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S-86-JN-2, -5, & -15 Boosters Assembly and Testing Procedures Prepared By: M.

: VWI-076-1 STEP 1 Step Instructions Step Instructions ANSI approved eye protection, with side shields, is required at all times

7 for specific criteria STEP 2 Do not use these grey shaded cells Do not use these grey shaded cells before starting any

1 S-86-JN-2, -5, & -15 Boosters Assembly and Testing Procedures Prepared By: M. Dacar Manufacturing Approval: Quality Approval: Revision Date: July 15, 2008 Related documents: Document No.: VWI STEP 1 Step Instructions Step Instructions ANSI approved eye protection, with side shields, is required at all times on the shop floor see ANSI Z80.7 for specific criteria STEP 2 Do not use these grey shaded cells Do not use these grey shaded cells before starting any assembly or subassembly, ensure the work area is clean and free of dirt and debris STEP 3 review Production Order for appropriate parts and part numbers check print with latest revision number as listed on Production Order K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 1 of 31

soak the Seal (P/N 92509) in a cup of hot water to

the Stop Ring (P/N S-216-56) as shown to

Ring into the groove in the Air Valve Body (P/N

$K:\Data\Visual Work Instructions\VWI-076-1 S-86$

2 soak the Seal (P/N 92509) in a cup of hot water to make it more flexible for assembly STEP 13 fold the Stop Ring (P/N S ) as shown to facilitate installation STEP 14 install the Stop Ring into the groove in the Air Valve Body (P/N ) STEP 15 lubricate the inside of the Air Valve Body with Molykote 55 or equivalent K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 2 of 31

STEP 16 lubricate the Shuttle Assembly with Molykote 55 or

Valve Body ensure the end marked "Top" is up STEP 34 install one

78238) install one (1) Spring (P/N 88543) into each Bolt install

$K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15) Booster.$

3 STEP 16 lubricate the Shuttle Assembly with Molykote 55 or equivalent STEP 17 install the Shuttle Assembly into the Air Valve Body ensure the end marked "Top" is up STEP 34 install one (1) O-Ring (P/N ) around each of two (2) Bolts (P/N 78238) install one (1) Spring (P/N 88543) into each Bolt install one (1) Detent Pin (P/N 82871) into each Bolt over the Spring coat the tips of the Detent Pins with Molykote 55 or equivalent K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 3 of 31

STEP 35 thread the Detent assemblies into the Upper Housing assembly use wrench or pneumatic gun to tighten

55 or equivalent place O-Ring (P/N 91417-256) on Air Motor Cover lubricate O-Ring (P/N 91417-225) with Molykote

$correctly with the Inlet Port of the Air Valve assembly K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15)$

4 STEP 35 thread the Detent assemblies into the Upper Housing assembly use wrench or pneumatic gun to tighten completely (must be able to remove in field using standard tools) lubricate O-Ring (P/N ) with Molykote 55 or equivalent place O-Ring (P/N ) on Air Motor Cover lubricate O-Ring (P/N ) with Molykote 55 or equivalent place O-Ring in Air Motor Cover (P/N ) install Retaining Clips (P/N ) and Air Valve assembly (P/N ) onto Air Motor Cover ensure the lettering on the Air Motor Cover is aligned correctly with the Inlet Port of the Air Valve assembly K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 4 of 31

place one (1) Lock Washer (P/N MS35335-33) over

thread six (6) Hex Head Screws (P/N MS90725-3)

Cover; tighten completely secure the Piston

$88623) over the Piston K:\Data\Visual Work$

5 place one (1) Lock Washer (P/N MS ) over each of six (6) Hex Head Screws (P/N MS ) thread six (6) Hex Head Screws (P/N MS ) through Retaining Clips into the Air Motor Cover; tighten completely secure the Piston (P/N 88622) in a vise install the Cover (P/N 88623) over the Piston K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 5 of 31

install O-Ring (P/N 91417-431) into the groove in the

subassembly onto End Cap subassembly install Washer

install the Seal (P/N 92508) onto the Air Pump Piston

$K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15)$

6 install O-Ring (P/N ) into the groove in the Air Pump Piston (P/N ) install Air Pump Piston subassembly onto End Cap subassembly install Washer (P/N AN ) and Nut (P/N MS ) onto Piston install the Seal (P/N 92508) onto the Air Pump Piston over the O-ring the Seal System should fit completely into the groove around the Air Pump Piston K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 6 of 31

thread the Shifting Nut (P/N 78259) onto the end

longer threads place Lock Washer (P/N MS35335-33)

Motor Piston and tighten do not over-tighten

$threads of the Connecting Rod K:\Data\Visual Work$

7 thread the Shifting Nut (P/N 78259) onto the end of the Connecting Rod (P/N ) with the longer threads place Lock Washer (P/N MS ) over Connecting Rod screw Connecting Rod into Air Motor Piston and tighten do not over-tighten place a small amount of Loctite 271 onto the threads of the Connecting Rod K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 7 of 31

STEP 25 install Air Pump Cylinder (P/N 88191) around Air

lies flat against the End Cap subassembly place Stop

Motor Cover over the Connecting Rod and onto the Cylinder

$K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15)$

8 STEP 25 install Air Pump Cylinder (P/N 88191) around Air Motor Piston subassembly at a 45 angle ensure the Cylinder lies flat against the End Cap subassembly place Stop Sleeve (P/N ) over Connecting Rod install the Air Motor Cover over the Connecting Rod and onto the Cylinder ensure the Connecting Rod goes through the center of the Guide Sleeve (P/N 92249) in the Air Valve Assembly K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 8 of 31

ensure the air inlet port on the Air Valve Body is aligned with the air transfer port on the End

Bracket (P/N 88187) onto Air Motor Cover with two (2) Bolts the head of the Bolts should be on the

