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3040592MM 2.0-1 Manual de Motor
3040592MM 2.0-1 Manual de Motor
This manual contains proprietary information of Pratt & Whitney Canada Corp. (″P&WC″), which P&WC provides in
confidence and solely for the purposes of supporting engine certification and providing applicable information regarding
the proper use, maintenance, inspection, repair, servicing and parts application of P&WC products and services, as
directed therein. Neither this manual nor any information in it may be disclosed to others, or used for any other
purpose, including, without limitation, to design, create, develop, reproduce, manufacture or derive any design, part,
product, material, process, modification, configuration change or repair, or obtain FAA or other government approval to
do so. Possession and use of this manual is also subject to the restrictions set out in P&WC’s Technical Data
Agreement (a copy of which may be obtained by contacting P&WC Technical Publications). The contents of this
manual may be subject to export control laws. Unauthorized export or re-export of the manual, or parts thereof, is
prohibited. By accepting and possessing this manual, you agree to be bound by the foregoing terms.
If a Government agency or department intends to disclose any information, written notice should be given to:
VP - Legal Services, Pratt & Whitney Canada Corp., 1000 Marie-Victorin (01BE5), Longueuil, Quebec J4G 1A1.
Jul 18/2016
© 1993 Pratt & Whitney Canada Corp.
PRINTED IN CANADA
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(X) if Applicable
Contains no Technical Data ()
Not Subject to the EAR pursuant to 15 CFR 734.7(a)(1) or Not ()
Subject to the ITAR pursuant to 22 CFR 120.11 (NSR)
Jurisdiction and Location Regulations
Classification based on
EAR ITAR
Physical Location of the
Item. Outside US* NSR NSR
* Additionally, refer to the U.S. 9E991 NSR
classification under the local
EIPA (ECL) DPA (CG)
export regime where the
item is located, as provided Canada NSR No
in the grid.
Pratt & Whitney Canada Corp.
1000, Marie-Victorin
Longueuil, Québec, Canada J4G 1A1
Tél. 450-677-9411
TO: Holders of the Pratt & Whitney Canada Maintenance Manual for PT6T-3D/-3DE/-3DF
Engines, Manual Part No. 3040592.
Please insert the attached Revision No. 31 pages into your copy of the PT6T-3D/-3DE/-3DF
Maintenance Manual. Remove and destroy superseded pages.
Extreme care should be exercised in updating your copy of the manual. To ensure that you do not
inadvertently discard pages that should be retained, the manual should be updated in accordance with
the Lists of Effective Pages.
Pages supplied with the new date and revision bars but no visible change may contain coding
changes transparent to the user and should be inserted as part of the revision.
Any discrepancies, problems or suggestions regarding this revision should be forwarded in writing
using the Pratt & Whitney Canada Customer Feedback Sheet (RSVP), and directed to:
Customer Feedback Sheets are contained with new manuals and each subsequent revision. You
may also submit your feedback via our on-line RSVP form available at:
www.pwc.ca/en/3_0/3_0_6/3_0_6_5_7.asp.
Page 1
HIGHLIGHTS Jul 18/2016
Pratt & Whitney Canada Corp.
Page 2
HIGHLIGHTS Jul 18/2016
Pratt & Whitney Canada Corp.
Page 3
HIGHLIGHTS Jul 18/2016
Pratt & Whitney Canada Corp.
Page 4
HIGHLIGHTS Jul 18/2016
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
RECORD OF REVISIONS
CHAPTER
SECTION PAGE DATE
Title Page Jul 18/2016
LIST OF CHAPTER/SECTION/SUBJECTS
CHAPTER/SECTION/SUBJECT TITLE
INTRODUCTION Introduction
AIRWORTHINESS LIMITATIONS Airworthiness Limitations
70-00 Standard Practices
72-00-00 Engine
72-00-01 Power Section
CHAPTER/SECTION/SUBJECT TITLE
73-20-07 Py Accumulator
74-00 Ignition
74-00-00 Ignition
74-10 Ignition
75-00 Air
CHAPTER/SECTION/SUBJECT TITLE
75-30 Air
75-30-00 Compressor Bleed Valve
77-20 Temperature
79-00 Oil
79-00-00 Oil
All succeeding Temporary Revisions must be retained in your printed manual until directed
otherwise by subsequent revision activity.
The 5000 series of Service Bulletins (SB’s) are used for various engine models, however, the
following list only identifies SB’s applicable to the PT6T-3D/-3DE/-3DF engine models. Bulletins
considered to have no effect on manual text have the words ‘‘No Effect’’ added; effective Bulletins
give the date incorporated in the manual.
The incorporation of Service Bulletins on each engine is recorded in the engine log book and
related documents.
NOTE: The noted Service Bulletins are being continually revised to reflect P&WC
recommendations for oil, fuels, engine planned maintenance, etc., and are concurrent
with incorporation of engine modifications.
TABLE OF CONTENTS
SUBJECT PAGE
TITLE PAGE
REVISION HIGHLIGHTS
RECORD OF REVISIONS
LIST OF CHAPTER/SECTION/SUBJECTS
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
LEP 1 Jul 18/2016 6 Jul 18/2016
2 blank Jul 18/2016 7 Jul 18/2016
8 Jul 18/2016
Contents 1 Jul 18/2016 9 Jul 18/2016
2 Jul 18/2016 10 Jul 18/2016
11 Jul 18/2016
Introduction 1 Jul 18/2016 12 Jul 18/2016
2 Jul 18/2016 13 Jul 18/2016
3 Jul 18/2016 14 Jul 18/2016
4 Jul 18/2016 15 Jul 18/2016
5 Jul 18/2016 16 Jul 18/2016
6 Jul 18/2016 17 Jul 18/2016
7 Jul 18/2016 18 Jul 18/2016
8 Jul 18/2016 19 Jul 18/2016
9 Jul 18/2016 20 Jul 18/2016
10 Jul 18/2016
TABLE OF CONTENTS
SUBJECT PAGE
INTRODUCTION
1. General 1
2. Customer Service 1
3. Maintenance Concept 2
A. Line Maintenance 2
B. Heavy Maintenance 2
4. Supplementary Documentation 2
5. Safety 3
A. Layout 3
1. General 1
2. Special Tools 1
TABLE OF CONTENTS
SUBJECT PAGE
CONSUMABLE MATERIALS
1. General 1
2. Consumable Materials 1
INTRODUCTION
1. General
NOTE: 1. An on-line RSVP form is available via the P&WC website at (http://www.pwc.ca).
NOTE: 2. Customer Feedback Sheets are enclosed with new manuals and each
subsequent revision. Additional forms may be obtained by contacting: Supervisor,
Publications Customer Services, at the above address.
2. Customer Service
Customer Service representatives maintain contact with operators and service activities and
are available for investigation of any specific difficulty or problem. Requests for assistance
and/or AOG support should be directed to:
3. Maintenance Concept
The maintenance functions for the PT6T-3D series engines detailed in this manual fall into
two categories: Line Maintenance and Heavy Maintenance.
A. Line Maintenance
The scope of line maintenance consists essentially of the removal and installation of
external components and engine accessories. All procedures are to be considered line
maintenance in the absence of the words ‘‘(Heavy Maintenance Only)’’ appearing with
procedure title in Maintenance Practices.
B. Heavy Maintenance
Heavy maintenance details Hot Section Refurbishment, repair and removals considered
beyond the normal capabilities of the average line maintenance shop. The scope
includes the removal and installation of engine internal components and limited repair to
the hot section area. Instructions are given with the understanding that Standard
Practices, Chapter 70, has been read, entirely understood and is followed.
Repairs beyond the levels detailed in this manual are not recommended and must be
done by a qualified overhaul facility.
4. Supplementary Documentation
Users of this manual should aquaint themselves with the contents of the
PT6T-3D/-3DE/-3DF Illustrated Parts Catalog, which lists and illustrates the components
of the engine.
As the engine is still undergoing design and manufacturing improvements, certain parts
or details may change as refinements are introduced. This manual will be periodically
revised to incorporate the latest approved data. In the PDF version of this manual, the
portion of the text affected by the latest change is indicated by a black line in the left
margin of the page. Changes to illustrations are also indicated by a black line in the left
margin of the page. In the IETM version of this manual, the portion of the text affected
by the latest change is indicated by a grey zone. Changes to illustrations are also indicated
by a grey zone.
NOTE: Post Service Bulletin configurations may also apply to later engine models, refer
to Illustrated Parts Catalog and applicable conversion Service Bulletin.
This publication, which is a compilation of the special tool service bulletins, provides
instructions for the modification of special tools.
The names of any companies provided in this publication as a possible source for
required services or supplies are furnished for information purposes only. Pratt & Whitney
Canada does not endorse the work performed or supplies procured from these
companies. Furthermore, Pratt & Whitney Canada does not accept responsibility, to any
degree, for the selection of such companies for such work performed or supplies
procured.
In addition to consumables used in this manual, the CML contains details of all
consumable materials used throughout applicable P&WC Engine Manuals.
5. Safety
This manual describes processes that may require the use of chemicals, solvents, paints or
other commercially available materials.
Before using any of the consumable materials, be aware of all handling, storage and
disposal precautions recommended by the manufacturer or supplier. Failure to comply with
manufacturer’s or supplier’s recommendations may result in injury or disease.
Material Safety Data Sheets (MSDS) containing information about Trade Name, Safety
Hazards, Reactivity, Spill or Leak Procedures, Special Protection Information, Special
Precautions and Transportation and Labelling are available from the manufacturer. Read prior
to using consumable materials.
A. Layout
This manual is written in accordance with the general directives contained in the Air
Transport Association of America Specification No. 100 (ATA -100). All information is
allocated to the major Chapter/System number 72 (first element). Further subdivision of
material is achieved by allocating section (second element) and unit (third element)
numbers as outlined below.
Chapter/Section/Unit Subject
72-10-00 Reduction Gearbox
* 72-20-00 Air Inlet Section
Chapter/Section/Unit Subject
72-30-00 Compressor Section
* 72-40-00 Combustion Section
72-50-00 Turbine Section
72-60-00 Accessory Gearbox
Component parts are treated under engine section (second element) numbers by
allocating unit (third element) numbers as follows:
Page block numbering of maintenance practices is applicable only when the manual is
published as a PDF version and not as an online IETM version.
* Whenever two or more maintenance practices applicable to any one subject component
are brief, they are combined under the heading Maintenance Practices in Page Block 201.
The following is a list of abbreviations and symbols used in Pratt & Whitney Canada
manuals and throughout this manual; where applicable:
AA Arithmetic Average
ACC Accessory
AFCU Automatic Fuel Control Unit
AGB Accessory Gearbox
ALT Alternator
AMS Aerospace Material Specification
Assy Assembly
ATA Air Transport Association
BRG Bearing
°C Degrees Celsius (Centigrade)
CCW Counterclockwise
CG Center of Gravity
CMM Component Maintenance Manual
CSU Constant Speed Unit
CT Compressor Turbine
CW Clockwise
Delta P Observed/P Standard Day
Dia Diameter
Dim Dimension
DIR Direction
EEC Electronic Engine Control
eshp Equivalent Shaft Horse Power
°F Degrees Fahrenheit
FLG Flange
FLGD Flanged
FOD Foreign Object Damage
Fwd Forward
GG Gas Generator
GSHFT Gearshaft
in. Hg Inches of Mercury
HD Headed
HDLS Headless
HMU Hydromechanical Unit
hr hour
HP High Pressure
HSG Housing
HYD Hydraulic
ID Inside Diameter
Imp Imperial
IPC Illustrated Parts Catalog
in. Inch
kg kilogram
LH Left-hand
lb. pound
lb.in./lbf.in. pound force inch
LP Low Pressure
Max. Maximum
MFCU Manual Fuel Control Unit
Min. Minimum
mm millimeter
NBLG Normal Backlash on Gear
Nf Power Turbine Speed (rpm)
Ng Gas Generator Speed (rpm)
Np Propeller Speed (rpm)
Ns Output Shaft Speed (rpm)
OD Outside Diameter
OEI One Engine Inoperative
Pam Ambient Air Pressure
psi Pounds per square inch
psig pounds per square inch gage
PT Power Turbine
P&WA Pratt &Whitney Aircraft
P&WC Pratt & Whitney Canada Corp.
PWC Special Tool Prefix Letters - Engine
Px Control Pressure (Bleed Valve)
Py Governor Servo Pressure
Po Bypass Pressure
P1 Unmetered Fuel Pressure
P2 Metered Fuel Pressure
P3 Compressor Discharge Air Pressure
LHV Lower Heating Value of Fuel
RDCN Reduction
Ref. Reference
RGB Reduction Gearbox
RH Right-hand
rpm revolutions per minute
RTNG Retaining
RTNR Retainer
SB Service Bulletin
SCAV Scavenge
D. Equipment Required
Complete lists of Special Tools, Equipment and Consumable Materials including supplier
addresses applicable to the overall engine are detailed in TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS section respectively.
To facilitate planning prior to carrying out a specific maintenance task on the engine,
each maintenance function (or combination of) detailed in this manual opens with lists of
tools, equipment and consumable material required.
Material Safety Data Sheets (MSDS) containing information about Trade Name, Safety
Hazards, Health Hazards, Reactivity, Spill or Leak Procedures, Special Protection
Information, Special Precautions, and Transportation and Labelling are available from
the manufacturer of the products. Read the data sheets prior to using the consumable
materials.
The Table of Contents included at the beginning of Chapter 72 lists the entire contents
of this maintenance manual in Chapter/Section/Unit sequence.
Table 1 following contains an alphabetical index of all components for which maintenance
practices are given in this manual along with the Chapter/Section/Units and Page
Blocks in which these maintenance practices are to be found.
PAGE BLOCK
0 1 2 3 4 5 6 7 8
CHAP/SECT/ 0 0 0 0 0 0 0 0 0
COMPONENT UNIT 1 1 1 1 1 1 1 1 1
Power Plant 71-00-00 X
Accumulator, Fuel Surge 73-10-03 X
Accumulator, Air (Pg) 73-20-03 X
Accumulator, Air (Py) 73-20-07 X
Adapter, Fuel Manifold (and Nozzles) 73-10-05 X
Case, Bleed Valve 72-20-00 X
Case, Gas Generator 72-30-04 X
Compressor Rotor 72-30-05 X
Compensator, T5 Temperature 77-20-01 X
Detector, Chip Magnetic (AGB) 79-30-01 X
Detector, Chip Magnetic (RGB) 79-30-01 X
Disk Assembly, Compressor Turbine 72-50-02 X
Disk Assembly, Power Turbine 72-50-04 X
Duct Exit, Large 72-40-01 X
Duct Exit, Support Flange 72-50-01 X X X
Engine, Twinned Turboshaft 72-00-00 X X X X X X X X
Filter, Fuel Pump 73-10-02 X
Filter, Oil 79-20-02 X
Filter Air (P3) 73-10-07 X
Governor, Power Turbine (Nf) 73-20-04 X
Heater, Oil-to-fuel 73-10-01 X
Ignition 74-00-00 X
Ignition, Exciter 74-10-00 X
Igniters and Ignition Cables 74-20-00 X
PAGE BLOCK
0 1 2 3 4 5 6 7 8
CHAP/SECT/ 0 0 0 0 0 0 0 0 0
COMPONENT UNIT 1 1 1 1 1 1 1 1 1
Inserts, Accessory Gearbox 72-60-00 X
‘‘Keensert’’
Inserts, Output Housing ‘‘Keensert’’ 72-10-00 X
Keywasher, No. 8 Bearing 72-10-00 X
Limiter, Torque Control 73-20-06
Liner Combustion Chamber 72-40-01 X
Pump, Fuel 73-10-02 X
Screen, Air Inlet 72-20-00 X
Seal, Accessory Drive (AGB) 72-60-00 X
Seal, Blower Drive 72-10-00 X
Seal, Carbon, Centrifugal Breather 72-60-00 X
Seal, Face-type, Output Shaft 72-10-00 X
Seal, Runner, Output Shaft 72-10-00 X
Section, Accessory Gearbox 72-60-00 X
Section, Air Inlet 72-20-00 X
Section, Combustion 72-40-00 X
Section, Gas Generator 72-30-00 X
Section, Power 72-00-01 X
Section, Power Turbine and Exhaust 72-50-00 X X
Section, Reduction Gearbox 72-10-00 X X
Shroud, Compressor Turbine 72-50-01 X X X
Stator Assy., Power Turbine 72-50-03 X X X
System, T5 Temperature Sensing 77-20-01 X
Torquemeter 72-10-00 X
Unit, Fuel Control, Automatic (AFCU) 73-20-02 X
Unit, Fuel Control, Manual (MFCU) 73-20-01 X
Vane Ring, Compressor Turbine 72-50-01 X X X
Valve, Check and Regulating 79-20-04 X
Valve, Compressor Bleed 75-30-00 X
Valve, Drain, Fuel 73-10-06 X
PAGE BLOCK
0 1 2 3 4 5 6 7 8
CHAP/SECT/ 0 0 0 0 0 0 0 0 0
COMPONENT UNIT 1 1 1 1 1 1 1 1 1
Valve, Fuel Flow Divider and Dump 73-10-04 X
Valve, Oil Filter Bypass 79-20-03 X
Valve, Oil Pressure Adjustment 79-20-05 X
Valve, Pressure Regulating 73-20-01 X
Valve, Relief, Oil Pressure (RGB) 72-10-00 X
1. General
This section gives data about the special tools and the fixtures and equipment required to
maintain the engine.
2. Special Tools
Refer SIL GEN-022 for the list of tool suppliers and send a purchase order for the special
tools, listed in Table 1.
DELETED
NOTE: When ordering special tools, ensure that the prefix ’PWC’ is included as a
component of the tool part number, e.g. PWC30801, Sling.
Maintenance Level
Part No. Name CH/SE/SU Line Heavy HSI
PWC30046-52 Puller, Fuel Pump Carrier/AGB 72-60-00 X
Carbon Seal Carrier
PWC30046-54 Puller, Starter Generator 72-60-00 X
Carrier
PWC30046-57 Knocker Puller, Seal 72-60-00 X
72-10-00 X
PWC30046-70 Puller, Torquemeter Piston 72-10-00 X
Cover
PWC30075 Drift, Oil Seal Carrier 72-60-00 X
72-10-00 X
PWC30114-08 Wrench, T5 Thermocouple 72-50-01 X
Probe Retaining Nut
PWC30114-10 Wrench 72-00-01 X
PWC30269 Mount Ring 72-50-00 X
72-50-03 X
PWC30271-100 Replaced by PWC31771-100. 72-30-04 X
PWC30331 Wrench 72-50-02 X X
PWC30335 Spreader 72-50-02 X X
72-50-03 X X
PWC30336 Protector Sleeve 72-50-02 X X
72-50-03 X X
Maintenance Level
Part No. Name CH/SE/SU Line Heavy HSI
PWC30403 Puller 72-50-02 X X
72-50-03 X X
PWC30405 Fixture 73-10-05 X X
PWC30416 Puller 73-10-03 X X
PWC30425 Crimping Pliers 72-50-01 X X
PWC30458 Locking Tool 73-30-02 X X
72-50-03 X X
PWC30506 Test Rig 73-10-05 X X
PWC30530 Plug 73-10-05 X X
PWC30617 Bracket 72-00-00 X X X
72-00-01 X X X
PWC30618 Bracket 72-00-00 X X X
72-10-00 X X X
PWC30619 Bracket 72-00-00 X X X
72-10-00 X X X
PWC30631 Puller 72-10-00 X
PWC30633 Socket 72-10-00 X
PWC30646 Puller 72-10-00 X
PWC30675 Drift 72-60-00 X
PWC30712 Adapter 72-00-01 X X
72-50-00 X X
PWC30713 Mount Ring 72-00-01 X X
PWC30721 Assembly Stand 72-00-00 X X X
72-10-00 X X X
PWC30793 Fitting (Post-SB5312) 72-00-00 X
79-30-01 X
PWC30801 Sling 72-50-00 X X
PWC30804 Sling, Engine Assembly 72-00-00 X X X
(Obsolete - replaced by
PWC70079)
72-00-01 X X X
Maintenance Level
Part No. Name CH/SE/SU Line Heavy HSI
PWC30810 Pusher/Puller 72-10-00 X
Rev E.
PWC30811 Wrench 72-50-03 X
PWC30832 Sleeve 72-10-00 X X
PWC30835 Stand 72-00-01 X X
Obsolete, Replaced by
PWC70483
PWC30836 Bracket 72-00-01 X X
PWC30840 Ring 72-10-00 X
PWC30871 Puller 72-10-00 X
PWC30875 Puller 72-10-00 X
PWC31771-100 Flaring Tool 72-30-04 X
PWC32209 Adapter 72-50-01 X X
PWC32271 Wash Tube 72-00-00 X
PWC32380 Radius Gage 72-50-01 X X
PWC32366 Pusher 73-10-05 X
PWC32396 Jacking Screw 72-00-01 X
PWC32677-300 Wash Cart 72-00-00 X
PWC32810 Puller 72-60-00 X
PWC32811 Fixture 73-10-05 X X
PWC32820 Drift 72-10-00 X
PWC32823 Puller 72-50-01 X X
72-30-04 X X
PWC32828 Wrench 72-10-00 X
PWC32859 Socket 72-10-00 X
PWC34128 Grinding Wheel 72-50-01 X X
PWC34300 Assembly Stand 72-00-01 X X
72-50-00 X X
PWC34910-101 Borescope Assy 72-00-00 X
PWC34910-200 Guide Tube 72-00-00 X
PWC34913 Holding Fixture 72-00-00 X
PWC34941 Wrench 72-00-00 X
Maintenance Level
Part No. Name CH/SE/SU Line Heavy HSI
PWC37088-1 Drift, Seal 72-60-00 X
72-10-00 X
PWC37088-002 Drift 72-60-00 X
PWC37088-003 Drift 72-60-00 X
PWC37917 Dresser, Diamond 72-50-01 X X
PWC37918 Grinder 72-50-01 X X
PWC38147 Fitting (Pre-SB5312 or 72-00-00 X
Post-SB5354)
79-30-01 X
PWC50041 Bracket Assembly 75-30-00 X
PWC50054 Socket Nut 72-10-00 X
PWC50055 Adapter Nut 72-10-00 X
PWC50060 Injector, Oil 72-50-02 X X
72-50-03 X X
PWC50074 Pusher 73-10-05 X
PWC50064-100 Drill Jig Kit (Replacement 72-30-04 X
Center Drills are available as
P/N 50064-200.)
PWC50084 Locator 72-40-01 X X
PWC50237 Drift 72-60-00 X
PWC50495 Crimper 72-10-00 X
PWC50496 Unstaking Tool 72-10-00 X
PWC50497 Crimper 72-10-00 X
PWC50777 Retainer 72-10-00 X
PWC50778 Drift 72-10-00 X
PWC50779 Puller 72-10-00 X
PWC51063 Puller, Torquemeter Piston 72-10-00 X
Cover
PWC51139 Mount Ring 72-00-01 X X
PWC51261 Puller 72-10-00 X
PWC70249 Sling 72-10-00 X X
PWC70483 Stand Parking Support 72-00-01 X
Maintenance Level
Part No. Name CH/SE/SU Line Heavy HSI
PWC70513 Bracket Assembly (Compressor 75-30-00 X
Bleed Valve)
PWC71482 Sling, Engine Assembly 72-00-00 X X X
(Replaces PWC70079)
72-00-01 X X X
PWC71559 Puller, Cover (Replaces 72-50-01 X
PWC32822)
TOOL
NOT
ILLUSTRATED
PWC32209
PWC
TOOL
NOT
ILLUSTRATED
TOOL
NOT
ILLUSTRATED
TOOL
NOT
ILLUSTRATED
TOOL
NOT
ILLUSTRATED
PWC51261 PWC70513
TOOL
NOT
ILLUSTRATED
PWC70249 PWC71482
TOOL
NOT
ILLUSTRATED
PWC
PWC70483 PWC71559
TOOL TOOL
NOT NOT
ILLUSTRATED ILLUSTRATED
Table 2 provides a list of Fixtures and equipment required to maintain the engine.
CONSUMABLE MATERIALS
1. General
This section gives data about the consumable materials listed in this manual.
2. Consumable Materials
CHAPTER
SECTION PAGE DATE
LEP 1 Dec 02/2013
2 blank Dec 02/2013
TABLE OF CONTENTS
SUBJECT PAGE
AIRWORTHINESS LIMITATIONS
1. General 1
AIRWORTHINESS LIMITATIONS
AIRWORTHINESS
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
......................
1. General
The Airworthiness Limitations section specifies mandatory Rotor Component Service Life
Limits required for type certification. The Airworthiness Limitations section is approved by
Transport Canada and specifies maintenance required by any applicable airworthiness or
operational rule unless an alternative program has been approved by Transport Canada.
A. For Rotor Component Service Life Limits refer to the latest revision of Service Bulletin
5002.
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
LEP 1 Jul 18/2016 70-00-00 601 Jan 07/2005
2 blank Jul 18/2016 Inspection 602 Jan 07/2005
Check
Contents 1 Jul 18/2016
2 Jul 18/2016 70-00-00 701 Mar 09/2001
3 Jul 18/2016 Cleaning/ 702 Mar 09/2001
4 blank Jul 18/2016 Painting
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
A. General 208
TABLE OF CONTENTS
SUBJECT PAGE
A. General 219
A. Lockwire 404
D. Twisting 409
E. Procedure 409
A. General 601
B. Inspection 601
TABLE OF CONTENTS
SUBJECT PAGE
1. General 701
2. Cleaning 701
A. Precautions 701
1. General 801
1. General
This section contains the Pratt & Whitney approved general procedures to be used during
the performance of maintenance practices on engines.
All personnel engaged in the performance of these specific maintenance practices, or any
other operation on an engine involving partial or complete use of the associated procedures,
must be fully acquainted with the directives contained in the following paragraphs.
2. Removal/Installation Procedures
To ensure proper reinstallation, tag and mark all parts, clips and brackets as to their location.
During removal of tubes or engine parts, look for indications of scoring, burning or other
undesirable conditions. To facilitate reinstallation, record the location of each part during
removal. Tag unserviceable parts and units for investigation and possible repair.
Extreme care shall be taken to prevent dust, dirt, lockwire (safety wire), nuts, washers or
other foreign matter from entering the engine. It cannot be overemphasized that this precaution
applies whenever work is done on the engine either installed or removed from airframe.
Suitable plugs, caps and other coverings shall be used to protect all openings as they are
exposed.
If at any time items are dropped into the engine, the assembly process must stop until the
dropped articles are located and retrieved, even though this may require a considerable
amount of time and labor. Before assembling or installing any part, be sure it is thoroughly
clean.
Replace all gaskets, packings, and rubber parts at reassembly. Make sure that new
non-metallic parts to be installed (such as oil seals) show no signs of having deteriorated in
storage. Lubricate all preformed packings before installation using system fluid or as
otherwise stated.
In order to protect critical areas of engine parts (such as compressor and turbine disks)
against scratches and nicks, tool surfaces contacting these areas must be covered with a
protective material.
70-00-00
P&WC Proprietary Information. Subject to the restriction on the title page.
The export control classification with respect to this document is contained on the back of the title page.
Page 201
STANDARD PRACTICES - MAINTENANCE PROCEDURES Jul 18/2016
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
When installing engine parts that require the use of a hammer to facilitate assembly or
installation, use only a plastic or rawhide hammer.
Whenever adhesive tape has been applied to any part, the tape must be removed and the
part thoroughly cleaned of all tape residue with petroleum solvent (PWC11-027) prior to being
subjected to high temperature during engine run. Test results indicate that all tapes are
capable of causing surface attach and/or reduction in tensile ductility as temperature increases.
Do not leave tape or tape residue on engine parts.
If any part has been coated with a corrosion preventive compound, all traces of this
compound and accumulated foreign matter must be removed.
3. Standard Torques
Torque limits given in the following power plant and engine chapters are to be interpreted as
follows:
Unless otherwise specified, thread lubricants shall be applied to parts which are to be
torqued. Thread lubricant shall be engine oil unless otherwise specified.
If part to be tightened is hot, allow part to cool to ambient temperature before final torquing.
Flange bolts shall be drawn up evenly. This can be achieved by having two mechanics
working simultaneously 180 degrees apart.
Torque applications should be done slowly and evenly for consistency and the best possible
accuracy.
Six-point crowfoot adapters are recommended for applying torque values above 110 lb. in.
(12.4 Nm) to tube fittings.
A. Check torque indicating devices before using, and calibrate by means of weights and a
measured lever arm . Checking one torque wrench against another is not sufficient.
Some wrenches are quite sensitive to the way they are supported during a tightening
operation, and every effort must be made to adhere to the instructions furnished by the
respective manufacturers.
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Example:
A torque of 1440 pound-inches is desired on a part, using special extension having a
length of three inches from center to center of its holes, and a torque wrench measuring
15 inches from center of handle or handle swivel pin to center of its square adapter.
Then:
LT 15 X 1440
R=L+E= 15 + 3 = 1200 lb.in.
C. With the axis of the extension or adapter and the torque wrench in a straight line,
tightening to a wrench reading of 1200 pound-inches will provide the desired torque of
1440 pound-inches on the part.
(1) Oil Lubricated Parts. Torque limits detailed in relevant assembly instructions for oil
lubricated parts apply specifically to the use of engine oil, or equivalent, on the
parts.
(1) Bolts and nuts on flanges with metal tabular gaskets must be initially torqued to the
required torque and then retorqued until torque values given in relevant assembly
instruction remain constant.
C. Self-locking Nuts/Bolts
(1) Where self-locking bolts, nuts and helical coil inserts are used, the following
procedure applies:
(a) For bolts or helical inserts, record the torque necessary to turn bolt in the
helical insert or threads before seating the bolt.
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E L
C192A
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(b) For nuts record the torque necessary to turn nut on bolt before seating the nut.
(c) Add this torque to the value detailed in the assembly instructions for the
application. Use this new value as the total applied torque.
(1) When tightening a castellated nut, alignment of slot must be obtained without
exceeding the maximum torque. If this is not possible, replace nut with another
one. After tightening nut to recommended torque, nut must not be loosened to permit
insertion of lockwire or cotterpin.
(2) If slot in nut or lockwire hole in bolt or screw is not correctly aligned at the minimum
torque value given, the nut, screw or bolt should be further tightened to next
alignment position, but maximum torque value given must not be exceeded.
(3) Should alignment still be impossible without exceeding maximum torque, back off
nut, screw or bolt one-half turn and retorque.
(1) Effective locking of slotted, steel locknuts on bolts or studs requires full engagement
of all locknut threads. The chamfered section of the locknut ID does not exert force
on the bolt or stud; therefore, it is not necessary that the bolt or stud be flush
with, or protrude from, the outer face of the locknut.
(1) When the torque required to drive a stud to the correct protrusion does not reach
the minimum value given, or exceeds the maximum value given, a new stud must
be selected.
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6. Locking Devices
A. General
(1) Use the same type of lockwire as that employed during initial assembly. Except
where otherwise specified, the wire is heat and corrosion-resistant steel, 0.025
inch diameter (PWC05-089).
CAUTION: THESE TYPES OF WASHERS MUST BE USED ONCE ONLY. USE NEW
KEYWASHER(S) AT EACH ASSEMBLY.
(1) The terms keywasher, tabwasher and cupwasher are interchangeable, as used in
this manual.
(2) When bending or setting the tabs on these washers, do not use sharp-pointed
tools. Use of such tools can lead to subsequent failure of the locking tabs which,
on becoming detached, can pass through the engine causing extensive damage.
A. A permanent material designation code has been adopted for use in these engines.
Correct engine assembly requires that particular attention be paid to material
requirements for nuts and bolts used in the engine hot section, where parts must be
resistant to high operating temperature. During assembly of the engine or its components,
the properly coded parts, if serviceable, must be reassembled in their original location.
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C1189B
Examples of Typical Lockwashers
Figure 202
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B. The code system employs a letter ‘‘C’’ for corrosion-resistant steel for normal application
and ‘‘H’’ for heat resistant alloys in hot section application. The stamped or embossed
letter will be followed by a number of one or more digits, such as C1, C8, H3, and H12. Bolt
code identification will usually appear on the top of the head (Ref. Fig. 203) and nut
identification on one side of the hex . When the application is an AN or MS six-digit part
number, the code identification ‘‘C’’ or ‘‘H’’ will be preceded by the letter ‘‘E’’ as in
EC3 or EH10.
D. Parts from several engines should not be mixed at disassembly (removal) and cleaning,
because, at the time of engine manufacture, production requirements may necessitate
one or more material substitutions in a block of engines. Subsequent engine reassembly
with indiscriminate scrambling of hardware, may result in unnecessary confusion in
sorting these parts for proper reassembly.
At engine manufacture, it is the practice to provide bolts with reduced pitch diameter for use
in the hot section of engine. This will minimize the possibility of bolt and nut seizure and
is standard practice for locations where the parts are subjected to higher temperatures (Ref.
Fig. 204).
A. General
(1) When particles of metal are found, they may be steel, tin, aluminum, magnesium,
silver, bronze, titanium, or cadmium. In some instances the type of metal may be
identified by the color and hardness of the pieces. However, when the particles
cannot be positively identified visually, a few simple tests will iidentify the metal
present.
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C196
Hardware Code Identification
Figure 203
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120 °
0.109
0.079
STANDARD BOLT
C197B
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B. Test Procedure
(1) The following tests are recommended for identifying the unknown metal particles.
For best results, proceed as follows:
(a) Steel - the particles of many steels can be isolated by means of the permanent
magnet. Magnetic steel or iron is attracted by the magnet.
(b) Magnesium - a simple test for these particles is burning. Magnesium will burn
with a bright white flash.
(c) Cadmium - place the remaining particles in the aqueous (water) solution of
ammonium nitrate. If all or any of the particles dissolve in this solution, they
are cadmium. After this test, rinse and dry any remaining particles.
(d) Tin - the tin particles can be distinguished by their low melting point. With a
clean soldering iron heated to 260°C (500°F) and tinned with 50-50 solder
(50 percent tin - 50 percent lead), a tin particle dropped on the iron will melt and
fuse with the solder.
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(f) Aluminum Paint - Use this procedure to determine whether or not the material
is aluminum silicone paint, aluminum chips, or silver particles:
2 Place several drops of this solution in a watch glass and drop in the
suspected particles.
3 If the particles are aluminum silicone paint, there will be a mild reaction in
the form of gas bubbles and some visible gas as the particles change to
sodium aluminate.
4 If the particles are aluminum chips, the reaction will be much more active
with many more gas bubbles forming and more visible gas.
(g) Silver - When a silver particle is placed in nitric acid, it reacts rather slowly,
producing a whitish fog in the acid.
(h) Bronze - When a bronze (or copper) particle is placed in nitric acid, a bright
green cloud is produced.
(1) Debris analysis monitors wear of oil-wetted engine parts. This procedure improves
aircraft serviceability and dispatch reliability and reduces engine repair costs. This
is achieved by identifying potential engine problems at the earliest possible stage,
thus minimizing the possibility of in-flight shutdowns, away-from-base engine
changes and secondary damage.
(2) Rapid wear or surface fatigue (e.g. on gear teeth contact surfaces, bearing
raceways, rolling elements, housing bearing bores, etc.) or interference between
rotating and fixed components (e.g. oil pump pinions, associated housings and
labyrinth seals, etc.) produces debris. Magnetic debris over 100 microns in diameter
is usually captured by the chip detectors. Magnetic and non-magnetic debris over
10 microns in diameter is usually captured by the oil system filters.
(3) Analysis (form, appearance, dimensions, quantity and material) of the debris
captured by the filters and chip detectors is necessary to provide the information
needed to facilitate locating the source of the debris and determining any
preventive maintenance action required.
(1) The analysis should be done by a qualified laboratory (Ref. Para . F.).
(2) The operator must provide the laboratory with the following information:
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(b) Engine time since new (TSN) or time since overhaul or refurbishment (TSO or
TSR).
(3) Reports supplied by the laboratory to the operator containing the results of the
analysis must include:
(a) Information provided by the operator when submitting the material for analysis.
(d) If bearing material (Ref. Table 201) is found, the operator must be advised as
soon as possible by telephone and provided with a detailed written report.
E. Material Specifications
(1) To facilitate the identification of components which are the source of debris found in
the oil system, the material specifications are listed in Table 201 . The common
contaminants found in the oil system are listed in Tables 202 and 203.
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Contaminant
Detected Source
Black Fluorocarbon Rubber, Red Silicon Preformed Packings, Seal Gaskets
Rubber, Blue Fluorosilicon Rubber
Chloroprene Nitrile Rubber Gaskets
Carbon Decomposed Oil, Carbon Seals
Fibers
Plastics
Paint Flakes
F. Laboratories
(1) Chip and flake analysis must be done by approved laboratories; refer to Service
Information Letter No. GEN-123 for the list of approved oil laboratories.
A. General
(1) Permanent methods of marking, in which marking is legible during the entire
service life of the part, are described as follows:
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(1) Temporary methods of marking is one which ensures identification during ordinary
handling and storage of items prior to assembly.
(2) The following materials are approved for temporary marking of the cold areas of the
engine:
NOTE: The CML numbers shown in parentheses refer to the consumable material
item number in CONSUMABLE MATERIALS.
(3) The following materials are approved for temporary marking of the cold areas and
the hot section of the engine:
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(b) Brush Pin (Instant Dry) Marker (PWC05-046A) 400-1 (Black) 400-2 (Red)
and 400-7 (Purple)
(c) Unless otherwise specified, marking characters should be 0.060 to 0.160 inch
in height. In special cases, when the marking area is limited by size or
configuration, characters not less than 0.016 inch and not more than 0.025 inch
in height will be permitted.
