use a machined housing part number 3863058-6. When using a cast housing, the filler neck is pinned with three equally spaced pins. When using the machined housing, which has a square body, three pins are required, the three pins will not be equally spaced, but will be installed on the three faces away from the sight glass flange. (A) Remove Oil Fill Housing Assembly part number 3863058-5 or 3863058-6 and re-work as follows:

Seal Dynamics

13780 McCormick Drive Tampa, Florida 33626

Engineering Report Number: SD3062011INSTL Revision: IR

Initial Released Date: 04/26/2011

Seal Dynamics New Product Development Group 13780 McCormick Drive Tampa, FL 33626

Page 5 of 8

WARNING: USE THE CORRECT PERSONAL PROTECTION. PROCEDURES THAT NEED GRIND/MACHINE WORK WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. (1) Carefully drill or punch out pins holding filler neck to housing, taking care not to oversize the holes in the housing. WARNING: USE THE CORRECT PERSONAL PROTECTION. HEATED PARTS WILL CAUSE BURNS. (2) Heat housing with heat gun to loosen epoxy joint and remove filler neck and screen. Discard filler neck and clean all debris from screen for re-installation. WARNING: USE THE CORRECT PERSONAL PROTECTION. ABRASIVE BLAST PROCEDURES WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. (3) Glass bead to remove epoxy compound on housing. WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL USED DURING THIS INSPECTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. THE HOT BLACK LIGHT WILL CAUSE BURNS TO BODY AREAS WITH NO PROTECTION. (4) Do a fluorescent penetrant inspection on the oil fill housing with the instructions given in MIL-STD-6866 or equivalent. No cracks permitted. (5) Re-install screen into housing. (6) Install the new Oil Filler Valve Assembly part number SD92002 into oil fill housing as follows: (a) Apply adhesive (3M 2214 HI-TEMP) per manufacturer’s recommendations, on the housing and oil filler valve joint areas. (b) Press the oil filler valve assembly into the housing until it contacts the screen, see Figure 1 for orientation. Remove any excess adhesive. (c) Cure adhesive per manufacturer’s directions (250ºF for 40 Minutes).

Seal Dynamics

13780 McCormick Drive Tampa, Florida 33626

Engineering Report Number: SD3062011INSTL Revision: IR

Initial Released Date: 04/26/2011

Seal Dynamics New Product Development Group 13780 McCormick Drive Tampa, FL 33626

Page 6 of 8

Figure 1 Oil Filler Valve

Installation

(7) Install pins, part number SD92004, into housing as follows: WARNING: USE THE CORRECT PERSONAL PROTECTION. PROCEDURES THAT NEED GRIND/MACHINE WORK WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. (a) Drill three Ø.063/.062 holes in new Oil Filler Valve Assembly using existing housing holes for alignment, see Figure 2. (b) Install three (3) pins part number SD92004 with locking compound (Loctite 290) per MIL-S-46163, Type 3, Grade R. Pins to be flush to .020 below housing surface. Cure locking compound per manufacturer’s directions.

Oil Filler Valve Assy P/N SD92002

Housing P/N 3863058-6

Screen

Filler Neck Slot Orientation

Valve Hinge Pin Orientation

Apply adhesive to these surfaces

Seal Dynamics

13780 McCormick Drive Tampa, Florida 33626

Engineering Report Number: SD3062011INSTL Revision: IR

Initial Released Date: 04/26/2011

Seal Dynamics New Product Development Group 13780 McCormick Drive Tampa, FL 33626

Page 7 of 8

Figure 2 Pin Installation

(8) There is a small vent hole in the top of the sight glass cavity. Match drill a hole in the new Oil Filler Valve to align with this vent hole, see Figure 3.

Figure 3 Vent Hole Location

Pin P/N SD92004

3 Req’d

Match Drill Vent Hole

Seal Dynamics

13780 McCormick Drive Tampa, Florida 33626

Engineering Report Number: SD3062011INSTL Revision: IR

Initial Released Date: 04/26/2011

Seal Dynamics New Product Development Group 13780 McCormick Drive Tampa, FL 33626

Page 8 of 8

(9) Secure the new Filler Cap Assembly part number SD92006 onto top of new Oil Filler Valve Assembly and install the sight glass with sight glass packing onto oil fill housing as shown in Figure 4. Tighten sight glass bolts to a torque value of 25 in-lb.

Figure 4 Filler Cap & Sight Glass

Installation

(10) Pressure test the oil fill housing assembly at 10 PSIG for 2 minutes. No leaks permitted. (11) Permanently mark oil fill housing, see Figure 4, per AS478-2D with the following information:

“Seal Dynamics” “Tampa FL” “Modified per STC [Applicable STC]” “Date [STC Approval Date]” (12) Re-install the oil fill housing assembly onto the APU per Honeywell CMM procedures. Make a record of this STC modification in the applicable engine or airframe log books.

Filler Cap (shown in fully closed position) Filler Cap Assy

P/N SD92006

Attach Lanyard with this bolt

Apply marking to side of oil fill housing, see (11)