$into the remaining bolt holes K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15) Booster.$

9 ensure the air inlet port on the Air Valve Body is aligned with the air transfer port on the End Cap install one (1) Washer (P/N ) onto each of the six (6) Bolts (P/N 91661) install Mounting Bracket (P/N 88187) onto Air Motor Cover with two (2) Bolts the head of the Bolts should be on the same side as the Air Valve assembly and the Mounting Bracket should be opposite the lettering on the Air Motor Cover insert four (4) Bolts with Washers (P/N AN L) and Nuts (P/N MS ) into the remaining bolt holes K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 9 of 31

install Self-Locking Nut (P/N 90686) onto the

(91417-138) with Molykote 55 or equivalent

Air Valve Body install Air Valve Cover (P/N

$K:\Data\Visual Work Instructions\VWI-076-1 S-86$

10 install Self-Locking Nut (P/N 90686) onto the Connecting Rod lubricate Packing O-Ring ( ) with Molykote 55 or equivalent install Packing O-Ring into the groove in the Air Valve Body install Air Valve Cover (P/N ) onto Air Valve Assembly secure with four (4) Hex Head Screws (P/N MS ) K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 10 of 31

$K:\Data\Visual Work$

11 lubricate the threads on each Bolt with Petroleum Jelly place the other Mounting Bracket on the End Cap and secure with a Washer (P/N AN L) and Nut (P/N MS ) on each Bolt K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 11 of 31

secure Bolts with a Washer (P/N AN960-616L) and Nut (P/N MS21042-6) on

tape and lubricate the square male side of the 90 Elbow (P/N

$Cap K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15) Booster.$

12 secure Bolts with a Washer (P/N AN L) and Nut (P/N MS ) on each Bolt tighten each Nut with a 9/16" wrench torque to ft. lbs. tape and lubricate the square male side of the 90 Elbow (P/N MS D) thread one 90 Elbow into the air transfer port of the Air Valve Body thread one 90 Elbow into the air transfer port of the End Cap K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 12 of 31

13 K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 13 of 31

the 90 Elbows in the exhaust port of the

$Cooling Jacket K:\Data\Visual Work$

14 install the 3/8" tubing assembly onto the 90 Elbows in the air transfer ports of the Air Valve Body and End Cap install the 5/8" tubing assembly onto the 90 Elbows in the exhaust port of the Air Valve Body and the 90 Elbow in the Cooling Jacket K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 14 of 31

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STEP 61 visually examine the booster for

$adaptor into the air valve inlet K:\Data\Visual$

24 STEP 61 visually examine the booster for workmanship refer to the Pressure Rating Table to determine the appropriate Inlet Precharge and Minimum Outlet Pressures STEP 62 i install hose adaptor into the air valve inlet K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 24 of 31

$K:\Data\Visual Work$

25 install hose adaptor into the Inlet Check Valve Body install Test Muffler STEP 63 install the Discharge Pressure Gage into the Outlet Check Valve K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 25 of 31

$appropriate pressure K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15) Booster.$

26 STEP 67 connect the precharge hose to the Inlet Check Valve port STEP 68 connect the driving air supply (shop air at 100 PSI driving air pressure) to the air valve inlet STEP 69 close the Bleed Valve open the Air Shut Off Valve STEP 70 slowly raise the Precharge to the appropriate pressure K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 26 of 31

STEP 71 once the Precharge reaches the appropriate minimum pressure, verify that the rated Outlet Pressure has been obtained STEP 72 stall the booster to verify the

$leakage the booster should operate smoothly without sticking, binding, or hesitation at all pressures K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15) Booster.$

27 STEP 71 once the Precharge reaches the appropriate minimum pressure, verify that the rated Outlet Pressure has been obtained STEP 72 stall the booster to verify the Inlet Check Valve performance close the Air Shut Off Valve STEP 73 disconnect the driving air supply hose to verify the Outlet Check Valve performance the gage should continue to read the appropriate rated Outlet Pressure STEP 74 for the booster to be acceptable, there should be no indication of external leakage or check valve leakage the booster should operate smoothly without sticking, binding, or hesitation at all pressures K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 27 of 31

28 STEP 75 open the Bleed Valve STEP 76 open the Precharge Valve STEP 77 disconnect the precharge hose from the Inlet Check Valve port release the pressure in the booster by turning the red handle on the Discharge Pressure Gage K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 28 of 31

29 K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 29 of 31

STEP 78 unscrew and remove the test muffler remove the

install thread protector plugs into all of the ports STEP

$K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15)$

30 STEP 78 unscrew and remove the test muffler remove the Discharge Pressure Gage and all remaining adaptors STEP 79 install thread protector plugs into all of the ports STEP 80 make Nameplate add Nameplate to the front of the booster add sticker to the front of the booster K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 30 of 31

$in shipping to eliminate movement Comments: K:\Data\Visual Work Instructions\VWI-076-1 S-86 (2-15) Booster.$

31 STEP 81 make appropriate cardboard box ( x x ) write the model number, the part number, the serial number, and the date code onto the box STEP 82 place completed booster in box include an Operation and Maintenance Manual, a Warranty Tracking Form, the Illustrated Parts Breakdown, and the Rear Support in the box DO NOT staple the box closed; it will be "foamed" in shipping to eliminate movement Comments: K:\Data\Visual Work Instructions\VWI S-86 (2-15) Booster.xls Page 31 of 31

Relief Valve Assembly and Testing Procedures

Relief Valve Assembly and Testing Procedures Template Systems2win.com. Licensed for use only by Curtiss Wright Flow Control - Farris Group (4 locations) Prepared By: M. Dacar Engineering Approval: B. Smith Quality Approval: J. Kabat Revision Date: