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Rolls-Royce M250-C20R SERIES OPERATION AND MAINTENANCE 73-00-00
Rolls-Royce M250-C20R SERIES OPERATION AND MAINTENANCE 73-00-00
Rolls--Royce
General
NOTE:
The vacuum check is a troubleshooting procedure to detect engine or airframe fuel system leaks,
and not mandatory inspection unless otherwise specified by the airframe manufacturer.
NOTE:
The M250--C20R/1 series engines contain either a large compressor scroll or a reduced scroll.
A M250--C20R/1 engine assembly containing a large compressor scroll (single port customer
bleed) is identified as P/N 23034148. A M250--C20R/1 engine assembly containing a reduced
scroll (Dual port customer bleed) is identified as P/N 23038200. For illustration purposes, the
reduced scroll engine configuration P/N 23038200 will be referred to as M250--C20R/1(RS)
throughout this manual.
A.
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29.
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5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Union (2)
Not used
Elbow
Not used
Not used
Packing (2)
Accumulator (6 cu in.)
Not used
Nut
Bolt
Spacer
Clamp
Union (2)
Packing (2)
Bushing
Packing
Fuel pump and filter assy
Nut (3)
Washer (3)
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Gasket
Packing
Not used
Packing
Filter element
Packing
Fuel nozzle
Nut
Washer (2)
Check valve
End piece
Gasket
Spring
Poppet
Packing
Spring guide
Housing
Backup ring
Shroud
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2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
12A.
13.
14.
Elbow
Nut
Packing
Pc filter
Nut
Bolt
Clamp
Element
Seal
Housing
Not used
Not used
Plug
Packing
Elbow
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Nut
Packing
Union (2)
Packing
Governor
Nut (3)
Washer (3)
Packing
Fuel control
Nut (3)
Washer (3)
Packing (2)
Plug
Packing
Spring
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Clip
Filter
Pin
Washer
Spring
Strainer
Sleeve
Tee
Nut
Packing
Shutoff valve assy
Nut (2)
Bolt (2)
Plug and bleeder
Packing
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*2.
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*4.
*5.
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7.
*8.
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17.
18.
19.
20.
Union (2)
Union
Elbow
Elbow
Nut
Packing (2)
Accumulator (6 cu in.)
Accumulator (3 cu in.)
Nut
Bolt
Spacer
Clamp
Union (2)
Packing (2)
Bushing
Packing
Fuel pump and filter assy
Nut (3)
Washer (3)
Gasket
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Packing
Not used
Packing
Filter element
Packing
Fuel nozzle
Nut
Washer (2)
Check valve
End piece
Gasket
Spring
Poppet
Packing
Spring guide
Housing
Backup ring
Shroud
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30.
31.
32.
33.
34.
35.
36.
37.
38.
Gasket
Packing
Not used
Packing
Fuel filter element
Packing
Fuel nozzle assy
Nut
Washer (2)
Check valve assy
End piece
Gasket
Spring
Poppet
Oring
Guide
Housing
Ring
Shroud
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2.
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9.
10.
11.
12.
*12A.
*13.
14.
Elbow
Nut
Packing
Pc filter
Nut
Bolt
Clamp
Element
Seal
Housing
Not used
Not used
Plug
Packing
Elbow
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Nut
Packing
Union (2)
Packing
Governor
Nut (3)
Washer (3)
Packing
Fuel control
Nut (3)
Washer (3)
Packing (2)
Plug
Packing
Spring
30.
31.
32.
33.
34.
35.
36.
*37.
*38.
*39.
40.
41.
42.
43.
44.
Clip
Filter assy
Pin
Washer
Spring
Strainer assy
Sleeve
Tee
Nut
Packing
Shutoff valve assy
Nut (2)
Bolt (2)
Plug and bleeder
Packing
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7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Union (2)
Not used
Elbow
Not used
Not used
Packing (2)
Accumulator (6 cu in.)
Not used
Nut
Bolt
Spacer
Clamp
Union (2)
Packing (2)
Bushing
Packing
Fuel pump and filter assy
Nut (3)
Washer (3)
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Gasket
Packing
Not used
Packing
Filter element
Packing
Fuel nozzle assy
Nut
Washer (2)
Check valve assy
End piece
Gasket
Spring
Poppet
Packing
Spring guide
Housing
Backup ring
Shroud
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Union
Packing (2)
Accumulator (6 cu in.)
Accumulator
Nut (2)
Bolt (2)
Spacer (2)
Clamp (2)
Elbow
Union (2)
Packing (3)
Elbow
Nut
Packing
Tee Reducer
Cap Assy.
Nut
Packing
Pump And Filter Assy.
Nut (3)
Washer
Rubber Gasket
Packing
Fuel Pump Suction
Assy.
High Pressure Fuel
Filter Assy.
Bolt (3)
Washer (3)
Packing
Plug (2)
Packing(2)
31.
32.
33.
34.
35.
36.
37.
38.
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9.
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11.
12.
12A.
Elbow
Nut
Packing
Pc filter assy
Nut
Bolt
Clamp
Element
Seal
Housing
Not used
Not used
Plug
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Packing
Elbow
Nut
Packing
Union (2)
Packing
Governor
Nut (3)
Washer (3)
Packing
Fuel control
Nut (3)
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Washer (3)
Packing (2)
Plug
Packing
Spring
Clip
Filter
Pin
Washer
Spring
Strainer
Sleeve
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(1)
Loose lines can develop from improperly tightened Bnuts. Damaged fittings are the
result of incorrect handling or improper installation procedures. Insufficient tightening
of the Bnut allows wear of the fitting through normal operating vibrations applied to a
loose flare.
Remove the line and check the flares for wear, bends, dents, feathered edges or
other deformities.
(b)
Inspect nipple portion of fitting for damage, grooves or wear. Detect grooves in the
mating surface by placing a small metal straight edge on the beveled surface and
viewing for gaps.
(c)
Determine the cause of irregularities and take steps to correct the situation.
(d)
2.
Tube clamping should be in accordance with the 250C20R Series Parts Catalog (Pub. No. CSP23007).
For detailed installation instructions, refer to Rigid Tube Inspection and Installation,
para 8., 720000, EngineServicing.
Inspection/Check
A.
Isolate the source of leakage by immediately applying boost pump pressure to the system.
Fuel leakage shall be limited to the following specific areas and quantities.
Max. Leakage Rate
Drops/min
cc/min
Unit or Area
Seal drain of fuel pump
Splitlines, tubes and fittings
(2)
20
None
1
0
If the fuel leak cannot be isolated using only boost pump pressure, make an engine start;
then, carefully reinspect the engine compartment with the engine running. If necessary,
reinspect immediately upon shutdown.
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B.
Tighten all component fittings and coupling nuts to the recommended torque. If
leakage does not stop, replace the affected part.
(b)
After leakage repair has been accomplished, recheck the fuel system under boost
pump pressure.
(2)
Disconnect and remove the pressure sensing line between the scroll and the Pc
filter. Hold the filter and loosen the coupling nut.
(b)
(c)
Apply 50--80 psi (345--552 kPa) filtered air (10 micron) to the Pc filter. Air will immediately release from the pressure regulating air valve port on the power turbine governor.
(d)
Use a liquid soap solution to check all fittings and lines in the system for leaks.
Leakage is not permitted.
(e)
Use a liquid soap solution to check cover and parting surfaces on the fuel control
and governor. Cover and parting surfaces that produce small bubbles of the soap
solution does not indicate a leak of sufficient quantity to warrant concern. These
leaks were present during the initial calibration and were adjusted correctly at that
time.
(f)
Decrease the pressure to 20--22 psi (138--152 kPa) and check the govornor diaphragm for leakage. No leakage is permitted. If leakage is found from the governor
diaphragm, remove the safety wire from the screws, back off the screws and then
tighten to 8--11 lb in. (0.9--1.2 N m). After 20 minutes retighten the screws to
8--11 lb in. (0.9--1.2 N m). If diaphragm continues to leak, replace governor.
(g)
Return throttle to the closed position. Clean the soap solution from the engine after
the check is completed.
(h)
Reinstall Pc line. Tighten coupling nuts to 80--120 lb in. (9.0--13.6 N.m). Hold the Pc
filter while tightening the coupling nut.
Alternative methods for checking leaks in the fuel system (This alternative procedure must
not be considered standard practice, but only used when filtered air (10 micron) is not
available):
(a)
Install removed components. Refer to the OMM for installation procedures and
proper torque for all connections.
(b)
(c)
Use a liquid soap solution to check all fittings and lines in the system for leaks.
Leakage is not permitted.
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C.
(d)
Use a liquid soap solution to check cover and parting surfaces on the fuel control
and governor. Cover and parting surfaces that produce small bubbles of the soap
solution does not indicate a leak of sufficient quantity to warrant concern. These
leaks were present during the initial calibration and were adjusted correctly at that
time.
(e)
Return throttle to the closed position. Clean the soap solution from the engine after
the check is completed.
(f)
Operate the engine at maximum power to check for proper function of the fuel system components before the aircraft is returned for service.
(1)
WHEN THERE IS EVIDENCE THAT THE FUEL PUMP FILTER HAS BEEN BYPASSED, THE GAS PRODUCER FUEL CONTROL INLET FILTER, THE FUEL
NOZZLE FILTER,THE GOVERNOR FILTER, AND THE HIGH PRESSURE FUEL
FILTER, IF APPLICABLE, MUST BE CLEANED. (REFER TO SPECIAL INSPECTIONS, TABLE 603, 72--00--00, ENGINE--INSPECTION/CHECK, FOR DETAILS.)
IF ANY CONTAMINATION IS FOUND IN THE FUEL NOZZLE FILTER, THIS WILL
REQUIRE THAT THE FUEL CONTROL BE SENT TO AN AUTHORIZED REPAIR
FACILITY FOR INTERNAL CLEANING. REFERENCE MUST ALSO BE MADE TO
THE AIRFRAME MAINTENANCE MANUAL FOR FUEL SYSTEM MAINTENANCE
FOLLOWING FUEL CONTAMINATION.
(2)
(3)
(4)
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D.
Maintenance of the fuel system can result in air entrapment in the fuel lines. To prevent
subsequent false starts or flameouts, purge air from the fuel system whenever any of the
following conditions are encountered:
WARNING: THE FUEL/AIR DISCHARGE DURING PURGING IS IRRITATING TO THE
EYES AND HIGHLY FLAMMABLE. MECHANICS MUST TAKE SUITABLE
MEASURES TO PROTECT THEIR EYES AND PREVENT FIRE.
WARNING: MAKE SURE THAT THE AIRCRAFT IS ADEQUATELY GROUNDED. (SEE
AIRCRAFT MANUFACTURERS INSTRUCTIONS FOR PROPER
GROUNDING PROCEDURES.)
(2)
(a)
The fuel filter element or the fuel pump assembly has been replaced.
(b)
The fuel lines have been opened (anywhere between the fuel tank and the fuel
nozzle).
(c)
(d)
(e)
The fuel pump fuel filter bowl has been drained without start or boost pumps on.
(f)
The engine has been shut down using the emergency fuel shutoff valve.
(g)
(h)
(b)
Disconnect the fuel supply hose from the fuel nozzle. Be prepared to catch fuel
from the fuel hose.
(c)
(d)
(e)
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E.
(f)
(g)
Motor the engine for approximately 15 sec or until there is no evidence of air coming from the fuel supply hose.
(h)
Close the throttle and reconnect the fuel supply hose to the fuel nozzle. Tighten the
coupling nut at the fuel nozzle to 80--120 lb in. (9.0--13.6 N.m).
(i)
Turn off the boost pump(s)/start pump(s) and reactivate the ignition system.
Purging Air From Filter Bowl (Sundstrand (Pesco) and Argo--Tech (TRW) Pumps)
WARNING: THE FUEL/AIR DISCHARGE DURING PURGING IS IRRITATING TO THE EYES
AND HIGHLY FLAMMABLE. MAKE SURE TO PROTECT EYES AND PREVENT
FIRE.
WARNING: MAKE SURE THAT THE AIRCRAFT IS ADEQUATELY GROUNDED (SEE AIRCRAFT MANUFACTURERS INSTRUCTIONS FOR PROPER GROUNDING PROCEDURES.)
F.
(1)
Remove lockwire from the upper drain plug in the filter bowl cover.
(2)
Deactivate the ignition system and place the gas producer lever in FUEL OFF.
(3)
(4)
Loosen the upper drain plug (approx 1/2 turn) until a solid stream of fuel is emitted. Use a
shop towel to catch the spray. Retighten the plug to 40--65 lb in. (4.5--7.3 N.m).
(5)
(6)
Remove any fuel that may have spilled in the engine compartment.
(7)
(8)
Purge the fuel system. (Refer to Purging the Fuel System, para 2.D., this section.)
(2)
(3)
Turn on the aircraft boost pump (if equipped) or motor engine with starter until a solid
stream of fuel is emitted from the tee.
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G.
(4)
(5)
(6)
Reconnect the vapor line to the tee fitting (if provided in aircraft fuel system).
(7)
Purge the fuel system. (Refer to Purging the Fuel System, para 2.D., this section.)
Vacuum Check of Fuel System Lines and Components (M250--C20R, --C20R/1, --C20R/1(RS),
--C20R/2, --C20R/4, --C20R(ST) Engines).
NOTE:
The following vacuum check procedure is provided to check both the engine and airframe fuel
system components to isolate the location of a possible leak in the fuel system. (Refer to the applicable airframe manual for additional information.)
NOTE:
(1)
Figure 204 provides a flow diagram of the check procedure. Circled numbers on the
flow diagram refer to procedural steps in this procedure.
Verify at the aircraft fuel tank that the fuel selector valve is in the closed position.
NOTE:
During the vacuum check procedure, it will be necessary to disconnect various fuel
lines. Prior to disconnecting any fuel line, verify that the coupling nuts and fittings
were tightened to the proper torque. If insufficient torque was applied, note how
far the coupling nut or fitting rotates to reach the proper torque. Inspect the
connection areas for damage, or indications of misalignment, over--tightening,
cracks, bends, grooves and fretting wear.
(2)
Remove the upper drain plug from the rear of the engine fuel pump filter housing. Check
the packing for damage. Connect a vacuum pump to the port. Ensure that the vacuum
set--up includes a negative pressure gage (in. Hg) and a shutoff valve between the gage
and pump. Apply 8 in. Hg vacuum and close the shutoff valve. Record gage reading after
two minutes. If vacuum loss exceeds 1/2 in. Hg after the two minutes, proceed to the next
step. If vacuum loss is 1/2 in. Hg or less, no further checks are required.
(3)
Disconnect the aircraft fuel line at the inlet to the engine fuel pump and cap the pump inlet
port. Repeat the vacuum leakage check. If vacuum loss exceeds 1/2 in. Hg, the leakage
is in the engine fuel system; proceed to next step. If vacuum loss is 1/2 in, Hg or less, the
leakage is in the aircraft fuel supply system; proceed to step (12).
(4)
Disconnect the bypass fuel line between the engine fuel control and the fuel pump. Install
B--nut type caps on both the control and pump fittings. Repeat the vacuum leakage check.
If vacuum loss exceeds 1/2 in. Hg, proceed to next step. If vacuum loss is 1/2 in. Hg or
less, the leakage is in the bypass fuel line. Repair or replace parts as required, reassemble the engine fuel system components and repeat step (3) to verify that the leak has been
corrected.
(5)
Disconnect the pressure fuel line between the fuel pump and the fuel control. Install a B-nut type cap on the fuel pump fitting. Repeat the vacuum leakage check. If vacuum loss
exceeds 1/2 in. Hg, proceed to the next step. If vacuum loss is 1/2 in. Hg or less, proceed
to step (10).
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Disconnect the impending filter bypass switch system at the AF and BF ports on the engine fuel pump. Cap or plug both ports. Repeat the vacuum leakage check. If vacuum
loss exceeds 1/2 in. Hg, proceed to next step. If vacuum loss is 1/2 in. Hg or less, the
leakage is in the filter bypass switch or its associated hoses. Refer to the applicable airframe manual and repair as required. Reassemble the engine fuel system components
and repeat step (3) to verify that the leak has been corrected.
(7)
Inspect and check the two fuel bypass and pressure line fittings in the fuel pump and filter
assembly as follows:
(a)
Remove the two fittings from the engine fuel pump and filter assembly.
(b)
(c)
Inspect the packing sealing surfaces for damage and repair or replace parts as required.
(d)
(e)
Repeat the vacuum leakage check. If vacuum loss exceeds 1/2 in. Hg, proceed to
next step. If vacuum leakage is less than 1/2 in. Hg, reassemble the engine fuel
system components and repeat step (3) to verify that the leak has been corrected.
(8)
Remove the lower drain valve on the rear of the engine fuel pump fuel filter housing. Inspect the packing for damage. Also, inspect the valve stem packing for damage. Install a
plug and packing in the drain valve port and repeat the vacuum leakage check. If vacuum
loss exceeds 1/2 in. Hg, proceed to next step. If vacuum loss is 1/2 in. Hg or less, the
leakage is in the drain valve and/or packings. Replace parts as required, reassemble the
engine fuel system components and repeat step (3) to verify that the leak has been corrected.
(9)
Inspect and check the engine fuel pump and filter assembly as follows:
(a)
Ensure that the filter housing was securely attached to the pump. Remove the
housing and filter element. Inspect the large packing for damage or cuts. Inspect
the packing sealing surfaces for damage and repair as required. Inspect inside the
filter housing and pump housing for contamination and remove as required. Inspect
the filter element (in the fuel--wetted state) for contamination and replace if required.
(b)
Reassemble the filter element and housing on the pump using a new packing on
the housing.
(c)
(d)
If vacuum loss exceeds 1/2 in. Hg, replace the fuel pump and filter assembly, reassemble the engine fuel system components and repeat step (3) to verify that the
leak has been corrected.
(e)
If vacuum loss is 1/2 in. Hg or less, reassemble the fuel system components and
repeat step (3) to verify that the leak has been corrected.
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Connect the vacuum pump to the control inlet fuel fitting on the fuel control. Repeat the
vacuum leakage check. If vacuum loss exceeds 1/2 in. Hg, proceed to the next step. If
vacuum loss is 1/2 in. Hg or less, repair or replace the pressure fuel line, reassemble the
engine fuel system components, and repeat step (3) to verify that the leak has been corrected.
(11)
Inspect and check the two fuel bypass and pressure line fittings in the fuel control as follows:
(12)
(13)
(a)
(b)
(c)
Inspect the packing sealing surfaces for damage and repair or replace parts as
required.
(d)
Reinstall the two capped fittings with new packings. Be sure the bypass fitting is
capped and the vacuum pump is reconnected to the pressure fitting.
(e)
(f)
If vacuum loss exceeds 1/2 in. Hg, replace the fuel control, reassemble the engine
fuel system components and repeat step (3) to verify that the leak has been corrected.
(g)
If vacuum loss is 1/2 in. Hg or less, reassemble the engine fuel system components
and repeat step (3) to verify that the leak has been corrected.
Connect the vacuum pump to the free end of the aircraft fuel line (the end that connects to
the engine fuel pump). Apply 8 in. Hg vacuum and close the shutoff valve. Record gage
reading after two minutes.
(a)
If vacuum decreases, a leak in the aircraft fuel supply system is indicated. Check
and repair the leak in accordance with the applicable airframe manual.
(b)
If no leakage is detected, check the aircraft fuel line and the engine fuel pump inlet
fitting. Repair or replace parts as required. Reconnect the aircraft fuel line to the
inlet port of the engine fuel pump and filter assembly. Repeat step (3) to verify that
the leak has been corrected.
Purge air from the fuel system. (Refer to para 2.D., this section.)
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