A. General
(1) Prior to installation, new pre-formed packings must be coated with a film of
lubricant to the following specifications (Ref. CONSUMABLE MATERIALS):
(a) Packings used in engine fuel system: Engine synthetic lubricating oil,
(PWC03-001).
(b) Packings used in engine oil system: Engine synthetic lubricating oil,
(PWC03-001).
(c) Packings used in engine pneumatic system and in water system assemblies:
Petrolatum, (PWC06-002).
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(2) Remove preformed packing (4), packing retainers (back-up ring) (3) and locknut (2)
from elbow.
(1) Lubricate new preformed packing with light film of engine oil (Ref. SB5001) or fluid
used in line.
(2) Install preformed packing on fitting and screw fitting in boss or flange, as applicable.
(3) Tighten fitting in boss and torque to value detailed in relevant assembly instruction.
(4) Install locknut on flange-mounted fittings and torque locknut to recommended value
(Ref. Table 401).
(1) Lubricate new preformed packing (4), packing retainer (3) and thread of elbow (1)
with light film of fluid to be used in the line.
1
1
2
2
3
3
4 4
C3146A
1. Elbow Fitting
2. Locknut
3. Packing Retainer
4. Preformed Packing
(2) Assemble jam nut (2), packing retainer (3) and preformed packing (4) on elbow (1),
pressing packing retainer into counterbore of jam nut.
(3) Turn locknut (2) down elbow (1) until preformed packing (4) is seated in non-threaded
groove of fitting.
(4) Turn locknut (2) outward until preformed packing (4) is pushed firmly against first
lower thread of elbow (1).
(5) Install elbow (1) into boss, allowing locknut (2) to turn with elbow until preformed
packing (4) contacts boss mating face (this point will be recognized by increase in
torque).
(6) Hold locknut (2) stationary and turn elbow (1) into boss a further 1 1/2 turns.
NOTE: The elbow may be further turned inward of a maximum of one turn to
facilitate alignment. Should the locknut tighten on the elbow before the
elbow if fully installed in the boss, the nut may be allowed to turn with the
elbow.
(7) With elbow (1) correctly aligned, tighten locknut (2) and torque to recommended
torque (Ref. Table 401).
(8) Make sure that there is no protrusion of preformed packing (4) or packing retainer
(3).
(2) If removal of tube assemblies with clamps is necessary, identify and record clamp
locations and attaching hardware before tube removal. This will ensure correct
location of clamps and attaching hardware during assembly.
(4) Alignment must be obtained by adjusting the position of the adapters. Refer to
paragraphs C. and D. preceding, for instructions pertaining to the installation of
adapters.
(5) Refer to Table 402 for typical torque values for tube assembly coupling nuts unless
otherwise specified in the procedure.
A. Lockwire
(1) Use the same type of lockwire as that employed during initial assembly. Except
where otherwise specified, the wire is heat and corrosion resistant steel wire of
0.025 inch diameter (PWC05-089).
(1) Lockwire must be tight after installation to prevent failure due to rubbing or
vibration.
(2) Lockwire must be installed in a manner that tends to tighten and keep a part locked
in place, thus counteracting the natural tendency of the part to loosen.
(3) Lockwire must never be overstressed. It will break under vibration if twisted too
tightly. The lockwire shall be pulled taut when being twisted but shall have
minimum tension, if any, when secured.
(4) Lockwire ends must be bent toward the engine or part to avoid sharp projecting
ends that may present a safety hazard or vibrate in the airstream.
C194D
Lockwiring Procedure
Figure 402
C195_1
Lockwiring Examples
Figure 403 (Sheet 1 of 3)
EXAMPLE 12 EXAMPLE 13
EXAMPLES 12 AND 13 SHOW METHODS FOR ATTACHING LEAD SEAL TO PROTECT CRITICAL ADJUSTMENTS.
FITTINGS INCORPORATING WIRE LUGS SHALL BE WIRED AS SHOWN SMALL SIZE COUPLING NUTS SHALL
IN EXAMPLES 17 AND 18. WHERE NO LOCKWIRE LUG IS PROVIDED, BE WIRED BY WRAPPING THE WIRE
WIRE SHOULD BE APPLIED AS SHOWN IN EXAMPLES 19 AND 20 AROUND THE NUT AND INSERTING
WITH CAUTION BEING EXERTED TO ENSURE THAT WIRE IS WRAPPED IT THROUGH THE HOLES AS SHOWN.
TIGHTLY AROUND THE FITTING.
C195_2
Lockwiring Examples
Figure 403 (Sheet 2)
EXAMPLE 22 EXAMPLE 23
COUPLING NUTS ATTACHED TO STRAIGHT CONNECTORS SHALL BE WIRED
AS SHOWN WHEN HEX IS AN INTEGRAL PART OF THE CONNECTOR.
EXAMPLE 24
COUPLING NUTS ON A TEE SHALL
BE WIRED AS SHOWN ABOVE SO
THAT TENSION IS ALWAYS IN THE
TIGHTENING DIRECTION.
EXAMPLE 25
STRAIGHT CONNECTOR
(BULKHEAD TYPE)
EXAMPLE 26
EXAMPLE 27 EXAMPLE 28
EXAMPLES 26, 27 AND 28 SHOW THE VARIOUS STANDARD FITTINGS WITH CHECK NUT
WIRED SO THAT IT NEED NOT BE DISTURBED WHEN REMOVING THE COUPLING NUT.
C195_3
Lockwiring Examples
Figure 403 (Sheet 3)
(5) Internal wiring must not cross over or obstruct a flow passage when an alternate
method can be used.
C. Hole Alignment
(1) Check units to be lockwired to ensure that they have been correctly torqued and
that wiring holes are properly positioned in relation to each other. When there are
two or more units, it is desirable that holes in the units be in the same relationship to
each other. It should be possible to align the wiring holes when the units are
torqued within specified limits.
(2) Never overtorque or loosen units to obtain proper alignment of the holes. However,
if it is impossible to obtain a proper alignment of the holes without either over or
under torquing, select another unit which will permit proper alignment within the
specified torque limits.
D. Twisting
To prevent mutilation of the twisted section of the wire when using pliers, grasp wire at
ends or at a point that will not be twisted. Lockwire must not be nicked, kinked, or
mutilated. Never twist ends off with pliers and, when cutting off ends, leave at least
three complete turns after loop, exercising extreme care to prevent wire ends from falling
into engine. The strength of the lockwire holes is marginal; never twist wire off with
pliers. Cut lockwire close to hole, exercising extreme care.
E. Procedure
Figure 402 illustrates a typical lockwiring procedure. Although there are numerous
lockwiring operations performed on these engines, practically all are derived from the
basic examples shown in Figure 403.
Retaining rings must be installed using approved retaining ring pliers. Internal-type rings
must not be compressed beyond the point where ends of the ring meet. External-type rings
must be expanded only enough to allow installation without becoming bent. After
installation, ensure each retaining ring is completely seated in its groove, without looseness
or distortion.
A. General
Damage to engine parts may result from improper clearance, lack of lubrication,
undesired movement of parts which are bolted or pressed together, overload, uneven
load distribution, heat shock extension of minor injuries such as scratches, tool marks,
grinding cracks, nicks, etc. Damage to parts may also result from presence of foreign
matter such as grit, chips, moisture, chemicals, etc., or from improper techniques during
assembly or disassembly.
NOTE: While it is frequently possible to repair a damaged part so that it may be safely
reinstalled, it is important that the cause of the damage be determined and
corrected if possible. Otherwise more serious consequences may result.
B. Inspection
(1) Inspect parts for alignment, distortion, foreign matter, looseness, out-of-roundness,
sharp edges, scratches, taper, warping and wear. Additionally, check the following:
(d) Mounting pads, parting and seating surfaces, for smoothness and flatness.
(f) Studs, dowels, and similar protruding parts for alignment and projection length.
C. External Tubes
(1) Inspect all external tubing, except where special instructions apply:
(b) Nicks - Individual nicks should not be more than 0.062 inch long, 0.010 inch
wide, and 0.003 inch deep. Nicks to a maximum depth of 0.005 inch should
be blended out to remove sharp edges.
(c) Dents - Round bottom dents are acceptable provided the depth is not greater
than 10 percent of the normal outside diameter of the tube. No more than three
dents to the maximum depth are acceptable per 12-inch length of tube and
such dents must be separated by at least 0.250 inch. Dents are unacceptable
within 0.250 inch of ferrules or fittings.
(e) Pitting - Minor isolated pitting is permissible, provided pitting is not greater than
0.003 inch deep. Clusters of pitting should be blended out to a maximum depth
of 0.005 inch.
(f) Corrosion - Rust and stains are acceptable if removal by light polishing with
crocus cloth and oil.
(g) Inspect flexible hoses for cuts, crimping or buckling. No damage allowed.
NOTE: Ensure that contact faces of the micrometer are clean and that the contact
faces of part to be measured are clean and free of dirt and burrs.
(3) When using depth micrometer, the anvil must be held tightly and squarely against
the contact surface.
(4) When using dial indicator, its support must be firmly anchored and any swivel
connections securely tightened .
(5) When using feeler gages, the gage final size must be a reasonably snug fit.
1. General
The primary purpose of cleaning is to remove contaminants which might conceal minor
cracks and other defects which, if not detected, could eventually lead to failure of a component
or part. Engine components or parts should be cleaned only as necessary to perform
required inspection and repair. Overcleaning of components or parts is unnecessary and
should be avoided. The cleaning methods given in the following text are adequate for all
maintenance levels.
2. Cleaning
A. Precautions
(1) Wear rubber gloves, apron or coveralls and face shield or goggles, when working
with or near solvents.
(2) Use the least toxic of available cleaning materials which will satisfactorily accomplish
work.
(4) Ensure that adequate and usable fire fighting and safety equipment is conveniently
located and available to all personnel.
(6) Ensure that all degreasing agents are thoroughly removed from all parts after
cleaning.
(7) Except where specifically instructed, do not use steel brushes for any cleaning
operation. Use a stiff bristle fiber brush.
(1) Surfaces to be welded must be free from protective coatings, dirt, grease, oil and
other contaminants, and as free as practicable from oxide formation.
(2) Wire brushes and abrasives may be used to remove protective coatings and
oxides, except that the final step in removing oxides from aluminum alloys preferably
should consist of chemical treatment immediately prior to welding.
(3) Wire brushes, when used for cleaning corrosion-resistant alloys, must have bristles
of austenitic, corrosion-resistant steel.
1. General
2. Approved Repairs
A. Welding
(1) A tungsten inert gas fusion welding process must be used when repairing cracks in
engine parts. Argon or helium gas maybe used in inert gas welding; however, argon
is preferred by Pratt & Whitney Canada because its greater density reduces its
rate of diffusion with the atmosphere.
(2) Inert gas welding is a gas arc welding process which uses inert gas to protect the
weld area from the surrounding atmosphere. The heat necessary for welding is
provided by a very intense electric arc which is struck between a non-consumable
thoriated tungsten (tungsten and thorium alloy) electrode and the metal part.
On repairs where a filler material is required, a welding rod, of appropriate material,
is fed into the weld area and melted with the base metal in the same manner as
in conventional gas welding.
(a) The following equipment is required for the inert gas welding process (Ref.
TOOLS/FIX/EQUIP):
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(c) Insert a 1/16 inch diameter electrode (PWC05-147) into torch, allowing
approximately 5/16 inch of electrode to protrude from ceramic cup. The ceramic
cup used must not be smaller than a No. 6 for the HW-10 torch, in order to
provide a sufficient amount of inert gas to the weld area where cleanliness of the
surface beads is important.
NOTE: A plain tungsten electrode may be used, but a needle point must be
maintained on the electrode for more positive starting of arc. Where
possible, the electrode must be kept clean of material pickup.
(e) When high frequency controls are used, it is not necessary to strike an arc.
Hold torch vertically to work so that the shielding gas (argon) forms a
protective envelope around the weld. It is preferable to have area to be welded
in a horizontal position.
(f) When high frequency controls are not used, strike arc and hold electrode tip
approximately 1/8 to 1/4 inch above surface to be welded until a puddle is
formed. Add welding rod, as applicable, and proceed as in conventional gas
welding.
NOTE: Test welds, using corresponding material of same thickness and joint
design, should be made to determine correct gas pressure and arc
welder settings.
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(g) A high percentage of steel parts used in the engine are fabricated from 12
percent chromium corrosion-resistant steels. These are characterized by
their susceptibility to air hardening and, in consequence, field repair of cracks
by fusion welding is a special problem. The high temperatures at which fusion
weld repairs are made and the subsequent air cooling of the part, or parts,
from these temperatures usually results in an increase in material hardness and
a loss in ductility. Parts on which fusion weld repairs have been made have a
tendency to crack because the steel structure becomes unstable, brittle and
highly stressed. The structure of the material can be improved by reheating
the parts and controlling the cooling rate.
(a) Components which are not highly stressed may be repaired by fusion welding.
It is possible to partially restore the original properties of such welded parts
through use of local heat treatment. The localized heat may be applied by neutral
flame of an oxyacetylene torch. Extend the stress relief one inch minimum
beyond the welded area. After the desired heat has been applied to the part for
the correct length of time, reduce temperature of part gradually.
B. Blend Repair
(4) Lines, scratches, or sharp edges which may cause a concentration of stress are not
permitted.
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(2) Clean out hole and ensure swarf and other foreign matter is removed.
NOTE: Inserts must be coated externally with zinc chromate primer (PWC13-003)
prior to installation.
(3) Install new helical coil insert into threaded hole using installation tool. Outer thread
of insert must be between one and one-half threads below surface of hole or
counterbore, as applicable.
(4) Cut off driving tang at notch using approved tang removal tool and remove tang
from hole.
D. Replacement of Studs
(1) General
(a) When necessary, oversize studs are to be installed in place of those which are
broken, stretched, loose or have damaged external threads. Whenever a stud
which is already oversize requires replacement, install the next oversize
stud. Use correct stud drivers to install new studs and torque to appropriate
value (Ref. Tables 801 or 802, as applicable).
(b) When threads of a stud hole are damaged beyond dimensions suitable for
fitting a maximum oversize stud, it may be possible to effect repairs by the
installation of a helical coil (Ref. Subpara. C.) or key-type insert. However as
consideration should be given to reduction of thickness of walls or parent metal
around insert and the required strength, specific problems should be referred
to P&WC Customer Support (Ref. INTRODUCTION).
(b) Examine stud hole for condition. On worn stud holes use oversize studs.
(c) Install stud to correct protrusion height using an approved stud driver. Ensure
torque limits (Ref. Tables 801 or 802, as applicable) are not exceeded.
(1) Clean area to be treated with crocus cloth (PWC05-061) and/or cloth impregnated
with isopropyl alcohol (PWC11-014).
(2) On rough surfaces, remove corrosion using wire brush or abrasive paper.
(3) On finished surfaces, remove corrosion using swab or brush impregnated with hot
chromic acid solution (PWC05-197) at 85° to 93° C (185° to 200°F).
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(7) Apply the chromic acid solution (PWC11-019) or chrome pickel solution (PWC05-161)
at a temperature of 17 to 29 ° C (55 to 85 °F) for 30 to 45 seconds to prepared
area to be treated using a clean cloth. Repeat swabbing at frequent intervals to
ensure treated area is maintained wet with solution during treatment.
(8) Thoroughly rinse touched up area by swabbing several times with clean cloth
moistened with water.
(a) Prepare surface by cleaning with cleaning solution (PWC11-038). Keep surface
wetted with cleaning solution for one to five minutes.
(b) Rinse with clean water to remove all traces of cleaning solution.
(d) Rinse with clean water to remove all traces of excess chemical treatment
solution and allow surface to air dry.
(e) Examine treated surface and ensure that repair area is completely covered.
Reapply treatment if necessary.
0.112-40 4 - 8
0.138-32 8 - 14
0.164-32 10 30 30
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0.190-24 15 40 45
0.216-24 20 65 70
0.250-20 40 95 105
NOTE: 1. Symbol $: These limits apply where the unthreaded diameter of the stud is less
than the minimum minor diameter of the coarse pitch thread (drive end).
NOTE: 2. Symbol #: These limits apply where the unthreaded diameter of the stud is equal
to or greater than the minimum minor diameter of the coarse pitch thread (drive
end).
0.138-40 8 - 18
0.164-36 10 30 30
0.190-32 15 45 50
0.216-28 20 65 75
0.250-28 40 115 125
NOTE: 1. Symbol $: These limits apply where the unthreaded diameter of the stud is less than
the minimum minor diameter of the fine pitch thread (nut end).
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NOTE: 2. Symbol #: These limits apply where the unthreaded diameter of the stud is equal to
or greater than the minimum minor diameter of the fine pitch thread (nut end).
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CHAPTER
SECTION PAGE DATE
LEP 1 Jul 18/2016
2 blank Jul 18/2016
TABLE OF CONTENTS
SUBJECT PAGE
1. General 501
E. Fuel 505
F. Instruments 505
2. Ground Operating Limits 505
A. General 506
H. Starting 517
L. Acceleration 526
1. General
A. Use of Procedures
This section contains information for PT6T-3D/-3DE/-3DF engine ground running for
checks and adjustment/test procedures to verify integrity of installed/replaced items and
to facilitate troubleshooting. These procedures are applicable solely to Pratt & Whitney
Canada (P&WC) supplied items and do not cover any airframe supplied parts.
For up-to-date technical accuracy for ground running, trim adjustments etc., the
procedures contained in the Power Plant Section of the airframe manufacturer’s Flight
Manual take precedence and must be referred to.
Before making any control adjustment/check, engine should be run for ten minutes
minimum, and all parameters stabilized.
B. Symbols
The P&WC symbols designated for the working variables used in the adjustment/test
procedures contained in this section, are defined as follows:
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(2) The use of turbine-powered aircraft makes it necessary to improve existing ground
safety precautions. To prevent injury to personnel and damage to property, handling
and working procedures must be suitably modified depending on installations.
When handling or working on turbine-powered aircraft, not only must the areas with
rotating components be avoided, but allowances must also be made for the hot,
high velocity exhaust gases discharged from the exhaust nozzles (Ref. Fig. 501)
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6−FT
43 160 30
25
50 175
20
15
10
150
450
250 5
800
655 1100 0
C3042
Exhaust Danger Area - Typical
Figure 501
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D. Environmental Conditions
As temperature drops, water becomes less soluble in fuel, with the result that water
and fuel separate, and water seeks the lowest point in the fuel system or
accessory. If temperature drops sufficiently, water freezes in the fuel and forms tiny
needle-shaped crystals which may impinge on strainers and restrict fuel flow. In
extreme cases fuel flow may be blocked entirely. This condition is evidenced by a
drop in fuel pressure to the power section. The remedy for this condition is to apply
heat to affected components.
In cold weather, it is most important that all fuel pumps and strainers be thoroughly
inspected prior to flight. As long a fuel flows freely from drains in tank and
strainers, it can be assumed that the system is free of ice. Any indication of restricted
flow is cause for heat application. Collect all drainage in a clear container, and
inspect for water globules in the fuel.
A similar condition may exist in lubrication systems, with water coming from
condensation in oil tanks or power section casings.
(3) Precipitation
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E. Fuel
It is recommended that testing be carried out with the same fuel as is used in service
(Ref. SB5144).
F. Instruments
Testing procedures described depend, for their effectiveness, on the accuracy of cockpit
instrumentation. Instruments should be calibrated frequently to ensure continued
accuracy within the following limits:
Ambient ±1°F
temperature
Ambient ±0.05‘‘ Hg
pressure
Ng and Nf ± 0.5%
rpm
Tt5 ± 5°C (9°F) (system accuracy)
temperature
Torquemeter ± 7 lb.ft. (system accuracy)
The ground operating limits for each power section are as shown in Table 501.
Limits quoted apply for Standard Day Conditions unless otherwise stated.
NOTE: 1. Overtemperatures are usually preceded by an excessively rapid rise in fuel flow,
compressor speed and inter-turbine temperature. Most commonly they are caused
by excessive fuel in the combustion area prior to light-up. Several momentary
high overtemperatures affect power section life just as seriously as a single
prolonged lower overtemperature.
NOTE: 2. Serious damage to power sections occurs sooner at higher temperatures. When
an overtemperature has occurred, or is anticipated, carry out a normal power
section shutdown. Avoid an emergency shutdown, unless it appears that continued
operation will result in greater damage than is normally associated with an
overtemperature.
NOTE: 3. For approved oils and fuels refer to SB5001 and SB5144 respectively.
NOTE: For complete operating parameters refer to airframe manufacturer’s Flight Manual
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A. General
The object of ground testing is to test an engine for mechanical soundness and to
ensure that applicable ground operating parameters are within limits.
To eliminate unnecessary ground running and thus conserve fuel, ground testing
procedures are divided into the thirteen checks detailed in Para. C. through N.. These
checks are not intended to be carried out as routine periodic checks on an engine but as
required in the following cases:
- After component repair or replacement, in accordance with the sequence shown in
Table 502.
- Whenever required as part of troubleshooting (Ref. 72-00-00, FAULT ISOLATION).
- As specified by the Aircraft Manufacturer.
- At the discretion of the operator.
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CHECKS REQUIRED
COMPONENT REPLACED (PARA. REF. NO.)
Power Section 3.C., D., E.*, F., G., H., I., J., K., L., N.
Reduction Gearbox 3.E.*, G., H., J.,, L., N.
T5 Temperature Compensator 3.F.
Automatic Fuel Control Unit (AFCU) 3.C., D., E.*, G., H., I., J., K., L., N.
Manual Fuel Control Unit (MFCU) 3.C., D., G., H., I., N. (Ref. NOTE 2)
Fuel Pump 3.C., D., G., H., I., J., K., L., N.
Power Turbine (NF) Governor 3.E.*, G., H., J., K., N.
Ignition Exciter 3.G., H., N.
Torque Limiter 3.E.*, G., H., K., N.
Flow Divider and Dump Valve 3.C., D., G., H., K., N.
Oil-to-Fuel Heater 3.G., H., K., N.
Compressor Bleed Valve 3. H., K., N.O.
NOTE: 1. Where marked with an asterisk (*) , Pneumatic system pressure test (Para. 3.E.)
should only be carried out if an air leak is suspected.
NOTE: 2. Checks 3. C. D. and H. on manual fuel control unit must be carried out in manual
mode.
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(8) Maintain starter operation for the required duration (Approx. 15 seconds).
(12) Check that dump valves and gas generator drain valves operate correctly by
observing overboard drain.
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(15) Allow the required cooling period for starter before attempting any further operation
(Ref. Aircraft Flight Manual).
NOTE: The following procedure is used as required to clear a power section of trapped
fuel and vapor or in the event of fire in a power section. During the motoring
run, the airflow through the power section purges the fuel vapor or fire from the
combustion, gas generator, turbine and exhaust sections.
(11) Allow the required cooling period for starter before attempting any further starting
operating (Ref. Aircraft Flight Manual).
(1) Do the pressure test of fuel control pneumatic system by one of the following
methods:
(a) Method A:
3 Connect a 75 to 85 psig clean and dry air supply to the elbow (4) at the
fireseal.
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REGULATED AIR 7
PRESSURE 80 (± 5) PSI FRONT
FIRESEAL
6
4
C3602
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1. Tube Assembly
2. Adapter
3. Pressure Gage
4. Elbow
5. Tube Assembly
6. Locknut
7. Tube Assembly
4 Apply leak checking fluid (PWC05-007) to all connections in the fuel control
pneumatic system.
5 If leaks are detected, examine the components for defects and replace as
necessary.
1 Remove the P3 filter bowl and filter element from the power section.
3 Connect a 75 to 85 psig clean and dry air supply to the adapter (PWC70797).
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5 If leaks are detected, examine the components for damage and replace as
necessary.
NOTE: The Tt5 temperature compensator may be checked with engine running as
detailed in step (1) following or by using a tester to simulate operating
conditions as detailed in step (2).
(a) Note amount of trim indicated on trim value plates on center fireseal and on
gas generator case in intake plenum area (Ref. Fig. 503).
(c) Run for five minutes at a minimum of 75% Ng (90% optimum) to allow
stabilization of operating parameters.
(d) Disconnect power supply lead from temperature compensator (Ref. Fig. 504)
NOTE: This check requires the use of a Barfield Tester 2312G-8 or equivalent.
The tester may be obtained from the following address.
(a) Note amount of trim indicated on trim value plates on center fireseal and on
gas generator case in intake plenum area (Ref. Fig. 503).
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5
1 4
A 3
2
C D
VIEW B
(VIEW ON CENTER FIRESEAL)
REDUCTION GEARBOX
3
VIEW A
B
60 o
84o
VIEW C VIEW D
Pre-SB5509 C3603B
Location of Trim Value Plates
Figure 503 (Sheet 1 of 2)
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E
VIEW B
(VIEW ON CENTER FIRESEAL)
REDUCTION GEARBOX
VIEW E
Post-SB5509 C191044
Location of Trim Value Plates
Figure 503 (Sheet 2)
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ADJUSTER
PROTECTIVE CAP
INPUT LEAD
C9352
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(g) Reconnect power supply lead to compensator and observe that reading returns
to 750°C.
G. Pre-start Checks
(1) Inspect air inlets thoroughly, and ensure that they are clear of loose nuts, bolts,
tools and other objects which might cause damage and subsequent failure.
(2) Inspect area in vicinity of air inlets and exhaust, and remove any loose objects
which might possibly be ingested or blown rearward by exhaust gases.
(4) Check each power section fuel system for presence of water.
(5) Check engine controls for full travel, freedom of movement and correctness of
direction.
(6) Check oil level in each power section and reduction gearbox oil tank and service as
necessary.
H. Starting
NOTE: 1. Each power section may be started with its fuel system in MANUAL or
AUTOMATIC mode. However it is recommended that the AUTOMATIC mode
be used.
NOTE: 3. Refer to Tables 505 and 506 for power section/reduction gearbox operating oil
pressures and temperatures.
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(e) Fuel Boost Pump Switches - ON (Check power section fuel inlet pressure 5
psig minimum).
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(j) Power Control Lever - IDLE after stabilized Ng (gas generator speed) of not
less than 12% is reached.
(k) Observe that gas generator accelerates to Idle rpm (51% minimum), and that
nominal inter-turbine starting temperature is not exceeded (Ref. Table 501) .
2 Slowly increase power on second power section until equal power turbine
speed (Nf) on both power sections is obtained.
3 Check that small power increases on one power section produce equal Nf
increases on both power sections, this indicating that both clutches are
engaged.
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(e) Fuel Boost Pump Switches - ON (check power section fuel inlet pressure 5
psig minimum).
(j) Power Control Lever - IDLE after stabilized Ng (gas generator speed) of not
less than 12% is reached.
(k) Observe that gas generator accelerates to Idle rpm (51% minimum), and that
nominal inter-turbine starting temperature limits are not exceeded (Ref. Table
501) .
2 Slowly increase power on second power section until equal power turbine
speed (Nf) on both power sections is obtained.
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3 Check that small power increases on one power section produce equal Nf
increases on both power sections, this indicating that both clutches are
engaged.
(3) An unsatisfactory start will occur if one or more of the following take place:
(a) Hot Start - Interturbine temperature (Tt5) exceeds starting temperature limits.
NOTE: A hot start may also be caused by a False Start or a Hung Start.
(b) False or Hung Start - After light-up has occurred, gas generator speed does
not reach 51% within 30 seconds of Power Control Lever being set to IDLE.
(c) No Start - Power section does not light up within 15 second of Power Control
Lever being set to IDLE.
(e) Sprag clutch of second power section started, fails to engage. In the event of
clutch non-engagement, proceed as follows:
1 Hold power section with the normally engaged clutch at its stabilized speed
- do not decelerate.
2 Shut down power section with the non-engaged clutch and allow rotation to
stop.
4 Start power section with previously non-engaged clutch and listen carefully
for unusual noises indicating a damaged clutch.
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7 Run the power section with the suspect clutch, at Flight Idle for five
minutes.
8 Shut down power section and inspect reduction gearbox output section oil
filter and chip detector.
NOTE: If condition of oil filter and chip detector is satisfactory, the engine
may remain in service.
WARNING: ENSURE THAT THE AIRCRAFT IS PROPERLY TIED DOWN (REF. AIRCRAFT
FLIGHT MANUAL).
NOTE: 1. The maximum gas generator speed adjustment and the manual-automatic
interconnect linkage adjustment affect each other. Hence, the entire
procedure in this check must be carried out whenever either of these
adjustments requires checking.
NOTE: 2. To ensure the capability of setting the gas generator maximum speed stop
under a wide variety of ambient conditions without exceeding engine
operating limits, a slave part power trim stop (P/N 3243781, Table 504)
(Pre-SB5331) or integral part power trim stop (Post-SB5331) is provided. The
part power trim stop, when in use, enables adjustment of the maximum
obtainable Ng at lower power settings.
NOTE: 3. During adjustment of the gas generator maximum speed stop, ensure the
following conditions:
(1) Pre-SB5331: Install slave part power trim stop (P/N 3243781, Table 504).
(2) Post-SB5331: Remove pin securing part power trim stop in stowed position.
(3) Rotate stop so that it limits travel of automatic fuel control arm.
(4) Install cotterpin to secure stop and bend ends of pin over.
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2 PART POWER
TRIM STOP 2 PART POWER
‘IN USE’ POSITION TRIM STOP
‘STOWED’ POSITION
PART POWER TRIM STOP
LOCATION ON AUTOMATIC
FUEL CONTROL UNIT
VIEW A
Pg CONNECTION
6 ACCELERATION ADJUSTER
4 MANUAL−AUTOMATIC
INTER−CONNECT LINKAGE
ADJUSTMENT
MANUAL
MAXIMUM STOP MAXIMUM STOP ADJUSTMENT
5 (MANUAL CONTROL)
3 CLEARANCE MANUAL CONTROL ARM
C241160
Fuel Control Adjustment
Figure 505
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NOTE: Ensure that torque limit is not exceeded (Ref. Airframe Manual).
(d) Check that Ng falls within 35052 rpm (92.0%) to 35280 rpm (92.6%) with slave
(Pre-SB5331) or integral (Post-SB5331) part power trim stop.
(e) If necessary, adjust automatic fuel control arm maximum stop adjuster (1) to
get Ng value of 35166 rpm (92.3%) with slave part power trim stop (2).
(h) Pre-SB5331: Remove cotterpin and slave part power trim stop.
(i) Post-SB5331: Remove cotterpin and rotate part power trim stop to the stowed
position.
(j) Post-SB5331: Secure stop with a new pin and bend ends of pin over.
(6) Check that pointer on MFCU indicates 95 degrees. If not, adjust manual-automatic
interconnect linkage (4) as follows:
(a) With indicator at zero degrees (minimum stop), retard automatic fuel control
arm to compress spring and to disengage spacer tangs from self-locking nut.
(b) Adjust self-locking nut position as required and recheck indicator against 95
degree position.
NOTE: Ensure that spacer tangs are correctly positioned on nut flats and
between tangs of interconnect lever (Ref. Detail B).
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(7) Hold automatic fuel control arm in contact with maximum stop (95 degrees) and
check that clearance (3) between MFCU arm maximum stop adjuster (5) and
maximum stop is 0.015 to 0.020 inch.
NOTE: Ensure that torque required to turn adjustment nut is 1-1/2 lb.in.,
minimum. If necessary, replace nut.
(b) Retard Power Control Lever setting until MFCU minimum stop is contacted.
(d) If pointer deviates from 0 degrees by more than 1/16 (0.0625) in., MFCU must
be replaced.
(9) Carry out several transfers from Automatic to Manual and vice versa.
(10) Check that successful transfer has taken place in both directions by observing shift
of parameters.
NOTE: 2. If operator flies below 5000 ft., ground check as above is acceptable. If
operator flies above 5000 ft., the cross over must be checked as per
Aircraft Maintenance Manual.
(c) Check that Ng is between 20500 (53.8%) and 21000 rpm (55%).
(d) If necessary, adjust idle stop (7) to bring Ng within required range.
NOTE: The difference between Ng idle speeds of both power sections must
not exceed 250 rpm.
(e) On completion of check, torque idle stop locknut 20 to 25 lb.in. and lockwire.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
For instructions on setting the Nf governor maximum and minimum stops, refer to the
Aircraft Maintenance Manual.
The purpose of the performance/ power assurance check is to detect any signs of
engine deterioration.
All forms of engine deterioration can cause increased Tt5 and fuel consumption at a
given power output. Compressor deterioration which in most cases, is due to dirt deposits,
causes increase of Ng at given power settings. This can be remedied by Field
Cleaning (Ref. 72-00-00, ENGINE - CLEANING). Hot section deterioration, in addition to
causing Tt5 increases, causes decreases, in Ng at given power settings.
If the observed parameters are outside the limits quoted for the installed engine,
instrument or engine faults are indicated and reference must be made to the applicable
troubleshooting procedures (Ref. 72-00-00, FAULT ISOLATION).
L. Acceleration
(5) Record time taken to accelerate to 90% Ng. Maximum acceptable time is 4
seconds, with no more than 0.5 seconds between power sections.
(6) If acceleration time exceeds limits, the acceleration adjuster on fuel control unit may
be adjusted, as follows:
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MAINTENANCE MANUAL
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(a) Adjuster must be rotated one click at a time, to a maximum of six clicks
counter-clockwise (to slow acceleration rate) and three or six clicks (see Note)
clockwise (to speed up acceleration rate), repeating steps (3) and (4) after
each adjustment.
NOTE: Three clicks are allowed if the adjuster has a flat, ’’coin‘‘ shaped
lockwire seal. Six clicks are allowed if the adjuster has a small
cylindrical seal.
(b) If acceleration time is not met within these parameters, the AFCU must be
replaced.
(2) Retard throttle as quickly as possible (approximately one second), allowing the
power section to decelerate to idle speed.
(3) Repeat steps (1) and (2) for the second power section.
(4) Replace the fuel surge accumulator if engine flame-out, rumble, or compressor stall
occurs during the rapid deceleration check.
N. Shutdown
(2) Allow both power sections to stabilize for a minimum of one minute at Idle.
(4) Check for any changes in run-down time, which should not be less than 20
seconds from Idle and listen for any unusual noises such as scraping, rubbing or
grinding.
(7) Check that dump valves and gas generator drain valves operate correctly by
observing overboard drain.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(8) Check engine for fuel and/or oil leaks (Ref. Table 507).
(1) Perform Bleed valve closing point (Ref. 75-30-00 Adjustment/ Test).
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POWER PLANT - ADJUSTMENT/TEST Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
LEP 1 Jul 18/2016 117 Jul 18/2016
2 Jul 18/2016 118 Jul 18/2016
3 Jul 18/2016 119 Jul 18/2016
4 Jul 18/2016 120 Jul 18/2016
121 Jul 18/2016
Contents 1 Jul 18/2016 122 Jul 18/2016
2 Jul 18/2016 123 Jul 18/2016
3 Jul 18/2016 124 Jul 18/2016
4 Jul 18/2016 125 Jul 18/2016
5 Jul 18/2016 126 Jul 18/2016
6 Jul 18/2016 127 Jul 18/2016
128 Jul 18/2016
72-00-00 1 Jan 26/2015 129 Jul 18/2016
Description and 2 Jan 26/2015 130 Jul 18/2016
Operation 3 Jan 26/2015 131 Jul 18/2016
4 Jan 26/2015 132 Jul 18/2016
5 Jan 26/2015 133 Jul 18/2016
6 Jan 26/2015 134 Jul 18/2016
7 Jan 26/2015 135 Jul 18/2016
8 Jan 26/2015 136 Jul 18/2016
9 Jan 26/2015 137 Jul 18/2016
10 Jan 26/2015 138 Jul 18/2016
11 Jan 26/2015 139 Jul 18/2016
12 blank Jan 26/2015 140 Jul 18/2016
141 Jul 18/2016
72-00-00 101 Jul 18/2016 142 Jul 18/2016
Fault Isolation 102 Jul 18/2016 143 Jul 18/2016
103 Jul 18/2016 144 Jul 18/2016
104 Jul 18/2016 145 Jul 18/2016
105 Jul 18/2016 146 Jul 18/2016
106 Jul 18/2016 147 Jul 18/2016
107 Jul 18/2016 148 Jul 18/2016
108 Jul 18/2016 149 Jul 18/2016
109 Jul 18/2016 150 Jul 18/2016
110 Jul 18/2016 151 Jul 18/2016
111 Jul 18/2016 152 Jul 18/2016
112 Jul 18/2016 153 Jul 18/2016
113 Jul 18/2016 154 Jul 18/2016
114 Jul 18/2016 155 Jul 18/2016
115 Jul 18/2016 156 Jul 18/2016
116 Jul 18/2016 157 Jul 18/2016
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
158 Jul 18/2016 336 Jul 28/2014
159 Jul 18/2016 337 Jul 28/2014
160 Jul 18/2016 338 Jul 28/2014
161 Jul 18/2016 339 Jul 28/2014
162 Jul 18/2016 340 Jul 28/2014
341 Jul 28/2014
72-00-00 301 Jul 28/2014 342 Jul 28/2014
Servicing 302 Jul 28/2014 343 Jul 28/2014
303 Jul 28/2014 344 Jul 28/2014
304 Jul 28/2014 345 Jul 28/2014
305 Jul 28/2014 346 Jul 28/2014
306 Jul 28/2014 347 Jul 28/2014
307 Jul 28/2014 348 Jul 28/2014
308 Jul 28/2014 349 Jul 28/2014
309 Jul 28/2014 350 Jul 28/2014
310 Jul 28/2014 351 Jul 28/2014
311 Jul 28/2014 352 Jul 28/2014
312 Jul 28/2014 353 Jul 28/2014
313 Jul 28/2014 354 Jul 28/2014
314 Jul 28/2014 355 Jul 28/2014
315 Jul 28/2014 356 Jul 28/2014
316 Jul 28/2014 357 Jul 28/2014
317 Jul 28/2014 358 Jul 28/2014
318 Jul 28/2014 359 Jul 28/2014
319 Jul 28/2014 360 Jul 28/2014
320 Jul 28/2014 361 Jul 28/2014
321 Jul 28/2014 362 Jul 28/2014
322 Jul 28/2014 363 Jul 28/2014
323 Jul 28/2014 364 Jul 28/2014
324 Jul 28/2014 365 deleted
325 Jul 28/2014 366 deleted
326 Jul 28/2014
327 Jul 28/2014
328 Jul 28/2014
329 Jul 28/2014
330 Jul 28/2014 72-00-00 401 Jul 28/2014
331 Jul 28/2014 Removal/ 402 Jul 28/2014
332 Jul 28/2014 Installation 403 Jul 28/2014
333 Jul 28/2014 404 Jul 28/2014
334 Jul 28/2014 405 Jul 28/2014
335 Jul 28/2014 406 blank Jul 28/2014
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
72-00-00 601 Jul 18/2016 642 Jul 18/2016
Inspection 602 Jul 18/2016 643 Jul 18/2016
Check 603 Jul 18/2016 644 Jul 18/2016
604 Jul 18/2016 645 Jul 18/2016
605 Jul 18/2016 646 Jul 18/2016
606 Jul 18/2016 647 Jul 18/2016
607 Jul 18/2016 648 Jul 18/2016
608 Jul 18/2016 649 Jul 18/2016
609 Jul 18/2016 650 Jul 18/2016
610 Jul 18/2016 651 Jul 18/2016
611 Jul 18/2016 652 Jul 18/2016
612 Jul 18/2016 653 Jul 18/2016
613 Jul 18/2016 654 Jul 18/2016
614 Jul 18/2016 655 Jul 18/2016
615 Jul 18/2016 656 Jul 18/2016
616 Jul 18/2016 657 Jul 18/2016
617 Jul 18/2016 658 Jul 18/2016
618 Jul 18/2016 659 Jul 18/2016
619 Jul 18/2016 660 Jul 18/2016
620 Jul 18/2016 661 Jul 18/2016
621 Jul 18/2016 662 Jul 18/2016
622 Jul 18/2016 663 Jul 18/2016
623 Jul 18/2016 664 Jul 18/2016
624 Jul 18/2016 665 Jul 18/2016
625 Jul 18/2016 666 Jul 18/2016
626 Jul 18/2016 667 Jul 18/2016
627 Jul 18/2016 668 Jul 18/2016
628 Jul 18/2016 669 Jul 18/2016
629 Jul 18/2016 670 Jul 18/2016
630 Jul 18/2016 671 Jul 18/2016
631 Jul 18/2016 672 Jul 18/2016
632 Jul 18/2016 673 Jul 18/2016
633 Jul 18/2016 674 blank Jul 18/2016
634 Jul 18/2016
635 Jul 18/2016 72-00-00 701 Jul 18/2016
636 Jul 18/2016 Cleaning/ 702 Jul 18/2016
637 Jul 18/2016 Painting 703 Jul 18/2016
638 Jul 18/2016 704 Jul 18/2016
639 Jul 18/2016 705 Jul 18/2016
640 Jul 18/2016 706 Jul 18/2016
641 Jul 18/2016 707 Jul 18/2016
CHAPTER
SECTION PAGE DATE
708 Jul 18/2016
709 Jul 18/2016
710 Jul 18/2016
711 Jul 18/2016
712 Jul 18/2016
713 Jul 18/2016
714 Jul 18/2016
715 Jul 18/2016
716 Jul 18/2016
717 Jul 18/2016
718 Jul 18/2016
719 Jul 18/2016
720 blank Jul 18/2016
TABLE OF CONTENTS
SUBJECT PAGE
1. General 1
2. Engine Sections 6
A. Reduction Gearbox Section 7
3. Engine Operation 7
A. Starting 7
B. Running 9
1. General 101
2. Procedure 103
TABLE OF CONTENTS
SUBJECT PAGE
C. Flushing 304
A. General 305
1. General 401
5. Procedure 401
TABLE OF CONTENTS
SUBJECT PAGE
1. General 601
5. Procedure 601
A. 25 hours. 602
A. General 615
B. Overtorque 615
TABLE OF CONTENTS
SUBJECT PAGE
C. Overtemperature 615
D. Overspeed 615
A. General 627
B. Description 627
C. Procedure 636
12. In-service Borescope Inspection 639
TABLE OF CONTENTS
SUBJECT PAGE
A. General 649
B. Preparation 649
1. General 701
TABLE OF CONTENTS
SUBJECT PAGE
A. Preparation 717
1. General 201
5. Procedure 202
A. Removal from Engine 202
1. General
The engine comprises two identical free-turbine turboshaft power sections driving a single
output shaft through identical geartrains in a common reduction gearbox.
The terminology used for engine major assemblies, the directional references and the
leading particulars and specifications are as follows:
(1) Each complete engine consists of two power sections and the reduction gearbox
section which are defined as follows:
This comprises two input sections; one for each power section and an output
section.
(2) Terms such as clockwise, counterclockwise, right and left apply with the engine
viewed from the reduction gearbox end unless otherwise stated.
NOTE: The terms No. 1 and No. 2 power sections are defined as left and right
respectively with the engine viewed from this point.
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Page 1
ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
ACCESSORY ACCESSORY
GEARBOX GEARBOX
REDUCTION GEARBOX
REDUCTION
GEARBOX
C22651
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
B. Engine Data
Maximum SFC
Minimum SHP lbs/shp/hr
Rating Speed (Ns) RPM Twin Single Twin Single
2-1/2 Minute 6600 - 1133 - 0.601
Continuous 6600 - 1024 - 0.599
OEI
Take-off 6600 1800 900 0.602 0.603
Maximum 6600 1600 800 0.617 0.622
Continuous
NOTE: 1. Standard day, sea level, static conditions with no installation losses and no air bleed
or airframe accessory power absorption.
NOTE: 2. The leading particulars are provided for reference purposes only. For complete
operating parameters refer to 71-00-00 Table 501, Engine Specific Operating
Instructions and/or Airframe Manufacturers Flight Manual, as applicable.
Type Twin Power Section - Free
Turbine Turboshaft
Type of Combustion Chamber Annular
Engine Dimensions, Basic at
Room Temperature:
- Length 67 inches (1701 mm)
- Width 44 inches (1117 mm)
- Height 33 inches (838 mm)
Output Shaft:
-Rotation Clockwise
-Configuration Externally Splined
-Gear Ratio (to Free Turbine) 1:5
Compressor Pressure Ratio 7:1
Maximum Total Oil Consumption 0.4 lb./hr (182 cc/hr)
(Measured over 10 hours period) or 2 US Quarts in 10 hours
(1.8 Liters in 10 hours)
Specification Weight - Dry 676 lbs. (307 Kg.)
Weight of Additional Equipment - Dry 37.5 lbs. (17.05 Kg.)
Weight of Oil - approx. 37.3 lbs. (16.91 Kg.)
Total Weight - approx. 751 lbs. (341 Kg.)
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
Maximum SFC
Minimum SHP lbs/shp/hr
Rating Speed (Ns) RPM Twin Single Twin Single
2-1/2 Minute 6600 - 1133 - 0.601
Continuous OEI 6600 - 1079 - 0.599
Take-off 6600 1800 900 0.602 0.603
Maximum Continuous 6600 1600 800 0.617 0.622
NOTE: 1. Standard day, sea level, static conditions with no installation losses and no air bleed
or airframe accessory power absorption.
NOTE: 2. The leading particulars are provided for reference purposes only. For complete
operating parameters refer to 71-00-00 Table 501, Engine Specific Operating
Instructions and/or Airframe Manufacturers Flight Manual, as applicable.
Type Twin Power Section - Free
Turbine Turboshaft
Type of Combustion Chamber Annular
Engine Dimensions, Basic at
Room Temperature:
- Length 67 inches (1701 mm)
- Width 44 inches (1117 mm)
- Height 33 inches (838 mm)
Output Shaft:
-Rotation Clockwise
-Configuration Externally Splined
-Gear Ratio (to Free Turbine) 1:5
Compressor Pressure Ratio 7:1
Maximum Total Oil Consumption 0.4 lb./hr (182 cc/hr)
(Measured over 10 hours period) or 2 US Quarts in 10 hours
(1.8 Liters in 10 hours)
Specification Weight - Dry 676 lbs. (307 Kg.)
Weight of Additional Equipment - Dry 37.5 lbs. (17.05 Kg.)
Weight of Oil - approx. 37.3 lbs. (16.91 Kg.)
Total Weight - approx. 751 lbs. (341 Kg.)
Maximum SFC
Minimum SHP lbs/shp/hr
Rating Speed (Ns) RPM Twin Single Twin Single
2-1/2 Minute 6600 - 1133 - 0.601
Continuous 6600 - 1079 - 0.599
OEI
Take-off 6600 1800 900 0.602 0.603
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
Maximum SFC
Minimum SHP lbs/shp/hr
Rating Speed (Ns) RPM Twin Single Twin Single
Maximum 6600 1600 800 0.617 0.622
Continuous
NOTE: 1. Standard day, sea level, static conditions with no installation losses and no air
bleed or airframe accessory power absorption.
NOTE: 2. The leading particulars are provided for reference purposes only. For complete
operating parameters refer to 71-00-00 Table 501, Engine Specific Operating
Instructions and/or Airframe Manufacturers Flight Manual, as applicable.
Type Twin Power Section - Free
Turbine Turboshaft
Type of Combustion Chamber Annular
Engine Dimensions, Basic at
Room Temperature:
- Length 67 inches (1701 mm)
- Width 44 inches (1117 mm)
- Height 33 inches (838 mm)
Output Shaft:
-Rotation Clockwise
-Configuration Externally Splined
-Gear Ratio (to Free Turbine) 1:5
Compressor Pressure Ratio 7:1
Maximum Total Oil Consumption 0.4 lb./hr (182 cc/hr)
(Measured over 10 hours period) or 2 US Quarts in 10 hours
(1.8 Liters in 10 hours)
Weight of Additional Equipment - 37.5 lbs. (17.05 Kg.)
Dry
Weight of Oil - approx. 37.3 lbs. (16.91 Kg.)
Total Weight - approx. 751 lbs. (341 Kg.)
(1) The following service bulletins contain data recommended by Pratt & Whitney
Canada and approved by Transport Canada.
(b) Service Bulletin 72-001 (P&WC SB No. 5001) Approved List of (Synthetic)
Lubricating Oils.
(c) Service Bulletin 72-144 (P&WC SB No. 5144) Requirements and Approved
Listing of Engine Fuels and Additives.
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
D. Leading Particulars - Accessory and Reduction Gearbox Drive (Ref. Table 4and Fig. 2)
NOTE: Only a brief description of each engine section is given here. Full description and
operation of each section is included in the Chapter/Section/Unit applicable to each
subject. References to these Chapter/Section/Units are given in parenthesis after
each subject title.
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
This section comprises the reduction gearbox input and output sections, an integral
torquemeter, two power turbine (Nf) governors and two air (Pg) accumulators. The gearbox
also includes drive pads for the airframe supplied tachometer generator and oil cooler
blower.
This section contains those components associated with intake and compression of air,
the combustion section of the engine and the compressor turbine components.
This section comprises the exhaust duct and the power turbine components. The power
turbine stator assembly houses the inter-turbine temperature sensing probes.
Engine driven accessories, with the exception of the Nf governor, the Nf tachometer
generator and the oil cooler blower are mounted on the accessory gearbox and driven
from geartrains within the gearbox. The gearbox is driven by the compressor through a
coupling shaft.
3. Engine Operation
A. Starting
Rotation of the compressor causes air to be drawn in through the air inlet in the gas
generator section. This air is compressed by the axial and centrifugal stages of the
compressor at a ratio of 7:1. The air leaves the final (centrifugal) stage of the compressor
and passes through diffuser pipes in the gas generator case to the combustion
chamber. The diffuser pipes raise the static pressure of the air and turn its flow through
90 degrees.
The accessory gearbox driven fuel pump delivers fuel to the nozzles in the combustion
chamber via the fuel control units which are also mounted on the accessory gearbox.
The fuel is sprayed into the combustion chamber where it mixes with the air from the
compressor.
On activation of the aircraft ignition switches, the ignition exciter energizes the spark
igniters in the combustion chamber and the fuel air mixture is ignited.
As soon as light-up is obtained, the starter-generator and the ignition system are
deactivated.
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
2 2
1
1
3
3
FRONT VIEW
4 4
6 6
5 5
REAR VIEW
C3721A
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
Key to Figure 2
1. Starter-Generator
2. Fuel Pump & FCU
3. Ng Tachometer-generator
4. Blower Drive
5. Nf Governor
6. Nf Tachometer-generator
Air in excess of that required for combustion is used to cool the surfaces of the
combustion chamber liner.
B. Running
The gases produced by combustion of the fuel-air mixture expand from the combustion
chamber through the passage between the combustion chamber large and small exit
ducts to the compressor turbine guide vanes.
The turbine guide vanes direct the gas flow onto the compressor turbine blades at the
optimum angle to drive the turbine.
The compressor turbine thus drives the compressor and the accessory gearbox.
Gas flows to and from the combustion chamber in opposite directions. This reversal,
along with the second reversal beyond the combustion chamber, eliminates the need for
a long shaft between the compressor and the compressor turbine. Power section
overall length and weight are thus reduced.
Beyond the compressor turbine the still expanding gases pass through the power
turbine guide vanes which direct the gas flow onto the power turbine blades.
Each power turbine drives its corresponding input section of the reduction gearbox via
the power turbine shaft and the main input drive coupling shaft.
Exhaust gases leave each power section through the single exhaust port in the exhaust
duct and are directed into the airframe exhaust system.
Each reduction gearbox input section drives the common output section drive shaft
through sprag clutches which isolate an inoperative power section in the event of failure.
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
FLANGES
A REDUCTION GEARBOX TO EXHAUST DUCT
B BEARING HOUSING SUPPORT TO TURBINE SHAFT HOUSING
C EXHAUST DUCT TO GAS GENERATOR CASE
D EXHAUST DUCT TO POWER TURBINE VANE HOUSING
E COMPRESSOR TURBINE SHROUD HOUSING TO INNER EXIT DUCT
F GAS GENERATOR CASE TO COMPRESSOR INLET CASE
G COMPRESSOR INLET CASE TO ACCESSORY GEARBOX
C3003B_1
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
6 5 3 4 1
2.5 2
C3003B_2
Engine Cross Section
Figure 3 (Sheet 2)
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ENGINE - DESCRIPTION AND OPERATION Jan 26/2015
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
This section outlines the more common problems encountered during engine operation and
highlights their possible causes and solutions. Familiarization with the engine will minimize
operating defects but some may result from inadvertently exceeding operating limits under
adverse conditions. Before working on an engine that has been reported malfunctioning
in flight, it is recommended that flight reports and all available sources of pertinent information
be consulted.
The problems treated here fall into four main groups, Starting, Operating, Performance and
Lubrication. Each problem is allocated to a separate Figure No. which presents the
possible causes and solutions in logic flow form. Where remedial action requires removal
and replacement and/or checks or tests to be carried out, references to the applicable
Chapter/Section/Unit in this manual are given in parentheses after each instruction.
The four main groups of problems and the applicable figures are as follows:
STARTING
No RPM Figure 101
Insufficient RPM Figure 102
Uncontrolled Power Section Figure 103
Acceleration
Delayed Start Figure 104
Failure to Light Up Figure 105
Incorrect Acceleration to Idle Figure 106
Hot Start Figure 107
High Idle Torque Figure 108
Sprag Clutch Non-Engagement Figure 109
OPERATING
Engine Overspeed/ Figure 110
Uncommanded Acceleration
Inability to Switch from Automatic Figure 111
Manual Mode
Fuel Leakage from AFCU Vent Figure 112
Leakage from Fuel Pump Drain Figure 113
Ports
Vibration Figure 114
Uncontrolled Power Section Figure 115
Acceleration
Surge During Acceleration Figure 116
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ENGINE - FAULT ISOLATION Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
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MANUAL PART NO. 3040592
2. Procedure
B. Investigate each possible cause in the sequence in which it appears in the flow chart
and carry out the corrective action indicated.
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ENGINE - FAULT ISOLATION Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23941
Starting - No RPM
Figure 101 (Sheet 1 of 2)
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Page 104
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MANUAL PART NO. 3040592
C23942A
Starting - No RPM
Figure 101 (Sheet 2)
72-00-00
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MANUAL PART NO. 3040592
C23943
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Page 106
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23944A
Starting - Uncontrolled Power Section Acceleration
Figure 103
72-00-00
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MANUAL PART NO. 3040592
C23945A
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Page 108
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23946A
Starting - Failure to Light Up
Figure 105 (Sheet 1 of 5)
72-00-00
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Page 109
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MANUAL PART NO. 3040592
C24565A
72-00-00
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Page 110
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C24566A
Starting - Failure to Light Up
Figure 105 (Sheet 3)
72-00-00
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Page 111
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1
7
2 6
5
4 8
METERED
FUEL
FROM
AFCU 9
UNMETERED
3
FUEL TO AFCU
C24567
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Page 112
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Preformed Packing
2. Bolt
3. Fuel Interconnect Tube
4. Fuel Interconnect Tube
5. Pressure Regulating Valve
6. Fuel Interconnect Tube
7. Preformed Packing
8. Straight Nipple
9. Bolt
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Page 113
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
P3 ORIFICE FITTING
C24568
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Page 114
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23947
Starting - Incorrect Acceleration to Idle
Figure 106
72-00-00
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Page 115
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
CORRECT: CHECK STARTER SPEED. IF LOW, OK: REMOVE FUEL NOZZLES AND
CHECK POWER SUPPLY AND CONNECTIONS. PERFORM FUEL NOZZLE FUNCTIONAL
REPLACE STARTER IF REQUIRED. (REF AF MM). IF: CHECK (REF 73−10−00). IF:
C93071
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Page 116
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MANUAL PART NO. 3040592
C23949A
Starting - High Idle Torque
Figure 108
72-00-00
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Page 117
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
SPRAG CLUTCH
NON−ENGAGEMENT
PERFORM NON−ENGAGEMENT
PROCEDURE (REF. 71−00−00)
C39306
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Page 118
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
ENGINE OVERSPEED /
UNCOMMANDED ACCELERATION
(REF. 71−00−00 FOR LIMITS)
C23950B
Operating - Engine Overspeed/Uncommanded Acceleration
Figure 110
72-00-00
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Page 119
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MANUAL PART NO. 3040592
C23951B
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Page 120
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MANUAL PART NO. 3040592
C23952A
Operating - Fuel Leakage from AFCU Vent
Figure 112
72-00-00
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MANUAL PART NO. 3040592
C23953B
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Page 122
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MANUAL PART NO. 3040592
C23954A
Operating - Vibration
Figure 114
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Page 123
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MANUAL PART NO. 3040592
C23955A
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Page 124
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MANUAL PART NO. 3040592
C23956A
Operating - Surge During Acceleration
Figure 116
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Page 125
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
4. IF FAULT PERSISTS REMOVE AND CLEAN P3 ORIFICE IN AFCU (REF. FIG. 105,
SHEET 5).
C23957C
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Page 126
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C66179A
Operating - Off Idle Stall / Idle Stall
Figure 117 (Sheet 2)
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Page 127
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
ENGINE RUMBLE
CHECK FUEL
SURGE ACCUMULATOR IF−
C23958A
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Page 128
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23959
Operating - Failure to Accelerate Normally
Figure 119
72-00-00
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Page 129
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23960A
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Page 130
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
OVERTORQUE
C23961A
Operating - Overtorque
Figure 121
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Page 131
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
DURING ACCELERATION
WHEN ENGINE REACHES NORMAL AND/OR STEADY STATE
ONLY DURING ACCELERATION
OPERATING TEMPERATURE CONDITION
YES YES
YES
C245740
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Page 132
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23963
Operating - Torque Limiting Incorrect
Figure 123
72-00-00
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Page 133
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23964A
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
DURING RAPID
DECELERATION,
REPLACE FUEL
SURGE
ACCUMULATOR
(REF. 73−10−03)
73−10−04
C23965C
Operating - Flameout
Figure 125 (Sheet 1 of 2)
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Page 135
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
73−20−01
73−20−02
73−20−02
73−20−01
C24569B
Operating - Flameout
Figure 125 (Sheet 2)
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Page 136
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23966
Operating - Power Section Idle Speeds Incorrect
Figure 126
72-00-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
73−20−04
73−20−02
C23967B
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Page 138
ENGINE - FAULT ISOLATION Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C24570
Operating - Low Power Section Output
Figure 127 (Sheet 2)
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MANUAL PART NO. 3040592
C23968
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Page 140
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(REF. 75−30−00)
C23969B
Operating - Overtemperature
Figure 129 (Sheet 1 of 3)
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C24571A
Operating - Overtemperature
Figure 129 (Sheet 2)
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C24572A
Operating - Overtemperature
Figure 129 (Sheet 3)
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MANUAL PART NO. 3040592
C23970A
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Page 144
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
TORQUE SPLIT OR
UNUSUAL FUEL
CONTROL OPERATION
REPLACE AFCU IF
CORRODED. CLEAN AIR
ADAPTER IF CONTAMINATED
IN ACCORDANCE WITH
’AFCU’ CMM (REF. IPC
FOR CMM DETAILS).
C73448
Operating - Torque Split/Unusual Fuel Control
Figure 131
72-00-00
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Page 145
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
HIGH Tt5
C23971A
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Page 146
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23972A
Performance Check Problems - High Ng
Figure 133
72-00-00
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Page 147
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23973
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Page 148
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
72−50−01
72−50−03
C23974A
Performance Check Problems - High SFC
Figure 135
72-00-00
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Page 149
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
IF−
C23975B
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Page 150
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C37277
Lubrication - Chip Detector Light Comes On
Figure 136 (Sheet 2)
72-00-00
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Page 151
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
CHECK PRESSURE AND SCAVENGE OIL CHECK AIRFRAME OIL COOLING SYSTEM
TUBES FOR LEAKAGE IF− FOR LEAKAGE (REF. AIRCRAFT MANUAL)
IF−
C23976B
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Page 152
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23977A
Lubrication - Excessive Discharge Through Breathers
Figure 138
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23978A
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Page 154
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
OK
C23979A
Lubrication - Oil Leak to Compressor Inlet
Figure 140
72-00-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23980A
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Page 156
ENGINE - FAULT ISOLATION Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23981A
Lubrication - Low Power Section Oil Pressure
Figure 142
72-00-00
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Page 157
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
NOTE: THE REMOVAL OF SPACERS TO RECTIFY AN INCREASE IN OIL PRESSURE IS NOT RECOMMENDED.
AN INCREASE IN OIL PRESSURE OF AN IN−SERVICE RGB MAY BE DUE TO A RESTRICTION OF
OIL PASSAGES. IF OIL PRESSURE REMAINS HIGH, THE RGB MUST BE REMOVED AND SENT TO AN
OVERHAUL FACILITY FOR REPAIR.
C245190
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Page 158
ENGINE - FAULT ISOLATION Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C23983A
Lubrication - Low RGB Oil System Pressure
Figure 144
72-00-00
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Page 159
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
IF:
INCORRECT: CORRECT:
INSTALL CORRECT ELBOW INSPECT THE OIL TO FUEL HEATER
FOR SIGNS OF CRACKS
REPLACE IF NECESSARY
C93065
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Page 160
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
NOT OK OK
NO
YES
YES NO
REPLACE HEATER
(REF. 73−10−01)
DO AN ENGINE RUN AND
CHECK FOR FUEL LEAKS
C76608A
Lubrication - Oil Leaks at Oil-to-Fuel Heater
Figure 146
72-00-00
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Page 161
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
NOTE:
IT IS NORMAL FOR TURBINE OIL TO ACQUIRE AN AMBER OR LIGHT BROWN COLOR AFTER
50 TO 100 HOURS OF OPERATION. IN SOME INSTANCES THE OIL MAY APPEAR VERY DARK.
THIS ACCELERATED DISCOLORATION OF THE OIL IS NOT ITSELF A CAUSE FOR CONCERN
SINCE THE LUBRICATING PROPERTIES ARE NOT AFFECTED. THE DARKENING IS A RESULT
OF THE CHEMICAL ACTIVATION OF ANTI−OXIDANTS. PROVIDING THE OIL CONTAINS NO
PARTICULATE CARBON MATERIAL NO FURTHER ACTION IS REQUIRED.
NO
DEBRIS FOUND?
YES
YES
CARBON PARTICLES FOUND? DRAIN AND REPLACE
ENGINE OIL
NO
YES
OIL QUALITY CHECK OK?
NO
RETURN ENGINE TO
SEVICE AND NORMAL
PERIODIC INSPECTIION
C98464
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Page 162
ENGINE - FAULT ISOLATION Jul 18/2016
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
ENGINE - SERVICING
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
D. Oil system servicing involves oil level checks, replenishing, draining, flushing and
refilling.
E. Preparation of the engine for storage and service involves removal or installation of the
engine, power sections and reduction gearboxes from/in their shipping containers and
the associated depreservation or preservation of these components and the engine oil and
fuel systems.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
72-00-00
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Page 301
ENGINE - SERVICING Jul 28/2014
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
Not Applicable
NOTE: 1. Approved oils for use in PT6T-3 series engines are listed in the latest issue of
SB5001.
NOTE: 2. P&WC experience, over an extended period of time, has indicated that regular oil
changes are no longer necessary. However, operators should be aware of the
danger of oil contamination from extraneous matter such as hydraulic fluid, sand,
etc., which would require the oil system to be drained, flushed and replenished
with new oil of an approved brand.
NOTE: Check for oil leaks and remedy as detailed in Troubleshooting procedures.
NOTE: 1. Aircraft attitude may affect oil level sight glass readings. Avoid overfilling
oil tank.
NOTE: 2. If the engine has been stationary for more than 12 hours, run engine for
two minutes, shut down and check level.
(2) Replenish as required to bring oil level to a half quart below MAX. COLD on
accessory gearbox indicators and to within green band on reduction gearbox
indicator.
NOTE: Overfilling of the oil system may result in an increase in oil mist venting.
Operational experience will determine the appropriate oil level required to
minimize oil venting.
72-00-00
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Page 302
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REDUCTION GEARBOX
CHIP DETECTORS
CHIP DETECTOR
VIEW B
ACCESSORY GEARBOX
OIL LEVEL INDICATOR OIL TANK DRAIN PLUG
C3031C
Oil System Drain Points
Figure 301
72-00-00
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(b) Push chip detector while turning 90 degrees counterclockwise. Remove chip
detector from valve housing.
(c) Insert fitting (PWC38147) into housing and turn 90 degrees clockwise to open
valve and allow oil to drain.
(d) Unlock and remove drain plugs (one in each accessory gearbox).
(e) Allow oil to drain to a slow drip from all drain points.
(h) Push chip detector into valve housing and turn 90 degrees clockwise to lock in
position. The detector must move back when fully installed and the scallop on
detector must align with flat on the valve housing.
(b) Unlock and remove chip detector housings from valve housings (three in
reduction gearbox and one in each accessory gearbox).
(d) Unlock and remove drain plugs (one in each accessory gearbox).
(e) Allow oil to drain to a slow drip from all drains points.
(h) Install chip detector housings, torque 45 to 55 lb.in. and lockwire. Install drain
plugs, torque 275 to 300 lb.in. and lockwire.
NOTE: The two outboard chip detectors on the reduction gearbox are
lockwired to locking plates or adapters which are bolted to the
housing.
C. Flushing
NOTE: The following procedure is carried out in the event of oil system contamination
and/or if different oil is to be used in the engine.
(1) Drain oil and re-install drain plugs and chip detectors (Ref. Subpara. B.).
(2) Fill accessory gearbox to a half quart below MAX. COLD level and reduction
gearbox oil tank to middle of green band with fresh oil (Ref. SB5001).
72-00-00
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(3) Carry out a dry motoring cycle on each power section and check that oil pressures
are registered.
NOTE: Reduction gearbox output section oil pressure is not expected to register
during motoring run as output shaft may not rotate.
(4) Start both power sections and run at IDLE for five minutes.
(5) Drain oil and re-install chip detector valves and chip detectors (Ref. Subpara. B.).
(6) Remove filter elements from filter housings on reduction gearbox; clean elements.
and re-install.
(7) Fill accessory gearbox tanks to a half quart below MAX. COLD level and reduction
gearbox tank to middle of green band with fresh oil (Ref. SB5001).
(8) Start both power sections and run at IDLE for at least one minute checking systems
for leaks.
(9) Shut down engine and service oil systems as required to bring levels to a half quart
below MAX. COLD in accessory gearboxes and to middle of green band in
reduction gearbox.
NOTE: 2. For information on installation of engine, power section and reduction gearbox in
their respective stands prior to installation in shipping containers, refer to
appropriate procedures in 72-00-00, ENGINE - REMOVAL/INSTALLATION,
72-00-01, POWER SECTION - MAINTENANCE PRACTICES and 72-10-00,
REDUCTION GEARBOX - MAINTENANCE PRACTICES.
A. General
Two types of storage containers are in use. One type, of steel construction, is reusable
and is intended for long term storage under indoor or outdoor conditions. It consists
of two sections, which together, form an airtight unit. The other type, of fiberboard
construction on a rigid base, is non-reusable; engine protection is afforded by a plastic
envelope which is evacuated and sealed.
72-00-00
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Fiberboard containers are weather resistant only; they should not be exposed to climatic
conditions for more than one week, and must not be used for outdoor storage. They
are intended for domestic shipment in closed conveyances in the North American
continent, or domestic and overseas shipment by air, but are not intended for shipment by
sea.
To maintain internal moisture conditions at a safe level for storage, a specific quantity of
dehydrating agent (desiccant) is stowed in each container. Desiccant is packed in
individual bags, each containing eight units (one unit weighing one ounce). Each container
is provided with a humidity indicator to show the moisture level within the container
without disturbing the container or contents. At a safe moisture level (up to 40% relative
humidity) the indicator color is blue. As internal humidity increases, the color changes
gradually to pink. An all pink color indicates that an unsafe moisture condition has been
reached, and desiccant should be replaced with freshly activated material (Ref.
Subpara.P.).
72-00-00
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MINIMUM OVERHEAD
MINIMUM HOIST CLEARANCE REQUIRED
LOAD CATEGORY CAPACITY REQUIRED *
(LBS) (KG) (FT) (METRE)
* This clearance does not include distance between top of container or unit, and hoist hook.
On removal, the items should be placed in a suitable container along with their
attachment hardware and stowed in the container base for future use.
Locations of shipping covers, caps and plugs are shown on the illustration. For
provisioning purposes, part numbers of these items are included in Parts Catalog P/N
3040594.
(c) Cut adhesive tape (8) at top corners and remove reinforcing corners (2), cover
(1) and sleeve panels (6).
(d) Carefully cut engine envelope (7) across top seam (10) and expose engine.
(a) Attach the sling (PWC30804) or (PWC71482) (1) and take up weight of the
engine with the hoist.
(c) Steady engine by hand and raise clear of skid base (6).
(d) Remove bolts (5) and mounting brackets (2 and 4) from engine.
72-00-00
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2 3 4 5 2 3
1 4
9
1 6 12
5 10 11
8
21
6 13
21
7
7
13 14
20 15
13
13
19
6 17
7 12 15
6 7
13
18 15
16 12 7
18
16 17 16 15
C9335
72-00-00
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(f) Remove humidity indicator (4, Fig. 303) from envelope and retain for
re-installation. Discard envelope.
(h) Remove engine records envelope containing log books, log sheets etc.,
from receptacle in container.
(i) Remove pressure-sensitive tape (22, Fig. 304) and engine documentation box
(21), if supplied.
(j) Attach mounting brackets (2 and 4) to skid base (6) using pins (3).
(k) Remove shipping covers, caps and plugs from engine (Ref. Subpara. B.).
1 Release loop clamps (7 and 12) and cable straps (8) securing igniter
cables (9).
2 Remove bolts (11) and nuts and washers (17), securing support plate (18)
and shipping cover (14) to exhaust port.
72-00-00
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11
2
10
9
C3032F
72-00-00
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1. Container Cover
2. Reinforcing Corners
3. Skid Base
4. Humidity Indicator
5. Window
6. Container Sleeve
7. Engine Envelope
8. Adhesive Tape
9. Steel Strapping
10. Envelope Top Seam
11. Plywood Cover
NOTE: Retain support plate and hardware with container for future use.
5 Remove remaining bolts (13) and nuts and washers (15) securing shipping
cover (14) to exhaust port.
NOTE: Retain cover and hardware with container for future use and retain
ignition exciter with engine until required for airframe installation.
(3) Install container sleeve panels on skid base. Install cover and store container in a
dry area until required for re-use.
(4) Remove all desiccant bags for reactivation and re-use (Ref. Subpara. P.).
(b) Remove nuts (8) and washers (7) securing service receptacle cover (9) and
remove cover.
(d) Position hoist centrally over container and attach a sling (PWC30759) to lifting
points (1).
(e) Unlock quick-release fasteners (3) by rotating through one quarter of a turn.
(f) Raise container cover (2) clear of engine and remove from immediate work area.
72-00-00
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19 10 9
20 13 1
11 12 14
15
8 16
18
17
7 9
VIEW A
A
3 5
3
2
21
22
6
C9336A
72-00-00
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(a) Attach the sling (PWC30804) or (PWC71482) (1) to engine lifting eyes.
(c) Remove nuts (4), washers (3) and bolts (2) to release yokes (5) from support
brackets (6).
(e) Support yokes and remove six cotterpins from pins securing yokes to engine
mounting brackets (8).
(g) Remove bolts (7), securing mounting brackets to engine mount pads and
remove brackets.
72-00-00
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3
9
8
6
4
5
VIEW A
C3733B
72-00-00
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(h) Temporarily install mounting brackets, yokes and hardware in their original
locations in container.
(j) Remove pressure-sensitive tape (29) and engine documentation box (13),
if supplied.
(k) Remove shipping covers, caps and plugs (Ref. Subpara. B.).
1 Release loop clamps (20 and 28) and cable straps (21) securing upper and
lower igniter cables (24 and 27).
2 Remove four bolts (26) and nuts and washers (18) securing support plate
(19) and cover (15) to exhaust port.
NOTE: Retain support plate and hardware with container for future use.
5 Remove remaining bolts (14) and nuts and washers (16) and remove cover
(15) from exhaust port.
NOTE: Retain cover and hardware with container for future use and retain
ignition exciter with engine until required for airframe installation.
(m) Install cover on container using hoist and sling (PWC30759) and secure with
quick-release fasteners.
(n) Remove all desiccant bags from engine and retain for reactivation (Ref.
Subpara. P.).
72-00-00
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24 25 26 27 28
23 14
22 15
16 1
21 17 A
18
20
19
VIEW A
5
2
8
4 11
6
8 3 7 4
2
3
4 3
7
4 13 29
6
3
2
2
9 5 12
10
C9337A
72-00-00
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(b) Remove nuts (5) and washers (6) securing service receptacle cover (4) and
remove cover.
(d) Position hoist centrally over container and attach a sling (PWC30759) to lifting
points (1).
(e) Unlock quick-release fasteners (2) by rotating through one quarter of a turn.
72-00-00
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12 DETAIL A 11
1
10
9
2
3
7
6
A
4
5
C3138A
72-00-00
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1. Lifting Points
2. Quick-release Fasteners
3. Container Base
4. Service Receptacle Cover
5. Nut
6. Washer
7. Records Receptacle
8. Inspection Ports
9. Humidity Indicator Receptacle
10. Container Cover
11. Filler Valve
12. Relief Valve
(f) Raise container cover (10) clear of engine and remove from immediate work
area.
NOTE: When raising cover, ensure that extruded packing (7, Fig. 308)
remains with container base and is not damaged.
(a) Put moveable cable assemblies onto the central locations of the sling
(PWC30804) or (PWC71482) (1) and attach to power section lifting points.
(c) Remove eight bolts (3), washers and nuts, securing mounting yoke (5) and
bracket (11) to mounting bars (10) on container base.
(d) Steady power section by hand and carefully lift, complete with mounting yoke
and bracket, clear of container base.
(e) Remove bolts (12), washers and nuts securing mounting bracket (11) to flange
on power section and remove bracket.
NOTE: Cover (26) and plug (28) are not to be removed until power section
installation on reduction gearbox.
(g) Reinstall mounting bracket (11) on mounting bar (10), securing with bolts (3),
washers and nuts.
72-00-00
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15 17 18 14
19
20
25 16
21
14 1
24
23
22
13
A
27
VIEW A 26
28
3
2
6 4 5
12 7
11 3
10
C3140C
72-00-00
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(i) Reinstall yoke on mounting bar securing with bolts (3), washers and nuts.
(j) Remove bolts (4) and mounting bracket (2) from power section.
(l) Remove shipping covers, caps and plugs (Ref. Subpara. B.).
1 Release loop clamp (13) and cable strap (14) securing upper igniter cable
(15).
72-00-00
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2 Remove bolt (17) and nut and washer (22) to release loop clamp (18).
4 Remove remaining bolts (17) and nuts and washers (22) securing support
plates (20 and 23) and shipping cover (21) to exhaust port.
5 Remove bolts (25) and nuts and washers (16), securing support plates (20
and 23) to ignition exciter (24) and T5 compensator (19).
6 Retain exciter and compensator with power section until required for
airframe installation.
7 Place all loose hardware in suitable bags and secure to container mounting
brackets.
(n) Remove all desiccant bags from desiccant cage (8) and retain for reactivation
(Ref. Subpara. P.).
(a) Check that extruded packing is correctly seated on container base (3), install
cover (10) and secure with quick-release fasteners (2).
(b) Check that filling and relief valves (11 and 12) are correctly installed.
(c) Secure service receptacle cover (4) with nuts (5) and washers (6).
(e) Coat exposed hardware on container with compound (PWC15-014A) and store
container until required for re-use.
(b) Cut and remove steel strapping (9) and reinforcing corners (2).
(d) Remove cover (3) and container sleeve (6) from skid base.
(e) Cut power section envelope (7) across top seam (1) and expose power
section.
72-00-00
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(a) Put moveable cable assemblies onto central locations of the sling (PWC30804)
or (PWC71482) (13) and attach to lifting brackets on the accessory gearbox
and Flange C of the exhaust duct.
(c) Remove four bolts (6) and nuts and washers (22) securing bracket (4) to
mounting bars (2) on skid base (1).
(d) Withdraw pin (20) securing mounting bracket (17) to mounting yoke (21).
(e) Steady power section by hand and lift clear of skid base.
(f) Remove bolts (18) and mounting bracket (17) from accessory gearbox.
(h) Remove power section envelope (7) and remove humidity indicator (14) from
envelope.
(i) Remove 23 bolts (5) and washers and nuts (15) securing mounting bracket (4)
to Flange A of power section.
NOTE: Cover (8) and plug (32) are not to be removed until power section
installation on reduction gearbox.
(j) Reinstall mounting bracket (4) on mounting bars (2), securing with bolts (4) and
nuts and washers (22).
(l) Remove power section records from receptacle glued to skid base.
(m) Remove shipping covers, caps and plugs (Ref. Subpara. B.).
1 Release loop clamp (23) and cable strap (24) securing upper igniter cable
(25).
2 Remove bolt (27) and nut and washer (29) to release loop clamp (28).
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3
2
1
9
8
C3144D
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4 Remove remaining bolts (27) and nuts and washers (29) securing support
plates (9) and shipping cover (10) to exhaust port.
5 Remove eight bolts (30) and nuts and washers (26) securing support plates
(9) to ignition exciter (11) and T5 compensator (12).
6 Retain exciter and compensator with power section until required for
airframe installation.
(o) Remove all desiccant bags from power section and retain for reactivation (Ref.
Subpara. P.).
(p) Install container sleeve and cover on skid base and store container in a dry
area until required for re-use.
(a) Remove reduction gearbox log book, log sheets and other relevant documents
from records receptacle (3).
(b) Remove nuts (7) and washers (6) securing access cover to container base.
(d) Position hoist centrally over container and attach a sling (PWC30759) to lifting
eyes (2).
72-00-00
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25 27 28 24
12 13
30
9
26
10
24
11 29
9
A
23
14
VIEW A 31
8
32
15 16
5
17
6
20 18
21
4
1 22
C3616B
72-00-00
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1. Skid Base
2. Mounting Bars
3. Gasket
4. Mounting Bracket
5. Bolts
6. Bolts
7. Power Section Envelope
8. Cover
9. Support Plates
10. Shipping Cover
11. Ignition Exciter
12. T5 Temperature Compensator
13. Sling (PWC30804) or (PWC71482)
14. Humidity Indicator
15. Self-locking Nuts and Washers
16. Gasket
17. Mounting Bracket
18. Bolts
19. Deleted
20. Quick-release Pins
21. Mounting Yoke
22. Self-locking Nuts and Washers
23. Loop Clamp
24. Cable Strap
25. Upper and Lower Igniter Cables
26. Nut and Washer
27. Bolt
28. Loop Clamp
29. Nut and Washer
30. Bolt
31. Preformed Packing
32. Plug
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11
5
6
8
9
10
C3137A
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1. Inspection Ports
2. Lifting Eye
3. Records Receptacle
4. Humidity Indicator
5. Filler Valve
6. Washer
7. Nut
8. Access Cover
9. Relief Valve
10. Quick Release Fasteners
11. Container Cover
(e) Unlock quick-release fasteners (10) by rotating through one quarter of a turn.
(f) Raise container cover (11) clear of base and remove from immediate work area.
NOTE: Ensure that extruded packing (3, Fig. 312) remains with container
base and is not damaged.
(a) Remove eight bolts (14), washers (11) and nuts (10) securing mounting plates
(13) to mounting bars (15).
(c) Adjust sling so that gearbox will be level when lifting and sling cables clear
gearbox surfaces.
(d) Steady reduction gearbox by hand and lift from container base (7).
(e) Lower gearbox complete with mounting plates (13) onto a flat surface.
(h) Raise gearbox carefully, allowing it to rotate through 90 degrees until suspended
clear of surface.
(j) Remove nuts (5) and washers (4) securing mounting plates to studs on
gearbox and remove plates.
72-00-00
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16
2 3
15 4
10
5
11
13
12
6
11
14
8 7
C3139E
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1. Sling
2. Lifting Eye
3. Packing
4. Washer
5. Nut
6. Desiccant Cage
7. Container Base
8. Gaskets
9. Locating Dowel
10. Nut
11. Washer
12. Locating Dowel
13. Mounting Plate
14. Bolt
15. Mounting Bars
16. Sling
(m) Remove box containing hardware (retaining plates, transfer tubes and
preformed packings) from mounting bars (15) in container base. Remove
hardware from box and retain with gearbox for subsequent installation.
(o) Reinstall mounting plates (13) on mounting bars (15) securing with bolts (14),
washers (11) and nuts (10).
(p) Remove shipping covers, caps and plugs (Ref. Subpara. B.).
72-00-00
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(r) Remove all desiccant bags from desiccant cage (6) and retain for reactivation
(Ref. Subpara.P.).
(a) Check that extruded packing is correctly installed on container base, install
cover (11) and secure with quick-release fasteners (10).
(b) Check that filling valve (5) and relief valve (9) are correctly installed and secure
cover (8) to container with nuts (7) and washers (6).
(d) Coat all exposed hardware on container with corrosion preventive compound
(PWC15-014A) and store container until required for re-use.
(b) Cut adhesive tape (8) at top corners and remove cover (3), reinforcing corners
(2) and sleeve panels (6).
(c) Cut reduction gearbox envelope (7) across top seam (9) and expose gearbox.
(b) Attach sling (PWC30759) (12) to four eyebolts (7) on gearbox mounting plates
(9).
NOTE: Adjust sling so that gearbox will be level when lifting and sling cables
clear gearbox surfaces.
(c) Remove eight bolts (4), washers (2) and nuts (1) securing mounting plates (9)
to mounting bars (11) on skid base (10).
(e) Lower gearbox complete with mounting plates onto a flat surface.
72-00-00
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(i) Remove polyethylene envelope from gearbox, remove humidity indicator from
envelope and retain for reinstallation. Discard envelope.
(k) Remove nuts (5), washers (6) and mounting plates (9) from studs on gearbox.
(l) Retain nuts (5) and washers (6) for gearbox/power section assembly.
(n) Remove box containing hardware (retaining plates and preformed packings)
from mounting bars on skid base. Remove hardware from box and retain with
gearbox for subsequent installation.
(p) Remove records receptacle from skid base and remove envelope containing
log book, log sheets and other relevant documents.
(q) Remove shipping covers, caps and plugs (Ref. Subpara. B.).
(r) Place all loose hardware in suitable bags and secure to brackets on skid base.
(t) Remove all desiccant bags from reduction gearbox and retain for reactivation
and re-use (Ref. Subpara. P.).
(a) Install container sleeve panels (6) and cover (3) on skid base.
72-00-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
3
1 2
9
8
C3145D
72-00-00
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Page 334
ENGINE - SERVICING Jul 28/2014
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MANUAL PART NO. 3040592
1. Steel Strapping
2. Reinforcing Corners
3. Container Cover
4. Humidity Indicator
5. Window
6. Container Sleeve
7. Envelope
8. Adhesive Tape
9. Envelope Top Seam
(2) Install shipping covers, caps and plugs (Ref. Subpara. B.).
1 Position exciter (19) on support plate (18) and secure with bolts (20), nuts
and washers (10).
4 Secure upper cable with loop clamp (7) and cable strap (8).
5 Secure lower cable with cable strap (8), loop clamp (12), bolt (11) and nut
and washer (17).
6 Position support plate and exciter on shipping cover (14) and secure with
remaining bolts (11 and 13) and nuts and washers (15 and 17).
72-00-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
12
13
8
7
6
5
1
9
2
4
10
11
C3615C
72-00-00
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Page 336
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MANUAL PART NO. 3040592
1. Self-locking Nut
2. Washer
3. Locating Dowel
4. Bolt
5. Nut
6. Washer
7. Eyebolt
8. Gasket
9. Mounting Plate
10. Skid Base
11. Mounting Bar
12. Lifting Sling
13. Sling
(c) With engine suspended from sling, install engine envelope and align mounting
pad gaskets with corresponding mounting pads on engine.
(d) Attach four mounting brackets (2 and 4) to engine, using bolts (5) and plain
washers.
(f) Check that skid base (6) is free of loose hardware, dirt, water and oil. Renew
any damaged parts.
(g) Place engine log book, log sheets and other relevant documents in waterproof
envelope and seal with pressure sensitive tape (PWC05-070) or equivalent.
(j) Place bag in documentation box (21) and secure box to skid base (6) with
pressure-sensitive tape (22) (PWC05-070).
(l) Carefully lower engine onto skid base (6, Fig. 304), aligning pin holes in
mounting brackets (2 and 4) with holes in mounts on skid base.
(m) Install pins (3), secure with cotterpins and remove sling.
72-00-00
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(4) Heat-seal top seam of engine envelope, using suitable hand sealing iron. Leave
one corner of envelope open, to evacuate air.
(a) Check condition of container sleeve (6) and cover (1). If necessary replace
items.
(d) Fold envelope corners and tape down with pressure-sensitive tape
(PWC05-070).
(e) Install container cover (1), fold down flaps and secure with pressure-sensitive
tape (PWC05-070). Install two plywood covers (11).
(f) Secure sleeve and cover with two horizontal bands and five vertical bands of
steel strapping (9) and reinforcing corners (2) at joint of plywood covers.
(g) Stencil engine model and serial number and date of packing on each end of
container.
(2) Install shipping covers, caps and plugs (Ref. Subpara. B.).
1 Position exciter (23) on support plate (19) and secure with bolts (22) and
nuts and washers (25).
72-00-00
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4 Position exciter and support plate on cover and insert bolts (26) through
support plate and one bolt (14) through cover.
5 Install nuts and washers (18) on bolts (26) and nut and washer (16) on bolt
(14).
6 Route upper igniter lead (24) as shown and install cable strap (21).
7 Route lower igniter lead (27) as shown and secure with loop clamp (28),
bolt (14) and nut and washer (16) to cover (15).
(f) Install bag in documentation box (13) and secure box to container with
pressure-sensitive tape (29) (PWC05-070).
(h) With engine suspended from sling, install mounting brackets (8) on engine
mounting pads and secure with bolts (7) and plain washers.
(j) Remove nuts (4), washers (3) and bolts (2) securing yokes (5) to support
brackets (6).
(k) Attach yokes to mounting brackets (8), using two pins (11) and four pins (12).
(l) Carefully lower engine into container, aligning bolt holes in yokes (5) and
support brackets (6).
72-00-00
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24 25 26 27 28
23 14
22 15
16 1
21 17 A
18
20
19
VIEW A
5
2
8
4 11
6
8 3 7 4
2
3
4 3
7
4 13 29
6
3
2
2
9 5 12
10
C9337A
72-00-00
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Page 340
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MANUAL PART NO. 3040592
1. Sling
2. Bolt
3. Washer
4. Nut
5. Yoke
6. Support Bracket
7. Bolt
8. Engine Mounting Bracket
9. Desiccant Cage
10. Indicator
11. Pin
12. Pin
13. Engine Documentation Box
14. Bolt
15. Duct Cover
16. Nut and Washer
17. Cap
18. Nut and Washer
19. Support Plate
20. Clamp
21. Strap
22. Bolt
23. Exciter
24. Upper Igniter Cable
25. Nut and Washer
26. Bolt
27. Lower Igniter Cable
28. Clamp
29. Pressure-sensitive Tape
(o) Check condition of humidity indicator (10). Replace with serviceable unit if
necessary.
(a) Check that container is free of loose hardware, dirt, water and oil.
72-00-00
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MANUAL PART NO. 3040592
VIEW A
B 5
2
1
CONTAINER COVER FLANGE
B
CROSS PIN
1ST 4TH
7TH 6TH
C9308
72-00-00
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Page 342
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MANUAL PART NO. 3040592
1. Records Receptacle
2. Service Receptacle Cover
3. Breather Valve
4. Filling Valve
5. Quick Release Fastener
6. Cover Lifting Point
7. Container Cover
(c) Using suitable hoist and sling, position cover (7) on container base so that
locating dowels in base mate with corresponding holes in cover.
(d) Secure first eight quick-release fasteners (5) in sequence shown, to ensure
correct seating of cover on seal.
(f) Pressurize container to 5 psig through filling valve (4) with clean dry compressed
air or nitrogen.
(h) Leak-check seal and relief and filling valves using soap and water solution.
(j) After satisfactory leakage check, note pressure and ambient temperature and
allow container to remain undisturbed for 24 hours.
(k) Recheck pressure, taking into account any change in ambient temperature.
(l) Tighten filling valve cap and secure service receptacle cover (2) with nuts and
washers.
(m) Place engine log book, log sheets and other relevant documents in waterproof
envelope and seal with pressure sensitive tape (PWC05-070).
(n) Install envelope in records receptacle (1), close receptacle cover and secure
wing nuts with lockwire.
(o) Coat all exposed hardware on container with corrosion preventive compound.
(p) Stencil engine model, serial number and date of packaging on container.
72-00-00
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MANUAL PART NO. 3040592
(2) Install shipping covers, caps and plugs (Ref. Subpara. B.).
(a) Remove power section from stand (Ref. 72-00-01, POWER SECTION -
MAINTENANCE PRACTICES).
NOTE: Ensure that cover (26), preformed packing (27) and plug (28) are
installed on power section at Flange A.
(b) With power section suspended from sling, install mounting bracket (11) on
Flange A and secure with 23 bolts (12) and nuts and washers.
(d) Install mounting bracket (2) on accessory gearbox and secure with three bolts
(4).
(f) Install mounting yoke (5) on bracket (2) and secure with pin (6).
(g) Check that container is free of loose hardware, dirt, water and oil and that
extruded packing (7) is intact and correctly positioned in groove on base
mating flange.
(h) Carefully lower power section into container, aligning holes in mounting bracket
(11) and yoke (5) with holes in mounting bars (10).
72-00-00
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MANUAL PART NO. 3040592
5 Secure upper cable with loop clamp (13) and cable strap (14).
6 Secure lower cable with cable strap (14), loop clamp (18), bolt (17) and nut
and washer (22).
7 Locate support plates with exciter and compensator on cover (21) and
secure to exhaust port with remaining bolts (17) and nuts and washers
(22).
(l) Remove eight bags of freshly activated desiccant from protective polyethylene
envelopes and install in desiccant cage (8).
(a) Using a suitable hoist and sling, position cover (10) on container base (11) so
that locating dowels in base mate with corresponding holes in cover.
(b) Secure first six quick-release fasteners (2) in sequence shown to ensure
correct seating of cover on seal then secure remainder of fasteners.
(5) Pressurize container through filling valve (8) with clean dry compressed air or
nitrogen for corresponding ambient temperatures. (Ref. Table 302)
(7) Leak-check seal and relief and filling valves using soap and water solution.
72-00-00
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15 17 18 14
19
20
25 16
21
14 1
24
23
22
13
A
27
VIEW A 26
28
3
2
6 4 5
12 7
11 3
10
C3140C
72-00-00
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Page 346
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MANUAL PART NO. 3040592
1. Sling
2. Mounting Bracket
3. Bolt
4. Bolt
5. Mounting Yoke
6. Pin
7. Extruded Packing
8. Desiccant Cage
9. Locating Dowel
10. Mounting Bar
11. Mounting Bracket
12. Bolt
13. Loop Clamp
14. Cable Strap
15. Upper and Lower Igniter Cables
16. Nut and Washer
17. Bolt
18. Loop Clamp
19. T5 Temperature Compensator
20. Support Plate
21. Shipping Cover
22. Nut and Washer
23. Support Plate
24. Ignition Exciter
25. Bolt
26. Cover
27. Preformed Packing
28. Plug
(9) After satisfactory leakage check, note ambient temperature and allow container to
remain undisturbed for 24 hours.
(10) Recheck pressure, taking into account any change in ambient temperature.
NOTE: Allow a pressure difference of 0.037 psi for every °F change in ambient
temperature. If container pressure is within 0.50 psi of the original value,
any leakage may be considered insignificant.
(11) Install service receptacle cover (3) and secure with nuts and washers.
72-00-00
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MANUAL PART NO. 3040592
1
10
9
8 1
7 2
DETAIL A
6
11
A
3
CONTAINER
2ND 3RD COVER FLANGE
3 4 5 6 7 8
QUICK RELEASE
2 9 FASTENER
1ST 1 10 4TH
20 11
SPRING
WASHER
CONTAINER
19
B 12 LOCKING BASE FLANGE
WASHER
18 17 16 15 14 13 SECURING NUT
6TH 5TH DETAIL B
C9309
72-00-00
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Page 348
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MANUAL PART NO. 3040592
1. Lifting Points
2. Quick-release Fasteners
3. Service Receptacle Cover
4. Securing Nut and Washer
5. Records Receptacle
6. Inspection Ports
7. Humidity Indicator Receptacle
8. Filling Valve
9. Relief Valve
10. Container Cover
11. Container Base
(12) Place power section log book, log sheets and other relevant documents in
waterproof envelope and seal with pressure sensitive tape (PWC05-070).
(13) Install envelope in records receptacle (5), close receptacle cover and secure wing
nuts and lockwire.
(14) Coat all exposed hardware on container with corrosion preventive compound
(PWC15-014A).
(15) Stencil power section serial number and date of packaging on container.
(2) Install shipping covers, caps and plugs (Ref. Subpara. B.).
(3) Place power section log book, log sheets and other relevant documents in
waterproof envelope and seal with pressure sensitive tape (PWC05-070).
(4) Insert sealed envelope into box and glue box to skid base.
(5) Remove power section from stand (Ref. 72-00-01, POWER SECTION -
MAINTENANCE PRACTICES).
NOTE: Ensure that cover (8), preformed packing (31) and plug (32) are installed
on power section at Flange A.
72-00-00
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(a) With power section suspended from sling, install mounting bracket (4) on
Flange A and secure with bolts (5) and nuts and washers (15).
(c) Install envelope (7) on power section, aligning gasket (16) in envelope with
mount pad on accessory gearbox.
(d) Install mounting bracket (17) and secure with three bolts (18).
(f) Check that skid base (1) is free of all loose hardware, dirt, water and oil.
(g) Carefully lower power section onto skid base, aligning holes in mounting bracket
(4), gaskets (3) and mounting bars (2) and hole in mounting bracket (17) with
hole in yoke (21).
(h) Install pin (20) through bracket (17) and yoke (21).
(i) Secure bracket (4) to mounting bars (2) with four bolts (6) and nuts and
washers (22).
4 Secure upper cable with loop clamp (23), and cable strap (24).
5 Secure lower cable with loop clamp (28), cable strap (24), bolt (27) and
nut and washer (29).
6 Secure shipping cover (10) to exhaust port with remaining bolts (27) and
nuts and washers (29).
72-00-00
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(l) Remove eight bags of freshly activated desiccant from protective polyethylene
envelopes and tie each bag securely to power section.
(n) Heat-seal top seam of envelope using suitable hand sealing iron. Leave one
corner of envelope open, to evacuate air.
(a) Check condition of container sleeve (6) and cover (3). Replace items if
necessary.
(c) Align humidity indicator (5) with window (4) and if necessary, secure in this
position with pressure sensitive tape (PWC05-070).
(d) Position cover (3) on sleeve (6), fold down flaps and secure corners with
pressure sensitive tape (PWC05-070).
(e) Secure container assembly with two horizontal bands and four vertical bands of
steel strapping (9) and reinforcing corners (2).
(f) Stencil power section serial number and date of packaging on both ends of
container.
(2) Install shipping covers, caps and plugs (Ref. Subpara. B.).
NOTE: Ensure that T5 compensator has been removed from gearbox and has
been retained with power section.
(3) Remove bolts securing transfer tubes to gearbox/power section mating flange and
remove tubes.
72-00-00
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(4) Remove reduction gearbox from stand (Ref. 72-10-00, REDUCTION GEARBOX -
MAINTENANCE PRACTICES).
NOTE: With gearbox suspended vertically from hoist, ensure that polyethylene
sheets and retaining rings (preformed packings) are installed over
gearbox/power section mating flanges.
(a) Position mounting plates (13) and gaskets (8) on gearbox flanges and secure
with 23 nuts (5) and plain washers (4).
(b) Tighten nuts (5) evenly and progressively and torque 75 to 85 lb.in.
(d) Carefully lower gearbox, mounting plates downwards, onto a flat surface.
(f) Attach sling (1) (PWC30759) to four lifting rings (2) on mounting plates.
(g) Check that container base (7) is free of loose hardware, dirt, water, oil or other
contaminants and that packing (3) is intact and correctly positioned in groove
on base mating flange.
(h) Lift gearbox with hoist, move over container base and lower carefully into
place on mounting bars (15).
NOTE: Ensure that locating dowels (12) are engaged in mounting plates.
(i) Secure plates to mounting bars with bolts (14), washers (11) and nuts (10).
(k) Remove four bags of freshly activated desiccant from protective polyethylene
envelopes and install in desiccant cage (6).
(m) Pack oil transfer tubes, preformed packings and other loose hardware removed
from gearbox, in envelopes and stow in cardboard box.
72-00-00
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(n) Tape box securely to mounting bars, using pressure sensitive tape (PWC05-070).
(b) Attach sling (PWC30759) to lifting rings (2) on cover, raise cover and position
over container base.
(c) Carefully lower cover onto base aligning locating dowels with holes in cover
and quick-release fasteners with slots.
(d) Secure first four quick-release fasteners in sequence shown to ensure correct
seating of cover on seal then secure remainder of fasteners.
(e) Pressurize container through filling valve (5) with clean dry compressed air or
nitrogen for corresponding ambient temperatures. (Ref. Table 303)
(g) Leak check seal and relief and filling valves using soap and water solution.
(i) After satisfactory leakage check, note ambient temperature and allow
container to remain undisturbed for 24 hours.
(j) Recheck pressure, taking into account any change in ambient temperature.
(k) Install service receptacle cover (7) and secure with washers and nuts (6).
(l) Place reduction gearbox logbook, log sheets and other relevant documents in
waterproof envelope and seal with pressure sensitive tape (PWC05-070).
72-00-00
P&WC Proprietary Information. Subject to the restriction on the title page.
The export control classification with respect to this document is contained on the back of the title page.
Page 353
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MANUAL PART NO. 3040592
16
2 3
15 4
10
5
11
13
12
6
11
14
8 7
C3139E
72-00-00
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Page 354
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MANUAL PART NO. 3040592
1. Sling
2. Lifting Ring
3. Packing
4. Washer
5. Nut
6. Desiccant Cage
7. Container Base
8. Gaskets
9. Locating Dowel
10. Nut
11. Washer
12. Locating Dowel
13. Mounting Plate
14. Bolt
15. Mounting Bars
16. Sling
(m) Install envelope in records receptacle (3), close receptacle cover and secure
wing nuts.
(n) Coat all exposed hardware on container with corrosion preventive compound
(PWC15-014A).
(o) Stencil engine model and reduction gearbox serial number, along with date of
packaging, on container.
(2) Install shipping covers caps and plugs (Ref. Subpara. B.).
(3) Place reduction gearbox log book, log sheets and other relevant documents in
waterproof envelope and seal with pressure sensitive tape (PWC05-070).
(4) Insert sealed envelope into box and glue box to skid base.
NOTE: Position box so that it will not interfere with gearbox output shaft when
gearbox is installed in container.
(5) Ensure that T5 compensator has been removed from gearbox and has been
retained with power section.
72-00-00
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MANUAL PART NO. 3040592
10
4
1
A 5
9
7
CONTAINER 8
COVER FLANGE
3 4
1ST 4TH
2 5
QUICK RELEASE 1 6
DETAIL A FASTENER
CONTAINER
BASE FLANGE A
12 7
SPRING
WASHER LOCKING WASHER
11 8
SECURING NUT 3RD 2ND
10 9
C9310
72-00-00
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Page 356
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MANUAL PART NO. 3040592
1. Inspection Ports
2. Lifting Rings
3. Records Receptacle
4. Humidity Indicator
5. Filling Valve
6. Nut and Washer
7. Service Receptacle Cover
8. Relief Valve
9. Quick-release Fasteners
10. Container Cover
(6) Remove bolts securing oil transfer tubes to gearbox/power section mating flanges
and remove tubes.
(7) Remove reduction gearbox from stand (Ref. 72-10-00, REDUCTION GEARBOX -
MAINTENANCE PRACTICES).
NOTE: With gearbox suspended vertically from hoist, ensure that polyethylene
sheets and retaining rings (preformed packings) are installed over
gearbox/power section mating flanges.
(a) Position mounting plates (9) and gaskets (8) on gearbox flanges and secure
with 23 nuts (5) and washers (6).
(c) Carefully lower gearbox, mounting plates downwards, onto a flat surface.
(e) Attach a sling (12) (PWC30759) to four eyebolts (7) on mounting bolts.
(f) Check that skid base (10) is free of loose hardware, dirt, water, oil or other
contaminants.
72-00-00
P&WC Proprietary Information. Subject to the restriction on the title page.
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(g) Position reduction gearbox envelope on skid base with gaskets located over
four dowels (3) on mounting bars (11).
(h) Lift gearbox with hoist, move over container base and lower carefully onto
mounting bars, aligning holes in mounting plates with dowels (3).
(i) Secure mounting plates to mounting bars with bolts (4) nuts (1) and washers
(2).
(k) Remove four bags of freshly activated desiccant from protective polyethylene
envelopes and secure to gearbox.
(b) Heat-seal top seam (9) using suitable hand sealing iron. Leave one corner of
envelope open to evacuate air.
(d) Insert oil transfer tubes and other loose hardware removed from gearbox in
envelopes and stow in cardboard box.
(e) Tape box securely to mounting bars, using pressure sensitive tape (PWC05-070).
(f) Install container sleeve (6) on skid base and align humidity indicator (4) with
window (5).
(g) Install cover (3) on sleeve, fold down flaps and secure with pressure sensitive
tape (PWC05-070).
(h) Secure container assembly with two horizontal bands and two vertical bands of
steel strapping (1) and reinforcing corners (2).
(i) Stencil engine model and reduction gearbox serial number, along with date of
packaging, on each end of container.
O. Depreservation/Preservation
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(a) Preservation of a fuel control unit depends on the period of inactivity and
whether or not the AFCU is operated during the inactive period.
1 An AFCU is considered active if an engine is involved in normal flight
operations or if an engine is wet motored or run during preservation periods.
2 An AFCU is not considered active if an engine is not wet motored or run
during aircraft inactive periods.
(b) For fuel control units that remain on inactive engines in long term container
storage (off wing), the time accumulated in the container begins at the time
of packaging.
(c) For units that have been removed from the engine and are in storage three
years or more, refer to 73-20-02, Maintenance Practice, Storage, Three Year
Requirement.
(d) For units that have been removed from the engine and are in storage more
than six years, refer to 73-20-02, Maintenance Practice, Storage, Six Year
Requirement.
(e) For units on engines that are inactive for more than six months and that are
not preserved, refer to 73-20-02, Maintenance Practice, Storage, Unpreserved
Units Installed on the Engine.
(b) 8 to 28 Days - Desiccant and moisture barriers must be removed. Make sure
all previously sealed engine openings are reopened and are unobstructed.
(3) Depreservation schedule for power sections and reduction gearboxes stored in
metal or fiberboard containers:
(b) 8 to 28 Days - (Power Sections Only) - Desiccant and moisture barriers must
be removed. Ensure all previously sealed openings, except reduction
gearbox/power section mating (flange A), are reopened and are unobstructed.
NOTE: Protective cover and drive shaft plug at flange A are to be removed
only prior to actual assembly of power section to reduction gearbox.
(c) 29 to 90 Days (Power Sections Only) - Depreserve fuel system (Ref. step (4),
following).
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(e) 91 Days and Over (Power Sections Only) - Depreserve power section
completely (Ref. step (4), following):
(a) Fill accessory gearbox oil tank on each power section and reduction gearbox
oil tank with correct quantity of lubricating oil (Ref. Para. 5.).
(b) Disconnect fuel pressure tube assemblies at flow divider on each power
section. Loosen lines, as necessary, to allow drainage into a suitable container.
(c) Displace preservative oil from fuel system by switching on aircraft fuel supply
and motoring each power section (with ignition off) in both automatic and
manual modes until clean fuel flows from disconnected pressure tubes at flow
dividers. Move power lever through complete operating range during
motoring procedure.
(d) Reconnect fuel pressure tubes to flow dividers on each power section. Tighten
coupling nuts, torque to 90 to 100 lb.in. and lockwire.
(a) Install power section together with other power section on reduction gearbox
to form a complete engine assembly.
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(a) Assemble reduction gearbox and two power sections to form a complete
engine assembly.
(a) 0 to 7 Days- Engines that are to be left inactive up to seven days must be
sheltered, kept in a relatively dry area and not subjected to extreme
temperature changes which would produce condensation. No special action
necessary.
(b) 8 to 28 Days - Engines that are to be left inactive up to 28 days must have all
openings blanked off and sealed. Relative humidity must be maintained at less
than 40 percent. No other special action is required.
(c) 29 to 90 Days - Engines that are to be stored longer than 28 days must have
fuel system of each power section preserved (Ref. step (11), following), intake
and exhaust openings for each power section covered, and desiccant and
humidity indicators installed.
(d) 91 Days and over - Engines inactive over 90 days must in addition to 29 to 90
day procedures, have engine oil systems drained and unused accessory drive
splines sprayed with lubricating oil (Ref. step (10), following).
(8) Preservation schedule for power section and reduction gearbox in metal containers:
(a) Check and record pressures and relative humidity of container at least once
every 90 days. According to results noted, carry out the necessary action as
detailed in steps (b) through (e) following.
(b) Container internal conditions, pressure more than one psig above atmospheric
and below 20 percent relative humidity (indicator all blue) - No action required.
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(c) Container internal conditions, pressure less than one psig above atmospheric
and below 20 percent relative humidity - Repressurize container to 5 ( ±1) psig
with clean, dry, compressed air or nitrogen. Check pressure after seven
days, if pressure has dropped, remove unit (power section or reduction gearbox)
from container and reinstall in serviceable container.
(e) Container internal conditions, relative humidity more than 40 percent (indicator
all pink) - Remove unit (power section or reduction gearbox) from container
and inspect for corrosion. If severe corrosion is evident reinstall unit, with covers,
in container. Replace desiccant with freshly activated desiccant. Reverse or
renew humidity indicator as necessary. Repressurize container to 5 (± 1) psig
with clean, dry, compressed air or nitrogen. Return unit to an overhaul
facility as soon as possible for inspection and repair.
(9) Preservation schedule for power section and reduction gearbox in fiberboard
containers:
(a) Check and record relative humidity of container at or before expiration of first
90 days and every 30 days thereafter. According to results noted, carry out
necessary action as detailed in steps (b) through (d) following.
(b) Relative humidity in container less than 20 percent (indicator all blue) - No
action required.
(d) Relative humidity in container more than 40 percent (indicator all pink) -
Remove unit (power section or reduction gearbox) from container and inspect for
corrosion. If severe corrosion is evident, reinstall covers on unit, enclose in
protective envelope and insert freshly activated desiccant. Evacuate and seal
envelope and install in container. Return unit to an overhaul facility, as soon as
possible for inspection and repair.
(10) Oil system preservation (for engines or spare power sections inactive for periods
exceeding 90 days).
(b) Drain all engine oil from power sections and reduction gearbox (Ref. Para. 5.).
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(c) With drains open, motor each power section in turn, with starter (no ignition) to
permit scavenge pumps to clear each power section, indicated by cessation of
steady stream of oil from drains. To prevent excessive operation with limited
lubrication, limit rotation to shortest possible time to accomplish complete
draining.
(d) Remove oil filters and drain and clean filter elements. Allow oil to drain to a
slow drip (approx. 30 minutes), install oil filters and close drains.
(e) Remove cover plates from pads of accessory drive not in use and spray
exposed surfaces and gearshafts with clean engine lubricating oil. Replace cover
plates.
(f) Install all plugs, caps, covers or screens over all openings to prevent entry of
foreign material and accumulation of moisture.
(11) Fuel system preservation (for engines or power sections inactive for periods
exceeding 28 days).
(a) Close normal fuel supply shutoff valve. Disconnect fuel inlet lines to oil-to-fuel
heater on each power section.
(d) With ignition system off and power section fuel systems each in automatic
mode, carry out normal 30 second motoring cycle. During motoring cycle
move each power section throttle twist grip through its full range.
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(e) Repeat step (d), preceding, but with fuel system for each power section in
manual mode.
(f) Check that oil flows from opened fuel pressure lines at completion of motoring
runs; if not, repeat steps (d) and (e), preceding.
(g) Reconnect fuel pressure lines to each power section fuel divider. Disconnect
preservation oil supply from each power section oil-to-fuel heater.
P. Reactivation of Desiccant
(1) Place bags of desiccant and a pink humidity indicator in a suitable oven, controlled
at 121°C (250°F), until humidity indicator turns blue.
(2) Allow oven to cool to room temperature (approximately 22°C (72°F)), then remove
bags of desiccant and humidity indicator.
(3) As soon as possible after reactivation is complete, insert bags of desiccant into
polyethylene envelopes. Evacuate air from envelopes and seal with suitable
sealing iron.
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ENGINE - REMOVAL/INSTALLATION
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
5. Procedure
The following procedures are written with the understanding that the engine has been
removed from the airframe as per the instructions given in the applicable airframe maintenance
manual and is suspended in the P&WC approved sling.
72-00-00
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CAUTION: ENSURE THAT POWER SECTION OIL TANKS ARE DRAINED BEFORE
TIPPING OR ROTATING ENGINE OR POWER SECTION ABOUT THEIR
AXES. THIS WILL PREVENT OIL FROM ENTERING COMPRESSORS.
(1) With the engine hanged in the sling (PWC30804) or (PWC71482) (1), install the
bracket (PWC30618) (5) onto the RH mounting pad on the reduction gearbox and
attach with four bolts.
(3) Position bracket (4) (PWC30619) on LH mounting pad on reduction gearbox and
secure with four bolts.
(5) Position brackets (7) (PWC30617) on accessory gearbox mounting pads and
secure with six bolts.
(7) If necessary, remove shipping covers from tachometer generator mount pads on
reduction gearbox.
(8) Lower engine into stand (PWC30721) or (PWC70780) (6) and install lockpins (3)
and (8) through mounting brackets.
(9) Swing support and bracket assemblies (2) upwards to locate on tachometer
generator mount pads and secure each bracket with four screws.
(11) Make sure that the stand position locks are applied and remove the sling (PWC30804)
or (PWC71482) (1).
(1) Attach the sling (PWC30804) or (PWC71482) (1) to lifting brackets at Flanges C
and accessory gearboxes.
(3) Remove eight screws securing support and bracket assemblies (2) to tachometer
generator mount pads on reduction gearbox.
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(5) Remove locking pins (3 and 8) from mounting brackets (4, 5 and 7).
(7) Remove mounting brackets (4, 5 and 7) from reduction and accessory gearboxes.
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2
DETAIL A
4
7 3
5 3
8 8 7 2
C3034A
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ENGINE - INSPECTION/CHECK
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
C. Hours or Engine Hours means Engine Flight Hours. Engine flight hour is defined as the
engine operating time between aircraft takeoff (weight-off-wheels/skid off) and landing
(weight-on-wheels/skid on).
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
Test Set Barfield Model 2312G-8 or equivalent
5. Procedure
The inspections outlined in Paragraphs 6., 7. and 8. following are considered a normal
function of operating organizations and are intended as a guide for minimum inspection and
maintenance requirements. The intervals at which these inspections are performed
depend on the nature and condition of engine operation and are in addition to the routine
72-00-00
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daily checks detailed in the applicable aircraft manual. For example, engines operated in
sandy or dusty environments or in smog or salt-laden atmospheres should be subjected to
regular inspection for corrosion and compressor first-stage blade erosion as detailed in Table
601 and Paragraph 9., following.
Specific inspections (Ref. Para. 9.) and special condition inspections (Ref. Para. 10.) are
given for engines that have exceeded normal operating parameters or have been subjected
to abnormal operating conditions.
A. 25 hours.
Periodic inspection requirements detailed at this frequency shall not exceed 25 hours of
flight and may be performed in conjunction with applicable aircraft maintenance
schedule.
Unless otherwise stated, the tolerance for periodic inspections is ten percent (10%), or
up to a maximum of 100 hours operating time, whichever is less. The tolerance for
scheduled inspection is ten percent (10%) or 30 days, whichever is less.
Table 601 details periodic inspection criteria and frequency. Where no inspection limits are
given in the table, or in any other relative chapter within this manual, any item with wear or
damage as described in this table shall be replaced, or returned to an approved overhaul
facility for possible repair, as applicable.
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72-00-00
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72-00-00
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72-00-00
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8. Unscheduled Inspections
(1) If a chip detector warning light illuminates inspect chip detectors for particles. In
addition the oil strainer must be cleaned and checked and the appropriate oil filter
checked.
(2) Inspect chip detectors at each engine oil change (Ref. SB5001).
(1) On new aircraft, check filter after each day of operation until no contamination is
found.
(2) Whenever any component upstream of the filter has been replaced, check filter
after first engine run.
(1) If airframe boost pump (either electrically or engine driven) fails or is inadvertently
left off for a cumulative time in excess of 10 hours, the engine driven fuel pump
must be removed and replaced.
(2) The removed fuel pump should be forwarded to an approved overhaul facility for
inspection (Ref. Para. 10. A.).
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NOTE: Presence of silver flakes in the oil system is acceptable (Ref. 79-30-01).
(b) Inspect oil filters (Ref. 79-20-02) after next 5, 10, 25 and 50 flight hours. If after
50 flight hours silver flakes are no longer present, return to scheduled interval
(Ref Table 601). If silver particles are still evident after 50 flight hours,
consult your local P&WC field service representative.
(1) During ground test, check for air, and oil leaks. Rectify as required.
(2) Following the post installation ground test and after the first 5-10 and 20-25 flight
hours, inspect chip detectors and oil filters for contamination (Ref. 79-30-01).
(a) If silver flakes are found, flush oil system (Ref. Para. 8. D.).
(1) During ground test, check for air, oil and fuel leaks. Rectify as required.
(2) Following the post installation ground test and after the first 5-10 and 20-25 flight
hours, inspect chip detectors and oil filters for contamination (Ref. 79-30-01).
(3) If silver flakes are found, flush oil system (Ref. Para. 8. D.).
9. Specific Inspections
(1) General
NOTE: The following inspection should be done whenever the air inlet screen is
removed (Ref. 72-20-00). Due to limited access, the use of a mirror is
recommended.
(a) The limits stated under ’Acceptable Damage Limits’ and ’Acceptable Erosion
Limits’ are considered acceptable without repair. The actual damage must be
documented and additional inspections scheduled to assess the rate of defect
progression.
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(d) If damaged blade is within acceptable limits and is not reworked, inspect area
at 150 hours or less as established by the operator. Subsequent inspections
are at the discretion of the operator based on the type of operating environment
but must not exceed 300 hours.
NOTE: The operating environment affects the rate of erosion and incidence of
blade damage. Engines operating in a highly erosive and/or conditions
where there is a high potential for blade damage; require inspections
more frequently at an interval established by the operator.
(e) If damage to the blades is acceptable, and/or after blending, engine performance
is within acceptable limits, inspection of the subsequent stages, (rotors, stators
and impeller) is not required. Under these conditions, the engine is considered
acceptable for service.
(a) Defects/damage must be documented in the engine log book (i.e., engine
module TSN/TSO, cycles, component description, location and dimensions,
if obtainable).
(b) If the blade is repaired document the amount of material removed during
blending.
(a) Multiple superficial leading edge nicks 0.030 in. maximum depth on any
number of blades.
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TRAILING
EDGE ANY NUMBER
OF BLADES LEADING
EDGE
A A ORIGINAL
CHORD LENGTH
EROSION SECTION A−A
50% 30%
20%
b a
c
TRAILING
EDGE ANY NUMBER
OF BLADES
LEADING
EDGE
B
d
0.050 NO FOREIGN OBJECT DAMAGE
0.100 ALLOWABLE IN ROOT
FILLET RADIUS
DETAIL B
EROSION FOREIGN OBJECT DAMAGE
C78459B
Compressor First-stage Blades Inspection
Figure 601
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(b) Leading or trailing edge dents 0.055 in. deep by 0.080 in. long. Four dents per
blade on either leading or trailing edge on any number of blades.
(c) Leading or trailing edge tip curl without presence of tearing. Maximum
acceptable deformation is 0.100 in. on one edge; four blades only.
(d) Leading or trailing edge nicks 0.050 in. maximum depth. Four nicks maximum
per leading or trailing edge on any number of blades.
(f) Blade tip rub is acceptable providing there is no rolled over material and an
engine performance check is acceptable.
1 Corrosion pitting, nicks and dents 0.005 in. deep are acceptable.
(h) Area b;
1 Corrosion pitting, nicks and dents 0.010 in. deep are acceptable.
(i) Area d;
(a) Erosion at the root is acceptable providing that dimension from leading edge to
apex of eroded area does not exceed 0.250 inch and there is no feathered,
(i.e., sharp) edge(s).
(b) Feathered edges must be removed and original leading edge profile restored
(Ref. 72-30-05, COMPRESSOR ROTOR - MAINTENANCE PRACTICES) or
the engine or power section must be removed from the service.
(1) Remove external leads from terminal block on gas generator case.
NOTE: The system comprises an integral wiring harness which includes eight
thermocouple probes. The following check will reveal circuit malfunctions
such as intermittent short circuits or an open circuit in the harness lead. If
necessary, further checks may be carried out on the system by
disassembling the engine to gain access to probes as detailed in Chapter
77-20-01, Page Blocks 401 and 601.
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(2) Using Barfield Test Set Model 2312G-8 or equivalent, check insulation resistance of
harness when measured between either chromel or alumel terminal and ground.
Minimum acceptable resistance is 5000 ohms.
(3) Check continuity and loop resistance measured across chromel and alumel
terminals. Acceptable loop resistance is 1.8 to 2.6 ohms.
A. General
The inspection data given here apply to engines that have been subjected to abnormal
operating conditions. Whenever the corrective action to be taken requires that the
engine or component be sent to an overhaul facility, precise details of the condition(s)
must be provided to facilitate overhaul inspection. The following paragraphs treat each
special condition separately and prescribe the corrective action to be taken.
B. Overtorque
For action to be taken in the event of overtorque conditions, refer to Figure 602.
C. Overtemperature
(1) For action to be taken in the event of overtemperature conditions during starting,
refer to Figure 603.
(2) For action to be taken in the event of overtemperature conditions other than during
starting, refer to Figure 604.
D. Overspeed
For action to be taken in the event of overspeed condition refer to Figure 605.
For Take-off power rating condition: Power turbine speed (Nf) up to 103% with
single engine torque below 65.5% without exceeding 5 minutes, no action required.
For Transient condition: Power turbine speed (Nf) is between 105% to 110% with
single engine torque below 96.7% without exceeding 10 seconds, no action is
required.
For No-Load condition: Power turbine speed (Nf) not exceeding 105% with single
engine torque below 28%, no action is required.
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% (LB−FT)
98.9 1100
96.7 1075
94.5 1050
89.8 1000
OUTPUT TORQUE
85.3 950
SEND REDUCTION GEARBOX TO OVERHAUL
FOR OVERTORQUE INSPECTION
81.0 902
73.2 815
800
NO ACTION REQUIRED
67.4 750
0 10
SECONDS 60
120 180 240 300
TIME ( SECONDS )
PT6T−3D ONLY
C22135F
72-00-00
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Page 616
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MANUAL PART NO. 3040592
% (LB−FT)
NOTE:
98.9 1100
1) AREA "A" AND AREA "B" : RECORD
IN ENGINE LOG BOOK
96.7 1075
2) AFTER 12 EXCURSIONS INTO AREA "A"
SEND GEARBOX TO OVERHAUL
94.5 1050
AREA A FOR OVERTORQUE INSPECTION
3) AFTER 3 EXCURSIONS INTO AREA "B"
SEND GEARBOX TO OVERHAUL
FOR OVERTORQUE INSPECTION
89.8 1000
OUTPUT TORQUE
85.3 950
SEND REDUCTION GEARBOX TO OVERHAUL FOR OVERTORQUE
INSPECTION
81.0 902
AREA B
859
AREA A
73.2 815
800
NO ACTION REQUIRED
67.4 750
10
SECONDS 1 2 3 4 5 30
TIME ( MINUTES )
( TORQUE LIMIT REFERRED TO OUTPUT SHAFT )
C26954D
Overtorque Limits for Each Power Section
Figure 602 (Sheet 2)
72-00-00
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MANUAL PART NO. 3040592
1100
AREA C REMOVE POWER SECTION AND SEND TO OVERHAUL
FOR OVERTEMPERATURE INSPECTION
1080
1060
1040
INTER TURBINE TEMPERATURE C
° 1020
1000
980 AREA C
960
AREA B
940
AREA A
920
900
NO ACTION REQUIRED
880
860
0 5 10 15 20 25 30
TIME − SECONDS
C3088D
72-00-00
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MANUAL PART NO. 3040592
910 AREA C
°
900
INTER TURBINE GAS TEMPERATURE
890
880 AREA A
870
860
850
840
830
820
810
800
790
NO ACTION REQUIRED
780
770
760
750
0 5 15 1 2 3 4 5 6 7
SECONDS MINUTES
TIME ( SECONDS / MINUTES )
PT6T−3D ONLY
C33411C
Overtemperature Limits - All Conditions Except Starting
Figure 604 (Sheet 1 of 3)
72-00-00
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MANUAL PART NO. 3040592
NOTE:
AREA "A" : RECORD IN POWER SECTION LOG BOOK
AREA "B" : PERFORM HOT SECTION INSPECTION
AREA "C" : PERFORM POWER SECTION OVERTEMPERATURE
INSPECTION ( REF. LIGHT OVERHAUL )
1000
AREA B
INTER TURBINE GAS TEMPERATURE ( C )
AREA C
950
900
885
AREA A
850
800
NO ACTION REQUIRED
750
15
0 5 SECONDS 1 2 3 4 5 6 30
TIME ( MINUTES )
PT6T−3DE ONLY
C26714A
72-00-00
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MANUAL PART NO. 3040592
NOTE:
1) AREA "A" : RECORD IN POWER SECTION LOG BOOK
AREA "B" : PERFORM HOT SECTION INSPECTION
AREA "C" : PERFORM POWER SECTION OVERTEMPERATURE
INSPECTION ( REF. LIGHT OVERHAUL )
2) AFTER 12 EXCURSIONS MORE THAN 30 SEC. IN
AREA "A", PERFORM A HOT SECTION INSPECTION
1000
AREA B
INTER TURBINE GAS TEMPERATURE ( C )
AREA C
950
900
885
AREA A
850
800
NO ACTION REQUIRED
750
15
0 5 SECONDS 1 2 3 4 5 6 30
TIME ( MINUTES )
PT6T−3DF ONLY
C28605
Overtemperature Limits - All Conditions Except Starting
Figure 604 (Sheet 3)
72-00-00
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MANUAL PART NO. 3040592
(111.76%) 42,600
(111.32%) 42,400
GAS GENERATOR SPEED ( RPM )
(110.80%) 42,200
(110.28%) 42,000
(109.76%) 41,800
(108.97%) 41,500
0 5 10 15 20 30 40
TIME ( SECONDS )
C33413D
72-00-00
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If observed power turbine speed (Nf) exceeds 110%, with or without load send
affected power section to an overhaul facility for light overhaul (Engine Overspeed).
NOTE: 2. A power turbine overspeed that does not involve damage to No.3 and 4
bearings is not cause for rejection of reduction gearbox.
E. Sudden Stoppage
(1) If helicopter main rotor blades have suffered dynamic major collision damage
resulting in replacement of one or more main rotor blades, the complete twin
pac engine must be removed and sent to an overhaul facility for light overhaul
(Sudden Stoppage).
NOTE: Damage to the tail rotor, or seizure of any part of the tail rotor transmission
system shall not be considered to have caused engine sudden stoppage
unless indications exist that internal damage exists in the main gearbox.
(2) If damage to main rotor blade(s) does not warrant replacement or if any part of the
transmission system between reduction gearbox output shaft and main rotor has
seized while the engine is operating, inspect as follows:
(a) Inspect engine mounts and vibration insulators for distortion or damage.
(c) Inspect oil filters and chip detectors for metal particles.
(d) If any of the above conditions exist, engine must be shipped to overhaul facility.
(e) If none of the above conditions exist, remove reduction gearbox and both
power turbine and exhaust assemblies (Ref. 72-10-00 and 72-50-00
respectively) and proceed as follows in step (f).
(f) Inspect power turbine shroud for evidence of rub. If rub has occurred the
engine must be sent to an overhaul facility for light overhaul (Sudden Stoppage).
If there is no evidence of rub and no adverse conditions in reduction gearbox
the engine may remain in service subject to a satisfactory ground test (Ref.
applicable Aircraft Manual) and an oil filter inspection every 25 hours for the
next 100 hours of operation.
(3) If damage to main rotor blades is not severe enough to cause an engine anomaly
(generally occurs when one blade only is damaged), inspect as detailed in steps (2)
(a) through (d).
(4) If a non-engaged clutch engages during shutdown, remove reduction gearbox and
send to an overhaul facility for light overhaul (Sudden Stoppage).
72-00-00
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MANUAL PART NO. 3040592
(1) If power section or RGB oil temperature is in between 115 to 130 °C (239-266 °F)
for more than five minutes or 130 to 140 °C (266-284 °F) for more than one minute,
inspect as follows:
(a) Inspect oil filters and chip detectors for metal particles.
(c) Carry out a 20 minute engine ground run at moderate power (Ref. applicable
Aircraft Manual).
(e) If no metal particles are found, engine may remain in service. If metal particles
are found, reduction gearbox and/or power section affected must be sent to an
overhaul facility for light overhaul (Oil System Unusual Conditions).
(2) If oil temperature exceeds the above conditions, send power section and/or RGB to
an overhaul facility for light overhaul (Oil System Unusual Conditions).
(3) If engine has been subject to reduced oil level, excessive oil pressure fluctuations,
low oil pressure, significant metal particles in filter elements or oil contamination
beyond allowable limits, send power section and/or reduction gearbox to an overhaul
facility for light overhaul (Oil System Unusual Conditions).
NOTE: 1. If significant metal particles were found, state location of affected filter
elements and whether oil was contaminated.
NOTE: 2. If during normal operation, low or no oil pressure was observed for less
than one minute; drain oil, check chip detectors and filters. If no metal is
found; refill with oil and continue in service, checking filters on a daily
basis for the next 25 flying hours.
G. Immersion in Water
Send engine to an overhaul facility for light overhaul (Immersion in Water). State if
engine was stationary and cold, stationary and hot, or rotating at time of immersion.
Send engine or component to an overhaul facility for light overhaul (Dropped Engine or
Hard Landing).
I. Hard Landing
(3) Inspect all attachment hardware at engine flanges for shearing or other obvious
damage.
72-00-00
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(7) If any of the above conditions are found, engine must be sent to an overhaul facility
for light overhaul (Dropped Engine or Hard Landing). If none of the above
conditions are found, engine may remain in service subject to a satisfactory ground
test (Ref. applicable Aircraft Manual).
J. Inlet Blockage
K. Lightning Strike
Inspect oil filters and chip detectors daily for the next 25 hours.
(1) In the event of engine contamination by fire extinguishing agents perform cleaning
procedures as follows:
(a) Perform dry motoring run to remove any residual deposits (Ref. Chapter
71-00-00, Test).
(b) Wash engine externally using fresh water only (Ref. 72-00-00, ENGINE -
CLEANING).
(c) Perform engine motoring performance recovery wash omitting dry motoring
run(Ref. 72-00-00, ENGINE - CLEANING).
(3) Drain and refill oil system with new oil (Ref. 72-00-00, ENGINE - SERVICING).
(4) Clean or change oil filters (3 places) (Ref. 79-20-02, OIL FILTERS - MAINTENANCE
PRACTICES).
72-00-00
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(5) Examine the compressor blade for damage or indication of erosion (Ref. ENGINE -
INSPECTION/CHECK).
(6) Do a borescope inspection of the compressor turbine blades and shrouds (Ref.
ENGINE - INSPECTION/CHECK).
(10) Drain and refill oil system with new oil (Ref. 72-00-00, ENGINE - SERVICING) 50 ±
10 flight hours after original oil change.
(1) Inspect and flush the P3 (Pneumatic) system for possible contamination as follows:
(a) Remove the P3 air filter housing cover and filter element (Ref. 73-10-07).
(b) Using a high intensity light, inspect for debris at the inner area of the filter housing
assembly. Check center tube for security. Replace filter housing assembly if
center tube is loose (Ref. SB5367).
(c) Remove the filter element (6) from the cover (9) and inspect inside cover for
debris. Clean if required.
(d) Place suitable container under the P3 filter housing assembly (3) to contain
fluid during flushing procedure.
NOTE: Clamps and associated parts (10 thru 17) may be loosened or
removed as required to gain access to the fitting and prevent
damage to the P3 line.
(f) Using a high intensity light and a mirror if required, inspect the P3 air inlet ports
on the AFCU (Ref. Fig. 607). Replace AFCU if internal debris is evident.
(g) Inject flushing fluid through the P3 tube(s), allowing the fluid to flow freely
through the P3 filter housing. Tube assembly (2) may have to be removed
to be flushed adequately. Inspect contained fluid for presence of debris
(particles). Repeat flushing process until fluid is clean.
NOTE: The compressor wash cart and solutions may be used to flush the P3
tube(s) (Ref. 72-00-00, ENGINE - CLEANING) Ensure that the outlet
pressure is regulated to 10 psi. As an alternate method, manual
injection (pouring) of petroleum solvent (PWC11-027) in the tube(s) is
acceptable.
72-00-00
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(i) Dry the interior of the P3 tubes using clean dry shop air or equivalent.
(j) Install P3 tube assemblies to the AFCU. Torque tube fittings 90 to 100 lb.in.
and lockwire.
(k) If clamps securing tube assembly (1) have been removed or loosened, proceed
as follows:
1 Install grommets (15) and loop clamp (14) and secure tube assemblies with
bolt (12), bracket (13) and nut (10).
2 Install spacer (17) between bracket (13) and loop clamps (11) and secure
with bolt (12) and nut (10).
3 Secure loop clamps (11) to bracket (16) with bolt (12) and nut (10).
(l) Install P3 filter element and cover assembly (Ref. 73-10-07, P3 AIR FILTER,
MAINTENANCE PRACTICES).
A. General
The borescope is an optical device which enables an operator to perform visual specific
inspection of hot section areas of the engine as required to detect sulfidation due to
local environmental conditions, wear or damage, etc. Access is through ports or openings
created by removal of engine components. Personnel performing borescope inspection
must be qualified to do checks and analyse results.
B. Description
(1) The borescope assembly comprises a pattern-controlled rigid guide tube, direct
viewing flexible 5 mm fiberscope, light source, side viewing adapter and other
accessories. If required, a 35 mm camera may be used to photograph engine areas
being inspected.
(2) Using the borescope (PWC34910-101), an operator can perform periodic inspection
of the following:
72-00-00
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1 2
AUTO 11 10
FCU 17 11
13
12 12
3 12
FRONT 15 16
FIRESEAL 4 CENTER
MOUNT RING FIRESEAL 10 13
5 MOUNT RING
6 AUTO 14
FCU
7 10
FRONT
FIRESEAL
DETAIL A
C39222
72-00-00
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MANUAL PART NO. 3040592
(d) Cooling rings and dome section of the combustion chamber liner.
NOTE: 1. Before using the borescope, study the following procedures, the
borescope assembly and accessories (Ref. Fig. 608).
(a) Remove one fuel manifold adapter. The maximum suggested working
temperature is 66°C (150°F).
(b) Insert guide tube (PWC34910-200) through open manifold adapter port.
72-00-00
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P3 INLET TO
AIR REGULATOR
P3 AIR INLET
C38124
72-00-00
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CAMERA ADAPTER
FIBERSCOPE
GUIDE TUBE
HOLDING
FIXTURE FIBERSCOPE
GUIDE TUBE
EYEPIECE
LIGHT SOURCE
C21647A
Borescope and Accessories Installed (Typical)
Figure 608
72-00-00
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MANUAL PART NO. 3040592
(h) Install camera if needed (Ref. Fig. 608) to record inspection of hot section
areas.
(a) A halogen lamp is used to provide lighting from either 110V, 60-Hz or 220V, 50
Hz power supply.
(6) A camera may be used with borescope to photograph internal engine components.
It must be equipped with a 50 mm F1.8 lens. Refer to camera handbook for
guidance.
(a) Installation
72-00-00
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PROTECTIVE RING
DIRECTION OF ROTATION
FOR RING REMOVAL
RING REMOVAL
PRISM BODY
INDEXING LUG
INDEXING SLOT
THREADED RING
DIRECTION OF ROTATION
FOR RING REMOVAL
ADAPTER INSTALLATION
C12191
Side-viewing Adapter - Removal/Installation
Figure 609
72-00-00
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6 Set camera film speed to suit film and exposure compensation to -2 (Ref.
camera handbook).
(b) Removal
3 Remove film from camera and, using suitable label, add following data:
2 Ease guide tube (PWC34910-200) through fuel manifold adapter port into
combustion chamber and exit duct zone turning guide tube
counterclockwise to achieve a three-quarter turn.
72-00-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
FIBERSCOPE TIP
125 °
VANE RING
DISTAL TIP
C41525
Guide Tube Orientation
Figure 610
72-00-00
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MANUAL PART NO. 3040592
(8) Troubleshooting
(a) The possible sources of, and solutions for, problems encountered when using
borescope are shown in Table 602.
C. Procedure
72-00-00
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MANUAL PART NO. 3040592
NOTE: Ensure distal tip actuating lever is in neutral position when installing or
removing fiberscope.
(i) Examine CT blade tip, root and air foil section (Ref. Views A and B, Fig. 611
and Para. 13. I.).
(l) Remove wrench from splined gearshaft and reinstall starter-generator (Ref.
Aircraft Maintenance Manual).
(c) Fasten borescope (PWC34910-101) to holding fixture and connect light source.
NOTE: The use of side viewing adapter may add to inspection capability (Ref.
Subpara. B. (4)).
72-00-00
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MANUAL PART NO. 3040592
C27489
72-00-00
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MANUAL PART NO. 3040592
(e) Examine vane leading and trailing edges, inner and outer rings of vane ring
assembly (Ref. Views C and D, Fig. 611 and 13. F.).
(c) Insert fiberscope into a fuel manifold adapter port, fasten eyepiece to holding
fixture and connect light source.
(d) Inspect combustion chamber liner (Ref. View E, Fig. 611 and Para. 13.D.).
Using a borescope is more practical for this inspection. Removal and installation of the
power section, components/assemblies may result in damage to parts and/or
distortion of sealing surfaces causing gas leaks and performance loss.
If rotating components are found with unacceptable damage during inspection, an HSI
must be done before next flight. If damaged non-rotating components are found, except
when holes are burnt through the combustion chamber or the CT vane airfoil trailing
edge defects are beyond limits (Ref. Inspection), the HSI may be delayed, providing an
engine performance/ground power check is done.
72-00-00
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The ability of an engine to produce the power required by the flight manual power
assurance check is the only engine airworthiness requirement. If, at an anticipated high
ambient temperature and/or altitude, T5 and Ng will approach or exceed the maximum
limits, an HSI is recommended before the actual conditions occur. When T5 and Ng
approach, or are anticipated to approach or exceed the maximum limits, troubleshoot
the engine/installation before doing an HSI.
Carbon accumulation inside fuel nozzle passages is the principle cause of spray pattern
degradation resulting in non-uniform combustion and local high temperature peaks.
Exposure to these peaks contributes to premature hot section deterioration. Carbon
accumulation is progressive and can affect all nozzles. Therefore, inspect all nozzles (Ref.
73-10-05, Inspection/Check), to minimize premature deterioration occurring at other
locations.
The inspections are recommended concurrent with scheduled engine maintenance checks
applicable to individual aircraft installations.
NOTE: Combustion chamber includes small exit duct, inner and outer combustion
chamber liner assemblies.
(1) Combustion chamber liner cracks may be repairable, and an HSI is recommended
before component replacement is required. Converging cracks in the inner and
outer combustion chamber liner walls which do not meet are acceptable. Inspect
affected area at 100 hours. Subsequent inspections must not exceed 400 hours.
(2) Plasma top coating (ceramic) loss revealing undercoat (diffused aluminide) on outer
and inner liners is acceptable, providing base metal is not burnt or eroded.
(3) Small areas (approximately 1 sq.in.) bulging and/or hot spots on inner or outer liner
walls may be repairable and an HSI is recommended. Bulging and/or burning in the
dome area, associated or not with axial cracks, are acceptable provided the axial
cracks (circumferential cracks are unacceptable) do not exceed 1.0 inch in length or
0.030 inch in width. Engine may remain in service, providing the associated fuel
nozzle(s) is/are inspected (Ref. 73-10-05, Inspection/Check) and replaced if not within
limits. Subsequent inspections are at operators discretion, but must not exceed
400 hours.
(4) Holes in the inner and outer liner walls are unacceptable. An HSI must be done to
replace or repair the affected component, and the associated fuel nozzle(s)
inspected (Ref. 73-10-05, Inspection/Check) and replaced if not within limits.
72-00-00
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(6) Excessive carbon deposits inside combustion chamber could be result of poor fuel
atomization by the fuel nozzles (indicated by deposits around fuel nozzle bosses).
Distortion of combustion chamber liner cooling rings may produce carbon
deposits in the dome area downstream of the affected cooling ring. If excessive
carbon deposits are found, flow check fuel nozzles (Ref. 73-10-05, Inspection/Check).
If CT blades are eroded, refer to Inspection of CT Blades.
(a) If the nozzles are serviceable, the combustion chamber liner is the probable
cause of the deposits. Inspect the CT blades, as erosion by carbon particles
(some carbon particles remain in the gas stream and are not deposited in the
combustion area) may damage and cause CT blade replacement.
(b) If CT blades are not eroded, engine may remain in service and the CT blades
and combustion chamber liners inspected within 100 hours. Subsequent
inspections are at operators discretion, but must not exceed 400 hours.
(7) As the structural integrity of the small exit duct is not affected, cracks and open
radial cracks extending from the inner to the outer diameter are acceptable
(length not limited), and an unlimited amount of coating loss is acceptable.
(a) Holes less than 0.500 in. in diameter in the outer wall are acceptable.
NOTE: The engine may remain in service, and HSI delayed, providing it is
understood that the CT stator cooling air flow is affected, increasing
the rate of deterioration.
(c) When damage is found, inspect the CT vane ring (Ref. 72-50-01,
Inspection/Check) and associated fuel nozzle (Ref. 73-10-05, Inspection/Check).
(d) Inspect damage at 100 hours. Subsequent inspections are at the discretion of
the operator, but must not exceed 400 hours. If deterioration exceeds the
above limits, an HSI is recommended.
(8) Cracks along, or across, the dome to outer liner seam weld are acceptable
provided the cracks do not intersect the fuel manifold support bracket. Inspect
damage at 100 hours. Subsequent inspections are at the operators discretion
but must not exceed 400 hours.
72-00-00
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MANUAL PART NO. 3040592
NOTE: Burned areas on vanes increase flow area which accelerates downstream
component deterioration, decreases Ng and increases T5.
(2) Cracks (Ref. Fig. 613) are repairable. Keep the engine in service and monitor
deterioration progression. Do an HSI before defects progress to such an extent
that the CT stator becomes unrepairable. This will increase the cost of the subsequent
HSI. Inspect CT stator having the defects shown within 100 hours. Subsequent
inspections must not exceed 400 hours.
(3) If defects have progressed beyond repair limits shown, engine may remain in
service, providing an engine ground power check (Ref. Aircraft Maintenance
Manual) is done, and the airfoil trailing edge damage does not exceed limits shown
(Ref. Fig. 612). An HSI is recommended if the vane trailing edge defects are
beyond the limits shown or downstream components are affected by the CT vane
distress or engine performance is unacceptable.
(1) While performing compressor turbine blade inspection, operators might notice
surface anomalies that could be mistaken for sulfidation. In fact, these surface
anomalies are a result of the blade manufacturing process and do not affect turbine
performance. The following points of inspection will help operators determine if
the blades are serviceable:
v No loss of coating.
v No change in color.
v No evidence of sulfidation on adjacent blades.
v Geometrical deviations do not exceed 0.005 inches deep or 0.005 inches high.
There is no width limitation (Ref. Fig. 616).
(2) The condition of blades and tips is critical to obtain rated power. Most significant
blade tip defects (rubs and oxidation) increase interturbine temperature (T5). Even
if T5 is below maximum, an HSI may be recommended if damage is beyond
the limits shown (Ref. Fig. 615).
(a) Defects shown are acceptable, providing their condition is monitored by further
inspections and engine performance checks.
72-00-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
0.230
LEADING EDGE
OPEN CRACK
0.230
TRAILING EDGE SURFACE
0.920 MISSING (BURNT MATERIAL)
APPROX.
NOTE
TRAILING EDGE DEFECTS EXCEEDING THE ABOVE LIMITS
ARE NOT ACCEPTABLE. DIMENSIONS CANNOT BE
ACCURATELY MEASURED WHEN USING A BORESCOPE
THEREFORE THE EXTENT OF THE DAMAGE MAY BE
ESTIMATED AS A PERCENTAGE OF AIRFOIL LEADING
EDGE HEIGHT. (0.920 APPROX.)
C23015
CT Stator Damage - HSI Recommended
Figure 612
72-00-00
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MANUAL PART NO. 3040592
TRAILING EDGE
PARALLEL CRACKS
LEADING EDGE
CRACK
AIRFOIL CRACKS ON
PRESSURE AND SUCTION
SIDES
INNER/OUTER RING
CRACKS NOT EXTENDING
INTO FILLET RADIUS
NOTE
THE ABOVE DEFECTS ARE ACCEPTABLE FOR FURTHER
SERVICE. THE EXTENT OF THE DEFECTS(S) MUST BE
RECORDED AND MONITORED BY ADDITIONAL INSPECTIONS.
THE ASSOCIATED FUEL NOZZLE MUST BE INSPECTED AND
REPLACED IF NOT WITHIN SPECIFIED LIMITS.
C23016
72-00-00
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MAINTENANCE MANUAL
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BURNT OR MISSING
MATERIAL
SULFIDATION
(COATING BLISTERING
WITH SOME BLISTERS
BURST)
LEADING EDGE
C23065
CT Blade Damage - Unacceptable Damage
Figure 614
72-00-00
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0.050
TYPICAL
COATING
LOSS
TRAILING
EDGE
LEADING
EDGE
0.990
(REF.)
COATING LOSS
(CHANGE IN
COLOUR)
NOTE
THE ABOVE DEFECTS ARE ACCEPTABLE FOR FURTHER
SERVICE. THE EXTENT OF THE DEFECT(S) MUST BE
RECORDED AND MONITORED BY ADDITIONAL INSPECTIONS.
C23007A
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
0.005 IN
0.005 IN
C77352
CT Blade - Manufacturing Anomalies
Figure 616
72-00-00
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(b) Subsequent inspections are at the discretion of the operator, but must not
exceed 400 hours.
(c) Blades with cracks 0.050 in. long in the upper 1/3 of the trailing edge may
remain in service for 100 hours.
(d) If defects are beyond those shown (Ref. Fig. 614), an HSI is recommended.
(3) Check blades for axial shift. Normally, with components within assembly tolerances,
the blade platforms are approximately in line. When a blade shifts, the blade moves
axially and can be seen as having moved in relation to the adjacent platform.
NOTE: 2. The amount of blade shift may be estimated by using a 0.020 in. thick
wire wrapped tightly around the tip of borescope and held by tape. The
free end should be positioned within the field of view of the borescope.
When estimating the amount of shift, position the free end of the wire
adjacent to the platform being checked.
(1) Heavy rubbing and oxidation are acceptable, providing T5 is within limits. Operating
the engine with the shroud segments burned may cause damage to the CT shroud
housing (cracking and burning of the attachment rim), and an HSI is
recommended. A damaged shroud housing must be replaced at the next HSI or
refurbishment.
(1) Damage on the vanes may produce an increase in flow area which will increase Ng
and T5.
(2) Cracks on the inner and outer rings and vanes are repairable. Keeping the engine
in service, the defects will progress until the stator becomes unrepairable. This will
increase the cost of the subsequent HSI. Inspect the damaged area within 100
hours. Subsequent inspections must not exceed 400 hours.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(4) If the defects are not repairable, replace PT stator at the next power section repair.
Providing Ng and T5 are within limits, there is no need for power section repair and
PT stator change, regardless of the amount of damage, unless structural integrity
of the vanes are affected (e.g. wide open cracks, excessive foreign object damage
(FOD) and missing or burnt material are unacceptable).
G. Inspection of PT Blades
(1) Increased tip clearance of PT blades increases T5. If T5 is within limits, there is no
need to change the PT assembly, regardless of the amount of damage, providing
structural integrity of the components is not affected.
(a) Cracks, missing material, excessive FOD, heavy sulfidation or blade distortion
are unacceptable.
A. General
The inspection procedures given in the following paragraphs cover the entire scope of
the engine hot section inspection. The complete inspection procedure is performed
whenever power sections have been subjected to overtemperature conditions, or on
a periodic basis (Ref. SB5003) .
Basically, the procedure involves partial disassembly of the engine to gain access to the
hot section components, inspection of the components and repair or replacement as
applicable, followed by re-assembly.
Subparagraph B. lists the referenced procedures for disassembly to gain access. Table
603 lists the hot section components to be inspected. The table also indicates if
repair or replacement procedures are given in this manual and the Chapter/Section/Units
in which these procedures are to be found.
B. Preparation
(3) With assembly loaded to produce smallest gap, measure and record compressor
turbine blade tip clearance at the center and ends of each shroud segment using a
wire or tapered feeler gage. Average clearance must be between 0.018
and 0.020 in.
NOTE: With used segments the tip clearance at any one location should not
exceed 0.021 in. or be less than 0.018 in.
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(7) Remove compressor turbine vane ring, shroud and exit duct support flange (Ref.
72-50-01, COMPRESSOR TURBINE VANE RING - REMOVAL/INSTALLATION).
(9) Remove combustion chamber large exit duct (Ref. 72-40-01, COMBUSTION
CHAMBER LINER ASSEMBLY - MAINTENANCE PRACTICES).
(1) Inspect case for cracks (Ref. Step (2)), distortion, overheating or heavy corrosion.
Repair of case is not authorized at maintenance level. If condition of case warrants
repair, power section must be shipped to an overhaul facility for inspection/repair
in accordance with the Overhaul Manual.
(2) Using a high intensity light, 10X magnifying glass and mirror if necessary, visually
inspect gas generator case for cracks. Inspect weldments at bosses and spot
welds(Areas a) on surface of case for cracks (Ref. Fig. 617).
(a) If a crack is confirmed, power section must be removed and sent to overhaul
facility for inspection/repair in accordance with the Overhaul Manual.
(3) Inspect case for protective coating loss. If more than 25% of surface area is
affected, return case to overhaul facility for strip and re-coat. If less than 25% of
surface area is affected, touch-up (Ref. 72-30-04).
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MANUAL PART NO. 3040592
SPOTWELDS
(TYPICAL)
a
a
a a
VIEW A
C60859
Gas Generator Case Inspection (Typical)
Figure 617
72-00-00
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MANUAL PART NO. 3040592
Chap/
Sec/
Component HSI Para. Repair Replacement Unit
Gas Generator Case Assy 13. C. X N/A 72-30-04
Combustion Chamber Liner 13. D. X X 72-40-01
Combustion Chamber Large Exit 13. E. N/A X 72-40-01
Duct
Compressor Turbine Vane Ring 13. F. X X 72-50-01
Compressor Turbine Shroud 13. G. X X 72-50-01
Segments
Compressor Turbine Shroud 13. H. X X 72-50-01
Housing
Compressor Turbine Disk Assy 13. I. N/A X 72-50-02
Power Turbine Disk Assy 13. J. N/A N/A 72-50-04
Power Turbine Vane Ring 13. K. X X 72-50-03
T5 Temperature Sensing System 13. L. X X 77-20-01
Exhaust Duct 13. M. N/A N/A -
Fuel Nozzles and Sheaths 13. N. N/A 73-10-05
(4) Inspect diffuser pipes in gas generator case (Ref. Fig. 618).
(a) Cracks of any length on inner surface of any number of diffuser pipes are
acceptable provided that they will not converge and cause loss of metal
(Ref. Details A, B and C) and that they are stop-drilled.
(b) Cracks terminating in fishtail seam weld are acceptable and require no repair.
(e) Fretting wear on outer face and edge adjacent to next fishtail is acceptable
after blend repair.
(5) Inspect threaded holes and shanknuts in center bore area for damage (Ref.
72-30-04).
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MANUAL PART NO. 3040592
E
IBL
ISS
PE AX.
RM
M
00
0.5
0.300 MAX. PERMISSIBLE
0.8
00
M
PE AX.
RM
ISS
IBLE
A B
FRETTED AREA
C D
C9493
Diffuser Pipe Inspection (Typical)
Figure 618
72-00-00
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NOTE: Cracks in the liner surfaces are usually of a stress-relieving nature, and as
such are not serious in that the rate of growth decreases as the crack
lengthens. Thermal stresses, in effect, relieve original stress conditions. It is
considered normal to observe a given type of deterioration repeated from liner
to liner. Typical liner distress consists of buckling and cracking of cooling
rings and buckling at the inner wall adjacent to the dome.
(1) The following conditions are acceptable without repair (Ref. Fig. 619).
(a) Localized buckling and/or burning of all cooling rings (except louvered type)
accompanied by cracking, provided cracks do not extend into seam weld.
(b) Cracks in louvered cooling rings; provided that circumferential cracks in seam
weld do not exceed 0.300 in. in length and are stop-drilled.
(d) A maximum of seven cracks (each crack not exceeding one inch in length) in
inner liner adjacent to dome end.
(e) Localized areas that have been heated to an extent to buckle the liner,
provided buckling is shallow and is not associated with burning effecting a
reduction in wall thickness causing structural weakening.
(a) Buckled cooling rings, in which the gap has been eliminated, must be
reworked. Use suitable bar to restore uniform gap.
(d) Cracks progressing from a free edge so that their meeting is imminent and
could allow a piece of metal to break loose must be repaired by welding.
(3) If any of the following conditions exist, the liner must be replaced.
(b) Multiple cracks (several small cracks propagating from one main crack).
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(d) Circumferential cracks adjacent to seam welds which are opened in excess of
0.030 in.
Inspect large (outer) exit duct for cracks, burning, distortion or fretting wear on the inner
diameter which contacts the combustion chamber liner. Any amount of coating loss in
contact area is acceptable. Coating loss in other areas acceptable provided parent metal
erosion (if present) is not in excess of 0.010 in. deep. No repairs authorized at
maintenance level.
(1) Inspect vane ring for cracks, coating loss, erosion of parent metal or impact
damage. The following acceptance limits apply. No repairs are permitted.
(a) Vanes
1 Multiple open cracks not exceeding 0.005 in. wide and up to 1.0 inch long
in the aerofoil is acceptable, provided there is no evidence of burning.
1 Multiple open cracks not exceeding 0.020 inch wide and up to 1.0 inch in
length are acceptable in the outer platform downstream of its mounting
flange. No two or more cracks may converge in such a manner that would
allow a piece of metal to become detached.
2 Outer ring open cracks which extend into the aerofoil are acceptable up to
1.0 inch in length, provided no two or more cracks converge in such a
manner that would allow a piece of metal to become detached.
1 Multiple open cracks through the wall of the inner ring less than 0.020 inch
wide and up to 1.0 inch in length are acceptable provided that 20% of the
axial length of the inner ring is intact.
2 Inner ring open cracks which extend into the aerofoil are acceptable up to
1.0 inch in length, provided no two or more cracks converge in such a
manner that would allow a piece of metal to become detached.
(a) Up to 0.250 square inch on any vane airfoil surface is acceptable provided that
erosion (if any) does not exceed 0.010 in. deep.
(b) Any amount of coating loss from both inner and outer rings is acceptable
provided erosion (if any) does not exceed 0.020 in. deep.
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MANUAL PART NO. 3040592
0.070
0.050
0.080
0.060
0.070
0.050 0.080
0.060
0.085
0.065
C22198
72-00-00
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MANUAL PART NO. 3040592
C42286
Combustion Chamber Liner Cooling Ring - Inspection
Figure 619 (Sheet 2)
72-00-00
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MANUAL PART NO. 3040592
C27490
72-00-00
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MANUAL PART NO. 3040592
(c) Oxidation: up to 0.250 square inch by 0.005 in. deep on any vane LE .
Maximum of seven affected vanes is acceptable.
(3) Burning
(a) Any number of vanes which exhibit burn through on the trailing edge of 0.125
square inch or greater (area of approx. 0.350 inch x 0.350 inch) and the void
may be seen when viewed from the leading edge in direction parallel to engine
longitudinal axis, requires the replacement of both the vane ring and the
complete set of compressor turbine blades.
(1) Inspect shroud segments for cracks, distortion, erosion or metal build up.
(b) If blade-to-shroud clearances are less than 0.018 in. due to a shroud high-spot
or if tip rub has occurred, the segment may be ground locally over a length not
exceeding one inch per segment. (Ref. Fig. 621).
(1) Inspect compressor turbine shroud housing for cracks (Ref. Fig. 622). Cracks are
not acceptable. Replace housing.
(2) Inspect interstage sealing ring for scoring wear on outer face and sides. Ring wear
is acceptable to the following limits:
Width: 0.225 in. min.
Thickness: 0.084 in.
Gap: 0.175 in. min.
(1) Inspect blades for tip rub, erosion, corrosion, impact damage, coating loss, cracks
or shift. Inspect condition of blade retaining rivets.
(a) Damage limits for blades are as follows (Ref. Fig. 623 and 624):
NOTE: If any of the following limits are exceeded or any cracks are found in
blades, disk assembly must be replaced. Send removed disk
assembly for overhaul inspection (Ref. Para. 10. A.).
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C22128
72-00-00
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A
A
AREA A
SECTION A−A
C22124
Compressor Turbine Shroud Housing - Inspection
Figure 622
72-00-00
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MANUAL PART NO. 3040592
❉
TRAILING LEADING
EDGE EDGE
LEADING
EDGE
A
PERFORMANCE IS
SATISFACTORY
FILLET
AREA B TIP RADIUS
EROSION LIMITS
C3112E
72-00-00
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STAGE 1 STAGE 2
STAGE 3 STAGE 4
C60623
Stages of Corrosion
Figure 624
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3 Impact damage in Area A: Three nicks, dents or pits no more than 0.005 in.
deep per blade.
4 Impact damage in Area B: One nick, dent or pit no more than 0.005 in.
deep per blade.
5 Impact damage on leading or trailing edges: One nick, dent or pit no more
than 0.020 in. deep per blade.
1 Blade protrusion beyond disk rim must be within 0.010 in. either side of
disk.
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1
1
2
2
C22120
Turbine Blade Protrusion
Figure 625
72-00-00
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(1) Inspect blades for corrosion, impact damage, coating loss, cracks or shift.
(a) Damage limits for blades are as follows (Ref. Fig. 626):
NOTE: If any of the following limits are exceeded or any cracks are found in
blades, disk assembly must be replaced. As replacement of disk
involves balancing procedures, the complete power turbine and exhaust
section must be sent to an overhaul facility.
1 Examine blade airfoil surfaces for signs of corrosion and pitting as follows:
2 Impact damage in Area A: Three nicks no more than 0.015 in. long by
0.005 in. deep. Three dents or pits no more than 0.010 in. deep per blade.
3 Impact damage in Area B: One nick, dent or pit no more than 0.020 in. deep
per blade.
4 Impact damage on leading or trailing edges: One nick, dent or pit no more
than 0.020 in. deep per blade.
1 Blade protrusion beyond disk rim must be within 0.005 in. either side of
disk.
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(1) Inspect vane ring for cracks, coating loss, erosion of parent metal or impact
damage. The following acceptance limits apply. No repairs are permitted.
NOTE: Power turbine vane rings are classified. If replacement is required, install
like class.
(a) Cracks
1 Up to 0.250 in. square by 0.010 in. deep on any one vane for any number
of vanes is acceptable.
(2) Carry out resistance and probe heat response checks (Ref. 77-20-01).
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FILLET AREA
(SEE NOTE)
0.125 B
0.0625
LEADING EDGE
0.125
A 0.125
TRAILING EDGE
0.050 B 0.125
NOTES:
1. RIPPLING OF TRAILING EDGE
FILLET AREA (SEE NOTE) IS NOT ACCEPTABLE
2. NO DAMAGE PERMITTED
IN FILLET AREAS
C3113A
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C67126
Power Turbine Blades - Inspection
Figure 626 (Sheet 2)
72-00-00
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OUTER RING
TRAILING EDGE
INNER RING
C3117
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M. Exhaust Duct
(1) Inspect exhaust duct for cracks or distortion. A maximum of three cracks in exhaust
port flange, emanating from bolt holes, are acceptable provided cracks are not
across the flange-to-case butt weld or circumferentially around flange or weld (Ref.
Fig. 628). Cracks may be stop drilled using 1/16 (0.0625) inch diameter drill.
(1) Inspect nozzles for dissimilarity of carbon build up. Clean or replace as necessary
and perform functional check as detailed in Chapter 73-10-05.
(2) Inspect sheaths for fretting wear, erosion and carbon build up.
P. Reassembly of Engine
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2
3
1
C11786
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1. Exhaust Flange
2. Butt Weld
3. Typical Crack
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ENGINE- CLEANING
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
72-00-00
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MANUAL PART NO. 3040592
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
5. Procedure
To perform a compressor turbine wash, the engine is motored using the starter and washing
fluids are sprayed into the engine intake through a high flow (2 to 3 gal/min) (7.57 to
11.36 liters/min) spray ring/wash tube (Ref. Fig. 703) respectively.
Motoring washes are carried out at an Ng of 14 to 25% and the water or cleaning mixture,
which is pressurized at 30 to 50 psi (207 to 345 KPa) is sprayed into the compressor inlet
through the high-flow spray ring. Washing while motoring the engine ensures that the
cleaning mixture remains in liquid form.
An external wash with fresh water is recommended when the engine is contaminated with
salt. Demineralized water is not necessary. The engine must never be left for an extended
period, such as overnight, in a contaminated condition.
NOTE: Before performing an external wash, the engine must be allowed to cool for a
minimum of 40 minutes after shutdown.
7. Compressor Wash
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MANUAL PART NO. 3040592
MECHANICAL
AGITATOR
VALVE VALVE
RELIEF VALVE
TO SPRAY RING
OR WASH TUBE
AIR / NITROGEN CONNECTION
PRESSURE SOURCE RECIRCULATION
REGULATED UP TO PUMP
50 P.S.I. (345 kPa)
C22126
Compressor Wash System - Schematic
Figure 701
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MANUAL PART NO. 3040592
(1) Obtain a supply of demineralized water complying with the following criteria:
(2) Obtain a supply of drinking quality water complying with the following criteria.
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MANUAL PART NO. 3040592
(3) Prepare cleaning solution as per the following Tables 702, 703, 704 and 705 using
one of the following cleaning agents:
NOTE: 1. Wear proper protection when using chemicals. Refer to Material Safety
Data Sheets.
NOTE: 2. Do not mix different types of cleaning solution, they may be chemically
incompatible.
(a) Mix items 1 and 2 in function of ambient temperature (Ref. Table 702).
(b) Mix items 1, 2 and 3 in function of ambient temperature (Ref. Table 703).
1 Zok 27 (PWC11-003D).
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MANUAL PART NO. 3040592
TABLE 703, Cleaning Solution Formula - Zok 27, Turboclean 2/Ardrox 6345
(c) The following cleaning agents do not require any pre-mixing; proceed (Ref.
Table 704).
7 CLIX (PWC11-001).
Cleaning
Agent Aviation Methanol Water
Ambient See Note 1 Kerosene (PWC11-010) See Note 2
Temperature % by Vol. % by Vol. % by Vol. % by Vol.
+36°F (+2°C) Up 25 Nil Nil 75
-12°F to +36°F (-25 to +2°C) 25 15 20 40
Below -12°F (-25°C) 25 15 40 20
NOTE: 1. Solution strength must be as per manufacturer’s/supplier’s instructions. Where no
specific instructions are given proportion of cleaning agent is as indicated.
NOTE: 2. Use of drinking quality water is permissible when performing motoring washes.
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MANUAL PART NO. 3040592
Cleaning
Agent Aviation Methanol Water
Ambient See Note 1 Kerosene (PWC11-010) See Note 2
Temperature % by Vol. % by Vol. % by Vol. % by Vol.
NOTE: 3. If Kerosene is used, add required quantity of Witco P10-59B emulsifying agent
(PWC05-005) and shake mixture thoroughly before use (150 ml Witco P10-59B per
2000 ml Kerosene).
(4) Prepare 1.33 U.S. gallons (5.0 liters) as a cleaning solution for a motoring wash.
(5) Prepare 2.66 U.S. gallons (10 liters) of rinse solution for a motoring wash.
AMBIENT
AIR WATER % by ISOPROPYL ALCOHOL (PWC11-014) %
TEMPERATURE VOL. See NOTE 1 by VOL.
40° F (4.4 °C)
And Above 100 0
39 °F (3.9 °C) 95 5
36 °F (2.7 °C) 91 9
33 °F (0.6 °C) 86 14
31 °F (-0.6°C) 83 17
28 °F (-2.2 °C) 80 20
26 °F (-3.3 °C) 78 22
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MANUAL PART NO. 3040592
AMBIENT
AIR WATER % by ISOPROPYL ALCOHOL (PWC11-014) %
TEMPERATURE VOL. See NOTE 1 by VOL.
25 °F (-3.9 °C) 77 23
20 °F (-6.7 °C) 73 27
15 °F (-9.4 °C) 68 32
10 °F (-12.2 °C) 64 36
5 °F (-15 °C) 61 39
0 °F (-17.8 °C) 57 43
NOTE: 1. Use of drinking quality water is permitted when performing a rinse following a
motoring wash.
(2) For Post-SB5423 engines; remove cap (18) at tee fitting (13) on gas generator
case.
(3) Connect engine wash ring to supply from wash rig. Alternatively connect via
suitable hose to drinking quality water supply for ambient temperatures above +4°C
(+39°F).
(4) Fill wash tank with prepared rinse solution (Ref. Table 705).
(5) Pressurize tank at 30 to 50 psi (207 to 345 KPa) with air or nitrogen supply.
NOTE: 1. If drinking water tap is being used and pressure is less than 30 psi (207
KPa), connect through a centrifugal pump.
NOTE: 2. To prevent precipitation of deposits through the use of hard water, engine
must be allowed to cool to below 65°C (150°F). Minimum cooling period
of 40 minutes must be allowed since the engine was last operated.
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MANUAL PART NO. 3040592
(6) Ensure that ignition circuit breaker is pulled and aircraft bleed air system is OFF.
NOTE: For additional procedures for fuel shut-off valve and fuel boost pump,
refer to Aircraft Flight Manual.
(7) Disconnect flow divider/dump valve hose at each power section prior to injecting
water and water mixture. Place detached end of flow divider/dump valve hose into
suitable container for collection of water mixture.
(8) Fuel Boost Pump Switch - ON. Check fuel pressure (Ref. to the Airframe Maintenance
Manual).
(9) Motor engine and when Ng reaches 5%, inject wash mixture (or water) into engine.
(14) Perform two consecutive dry motoring runs. Observe starter limitations (Ref. Starter
Manufacturer’s Manual).
(15) For Pre-SB5423 engines; reconnect P3 line (6) to elbow (13) and torque coupling
nut 135 to 150 lb.in. and lockwire.
(16) For Post-SB5423 engines; install cap (18) on tee fitting (13) and torque 100 to
110 lb.in. and lockwire.
(18) Run the engine at flight idle to fully dry the engine.
NOTE: 1. This step is not necessary if the engine is run in the next 15 minutes.
NOTE: 2. Run the engine at idle for a minimum of five minutes with the MOT above
50°C (122 °F).
(19) Reconnect flow divider/dump valve hose at each power section after drying cycle
(Ref. Aircraft Maintenance Manual).
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MANUAL PART NO. 3040592
17 1
16
15
2
3
4
5
14
6
12 10
11 9
13 8
7
A
REF.
PRE−SB5423
POST−SB5423
18
DETAIL A
C71372
P3 System - Wash
Figure 702
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1. Bolt
2. Nut
3. Bracket
4. Nut
5. Loop Clamp
6. Tube Assembly
7. Locknut
8. Reducer
9. Tube Connection
10. Loop Clamp
11. Copper Gasket
12. Locknut
13. Elbow (Pre-SB5423); Tee Fitting (Post-SB5423)
14. Tube Connection
15. Bolt
16. Clamp
17. Nut
18. Cap
(1) For Pre-SB5423 engines; disconnect P3 line at gas generator case to prevent
ingress of fluid into RGB.
(2) For Post-SB5423 engines; remove cap at tee fitting on gas generator case.
(3) Fill wash tanks with appropriate cleaning and rinse solutions (Ref. Subpara. B.).
Connect engine wash ring to wash rig.
(4) Pressurize tanks at 30 to 50 psi (207 to 345 KPa) with air or nitrogen supply.
NOTE: To prevent precipitation of deposits through the use of hard water, engine
must be allowed to cool to below 65°C (150°F). Minimum cooling period of
40 minutes must be allowed since the engine was last operated.
(5) Ensure that ignition circuit breaker is pulled and aircraft bleed air system is OFF.
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MANUAL PART NO. 3040592
(6) Disconnect flow divider/dump valve hose at each power section prior to injecting
water and water mixture. Place detached end of flow divider/dump valve hose into
suitable container for collection of water mixture.
(8) Motor engine and when Ng reaches 5%, inject cleaning solution into engine.
(12) Motor engine and when Ng reaches 5%, inject rinse solution into engine.
(17) Perform two consecutive dry motoring runs. Observe starter limitations (Ref. Starter
Manufacturer’s Manual).
(18) For Pre-SB5423 engines; reconnect P3 line to elbow and torque coupling nut 135
to 150 lb.in. and lockwire.
(19) For Post-SB5423 engines; install cap on tee fitting and torque 100 to 110 lb.in. and
lockwire.
(20) After starter cooling period, start engine (Ref. 71-00-00, POWER PLANT -
ADJUSTMENT/TEST).
(21) Run the engine at flight idle to fully dry the engine.
NOTE: 1. This step is not necessary if the engine is run in the next 15 minutes.
NOTE: 2. Run the engine at idle for a minimum of five minutes with the MOT above
50°C (122 °F).
(22) Reconnect flow divider/dump valve hose at each power section after drying cycle
(Ref. Aircraft Maintenance Manual).
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MANUAL PART NO. 3040592
NOTE: 1. The proven method to decrease the possibility of sulfidation is the turbine
desalination wash with plain water. This procedure does not replace the
compressor wash and is a method to wash the compressor turbine blades.
The frequency is based on the choice of the customer and previous sulfidation
experience.
(1) Depending on ambient temperatures, fill wash tank with appropriate rinse solution
(Ref. Table 705).
(2) Connect compressed air supply regulated 30 to 50 psig (207 to 345 kPa) to wash
tank.
(3) Disconnect flow divider/dump valve hose at each power section prior to injecting
water and water mixture. Place detached end of flow divider/dump valve hose into
a suitable container for collection of water mixture.
(5) Install wash tube (PWC32271). Ensure arrow on wash tube tab is parallel to engine
center line and pointing to RGB (Ref. Fig. 703).
(8) Carry out 30 second motoring run. Introduce solution at approximately 5% Ng.
(10) Disconnect wash rig, and remove wash tube from gas generator case.
(11) Fit new gaskets on spark igniter and torque 300 lb.in., loosen to zero, and retorque
300 to 360 lb.in.
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2
1
3 A
RGB
VIEW A
C22196
72-00-00
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MANUAL PART NO. 3040592
1. Spark Igniter
2. Gasket
3. Tube Spray
(12) Perform two consecutive dry motoring runs. Observe starter limitations (Ref. Starter
Manufacturer’s Manual).
(13) Start engine (Ref. 71-00-00, POWER PLANT - ADJUSTMENT/TEST) and run at
idle to fully dry the engine.
NOTE: 1. This step is not necessary if the engine is run in the next 15 minutes.
NOTE: 2. Run the engine at idle for a minimum of five minutes with the MOT above
50°C (122 °F).
(14) Reconnect flow divider/dump valve hose at each power section after drying cycle
(Ref. Aircraft Maintenance Manual).
8. Corrosion Inhibitor
A. Procedure
NOTE: To obtain full benefit of the corrosion inhibitor, remove traces of corrosion and
touch-up with epoxy enamel paint prior to applying the corrosion inhibitor.
(1) Do an external engine wash in accordance with the Engine Maintenance Manual,
Section 72-00-00, Engine-Cleaning.
(c) After 1 hour, when the epoxy primer is dry, apply one coat of epoxy enamel
(PWC05-037).
(d) You can use a heat gun to heat the surface, 140 to 160 °F (60-82 °C) for one
hour to bake the enamel coating or wait 24 hours at room temperature.
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MANUAL PART NO. 3040592
For in-situ cleaning of nozzles, cleaning rig (PWC32677-300) is required. Prior to the wash
cycle, the cleaning rig must be prepared and operated in accordance with the Cleaning Rig
Manual.
NOTE: 1. It is recommended that this method of cleaning should only be initiated on new or
newly cleaned nozzles as the procedure will not clear previous blockages.
NOTE: 2. Introduction of contaminants may cause blockage of the fuel nozzles, power
degradation and hot section damage. Ensure that the wash and rinse solutions
are free of contaminates and that the fluid filter is routinely checked in accordance
with the Cleaning Rig Manual.
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MANUAL PART NO. 3040592
A. Preparation
(a) At ambient temperatures of 2°C (35.5°F) and above, mix by volume: 1 part
Turco 5884 (PWC11-001G) to 4 parts demineralized water.
(b) At ambient temperatures below 2°C (35.5°F), mix a 50% solution of methanol
and demineralized water, then mix 4 parts of water/methanol (by volume) to 1
part Turco 5884 (PWC11-001G).
(2) Fill solution reservoir with appropriate volume of Turco 5884 (PWC11-001G) (Ref.
step (1)).
(3) Fill rinse reservoir with appropriate volume of demineralized water or demineralized
water/methanol mixture according to ambient temperature (Ref. step (1)).
(4) Disconnect and remove engine fuel delivery line from flow divider inlet fitting
located at 6 o’clock position on engine gas generator case (Ref. 73-10-05). Install and
torque blanking cap assembly at fuel inlet to flow divider/dump valve.
(5) Disconnect airframe drain line from flow divider/dump valve outlet fitting (elbow or
nipple) (Ref. 73-10-05).
(6) Install and connect rig fluid delivery hose to flow divider/dump valve outlet fitting
using proper adapter (0.4375-20 UNJF) (Ref. Fig. 704).
(7) Connect rig fluid delivery hose to rig quick disconnect (Location: ‘‘FUEL NOZZLE’’).
(9) Set wash rig reservoir pressures to 60 psig using reservoir regulator.
B. Cleaning Cycle
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C11071A
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VALVE POSITION
OPERATION A B C
(1) Agitate detergent solution for two minutes Agitate Agitate OFF
(2) Detergent wash for three minutes Wash Wash ON
(3) Soak for 10 minutes OFF OFF OFF
(4) Detergent wash for three minutes Wash Wash ON
(5) Soak for 10 minutes OFF OFF OFF
(6) Rinse for six minutes Rinse Rinse ON
(7) Air dry for five minutes OFF OFF Air
Dry
(8) Reduce both reservoir and pulse pressure to zero OFF OFF OFF
C. Post-cleaning Operation
(1) Upon completion of the Cleaning Cycle (Ref. Subpara.B., preceding), perform the
following steps:
(a) Disconnect and remove compressed air supply from wash rig.
(b) Disconnect and remove wash rig fluid delivery hose from flow divider/dump
valve elbow or nipple.
(c) Remove blanking cap assembly at fuel inlet to flow divider/dump valve.
(d) Reconnect fuel delivery line to flow divider/dump valve fitting (Ref. 73-10-05).
(e) Perform two consecutive dry motoring runs, if the ambient temperature is below
2°C (35.5°F) and the water/methanol solution has been utilized. Observe
starter limitations (Ref. Starter Maintenance Manual).
(f) Perform an engine ground run (Ref. applicable Aircraft Manual) and check for
leaks.
(g) Clean wash rig, stow fluid delivery hoses and bleed air pressure from
reservoirs.
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MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
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5. Procedure
The following procedures are written with the understanding that they are to be carried out
on an engine that has been removed from the airframe and is installed in its stand as detailed
in Chapter 72-00-00, Page Block 401.
NOTE: Prior to removal of power section, oil system must be completely drained.
(a) Remove nuts (4 and 5), disconnect and remove T5 compensator leads (16).
(b) Replace nuts (4 and 5) to retain jumper leads (2 and 3) on terminal studs.
(a) Remove nuts and bolts securing clamps (11 and 13) to P3 tube (8).
(b) Pre-SB5516: Remove clamps and grommets (18) from lead (12). Remove nut
(25), bolt (22) and clamp (24). Remove bolts (20), nuts (23), bracket (26),
sealing plates (19) and grommet halves (21).
(c) Post-SB5516: Remove clamps and grommets (18) from lead (12). Remove nut
(25), bolt (22) and clamp (24). Remove bolts (20), nuts (23), bracket (26),
sealing plates (19) and grommet (27).
(d) Disconnect lead from compensator (6) and withdraw lead through fireseal
mount ring (10).
(b) Attach the sling (PWC30804) or (PWC71482) (1) to lifting brackets (2) on the
accessory gearbox (3) and Flange C (4).
(d) Remove lockpin (7) from mounting bracket (19) and link (9).
(e) Using wrench (PWC30114-10), remove 23 nuts (5) securing power section to
studs (16) on reduction gearbox.
(f) Install three jacking screws (6) (PWC32396-200) at Flange A and turn in equal
increments until coupling shaft (11) and reduction gearbox input shaft splines
are separated.
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1 2 3 5
4
16
13
17 6
15 14 13
12
11 7
10
POST−SB5443 POST−SB5449
C22098A
Removal/Installation of T5 Compensator Lead
Figure 201 (Sheet 1 of 2)
72-00-01
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1. Nut (Chromel)
2. Jumper Lead (Chromel)
3. Jumper Lead (Alumel)
4. Nut (Alumel)
5. Nut (Chromel)
6. T5 Compensator
7. Clamp
8. P3 Tube
9. P3 Tube Coupling
10. Fireseal Mount Ring
11. Loop Clamp
12. T5 Compensator Lead
13. Loop Clamp
14. Nut (Alumel)
15. Nut
16. T5 Compensator Lead
17. T5 Terminal Block
18. Clamps and Grommets
19. Sealing Plate
20. Bolt
21. Grommet Halves (Pre-SB5516)
22. Bolt
23. Nut
24. Loop Clamp
25. Nut
26. Bracket
27. Grommet (Post-SB5516)
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CLAMPING CONFIGURATION
A A
18 18
24 25 25
24
26 26
19 19
23 23
12
12
22 22
27
10
20 20
21
19 19
DETAIL A DETAIL A
(PRE−SB5516) (POST−SB5516)
C212326
Removal/Installation of T5 Compensator Lead
Figure 201 (Sheet 2)
72-00-01
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19 DETAIL B
18
B
1
15
16 14 2
3
12 2 4
13
21 20
DETAIL A
11 5
10 6
A
7
17
C3052A
72-00-01
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72-00-01
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CENTER
FIRESEAL
FRONT
REAR C FIRESEAL
FIRESEAL
22
23
25 24
DETAIL C
C71198
72-00-01
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MANUAL PART NO. 3040592
(i) Remove bolt and flat washer securing transfer tube (20) to No. 3 and 4 bearing
housing support.
(j) Remove transfer tube and place tube washer and bolt in a polyethylene
envelope. Seal envelope and retain with power section.
(k) Install protective cover and input drive shaft plug on power section at Flange A.
(l) Install polyethylene sheet over reduction gearbox at Flange A and secure
with retaining ring (preformed packing (15)).
(m) Cap all open lines on reduction gearbox and power section.
(n) Remove mounting bracket (19) from accessory gearbox mounting pad.
(a) Remove four nuts and bolts securing T5 compensator to reduction gearbox.
(b) Remove compensator, tag for identification and retain with power section.
(c) Remove Engine Control Number Plates from center fireseal mounting bracket
locations and retain for installation of replacement power section.
NOTE: Protective sheet at Flange A and plug in input drive shaft must not be removed.
(1) With the power section hanged in the sling (PWC30804) or (PWC71482) (1),
install the bracket (PWC30836) (3) and attach with three bolts (4).
(3) Lower power section into stand (5) (PWC30835) or (PWC70483) and enter input
drive shaft (11) into center of cushioned boss (13) on mounting plate (12).
(4) Align bracket (3) with bracket (6) on stand and insert pin (7).
(5) Secure power section at Flange A to mounting plate (12) with 16 bolts (14).
72-00-01
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2
A 3
4
10
A
9
3 5
12 11
6
7
14
B
12
8
13
B
C3054
72-00-01
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(1) Install adapter (16) (PWC30712) on stand (13) (PWC34300) and secure with six
bolts (14), nuts and washers (15).
NOTE: Ensure that both faces of adapters lie in the same vertical plane.
(a) Remove bolts (17), cover (18) and gasket (19) from P3 boss (20) on gas
generator case.
(b) Position mount ring upper half and secure bolt assembly (5) to P3 boss (20)
with two bolts (4).
(c) Secure lower half of mount ring to upper half with lockplates (3), bolts (9) and
nuts and washers (8).
(d) Adjust support assemblies (6) so that all pads contact gas generator case and
mount ring is positioned symmetrically around case.
(3) Lower power section into stand, aligning holes in mount ring with holes in adapters.
(4) Secure mount ring to adapters with screws and washers (11).
(5) Check that all fasteners are tight and that both indexing pins are correctly installed
at pivot. Remove sling.
72-00-01
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MAINTENANCE MANUAL
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2
2
4
10
5
A
7
8
1
2
9 16
B
15
14
11
A
12 17
18
19
20
VIEW B
13
C3053B
72-00-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Mount Ring
2. Locating Pin
3. Lockplate
4. Bolt
5. Bolt Assembly
6. Support Assembly
7. Locknuts
8. Nut and Washer
9. Bolt
10. Sling (PWC30804) or (PWC71482)
11. Screw and Washer
12. Flange
13. Stand
14. Bolt
15. Nut and Washer
16. Adapter
17. Bolt
18. Cover
19. Gasket
20. P3 Bleed Boss
(1) Attach the sling (PWC30804) or (PWC71482) (1) to lifting brackets on Flange C and
the accessory gearbox and take up weight of the power section with the hoist.
(2) Remove 16 nuts and washers (9) and withdraw bolts (14) and washers.
(3) Remove pin (7) and ease stand (5) away until input drive shaft (11) clears cushioned
boss (13).
NOTE: Protective sheet at Flange A and plug in input drive shaft must not be
removed.
(5) Remove bolts (4) and bracket (3) from accessory gearbox.
(1) Attach the sling (PWC30804) or (PWC71482) (10) to lifting brackets on Flange C
and the accessory gearbox and take up weight of the power section with the hoist.
(2) Remove screws and washers (11) securing mount ring (1) to adapters (16).
72-00-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(4) Slacken locknuts (7) and back off support assemblies (6) until clear of gas
generator case.
(5) Remove nuts and washers (8) and bolts (9) and separate lower half of mount ring
from upper half.
(6) Remove bolts (4) securing bolt assembly (5) to P3 boss and remove upper half of
mount ring.
(7) Install gasket (19) and cover (18) on P3 boss (20) and secure with bolts (17).
NOTE: Install stainless steel gasket (19) with ridge against P3 bleed boss.
(8) Apply initial torque of 35 to 40 lb.in., then without slackening bolts, torque 75 to
85 lb.in.
F. Installation on Engine
(a) With the power section hanged in the sling (PWC30804) or (PWC71482) (1),
remove all caps from oil and pneumatic tubes at Flange A of the power section
and the reduction gearbox.
(b) Install new preformed packings (13) on two oil transfer tubes (12) on reduction
gearbox.
(c) Install bracket (19) (PWC30617) on accessory gearbox mounting pad and
secure with bolts (18).
(e) Loosen adjustable brackets (24) on oil pressure and scavenge tubes.
(f) Remove retaining ring and polyethylene sheets from Flange A of reduction
gearbox and power section.
(h) Install new preformed packing (15) in groove in Flange A of reduction gearbox.
(i) Remove transfer tube (20), washer and bolt from envelope attached to
power section.
(k) Install transfer tube in boss at 10 o’clock position on No. 3 and 4 bearing
housing support and secure with bolt and washer.
72-00-01
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MAINTENANCE MANUAL
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(m) Inspect spiral retaining ring installed in groove at end of each main input drive
shaft for condition and replace if distorted beyond normal outside diameter
dimensions.
(n) Apply engine oil (PWC03-001) to retaining ring and inner diameter of power
section output shaft.
(o) Check that one spiral retaining ring is installed in groove at end of each main
input drive shaft. If not, proceed as follows:
(p) Lower power section and engage studs (16) on gearbox with holes in power
section flange.
(q) Rotate power turbine by hand (through exhaust duct) until input shaft splines
(14) and drive shaft splines engage and power section and reduction gearbox
flanges mate.
NOTE: Ensure that the three oil transfer tubes engage correctly in their
respective bosses.
(t) Install lockpin (7) through bracket (19) and link (9).
(v) Connect Pg pressure tube (17), torque coupling nut 90 to 100 lb.in. and
lockwire.
(w) Torque bolts (22) and nuts (25) on bracket (24) 36 to 40 lb. in.
72-00-01
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MAINTENANCE MANUAL
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(2) Connect P3 tube and install T5 compensator lead (Ref. Fig 201).
(c) Insert T5 compensator lead (12) through aperture in fireseal mount ring (10)
from reduction gearbox side.
(f) Pre-SB5516: Install grommet halves (21), sealing plates (19), bracket (26), bolt
(20) and nuts (23). Torque 7 to 8 lb.in.
(g) Post-SB5516: Install grommet (27), sealing plates (19), bracket (26), bolt (20)
and nuts (23). Torque 7 to 8 lb.in.
(h) Install clamp (24) on lead (12) and secure with bolt (22) and nut (25). Torque
32 to 36 lb.in.
(a) Remove nuts (5 and 4). Ensure jumper leads (2 and 3) remain on terminal
studs.
(b) Install T5 compensator leads (16), secure with nuts (4 and 5). Torque nut (5)
20 to 22 lb.in. and nut (4) 32 to 36 lb.in.
(a) Install clamps (11 and 13) on lead and tube, secure with nuts and bolts. Torque
nuts 32 to 36 lb.in.
72-00-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
LEP 1 Nov 23/2015 229 Nov 23/2015
2 blank Nov 23/2015 230 Nov 23/2015
231 Nov 23/2015
Contents 1 Nov 23/2015 232 Nov 23/2015
2 Nov 23/2015 233 Nov 23/2015
234 Nov 23/2015
72-10-00 1 Mar 22/2002 235 Nov 23/2015
Description and 2 Mar 22/2002 236 Nov 23/2015
Operation 3 Mar 22/2002 237 Nov 23/2015
4 Mar 22/2002 238 Nov 23/2015
5 Mar 22/2002 239 Nov 23/2015
6 blank Mar 22/2002 240 Nov 23/2015
TABLE OF CONTENTS
SUBJECT PAGE
1. General 1
2. Description 1
A. Housing and Covers 1
C. Output Section 3
3. Operation 3
A. Sprag Clutch 3
B. Torquemeter 3
1. General 201
TABLE OF CONTENTS
SUBJECT PAGE
6. Inspection/Check 233
A. Removal 235
B. Installation 237
1. General
The reduction gearbox basically comprises input section, containing a three-stage reduction
geartrain and an output section which contains the engine output shaft. In operation,
rotation of each power turbine shaft is transmitted, through the input section geartrains, to
the output section shaft at a reduction ratio of 5:1.
The gearbox casings comprise five castings; an output housing, a diaphragm, an input
housing and two covers. The output housing is secured to each power section at Flange A.
Input and output housings are secured together by means of studs with the diaphragm
installed between them. The covers are secured to the input housing to provide accessory
mounting pads and protect reduction gearshaft bearings.
Each input section reduction geartrain consists of three gearshafts driving a common
output shaft. Accessory drives for Nf governor, tachometer-generator and blower are taken
from the second-stage of each reduction geartrain. The input shaft carries a single
spur gear and is supported by No.5 and No.6 bearings. No.5 bearing is a duplex ball
bearing mounted on the diaphragm. No.6 bearing is a roller bearing mounted on the input
housing. The first stage spur gear on the input shaft meshes with the larger of two
spur gears on the second-stage shaft which is supported by No.7 and No.8 bearings.
No.7 bearing is a roller bearing mounted on the diaphragm. No. 8 bearing is a duplex ball
bearing mounted on the input housing. The larger spur gear on the second-stage
shaft transmits drive to an independently mounted clutch gear on the third-stage shaft.
The second-stage spur gear transmits drive to a blower shaft via an idler gear. This
second-stage gear also drives the power turbine governor shaft via the gear on the
tachmometer generator shaft. The idler gear and blower shaft are mounted in roller
bearings. The tachometer-generator and governor shafts are supported in journal
bearings.
The clutch gear is supported by No.10 1/2 and 12 1/2 roller bearings which are mounted
on the input housing and diaphragm respectively. A sprag clutch, housed in the clutch
gear, transmits drive from this gear to the clutch drive shaft. The clutch drive shaft is
supported in the clutch gear by No.11 and No.12 ball bearings. An intermediate drive
shaft, splined within the clutch drive shaft is secured against a shoulder of the shaft by a
nut and keywasher at the torquemeter end.
A helical gear supported by No.13 and No.14 roller bearings, which are mounted on the
diaphragm and output housing respectively, is splined onto the intermediate drive
shaft and secured by spiral retaining rings in slots within the gear.
72-10-00
Page 1
REDUCTION GEARBOX - DESCRIPTION AND OPERATION Mar 22/2002
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
DIAPHRAGM
OUTPUT
HOUSING
RGB OIL SYSTEM
OIL PUMP
OUTPUT
15 SHAFT
CLUTCH GEAR
SPRAG CLUTCH 16 17
_1
10
TORQUEMETER 2
10 _1
PISTON COVER 12 3RD STAGE
2 HELICAL GEAR
TORQUEMETER 14
VALVE
11 12 13 RETAINING RINGS
BLOWER
DRIVE PAD
INTERMEDIATE
DRIVE SHAFT
TACHO−GENERATOR 5
6
CLUTCH GEAR
2ND STAGE GEAR
C22082
72-10-00
Page 2
REDUCTION GEARBOX - DESCRIPTION AND OPERATION Mar 22/2002
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C. Output Section
The output shaft is supported by No.15 roller bearing which is mounted in the diaphragm
and No.16 roller bearing and No.17 ball bearing which are mounted in the ouput
housing. The shaft has a single helically-toothed spur gear which meshes with the
third-stage gear in the input section. An insert in the ouput shaft extends into the input
housing to drive the reduction gearbox oil system pump.
NOTE: Reduction gearbox oil system component description and operation is covered
in Chapter 79-00-00.
3. Operation
Under normal operating conditions, i.e., when the clutch gear (outer race) is driven by
the engine, the clutch sprags are engaged. The center of gravity of each sprag is arranged
in relation to the centers of curvature so that under rotational movement the sprags tilt
towards the upright position and engage the inner race (shaft) and outer race (clutch gear).
In the event of failure of one power section the clutch drive shaft of that section
assumes a driving instead of driven mode. This action allows the sprags to tilt in the
opposite direction leaving the clutch and the clutch gear (outer race) free.
As the helical gear on the clutch gear shaft is in direct contact with the output shaft
gear, changes in engine torque are translated into axial movement of the helical gear,
the intermediate drive shaft, the clutch drive shaft and the torquemeter piston. A
torquemeter valve on the piston cover moves within a sleeve to produce a change in the
oil presusresignal to the torque control unit and the airframe instruments.
72-10-00
Page 3
REDUCTION GEARBOX - DESCRIPTION AND OPERATION Mar 22/2002
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
SPRAG CLUTCH
ASSEMBLY CLUTCH GEAR
CLUTCH GEAR
CLUTCH GEAR (FREE)
PAWLS (DRIVING
SPRING
C3013B
72-10-00 Page 4
REDUCTION GEARBOX - DESCRIPTION AND OPERATION Mar 22/2002
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
TORQUEMETER PISTON
TORQUEMETER VALVE
TORQUEMETER VALVE
SLEEVE
POWER INCREASED
C3014
Torquemeter Operation
Figure 3
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
72-10-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
TD1032L Locking Tool (Keensert)
5. Removal/Installation
NOTE: The following procedure is written with the understanding that it is to be carried
out on an engine that has been removed from the airframe and is installed in
its stand as detailed in 72-00-00, ENGINE - REMOVAL/INSTALLATION.
(1) Remove both power sections (Ref. 72-00-01, POWER SECTION - MAINTENANCE
PRACTICES).
(2) Attach sling (PWC70249) to lifting bracket (2) and take up weight of gearbox.
(6) Lift gearbox clear of stand and lower onto a suitable flat surface.
72-10-00
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B. RGB - Installation
NOTE: The following procedure is written with the understanding that it is to be carried
out on an engine that has been removed from the airframe and is installed in
its stand as detailed in 72-00-00, Page Block 401.
(1) Position mounting brackets (3 and 8) (PWC30619 and PWC30618) on gearbox and
secure each bracket with bolts (7).
(5) Lower gearbox into stand, aligning brackets (3 and 8) with brackets on stand.
(7) Swing support and bracket assemblies (5) upwards to engage on tachometer
mounting studs (10).
(8) Secure support and bracket assemblies to mounting stud with nuts (9).
(11) Remove polyethylene sheets and retaining rings from power section mounting faces
on gearbox.
(12) Check that one spiral retaining ring is installed in groove at end of each main input
drive shaft. If not, proceed as follows:
(a) Push retaining ring over tapered portion of sleeve (PWC30832) to maximum
diameter end.
72-10-00
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MANUAL PART NO. 3040592
9
10 A
5
DETAIL A
8
3
4
4
5
7 7
PWC
C3055A
72-10-00
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MANUAL PART NO. 3040592
1. Sling
2. Lifting Brackets
3. Bracket
4. Ball-lockpin
5. Support and Bracket Assembly
6. Stand
7. Bolts
8. Bracket
9. Nuts
10. Tachometer Mounting Studs
C. Torquemeter - Removal
(a) Disconnect oil cooler return lines (7 and 11), catch oil drainage and cap both
lines.
(b) Disconnect torquemeter transmitter lines at torquemeter pressure port (9) and
cap.
(c) Disconnect and remove Pg tubes (1 and 6) from Nf governor and cross
coupling. Blank off connections and tag tubes.
(d) Disconnect torque control tubes (3 and 4) and blank off connections.
(f) Disconnect Nf tachometer cannon plugs (8 and 10) and cap connectors.
(a) Remove nuts (1) and washers (2) securing mounting bracket (7), anti-rotation
bracket (10), brackets (11 and 12) and cover assembly (3) to input housing.
72-10-00
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1 2 3 4 5 6
9 8
11 10 7
C74827
72-10-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Pg Tube
2. Pg Sealing Cap
3. Torque Control Tube
4. Torque Control Tube
5. Pg Sealing Cap
6. Pg Tube
7. Oil Cooler Return
8. Nf Tachometer Plug
9. Torquemeter Transmitters
10. Nf Tachometer Plug
11. Oil Cooler Return
(c) Carefully withdraw cover assembly from input housing studs and place on
workbench, suitably supported.
(a) Unlock keywasher (1) and remove bolt (2) and keywasher.
(b) Fill valve sleeve (3) bore to approximately one-third level with clean oil.
(c) Install drift (PWC32820) in valve sleeve and lightly tap drift with soft hammer.
Valve sleeve will be pushed out by oil pressure.
2 Remove the piston cover (3) and the torquemeter valve (1) using one of
the following methods:
72-10-00
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11
9
8
10
11 A
2
12 1 7
12
VIEW A
C75788
72-10-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Locknut
2. Washer
3. Cover Assembly
4. Input Housing
5. Diaphragm
6. Output Housing
7. Mounting Bracket
8. Preformed Packing
9. Preformed Packing
10. Breather Nipple Anti-rotation Bracket
11. Bracket
12. Bracket
72-10-00
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9 8 10
5
11
12
B
11
1
7 2 3
12
VIEW B
C75789
72-10-00
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MANUAL PART NO. 3040592
b Using a puller: Remove torquemeter valve (1) from piston cover (3).
Remove and discard preformed packing (4). Withdraw piston cover (3)
using puller (PWC51063) or (PWC30046-70).
NOTE: For installed RGB, use airframe tool to hold driveshaft coupling
(Ref. Airframe Maintenance Manual)
2 Unlock keywasher (18, Fig. 210). Remove nut (17) and keywasher (18).
Discard keywasher.
4 Prevent clutch shaft rotation by holding adapter nut (4), remove retaining
nut (2) using socket (PWC30633) (1) and remove keywasher (3).
(c) Remove grooved half bearing inner race (Ref. Fig. 207).
1 Using puller (PWC30631) (1) withdraw grooved half inner race (2) from
clutch driveshaft (4).
2 Install bearing retainer (PWC50777) into No. 10 bearing and cage (8, Fig.
210).
1 Remove torquemeter cylinder (9) complete with piston (12) and bearing
outer race and cage.
5 Using ring (PWC30840) as a support for prying action, remove retaining ring
(14).
6 Withdraw piston (12), complete with bearing outer race, from cylinder (9).
7 Remove and discard piston ring (11) and preformed packings (13) (‘‘Vee’’
seals).
72-10-00
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4
7
3
1
2
5
C6247B
72-10-00
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MANUAL PART NO. 3040592
1. Keywasher
2. Bolt
3. Valve Sleeve
4. Preformed Packing
5. Preformed Packing
6. Transfer Tube
7. Spacer
D. Torquemeter - Installation
1 Install two new preformed packings (5) opposed as shown (Ref. View A),
and piston ring (4) on torquemeter piston (3).
2 Insert piston assembly, complete with outer race (2), into cylinder (1) and
install retaining ring (6).
3 Place cylinder flanged end down on bench and position piston at top of
cylinder.
4 Apply a 3.5 lb. load on piston (3) and check piston movement by tapping
bench and noting that piston moves downward, full travel. If piston sticks,
replace preformed packings (5) or piston ring (4) or both.
(b) Install bearing cage and balls assembly and preformed packing (Ref. Fig.
210).
2 Insert No. 10 bearing and cage (8) in outer race (10), ensuring serial
numbers match and are both visible on the same side.
3 Install bearing retainer (PWC50777) into No. 10 bearing and cage (8, Fig.
210).
1 Install torquemeter assembly (13) over clutch shaft (14) and ease into
position with cylinder locating hole engaging dowel (15) on input housing. If
required seat housing using soft faced hammer.
72-10-00
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10
7
8 11 9
2
3
1
16
15
5
6
12 13
14
7
6
5
4
3
2
1
15
14
13
12
11
10
8 9
C3227
Torquemeter Disassembly
Figure 205
72-10-00
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MANUAL PART NO. 3040592
1. Torquemeter Valve
2. Spiral Retaining Ring
3. Torquemeter Piston Cover
4. Preformed Packing
5. Bearing Retaining Nut
6. Keywasher
7. No. 10 Ball Bearing
8. Preformed Packing - Small
9. Torquemeter Cylinder
10. Preformed Packing - Large
11. Piston Ring
12. Torquemeter Piston
13. Preformed Packing
14. Spiral Retaining Ring Piston
15. Clutch Drive Shaft
16. Bearing Grooved Half Inner Race
(d) Install No. 10 grooved half inner race (Ref. Fig. 210).
NOTE: Once drift (PWC50778) is placed on No. 10 bearing inner race, the
‘‘x’’ mark is no longer visible. It is recommended that a witness mark
is scribed on drift and that this mark is aligned with ‘‘x’’ mark on No. 10
bearing inner race.
1 Install No. 10 bearing grooved inner race (7) on drift (PWC50778) and
place in oil tank at 121 °C (250°F).
NOTE: Pusher (PWC30875) has 4 items: screw, sleeve, washer and nut.
5 Remove inner race (7) and drift (PWC50778) from oil and install grooved
half of No. 10 bearing inner race (7) and align X-marks to within 5
degrees. Remove drift (PWC50778).
7 Place sleeve over screw already installed on shaft (20) and attach washer
and nut. Tighten nut until resistance is felt. Remove pusher (PWC30875).
8 Apply oil to keywasher and nut mating surfaces and install slave keywasher
(6) and retaining nut (5).
72-10-00
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1 2
5 4
A
3
2 6
1
VIEW B
VIEW A 4
C3228
72-10-00
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1. Socket
2. No. 10 Bearing Retaining Nut
3. Retaining Nut Keywasher
4. Adapter Nut
5. Output Shaft
6. Output Shaft Spline
9 Clamp output shaft (5, Fig. 206) with adapter nut (4) (PWC50055).
NOTE: If RGB is installed use airframe tool to hold driveshaft coupling (Ref.
Airframe Maintenance Manual).
10 Using socket (PWC30633) seat inner race (7, Fig. 210) by tightening
retaining nut (5) and torque 640 to 855 lb.in., slacken to zero lb.in. Remove
nut (5) and slave keywasher (6). Install new keywasher (6), nut (5) and
torque 385 to 515 lb.in.
12 Install new keywasher (18) and nut (17). Torque nut (17) 275 to 300 lb.in.
using conventional socket while holding output shaft with adapter nut
(PWC50055) (4, Fig. 206).
13 Crimp keywasher (18, Fig. 210) onto nut (17) using crimper (PWC50495).
1 Install preformed packing (4) on piston cover (3) and install cover in
torquemeter assembly (13). Secure with retaining ring (2).
NOTE: Output shaft maybe rotated to align cylinder and piston slots.
72-10-00
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C3229
72-10-00
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MANUAL PART NO. 3040592
1. Puller (PWC30631)
2. Grooved Half Inner Race
3. Torquemeter Cylinder
4. Clutch Driveshaft
NOTE: While installing cover, ensure gears are fully meshed by slowly
rotating output shaft during installation. If resistance is felt remove
cover, inspect and re-install.
3 Install mounting bracket (7), anti-rotation bracket (10) and brackets (11
and 12).
4 Secure cover to input housing with nuts (1) and washers (2). Install Pg cap
clamps (2 and 5) on brackets and secure with bolt and nut.
(a) Remove caps and connect Nf tachometer cannon plugs (8 and 10).
(b) Remove blanking caps and install torque control oil tubes (3 and 4). Torque
fittings 90 to 100 lb.in.
(c) Remove blanking plugs and install Pg tubes (1) between Nf governors and
cross-couplings. Torque fittings 90 to 100 lb.in.
(d) Remove blanking caps and connect lines to torque transmitter (9). Tighten
(Ref. Aircraft Manual).
(e) Remove blanking caps and connect oil cooler return lines (7) and (11) to
gearbox. Torque connections (Ref. Aircraft Manual).
72-10-00
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MANUAL PART NO. 3040592
1 3 4
A 3
5 6
VIEW A
C3354C
Torquemeter Assembly
Figure 208
72-10-00
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MANUAL PART NO. 3040592
1. Torquemeter Cylinder
2. No. 10 Ball Bearing Outer Race
3. Torquemeter Piston
4. Piston Ring
5. Preformed Packing
6. Spiral Retaining Ring
(4) Remove retaining nut (3) using wrench (PWC32828) over nut in conjunction with
socket (PWC32859) over idler gearshaft (4).
(3) Using wrench (PWC32828), torque retaining nut (3) 1750 to 2000 lb.in., slacken to
zero and retorque 1500 to 1750 lb.in.
(4) Install keywasher (2) into nut, ensuring that washer tang fits into one of four slots
provided in the gearshaft.
72-10-00
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3.5 LBS. 1
LOAD
C3355B
72-10-00
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(4) Remove preformed packing (3) and seal (4) from carrier.
NOTE: Prior to installation, seal (4) must be lubricated with engine oil (PWC03-001).
(1) Remove bolts and washers (1) and withdraw drain cover (2) and gasket (3).
(3) Separate seal (6) from carrier using pusher/puller (PWC30810) Rev. E or subsequent.
NOTE: Prior to installation of replacement seal, check that seal runner (8) is square
within 0.0004 in. using a dial indicator or seal runner gage (PWC50024). If out
of limits, replace seal runner (Ref. Para. 5.K. and L.).
(1) Lubricate seal (6) with engine oil (PWC03-001) and ensure that carbon seal moves
in and out freely against spring.
(2) Install seal in carrier (4) using pusher/puller (PWC30810) Rev. E or subsequent.
(4) Position carrier over output shaft (7) and press into gearbox housing.
72-10-00
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MANUAL PART NO. 3040592
8
7
6
5
4
3
2
MATING NUMBER
X MARKS TO ALIGN WITHIN 5°
15
16
14
13 12 19
18
17
11
10
9
20
C6248B
Torquemeter Installation
Figure 210
72-10-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Torquemeter Valve
2. Cover Retaining Ring
3. Torquemeter Piston Cover
4. Preformed Packing
5. Bearing Retaining Nut
6. Keywasher
7. No. 10 Bearing Grooved Half Inner Race
8. No. 10 Bearing and Cage
9. Preformed Packing
10. No. 10 Bearing Outer Race
11. Torquemeter Cylinder
12. Preformed Packing
13. Torquemeter Assembly
14. Clutch Shaft
15. Dowel
16. No. 10 Plain Bearing Inner Race
17. Nut
18. Keywasher
19. Washer
20. Intermediate Drive Shaft
(6) Install bolts and washers (1), torque 32 to 36 lb.in. and lockwire in pairs.
(3) Position wrench assembly on output shaft, align dogs (8) on socket nut (PWC50054)
(2) with slots (9) in plain nut (5) and tighten screw (4).
(4) Hold adapter nut (PWC50055) (3) steady and apply torque to socket assembly (2)
in direction shown.
(6) Remove nut (5), keywasher (6), seal runner (7) and preformed packing (10).
(1) Install new preformed packing (10), seal runner (7), new keywasher (6) and plain
nut (5) on output shaft.
72-10-00
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MANUAL PART NO. 3040592
NO.8 BEARING
NO.8 BEARING
4 4
3 3
2 2
1 1
REDUCTION GEARBOX
WITH COVERS REMOVED
C22117A
72-10-00
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MANUAL PART NO. 3040592
1. Retaining Ring
2. Keywasher
3. Nut
4. Idler Gearshaft
(3) Position wrench assembly on output shaft, align dogs (8) on socket nut (PWC50054)
(2) with slots (9) in nut (5) and tighten screw (4).
(4) Hold adapter nut (PWC50055) (3) steady and torque nut (5) 1225 to 1540 lb.in.
(5) Slacken nut (5) to zero and final torque 1200 to 1300 lb.in.
(6) Using dial indicator or seal runner gage (PWC50024), check that seal runner is
square within 0.0004 in.
NOTE: If runner is not square within the above limit, slacken nut (5), rotate runner
through 90 degrees, tighten nut and repeat check. Repeat procedure as
necessary. If squareness within limit cannot be achieved, seal runner must
be replaced.
(7) When seal runner squareness is within limit, lock keywasher (6), using suitable
punch.
M. Reduction Gearbox Oil Pressure Relief Valve - Removal (Ref. Fig. 215)
(3) Remove oil filler adapter (1) and preformed packing (4).
(5) Using puller (PWC30871), remove housing (6), preformed packing (11), spacers
(7), spring (8) and valve (9).
72-10-00
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MANUAL PART NO. 3040592
A A
1 2 3 4 5
DETAIL A
C9315
72-10-00
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MANUAL PART NO. 3040592
1. Retaining Ring
2. Seal Carrier
3. Preformed Packing
4. Seal
5. Blower Drive Pad (Ref)
N. Reduction Gearbox Oil Pressure Relief Valve - Installation (Ref. Fig. 215)
(1) Lubricate new preformed packing (11) with clean engine oil and install on housing
(6).
(4) Insert valve assembly in inlet housing and secure with new retaining ring (5).
(5) Lubricate new preformed packing (4) with clean engine oil and install on oil filler
adapter (1).
(6) Position adapter on reduction gearbox studs and install washers (3) and nuts (2).
NOTE: 2. Make sure the area on the RGB surrounding the metering tee is cleaned prior
to removal of the metering tee.
(1) Disconnect and cap the pneumatic tubes (1) and (2) at metering Tee assembly (3).
72-10-00
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2 3 4 6
7
5 8
6
5
4
3
2
C22076
72-10-00
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MANUAL PART NO. 3040592
(3) Remove Tee assembly (3) and cap the opening in the RGB housing to prevent
contamination.
(4) Remove and discard packing (5) and backup ring (6).
(1) Install lock nut (4) and backup ring (6) on Tee assembly (3).
(2) Lubricate new packing (5) with engine oil (PWC03-001) and install on Tee assembly
(3).
(3) Remove cap previously installed on RGB housing and install Tee assembly (3) on
RGB.
(4) Position Tee assembly (3) correctly to line up with pneumatic tubes (1) and (2).
(5) Retain the Tee in position and torque locknut 40 to 65 lb. in.
(6) Remove the cap previously placed on tubes (1) and (2) and connect tube nuts (4)
to Tee assembly (3).
(7) Torque tube nuts 90 to 100 lb. in. and safety wire.
(2) Remove the seal carrier (3) with the puller (PWC30046-57).
(3) Remove and discard the preformed packing (2). Remove the seal (1) from the seal
carrier (3) with finger pressure.
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8
2
10
6
3
C3076
72-10-00
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MANUAL PART NO. 3040592
1. Wrench Assembly
2. Socket Nut
3. Adapter Nut
4. Screw
5. Plain Nut
6. Keywasher
7. Seal Runner
8. Dogs
9. Slots
10. Preformed Packing
(1) Put the oil seal carrier (3) in an oven at 141°C (285°F) for 15 minutes minimum.
(3) Use drift (PWC37088-1) to install the seal (1) in the carrier (3) with the flat face of
the seal at the bottom of the carrier.
(4) Lubricate the new preformed packing (2) with the engine oil (PWC03-001) and
install it on the carrier (3).
(5) Install the carrier assembly in cover with the drift (PWC30075).
6. Inspection/Check
(1) Inspect sealing face for chips, nicks and scratches. Seal is acceptable provided
that:
(b) A circular strip no less than 45% of original face width makes sealing contact.
(c) Scratches extending across sealing face are less than 0.005 in. deep
and 0.010 in. wide.
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10
9
2 4
3
11
C5469
72-10-00
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(2) Inspect condition of remaining areas of seal. Seal is acceptable provided that:
(c) Scratches are less than 0.005 in. deep and 0.010 in. wide.
(1) Flush inside of Tee with petroleum solvent (PWC11-027) and dry with clean shop
air.
(2) Visually inspect the metered orifice within Tee assembly for presence of
contamination with a strong light.
(3) Soak the Tee assembly in Carbon Compound (PWC11-021/21A/21B) for a period of
two hours if accumulation of contamination is found.
(4) Flush with petroleum solvent (PWC11-027) and dry with clean shop air.
NOTE: The following procedure applies only to specific sized inserts used in the RGB
output housing to airframe mounting pad. Refer to Illustrated Parts Catalog for
approved location and particular part number of insert.
A. Removal
(1) Drill out insert material between keys to depth shown using 13/32 inch diameter drill
(Ref. Detail A).
(2) Using small pin punch, bend keys inward and break them off (Ref. Detail B).
(3) Remove insert with a standard ‘‘E-Z-Out’’ type tool (Ref. Detail C).
72-10-00
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1
3
2
DETAIL A
C111163
72-10-00
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MANUAL PART NO. 3040592
1. Pneumatic Tube
2. Pneumatic Tube
3. Tee Assembly
4. Lock Nut
5. Packing
6. Backup Ring
B. Installation
(1) Screw in new insert, using fingers, to a depth of 0.010 to 0.030 in. below surface of
parent component (Ref. Detail D).
(2) Using a ‘‘Kee’’ driving-tool (item 11) and a hammer, drive down keys with several
light taps (Ref. Detail E).
72-10-00
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1
1
2
3 2
REDUCTION GEARBOX CASING
3
C233622
72-10-00
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MANUAL PART NO. 3040592
1. Seal
2. Preformed Packing
3. Oil Seal Carrier
72-10-00
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MANUAL PART NO. 3040592
13
32 IN. DRILL
LOCKING KEYS
0.200 INCH
DETAIL E
C3559
72-10-00
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MANUAL PART NO. 3040592
CHAPTER
SECTION PAGE DATE
LEP 1 Mar 09/2001
2 blank Mar 09/2001
Page 1/2
72-20 LEP Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
TABLE OF CONTENTS
SUBJECT PAGE
1. General 1
5. Removal/Installation 201
A. Removal of Bleed Air Case (Pre-SB5306) 201
6. Cleaning 205
Page 1/2
72-20 CONTENTS Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
Description and operation of the components associated with the intake of air is covered in
72-00-00 and 72-30-00.
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
5. Removal/Installation
(1) Position bleed air case with one side located on air inlet screen rubber molding and
the other side on center fireseal mounting flange.
(3) Post-SB5445: Align indication mark (arrow) on bleed air case assembly with joint
between upper and lower front fireseal.
C22111
1. Bolt
2. Nut
3. Bolt
4. Nut
STARBOAR
PORT D
ENGINE
ENGINE
FRONT FIRESEALS
ALIGN THIS ARROW ALIGN THIS ARROW
WITH THIS JOINT (VIEWED TOWARD AGB) WITH THIS JOINT
BETWEEN THE UPPER BETWEEN THE UPPER
AND LOWER FIRESEALS AND LOWER FIRESEALS
D
AR
BO
AR
ST
IN E
ENG
STARBOARD ENGINE
(TYPICAL)
POST-SB5445 C76029
(6) Manually constrain case with flanges aligned and circumferentially seated.
(7) Torque nuts (2) to 15 lb.in., ensuring that bolt retaining bands are locked together.
(8) Apply run-down torque to seat each nut (4) and record torque applied.
(9) When both nuts are seated, apply 10 lb.in., additional torque to each nut (4).
(2) Remove nuts (2), washers (3) and bolts (1) from 6 o’clock position on screen (4).
(2) Position screen (4) around inlet case with split joint at 6 o’clock position.
6. Cleaning
Remove screen as detailed in Paragraph 5 preceding and clean with petroleum solvent
(PWC11-027).Thoroughly dry with compressed air prior to reinstallation.
1
2 VIEW A
C3751
1. Bolt
2. Nut
3. Washer
4. Air Inlet Screen
5. Bleed Air Case
CHAPTER
SECTION PAGE DATE
LEP 1 Dec 02/2013
2 blank Dec 02/2013
TABLE OF CONTENTS
SUBJECT PAGE
1. General 1
2. Component Description 1
A. Air Inlet Screen and Bleed Air Case 2) 1
C. Compressor Assembly 3) 1
F. Compressor Turbine 6) 6
1. General 201
2. Consumable Materials 201
5. Inspection/Check 201
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
1. General
The compressor (gas generator) section is located between the accessory gearbox and the
power turbine and exhaust sections of the engine. The section contains the compressor
inlet, the compressor, the combustor and the compressor turbine components and the gas
generator case (Ref. Fig. 1). The compressor inlet components comprise an air inlet screen,
a bleed air case and a compressor inlet case. The compressor comprises three axial
stages and one centrifugal stage and is supported by No.1 and No.2 bearings. The combustor
components comprise a combustion chamber liner and an exit duct. The turbine components
comprise a bladed disk, which is secured to the compressor stubshaft, and a vane ring
and shroud assembly. The gas generator houses the compressor, combustor and compressor
turbine components. The compressor inlet case, which supports the air inlet screen and
the bleed air case is secured to the gas generator case at Flange F. The case also provides
mountings for the front and center fireseals. A compressor wash ring is installed on the
front fireseal mounting ring adjacent to the air inlet screen.
2. Component Description
The air inlet screen is a circular large area, wire-mesh screen located between the air
inlet fairing and the front fireseal. The function of the screen is to preclude the ingestion of
foreign objects by the compressor.
The bleed air case is a two-piece sheet metal band which is installed in the compressor
inlet area between the inlet screen and the center fireseal. The case encloses the
compressor bleed valve and includes an aperture to which the airframe overboard
discharge duct is connected. Compressor bleed air from the bleed valve enters the
chamber formed by the case and is thus ducted overboard.
The compressor inlet case is a circular casting which forms a plenum chamber for
passage of compressor inlet air. Studs at Flange G secure the case to the accessory
gearbox and at Flange F, to the gas generator case. The case centerbore houses No.1
bearing components. Breather holes in the centerbore flange operate in conjunction
with the labyrinth air seal and interstage pressure air to prevent No.1 bearing lubricating
oil from entering the compressor, the oil being scavenged through an outlet port
located at the 6 o’clock position in the centerbore.
The compressor basically comprises three axial rotor stages, three interstage spacers,
three stator assemblies and a single-stage centrifugal impeller and housing. The complete
assembly is housed within the gas generator case and is supported by No.1 bearing
assembly in the compressor inlet case and No.2 bearing assembly in the gas generator
case centerbore. When running at maximum continuous rating, the compressor
supplies air to the engine combustion section at a compression ratio of 7:1.
72-30-00 Page 1
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
FRONT FIRESEAL
COMPRESSOR TURBINE
VANE RING AND SHROUD
C22127
72-30-00 Page 2
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
GAS GENERATOR
CASE (REF.)
FRONT FIRESEAL
CENTER FIRESEAL
C9360
Air Inlet Screen and Compressor Bleed Air Case - Component Location
Figure 2
72-30-00 Page 3
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
COMPRESSOR
TIE−ROD BLADE
PRESSURE
OIL NOZZLE
STUB SHAFT
NO.2 BEARING
NO.1 BEARING
CENTRIFUGAL
IMPELLER
SHORT SPACER
IMPELLER
HOUSING COMPRESSOR
BLEED VALVE
C3006A
72-30-00 Page 4
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
No.2 bearing, the compressor stubshaft, the centrifugal impeller and the impeller
housing are positioned in that order, followed, sequentially by the third and second-stage
rotor and stator assemblies and their associated interstage spacers, the first-stage
stator assembly, and the first-stage rotor assembly of which the compressor hub is an
integral part. The hub is supported by No.1 bearing. The rotor components are stacked
and secured together by six tie rods.
No.2 roller bearing supports the compressor stubshaft and its attached turbine. The
bearing inner race is located between labyrinth rotor air seals which butt against shoulders
on the compressor stubshaft and the compressor turbine stubshaft.
The impeller housing is secured in the gas generator case by a retaining ring. Rotation
of the housing in the gas generator case is prevented by a stainless steel locating
pin in the case which mates with a slot in the housing.
Each rotor stage consists of rotor blades which fit into dovetail grooves in the rims of
rotor disks. First-stage rotor blades are made from titanium and second and third-stage
blades from cadmium plated stainless steel. The airfoil cross-sections of first-stage
blades differ from that of second and third-stage blades and blade length decreases
progressively from first-stage to third. The limited clearance between the blade root and
the disk groove produces the characteristic clicking sound heard during compressor
rundown. The interstage spacers installed between the rotor disks limit blade axial
movement during operation.
Each set of compressor stator assembly vanes is held in position by a circular ring
through which vane ends protrude and to which they are brazed. The first-stage
compressor stator assembly provides a shroud for the first and second-stage rotor blades,
and the third-stage vane and shroud assembly provides a shroud for the third-stage
blades. First and third-stage assemblies are bolted together, and the third-stage vane and
shroud assembly is secured to the impeller housing. The second-stage compressor
stator assembly is housed between first and third-stage assemblies and located by a
single staked pin. Interstage pressure air (P2.5) is vented to the compressor bleed valve
chamber in the gas generator case through slots in the third-stage vane and shroud
assembly.
The rows of vanes in each stator stage diffuse compressor air, raise its static pressure
and direct it to the next rotor stage. The air finally leaves the compressor at the centrifugal
impeller and is directed into the diffuser tubes in the gas generator case.
72-30-00 Page 5
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The combustion chamber liner is an annular heat-resistant steel liner open at one end
and domed at the other. The domed end of the liner is supported inside the gas generator
case by fourteen fuel nozzle sheaths and located by the two spark igniters in the case
which protrude into the liner at the 4 o’clock and 11 o’clock positions. Rings of plain,
plunged and shielded perforations, located around the inner and outer circumferences
and in the domed area of the liner, allow air to enter to provide optimum fuel/air ratios for
starting and sustained combustion. Cooling rings control airflow within the liner and
along with the perforations, ensure an even temperature distribution at the compressor
turbine inlet. Open end inner and outer circumferences are located by sliding joints in small
and large exit duct respectively.
E. Compressor Turbine Vane Ring and Shroud and Combustion Chamber Exit Ducts (Ref.
Fig. 5)
The vane ring comprises 14 integrally cast, cooled vanes between inner and outer
securing rings. The ring is secured between the combustion chamber large exit duct and
the flange of No.2 bearing cover at the gas generator case centerbore. Lugs on the
outer ring mate with slots in the shroud housing and lugs on the inner ring mate with slots
in No.2 bearing cover flange.
The combustion chamber liner and large exit duct together form an envelope, which
provides an outlet from the combustion area to the vane ring. The large exit duct outer
circumference mates with the sliding joints of the liner inner skin. The exit duct support
flange is bolted to the shroud housing slotted outer flange with the vane ring outer
lugs located in the slots. This assembly is secured by bolts and a vane ring lockplate
along with the large exit duct and No. 2 bearing cover, to a flange on the gas generator
case centerbore.
Cooling air from around the inner combustion liner wall enters the vane ring lugs. Air
then passes through internal passages in each vane to be vented axially from the vane
trailing edge root at the inner ring.
72-30-00 Page 6
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
COMPRESSOR TURBINE
PERFORATIONS
C22139
Combustion Chamber Liner - Component Location
Figure 4
72-30-00 Page 7
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
COMBUSTION CHAMBER
LARGE EXIT DUCT
BAFFLE
COMPRESSOR TURBINE
SHROUD ASSEMBLY
COMPRESSOR TURBINE
VANE RING
C22084
Compressor Turbine Vane Ring and Shroud and Combustion Chamber Exit Ducts - Component
Location
Figure 5
72-30-00 Page 8
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
BLADE
DISK
POWER TURBINE (REF.) BALANCING FLANGE
SPLINE
MOUNTING BOLT
KEYWASHER
INTERSTAGE BAFFLE ASSEMBLY
COMPRESSOR TURBINE
C22121
Compressor Turbine - Component Location
Figure 6
72-30-00 Page 9
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The compressor turbine receives the gas flow from the combustion chamber via the
vane ring assembly and drives the compressor in a clockwise direction. A cooling air flow
is directed across the trailing face of the disk by an interstage baffle assembly
installed between the compressor and power turbines. This baffle also acts as a seal
between the two turbine stages. Cooling air is directed over the leading face of the disk
by the air baffle mounted on No.2 bearing cover (Ref. Fig. 5).
The case consists of two stainless steel sections fabricated into a single structure and
houses the turbine, compressor and combustion sections of the engine. The case extends
between Flange C, where it is secured to the exhaust duct, and Flange F, where it is
secured to the inlet case. The diffuser pipes and straightening vanes are brazed to the
case center section. The outer section of the case contains various bosses and
apertures for fourteen nozzles, two spark igniters, two drain valves and a P3 air bleed
port. The compressor bleed valve is secured by four bolts to a port at the 5 o’clock position
on the case. The case centerbore houses the No.2 bearing components which are
lubricated and scavenged by oil tubes within the case. The No.2 bearing components
comprise two labyrinth air seals and the bearing itself, the outer race of which is bolted to
the centerbore. The single labyrinth air seal is bolted to the centerbore and the double
labyrinth air seal is secured by a retaining ring.
P3 air for the fuel control pneumatic system is bled from an outlet at the 7 o’clock
position on the case. A second boss at the 7 o’clock position opens directly into the
pressurized area of the case and provides P3 air to pressurize internal carbon seals in
the reduction gearbox. Pressurized air for compressor bleed valve operation is taken
through an internal pressure tube from the space behind the diffuser pipes. P3 air for
aircraft use is made available by the air bleed port at the 11 o’clock position on the case.
Pressure oil for No.2 bearing lubrication is taken from an inlet port at the 7 o’clock
position through an internal pressure tube to a passage in the case centerbore and then
to a duplex nozzle assembly at the 10 o’clock position. Scavenge oil is taken through
an internal tube at the 6 o’clock position to an outlet at the 5 o’clock position.
72-30-00 Page 10
COMPRESSOR SECTION - DESCRIPTION AND OPERATION Feb 28/97
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
SCAVENGE OIL TUBE DIFFUSER PIPE STRAIGHTENING VANE FLANGE F SCAVENGE OIL TUBE
C3007C
Gas Generator Case - Component Location
Figure 7
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
Keensert Insert KN1032 (NAS1394C-3)
Locking Tool TD1032L
5. Inspection/Check
Inspection procedures and damage limits applicable to the gas generator case are covered
in engine hot-section inspection procedures as detailed in 72-00-00, INSPECTION/CHECK,
Hot Section Inspection.
72-30-04
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GAS GENERATOR CASE - MAINTENANCE PRACTICES Dec 02/2013
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
6. Approved Repairs
NOTE: Cracks in outer wall of pipes may be reached by drilling access holes in inner
walls using 1/4 (0.250) in. drill (Ref. Detail D). These access holes are
acceptable without repair.
(2) Blend out areas where material has become detached (Ref. Details A and B).
(3) Blend out cracks on edge of fishtail which may join and cause sections to become
detached (Ref. Detail C).
(1) Drill through flared end of shanknut to partially weaken flare. Do not drill through to
flange.
(4) Position shanknut on flange and flare nut end using tool as shown.
NOTE: This repair applies to damaged fuel nozzle pad threaded holes and bleed valve
attaching bolt holes.
(2) Drill out damaged hole using letter I (0.271 inch) or (6.9 mm) drill.
(5) Screw in ‘‘Keensert’’ insert, Part No. KN1032 (NAS1394C-3) using fingers, to depth
of 0.010 to 0.015 inch below surface of parent component.
(6) Using ‘‘Kee’’ driving tool, (TD1032L) and hammer, drive down keys with several
light taps.
72-30-04
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
STOP−DRILL AND SMOOTH OUT HOLE STOP−DRILL AND SMOOTH OUT HOLE
A B
STOP−DRILL, REMOVE METAL AND BLEND OUT HOLE STOP−DRILL THROUGH WINDOW
0.800 ON INNER WALL
MAX.
0.400 MAX.
0.500 MAX.
0.250 MAX.
0.800 MAX.
C D
C348C
Diffuser Pipe Crack Repairs
Figure 201
72-30-04
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GAS GENERATOR CASE - MAINTENANCE PRACTICES Dec 02/2013
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
3
2
NUT AFTER FLARING
2
NUT BEFORE FLARING
C6097
72-30-04
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
Interfast Inc.
21 Constellation Court
Rexdale, Ontario
Canada M9W 1K4
(1) Drill out insert material between keys and internal thread to a maximum depth of
5/32 (0.156) inch, using a 7/32 (0.219) inch drill (Ref. Detail A).
(2) Using small pin punch, bend keys inward and break them off (Ref. Detail B).
(3) Remove insert with a standard ’’E-Z Out‘‘ type tool (Ref. Detail C).
(4) Screw in new ’’Keensert‘‘ insert, Part No. KN1032 (NAS1394C-3), using fingers, to
a depth of 0.010 to 0.015 inch below surface of parent component (Ref. Detail D).
(5) Using ’’Kee‘‘ driving-tool (TD1032L) and hammer, drive down keys with several light
taps (Ref. Detail E).
NOTE: Refer to Subparagraph C. for ’’Keensert‘‘ Insert and ’’Kee‘‘ Driving Tool
suppliers.
(1) Wash salt and smog deposits from gas generator case with clean water. Dry with
clean, dry compressed air.
(1) Clean grease and oil from touch-up areas with methyl-ethyl-ketone.
(3) Sand area(s) to bare metal with 180 grit alumimum-oxide abrasive cloth. Clean with
dry, oil free shop air and wipe with a clean, dry cloth. Do not apply solvent to
sanded surface and do not touch area with bare hands.
(4) Option 1: Apply SermeTel 249 (PWC07-023) and air dry 15-30 minutes or until dry
to touch. Spray, brush or swab the coated surface with SermeTel 273 (PWC07-024)
catalyst. Allow to stand one hour. Wash with water and dry with shop air.
72-30-04
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
_7
32 INCH DRILL
LOCKING KEYS
KEENSERT
0.015
0.010 INCH
DETAIL D
DETAIL E
C11787A
72-30-04
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(5) Option 2: Apply SermeTel 196 (PWC07-034) touch-up coating in two applications
with either spray or brush. Air dry 30-60 minutes between coats. Air dry second
coat 6-8 hours.
(1) Remove fuel manifold adapter assembly as necessary to expose broken bolt (Ref.
73-10-05).
(2) Install drill jig (PWC50064), attach with jig screw, on fuel nozzle pad.
NOTE: DELETED.
(3) Drill pilot hole with center drill using jig guide.
(6) Remove bolt. Examine threads for damage, and repair if necessary.
72-30-04
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
C. Install suitable protective caps/covers over all disconnected tubes/lines and component
openings.
2. Consumable Materials
Not Applicable
3. Special Tools
Not Applicable
Not Applicable
A. General
(1) Blend repair limits are provided to possibly prevent unnecessary engine removal
due to FOD. Should the damage be extensive, an evaluation should be made to
proceed with the repair or remove the engine and send to a facility capable of
performing the repair.
(2) Any blend repair performed should be documented (Ref. 72-00-00, Inspection)
(3) Blend repair limits provide the maximum permissible amount of material that can be
removed from any one blade.
(4) Blending to maximum permissible depth may result in compressor unbalance. If the
amount of material removed exceeds 50% of the recommended limit, the diametrally
opposite blade should be blended to the same dimension.
(5) Unless otherwise noted an unlimited number of blades can be blended to the
specified limits, provided the engine performance remains satisfactory. However
the affected components may have to be replaced at the next overhaul.
(6) Maintain leading edge profile and fillet radius as close as possible to original .
72-30-05
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COMPRESSOR ROTOR - MAINTENANCE PRACTICES Nov 16/2012
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
CAUTION: KEEP THE COMPRESSOR INLET AREA CLEAR OF ALL FOREIGN MATERIAL
AND OBJECTS WHICH COULD BE INGESTED BY THE ENGINE AND
CAUSE SERIOUS DAMAGE DURING OPERATION.
(1) Repair the first-stage blade leading edge within the following limits using fine hand
files and stones.
(3) In case of multiple leading edge defects situated closer than 0.200 in., the entire
leading edge of an unlimited number of blades may be cut back 0.025 in.
maximum (Detail A). If blade has been previously cut back, reduce repair limit by
previous cut back. Maintain the leading edge profile and fillet radius as close as
possible to the original.
NOTE: If cutting back the leading edge by 0.025 in. does not eliminate or make
defects acceptable, the blade cutbacks may be extended to 0.050 in.
maximum, providing engine performance is within limits. This is acceptable
to permit the engine to remain in service; however, the affected
components may have to be replaced at the next overhaul.
(4) Nicks and tears may be smoothed to 0.300 inch wide maximum by 0.165 inch deep
maximum, provided repaired area is 0.220 in. minimum from blade tip (Detail C).
NOTE: 1. If repairing within the above limits does not eliminate the defects or make
them acceptable, individual defects may be smoothed to 0.500 inch wide
maximum and 0.250 inch deep maximum, provided repair area is
0.350 inch minimum from blade tip, and engine performance is within
limits. However, the affected components may have to be replaced at next
overhaul.
NOTE: 2. If any blade is smoothed to the maximum limit, the blade 180 degrees
opposite must be smoothed to the same shape to prevent compressor
rotor imbalance.
(5) Bent or torn leading edge tips may be repaired to 0.375 inch wide maximum by
0.280 inch deep maximum (Detail D).
NOTE: If any blade is smoothed to the maximum limits, the blade 180 degrees
opposite must be smoothed to the same shape to prevent compressor
rotor imbalance.
72-30-05
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MANUAL PART NO. 3040592
(6) Smooth sharp edge at the blade leading edge root eroded area to restore as near
as possible the original radius and smoothness (Detail E). After repair, make sure
the original airfoil chord at the repair area was not reduced by more than 0.250 inch.
(7) Clean entire compressor inlet area thoroughly with a suitable suction cleaner.
Remove masking material and repeat cleaning.
(1) Dents and nicks up to 0.050 in. deep and wide, not less than 0.200 in. apart and
not within 0.250 in. of blade tip, are acceptable (maximum 4 per blade), providing
there are no tears or cracks.
(2) Sharp corners must be smoothed to an approximate radius of 0.050 in. and a
maximum of 0.050 in. deep and wide. Tip corner radius must not exceed 0.100 in.
72-30-05
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MANUAL PART NO. 3040592
0.165 DEEP
MAX
0.050 MAX
CUT BACK AREA
0.220
MIN
0.300
MAX
MAINTAIN LEADING EDGE RADIUS
AVOID SHARP EDGES OR FLAT AREAS
ENLARGED VIEW B
DETAIL C
B
0.280 DEEP
MAX
0.050
MAX
0.375
MAX
DETAIL A DETAIL D
C22550F
72-30-05
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F F
DETAIL E
C61332
Compressor First-stage Repair Limits
Figure 201 (Sheet 2)
72-30-05
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MANUAL PART NO. 3040592
CHAPTER
SECTION PAGE DATE
LEP 1 Nov 16/2012
2 blank Nov 16/2012
TABLE OF CONTENTS
SUBJECT PAGE
5. Removal/Installation 201
A. Removal 201
B. Installation 203
6. Inspection/Check 205
The combustion section of the engine is contained in the front part of the gas generator
case, and consists of the combustion chamber liner and the large and small exit ducts.
Compressor delivery air from the diffuser section discharges into the combustion section. The
air enters the liner through straight and plunged holes, mixes with the fuel from the
manifold, and is ignited. The expanding gases flow to the rear and into the exit duct zone,
where the gas flow is turned 180 degrees inward to flow forward through the compressor
turbine stator to the compressor turbine.
72-40-00
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COMBUSTION SECTION - DESCRIPTION AND OPERATION Nov 16/2012
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MAINTENANCE MANUAL
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The combustion chamber liner is an annular heat-resistant steel liner open at one end and
domed at the other. The domed end of the liner is supported inside the gas generator case by
fourteen fuel nozzle sheaths and located by the two spark igniters in the case which
protrude into the liner at the 4 o’clock and 11 o’clock positions. Rings of plain, plunged and
shielded perforations, located around the inner and outer circumferences and in the domed
area of the liner, allow air to enter to provide optimum fuel/air ratios for starting and
sustained combustion. Cooling rings control airflow within the liner and along with the
perforations, ensure an even temperature distribution at the compressor turbine inlet. Open
end inner and outer circumferences are located by sliding joints in small and large exit
duct respectively.
72-40-01
Page 1
COMBUSTION CHAMBER LINER ASSEMBLY - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
COMPRESSOR TURBINE
PERFORATIONS
C22139
72-40-01
Page 2
COMBUSTION CHAMBER LINER ASSEMBLY - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
A. Removal
(6) Remove vane ring, shroud exit duct support flange (Ref. 72-50-01).
72-40-01
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1 2
C22650
72-40-01
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(7) Withdraw combustion chamber liner (1, Fig. 201) from gas generator case (2).
NOTE: Do not attempt to pry liner loose as damage may result. If difficulty is
experienced, strike inside of liner sharply with palm of hand.
(a) Remove No.2 bearing housing cover flange (1) using puller (PWC32823) or by
using four 190-32 UNF bolts as jacking screws.
(a) Position exit duct in gas generator case and align offset holes in duct flange
and gas generator case centerbore.
(b) Clean the area of No. 2 bearing housing cover flange with abrasive cloth
(PWC05-101) and then clean with isopropyl alcohol (PWC11-014) or as per
SPOP 209.
(c) Apply thin layer of coating (PWC07-023) to area a and let dry 5 to 10 minutes.
(e) Position No. 2 bearing housing cover flange (1) with offset holes in flange and
exit duct aligned.
(2) Insert combustion chamber liner (1) into gas generator case (2).
(3) Carefully rotate liner to align spark igniter locating holes (4) with bosses (3) and
secure using locator (PWC50084).
(4) Install vane ring, shroud and exit duct support flange (Ref. 72-50-01).
72-40-01
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A
3
a
1
SECTION A−A
C22103
72-40-01
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6. Inspection/Check
Inspection procedures and damage limits applicable to the large exit duct and combustion
chamber liner are covered in the engine hot-section inspection procedures (Ref. 72-00-00,
ENGINE - INSPECTION/CHECK).
7. Approved Repairs
(1) Stop-drill both ends of crack using 1/16 in. (0.0625 in.) drill.
(2) Thoroughly wire brush area and swab with ethyl alcohol (PWC11-009).
(3) Weld crack using inert gas fusion method and welding wire (PWC05-180).
NOTE: 2. Stress relief after welding and dressing of weld are not required.
72-40-01
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MANUAL PART NO. 3040592
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
LEP 1 Dec 02/2013 72-50-01 601 Mar 09/2001
2 Dec 02/2013 Inspection 602 blank Mar 09/2001
Check
Contents 1 Dec 02/2013
2 Dec 02/2013 72-50-01 801 Dec 02/2013
3 Dec 02/2013 Approved 802 Dec 02/2013
4 Dec 02/2013 Repairs 803 Dec 02/2013
804 Dec 02/2013
72-50-00 1 Nov 16/2012 805 Dec 02/2013
Description and 2 Nov 16/2012 806 Dec 02/2013
Operation 3 Nov 16/2012 807 Dec 02/2013
4 Nov 16/2012 808 Dec 02/2013
5 Nov 16/2012 809 Dec 02/2013
6 Nov 16/2012 810 blank Dec 02/2013
7 Nov 16/2012
8 Nov 16/2012 72-50-02 201 Nov 16/2012
9 Nov 16/2012 Maintenance 202 Nov 16/2012
10 blank Nov 16/2012 Practices 203 Nov 16/2012
204 Nov 16/2012
72-50-00 201 Dec 02/2013 205 Nov 16/2012
Maintenance 202 Dec 02/2013 206 Nov 16/2012
Practices 203 Dec 02/2013 207 Nov 16/2012
204 Dec 02/2013 208 Nov 16/2012
205 Dec 02/2013 209 Nov 16/2012
206 Dec 02/2013 210 blank Nov 16/2012
207 Dec 02/2013
208 Dec 02/2013 72-50-03 401 Nov 16/2012
209 Dec 02/2013 Removal/ 402 Nov 16/2012
210 Dec 02/2013 Installation 403 Nov 16/2012
211 Dec 02/2013 404 Nov 16/2012
212 Dec 02/2013 405 Nov 16/2012
406 Nov 16/2012
72-50-01 401 Dec 02/2013
Removal/ 402 Dec 02/2013 72-50-03 601 Mar 09/2001
Installation 403 Dec 02/2013 Inspection 602 blank Mar 09/2001
404 Dec 02/2013 Check
405 Dec 02/2013
406 Dec 02/2013 72-50-03 801 Mar 09/2001
407 Dec 02/2013 Approved 802 Mar 09/2001
408 blank Dec 02/2013 Repairs
CHAPTER
SECTION PAGE DATE
72-50-04 201 Dec 02/2013
Maintenance 202 Dec 02/2013
Practices 203 Dec 02/2013
204 Dec 02/2013
205 Dec 02/2013
206 Dec 02/2013
207 Dec 02/2013
208 Dec 02/2013
209 Dec 02/2013
210 blank Dec 02/2013
TABLE OF CONTENTS
SUBJECT PAGE
1. General 1
2. Component Description 1
A. Compressor Turbine Vane Ring and Shroud and Combustion
Chamber Exit Ducts 1
B. Compressor Turbine 4
G. Exhaust Duct 8
1. General 201
2. Consumable Materials 201
5. Removal/Installation 201
A. Removal 201
B. Installation 207
COMPRESSOR TURBINE VANE RING - REMOVAL/INSTALLATION 72-50-01
1. General 401
A. Preparation 401
TABLE OF CONTENTS
SUBJECT PAGE
B. Removal 401
C. Installation 404
1. General 601
COMPRESSOR TURBINE VANE RING - APPROVED REPAIRS 72-50-01
1. General 801
B. Procedure 802
A. General 802
B. Preparation 802
C. Calculation of Grinding Requirements 806
1. General 201
2. Consumable Materials 201
5. Removal/Installation 201
TABLE OF CONTENTS
SUBJECT PAGE
A. Removal 201
B. Installation 205
6. Inspection/Check 207
1. General 401
2. Consumable Materials 401
5. Procedure 401
A. General 401
B. Removal 405
C. Installation 405
1. General 601
1. General 801
2. Consumable Materials 801
5. Procedure 801
TABLE OF CONTENTS
SUBJECT PAGE
5. Removal/Installation 201
A. Removal 201
B. Installation 203
6. Inspection/Check 203
1. General
There are two turbines incorporated in the engine, a compressor turbine in the gas generator
section coupled to the compressor rotor and a ‘‘free’’ power turbine in the power turbine
and exhaust section mounted on the power turbine shaft driving the reduction gearbox. The
term ‘‘free’’ is used to indicate that the power turbine is not mechanically linked to the
compressor turbine.
The power turbine and exhaust section (Ref. Fig. 1) is located between the gas generator
and reduction gearbox sections of the engine. The section contains the power turbine stator
assembly, the power turbine, the power turbine shaft and shaft housing, No.3 and 4
bearing housing support and the exhaust duct.
The compressor turbine is driven by the gas flow from the combustion section being
deflected onto the turbine blades by a stator assembly. The compressor turbine comprises a
bladed disk assembly running in a shroud housing assembly.
The power turbine is rotated by the remaining energy in the gas flow from the compressor
turbine being deflected on to the power turbine disk by the stator assembly.
2. Component Description
A. Compressor Turbine Vane Ring and Shroud and Combustion Chamber Exit Ducts (Ref.
Fig. 2)
The vane ring comprises 14 integrally cast, cooled vanes between inner and outer
securing rings. The ring is secured between the combustion chamber large exit duct and
the flange of No.2 bearing cover at the gas generator case centerbore. Lugs on the
outer ring mate with slots in the shroud housing and lugs on the inner ring mate with slots
in No.2 bearing cover flange.
The combustion chamber liner and large exit duct together form an envelope, which
provides an outlet from the combustion area to the vane ring. The large exit duct outer
circumference mates with the sliding joints of the liner inner skin. The exit duct support
flange is bolted to the shroud housing slotted outer flange with the vane ring outer
lugs located in the slots. This assembly is secured by bolts and a vane ring lockplate
along with the large exit duct and No. 2 bearing cover, to a flange on the gas generator
case centerbore.
Cooling air from around the inner combustion liner wall enters the vane ring lugs. Air
then passes through internal passages in each vane to be vented axially from the vane
trailing edge root at the inner ring.
72-50-00
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Page 1
TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
EXHAUST DUCT
POWER TURBINE
SHAFT HOUSING
THERMOCOUPLE
PROBE
MAIN INPUT DRIVE
COUPLING SHAFT
POWER TURBINE
NO.3 BEARING STATOR ASSEMBLY
NO.4 BEARING
POWER TURBINE DISK
POWER TURBINE
POWER TURBINE BLADES
SHAFT
REAR FIRESEAL
C9330
Power Turbine and Exhaust Section - Major Components, Bearings and Flanges (Typical)
Figure 1
72-50-00
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Page 2
TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
COMBUSTION CHAMBER
LARGE EXIT DUCT
BAFFLE
COMPRESSOR TURBINE
SHROUD ASSEMBLY
COMPRESSOR TURBINE
VANE RING
C22084
C/T Vane Ring and Shroud and Combustion Chamber Exit Ducts - Component Location
Figure 2
72-50-00
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Page 3
TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The compressor turbine receives the gas flow from the combustion chamber via the
vane ring assembly and drives the compressor in a clockwise direction. A cooling air flow
is directed across the trailing face of the disk by an interstage baffle assembly
installed between the compressor and power turbines. This baffle also acts as a seal
between the two turbine stages. Cooling air is directed over the leading face of the disk
by the air baffle mounted on No.2 bearing cover (Ref. Fig. 2).
The power turbine stator assembly comprises a stator housing, a stator and a shroud.
The assembly is bolted at Flange D to the exhaust duct. The stator housing is a flanged
cylinder containing the vane ring and interstage baffle assembly which make up the
power turbine stator. The PT6T-3DF stator housing is reinforced in line with the power
turbine and is attached through the exhaust duct flange by shorter bolts into blind holes in
the stator housing. The housing incorporates threaded bosses which receive the
inter-turbine temperature (T5) sensing probes and clips for attachment of the associated
wiring harness. The vane ring which comprises inner and outer rings and integrally
cast vanes is located by a flange on its outer ring which is retained between the power
turbine shroud and the stator housing. The interstage baffle assembly, a riveted
assembly of baffle and sealing plate, is located within the vane inner ring and secured
against rotation by lugs. Slots are incorporated in the vane outer ring to provide clearance
for the T5 probes. The double knife edge shroud operates in conjunction with the
power turbine notched blades to optimize turbine efficiency. The gas flow from the
compressor turbine passes through the vane ring and is directed by the vanes, onto the
power turbine blades, at the optimum angle for turbine drive. The interstage baffle
assembly directs cooling air up the leading face of the power turbine disk.
The power turbine disk assembly comprises a disk, blades and classified weights. The
disk incorporates an externally splined stubshaft which extends forwards to mate with the
internal splines in the power turbine shaft. The disk is secured to the shaft by a
stubshaft bolt and a keywasher. A master spline on the stubshaft ensures that the disk is
always installed in the same position on the power turbine shaft, thus maintaining
original balance. The disk includes a circumferential groove to enable growth to be
checked and a single flange on its leading face for the addition of classified weights and
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Page 4
TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
BLADE
DISK
POWER TURBINE (REF.) BALANCING FLANGE
SPLINE
MOUNTING BOLT
KEYWASHER
INTERSTAGE BAFFLE ASSEMBLY
COMPRESSOR TURBINE
C22121
Compressor Turbine - Component Location
Figure 3
72-50-00
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Page 5
TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
STATOR HOUSING
EXHAUST DUCT
SHROUD T5 PROBE
POWER TURBINE
COMPRESSOR TURBINE
INTERSTAGE BAFFLE ASSEMBLY
PT6T−3DF
ONLY
C22130A
72-50-00
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Page 6
TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
COUPLING
NO.4 BEARING
POWER TURBINE DISK
POWER TURBINE
POWER TURBINE SHAFT STATOR ASSEMBLY
POWER TURBINE BLADES
SCAVENGE
FLANGE B OIL TUBE
SHROUD
C9332
Power Turbine, Shaft and Shaft Housing - Component Location (Typical)
Figure 5
72-50-00
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TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
balance rivets. The outer rim of the disk incorporates machined fir-tree serrations in
which the blades are mounted. Power turbine blades differ from compressor turbine blades
in that they are cast with notched and shrouded tips. The blades are secured in the
fir-tree serrations by individual tubular rivets.
The assembly comprises a shaft housing containing No.3 and 4 bearing components, a
stator air seal, the power turbine shaft and pressure and scavenge oil tubes associated
with lubrication of the bearings.
The shaft housing is a fabricated steel cylinder which is secured at Flange B to studs on
the No.3 and 4 bearing housing support. No.3 roller bearing and No.4 ball bearing
assemblies, which are bolted to the housing, support the power turbine shaft. The shaft
is internally splined at the No.3 bearing journal end for attachment of the turbine disk
assembly and externally splined at the other end to mate with a coupling which connects
the shaft to the main input drive coupling shaft.
No.3 bearing is positioned between a shoulder on the shaft and a rotor air seal. No.4
bearing includes a split inner race and is secured between a shoulder on the shaft and the
coupling by a cup washer and a spanner nut. The No.3 bearing cover is an integral
part of the exhaust duct.
The housing support is a conical casting which is secured by studs at Flange A, to the
reduction gearbox and at Flange B to the power turbine shaft housing. Passages in the
housing support carry pressure oil from the reduction gearbox output housing at the
11 o’clock position, for lubrication of No.3 and 4 bearings. Various bores within the support
contain oil transfer tubes, a check valve and a jet pump. The jet pump, which scavenges
No.3 and 4 bearing oil, is only efficient at oil system normal operating pressures.
For this reason the check valve is included in the system to prevent flooding of No.3
and 4 bearing compartments during run-up and run-down. During normal operation the
check valve is fully open and the oil is withdrawn from the bearing area by the jet pump
and sprayed into a sump area formed by the lower portions of the housing support
and reduction gearbox housing.
The exhaust duct, which is located between the gas generator section of the power
section and the reduction gearbox, is a divergent heat-resistant steel duct, incorporating
a single outlet port. The duct is secured at Flange A to the reduction gearbox, Flange
C to the gas generator case and Flange D to the power turbine stator assembly. The power
turbine shaft and shaft housing assembly and No.3 and 4 bearing housing support are
housed within the exhaust duct. An insulation blanket is interposed between these
components and the duct to reduce heat transmission from the exhaust gases.
A drain hole at the 6 o’clock position, allows fuel accumulated during engine shutdown,
to drain into the gas generator case and out through the drain valves. The duct
receives the gas flow from the power turbine, and directs it to the airframe exhaust via
the outlet port.
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TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
OUTLET PORT
FLANGE D
FLANGE A
FLANGE C
C3011A
Exhaust Duct
Figure 6
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Page 9/10
TURBINE SECTION - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
5. Removal/Installation
A. Removal
NOTE: Discard all removed preformed packings, packing retainers and plastic
rings.
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Page 201
TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(2) Remove external oil and air tubes (Ref. Fig. 201).
(a) Remove nut and bolt securing clamp (1) to bracket on Flange C, disconnect
coupling nuts of Pg tube (2) at rear and center fireseals and remove tube.
(b) Remove nuts and bolts securing brackets (6) to positioning plate (7).
(c) Remove nuts and bolts securing clamps on oil tubes (5) to brackets (6) and
rotate parts around tubes to clear positioning plate (7).
(d) Remove nuts and bolts securing retaining plate (8) to rear fireseal and remove
plate and plastic rings (9).
(e) Withdraw oil tubes (5) from center and rear fireseals and remove preformed
packings (3) and packing retainers (4).
(f) Disconnect jumper leads (11 and 12) from T5 terminal block.
NOTE: Jumper leads can remain connected to and be removed with bracket
(13) (Ref. step (3) (c) following).
(g) Remove nuts and bolts securing clamps (23 and 24) to ignition harness (10)
and Flange C respectively, loosen coupling nuts of P3 pressure tube (14) at
gas generator case elbow connection and rear fireseal and remove tube.
(h) Remove nuts and bolts securing retaining plate (19), split insulation plates (17)
and seal plate (18) to rear fireseal. Retain parts as set.
(i) Remove nut and bolt securing clamp (21) to bracket on Flange C.
(j) Remove bolts securing tube stop (25) to tee assembly. Ease tube assembly
(20) out of tee assembly and withdraw from rear fireseal. Remove retainers
(16 and 26), and preformed packings (15 and 22) from tube assembly (20).
(l) Place all loose parts in suitable containers and retain with engine.
(3) Remove power turbine and exhaust section (Ref. Fig. 202).
(a) Remove bolts (1) securing terminal block (2) and shield (6) to gas generator
case and push terminal block through case.
(c) Support weight of assembly and remove nuts (4) and bolts (5) from Flange C.
Remove brackets as bolts are withdrawn from flanges.
(d) Carefully withdraw assembly from gas generator case ensuring that terminal
block (2) is clear. Remove gasket (3) from terminal block and discard.
(e) Post-SB5341 and PT6T-3DF Engines: Remove and discard sealing ring (7).
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TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
2 1
4
5
7
9 6
8
C22104
Power Turbine and Exhaust Section - Removal/Installation of Air and Oil Tubes
Figure 201 (Sheet 1 of 2)
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TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Clamp
2. Pg Tube
3. Preformed Packing
4. Packing Retainer
5. Oil Tube
6. Bracket
7. Positioning Plate
8. Retaining Plate
9. Plastic Ring
10. Ignition Harness
11. Jumper Lead
12. Jumper Lead
13. Bracket Terminal Support
14. P3 Pressure Tube
15. Preformed Packing
16. Packing Retainer
17. Split Insulation Plate
18. Split Seal Plate
19. Retaining Plate
20. Tube Assembly
21. Clamp
22. Preformed Packing
23. Clamp
24. Clamp
25. Tube Stop
26. Packing Retainer
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TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
10
11
12
13
24
FLANGE C
23
17
15
14
18
19
16
20
21
22
26
25
C22138
Power Turbine and Exhaust Section - Removal/Installation of Air and Oil Tubes
Figure 201 (Sheet 2)
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TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
A
FLANGE C
6
B
❉
1
2
3 4
8
3
1 9
SECTION AT A
WITH FLANGE C MATED
POST−SB5341 AND PT6T−3DF ONLY
10
2
(POST−SB5377) DETAIL B
C28658A
Power Turbine and Exhaust Section - Removal from Gas Generator Case
Figure 202
72-50-00
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TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Bolt
2. Terminal Block
3. Gasket
4. Nut
5. Bolt
6. Thermocouple Shield
7. Sealing Ring (Post-SB5341 and PT6T-3DF only)
8. Nut (Chromel Terminal) (Post-SB5377)
9. Nut (Alumel Terminal) (Post-SB5377)
10. Shield (Post-SB5377)
(b) Position mount ring (PWC30269) on Flange C of exhaust duct and secure with
bolts (9) and nuts (10).
(c) Position assembly in stand and align holes in mount ring (8) with holes in
adapters (13).
(d) Secure assembly to adapters with bolts (7) and washers (6).
B. Installation
(a) Attach sling (PWC30801) or (PWC70102) to exhaust port flange with bolts (3),
nuts (1) and washers (2).
(c) Remove bolts (7) and washers (6) and remove assembly from stand.
(d) Remove nuts (10) and bolts (9) and remove mount ring (8) from Flange C.
(a) Clean mating surface of flange C on gas generator case with abrasive cloth
(PWC05-101) and then clean with isopropoyl alcohol (PWC11-014) or as per
SPOP 209.
(b) Apply thin layer of coating (PWC07-023) to mating surface and let dry 5 to 10
minutes.
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
5 6 7
4
3
1
2 8
9
13
10
15 POST−SB5364
11
13 12
14
2
1
C6017B
Power Turbine and Exhaust Section - Installation and Removal from Stand
Figure 203
72-50-00
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Page 208
TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Nut
2. Washer
3. Bolt
4. Sling
5. Hoist
6. Washer
7. Bolt
8. Mount Ring
9. Bolt
10. Nut
11. Flange C
12. Stand
13. Adapter
14. Shipping Cover
15. Sealing Ring (Post-SB5341)
(c) Apply second layer of coating (PWC07-023) to mating surface to obtain 0.002
to 0.003 thickness. Let dry 5 to 10 minutes.
NOTE: Assembly of power turbine and exhaust section to gas generator must
be completed within 15 minutes of final application of coating.
(a) Clean mating surface of Flange C on gas generator case with abrasive cloth
(PWC05-101) and wipe clean with solvent (PWC11-027).
NOTE: When necessary, remove old sealant by carefully scraping off all
sealing surfaces with a scraper before applying new sealant.
(b) Apply a thin even layer of coating (PWC09-005A) to mating surface. Remove
any excess sealant and ensure flange holes and inside flange are clean and
free of solvent.
(4) Post-SB5341: Apply adhesive (PWC08-014) at four equally spaced locations on the
new sealing ring (15).
(5) Post-SB5341: Install new sealing ring (15) on the exhaust duct at Flange C (11)
with the adhesive facing the groove in the exhaust duct.
(6) Install assembly into gas generator case (Ref. Fig. 202).
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(a) Carefully insert assembly into gas generator case, ensuring that terminal block
(2) is clear and enters freely until mating flanges are approximately six inches
apart.
(b) Install new gasket (3) on terminal block (2), insert terminal block into mounting
boss of gas generator case. Install shield (6) over terminal block.
(c) Secure terminal block with bolts (1). Torque 32 to 36 lb.in. and lockwire.
(d) Proceed with installation of assembly into gas generator case until respective
flanges are mated and ensure that bolt holes are aligned.
(e) Temporarily secure with four bolts (5) and nuts (4).
(f) Position brackets at locations shown on Figure 204 and secure components at
Flange C with bolts (5, Fig. 202) and nuts (4). Torque nuts (4) 44 to 48 lb.in.
(7) Install external oil and air tubes (Ref. Fig. 201).
(b) Install new preformed packing (22) and packing retainer (26) on flanged end of
pressure oil tube (20), followed by preformed packing (15) and packing retainer
(16), on opposite end of oil tube (20).
(c) Slide retaining plate (19), followed by seal plate (18), over pressure oil tube
(20). Insert end of tube through aperture in rear fireseal and opposite end
into transfer tee at center fireseal.
(d) Position stop (25) at flanged end of pressure oil tube (20) and secure to
transfer tee with bolts. Torque bolts 32 to 36 lb.in. and lockwire.
(e) Align clamp (21) of pressure oil tube (20) or (28) with bracket on Flange C and
secure with bolt and nut. Torque nut 36 to 40 lb.in.
(f) Insert split insulation plates (17) on each side of seal plate (18), align parts with
bolts holes in rear fireseal and secure with bolts and nuts. Tighten nut until firm
contact, plus 180 degrees.
(g) Install P3 pressure tube (14) between elbow on gas generator case and
reducer at rear fireseal. Align clamp (24) on tube with bracket on Flange C and
secure with bolt and nut. Torque nut 36 to 40 lb.in.
(h) Torque tube (14) coupling nuts 90 to 100 lb.in. and lockwire.
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TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
NOTES:
1. BRACKET LOCATIONS IDENTICAL FOR BOTH POWER
SECTIONS EXCEPT WHERE SPECIFIED
2. BOLT HOLES ARE COUNTED CLOCK−WISE FROM FIRST HOLE
TO RIGHT OF ENGINE CENTERLINE WHEN VIEWED IN
DIRECTION OF ARROW A
FLANGE C
60 1
55
T5 HARNESS
53
52
50
FLANGE C
45 16
Pg PRESSURE TUBE
P3 TUBE
36 25
33
SURGE
ACCUMULATOR
C22129
Bracket Locations at Flange C
Figure 204
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(i) Secure clamp (23) to tube (14) with bolt and nut and torque 36 to 40 lb.in.
(j) Connect jumper leads (11 and 12) to T5 terminal block on gas generator case.
Torque smaller nut 8 to 12 lb.in. and larger nut 10 to 15 lb.in.
(l) Install clamps (23) on P3 pressure tube (14) and harness (10) and secure with
bolts and nuts. Torque nuts 36 to 40 lb.in.
(m) Loosely assemble plastic rings (9) and retaining plate (8) on rear fireseal with
bolts and nuts.
(n) Assemble packing retainers (4) and preformed packings (3) on oil tubes (5).
Insert ends of oil tubes into retaining plate and plastic rings at rear fireseal
and into coupling at center fireseal.
(o) Rotate brackets (6) and associated clamps on oil tubes (5) to align with
positioning plate (7). Secure brackets to plate with bolts and nuts. Torque nuts
36 to 40 lb.in.
(p) Install Pg tube (2) between couplings at center and rear fireseals and align
clamp (1) on Pg tube with bracket on Flange C. Secure clamp to bracket
with bolt and nut. Torque 36 to 40 lb. in. Torque tube coupling nuts 90 to 100 lb.
in., and lockwire.
72-50-00
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Page 212
TURBINE SECTION - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
NOTE: Contents of 72-50-01 (T5 Temperature Sensing System) can be found in 77-20-01.
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
5. Procedure
A. Preparation
72-50-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
8
7
VIEW ON B 4 10
3
2
1
3
❉
6 A POST−SB5314
16 5 INSTALLATION
❉
9
10
11 UNLOADED SIDE OF LUGS
12
13 LOADED SIDE OF LUGS
14 8
15 19 10
14
17
DETAIL C C
POST−SB5314 ❉ INDEX MARKS: REFER TO 18
PRE−SB5321
TEXT FOR DETAILS
VIEW ON ARROW A
C22088B
72-50-01
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MANUAL PART NO. 3040592
1. Bolt
2. Keywasher
3. Baffle
4. No.2 Bearing Housing Cover
5. Bolt
6. Keywasher
7. Vane ring Lockplate
8. Vane Ring, Shroud and Exit Duct Assembly
9. Exit Duct Support Flange
10. Vane Ring
11. Shroud Segments
12. Shroud Housing Slots
13. Plug Bolt
14. Shroud Housing
15. Interstage Sealing Ring
16. Bolt
17. Vane Ring Outer Lugs
18. No. 2 Bearing Cover Flange
19. Vane Ring Inner Lugs
(3) Remove No. 2 bearing housing cover (4) with puller (PWC71559).
(4) Unlock keywashers (6) and remove bolts (5) from vane ring lockplate (7).
(7) Separate vane ring, shroud and exit duct support flange as follows:
NOTE: Prior to disassembly, ensure that parts are index marked as illustrated. If
necessary, make temporary marks with an approved marker and
vibropeen after disassembly.
(b) Separate shroud housing from exit duct support flange by using bolts (16)
through plug bolt holes.
72-50-01
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MANUAL PART NO. 3040592
(a) Place shroud housing, flange side down, on a workbench and carefully drift
out shroud segments (11).
(b) Remove all traces of locking compound (if present) from segment grooves in
shroud housing using a plastic scraper and/or fine emery cloth.
NOTE: Shroud segments are obtainable in classified sets. These segments are
designed to provide a shroud I.D. compatible with the O.D. of the
compressor turbine disk assembly being used. After installation, localized
grinding may be necessary to remove high spots and/or any slight
eccentricity of shroud to obtain required blade-to-shroud clearance. For
details of shroud segment classes, grinding procedures and applicable
blade-to-shroud clearance (Ref. 72-50-01, COMPRESSOR TURBINE
VANE RING - APPROVED REPAIRS).
(b) Install segments (12) in grooves in shroud housing (15) and position so that
inter-segment gaps are located 0.250 in. minimum from center of any
adjacent cooling hole (Ref. View on B).
(2) Assemble vane ring, shroud and exit duct support flange.
NOTE: To avoid the possibility of air leakage during engine operation, the mating
faces of shroud, vane ring, exit duct and vane ring lockplate must be
lapped as detailed in 72-50-01, COMPRESSOR TURBINE VANE RING -
APPROVED REPAIRS.
(a) Place shroud housing (14), slotted flange uppermost, on a workbench and
install compressor turbine vane ring (10) in shroud housing (14), aligning
index marks.
72-50-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(b) Position vane ring (10) so that loaded side (Ref. NOTE following) of outer lugs
(17) are touching one side of shroud housing slots.
NOTE: The term ‘‘loaded side’’ is used to define which side of vane ring lugs
are in contact with wall of mating slots. Compressor air flowing
through the vane ring tends to turn or ‘‘load’’ vane ring in a clockwise
direction until restricted by wall of mating slots.
(c) Check clearance at both loaded and unloaded side of all 14 lugs using feeler
gages. Clearance of each lug at loaded side should be 0.000 to 0.002 inch
and at unloaded side 0.001 to 0.007 inch. Rotational motion (play) at outer lugs
should not exceed 0.004 inch.
(d) If lug-to-slot fit is not within limits, rotate vane ring (10) into another position
and repeat steps (b) and (c) until suitable fit is obtained.
(e) It is permissible to remove part and stone lugs and/or slots to obtain required
fit. After stoning, width of outer lugs must be 0.395 inch minimum and width of
housing slots must be 0.402 inch maximum.
NOTE: If lug-to-slot limits are exceeded (Ref. steps (c) and (e)), ship parts to
an approved overhaul facility for rework.
(f) Remove previous index markings from repositioned part and index mark in
correct position using an approved temporary marker (PWC05-018) or
(PWC05-018A).
(h) Place compressor turbine vane ring (10), inner lugs uppermost, on a workbench
and install No. 2 bearing cover flange (18) on vane ring (10), aligning index
marks.
(i) Position No. 2 bearing cover flange (18) so that loaded sides (Ref. NOTE, step
(b)) of vane ring inner lugs (19) are touching side of No. 2 bearing cover flange
slots.
(j) Check clearance at both loaded and unloaded side of all 8 lugs using feeler
gages. Clearance of each lug at loaded side should be 0.000 to 0.002 inch
and at unloaded side 0.001 to 0.005 inch. No rotational motion (play) is permitted.
(k) Post-SB5314: If lug-to-slot fit is not within limits, rotate No. 2 bearing cover flange
(18) into another position and repeat steps (i) and (j) until suitable fit is
obtained.
NOTE: Pre-SB5314 and Post-SB5321 No. 2 bearing cover flanges are not
indexable.
72-50-01
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(l) It is permissible to remove part and stone lugs and/or slots to obtain required
fit. After stoning, width of inner lugs must be 0.249 inch minimum and width of
flange slots must be 0.255 inch maximum.
NOTE: If lug-to-slot limits are exceeded (Ref. steps (j) and (l)), ship parts to
an approved overhaul facility for rework.
(m) Remove previous index marking from repositioned part and index-mark in
correct position using an approved temporary marker (PWC05-018) or
(PWC05-018A).
(n) Remove No. 2 bearing cover flange (18) from vane ring (10).
(o) Align index marks and position vane ring (10) in shroud housing (14).
(p) Align index marks and install assembly into exit duct support flange (9).
(q) Install 28 bolts (16), torque 15 to 20 lb. in. and lockwire (PWC05-089) in pairs.
(r) Install four plug bolts (13), torque 32 to 36 lb.in. and lockwire (PWC05-089)
to adjacent bolts (16).
NOTE: Bolts (13 and 16) are silver plated and do not require lubrication.
(5) Position vane ring lockplate (7) on vane ring inner lugs with chamfer on lockplate
inner diameter towards lugs.
(6) Position assembly (8) and lockplate in gas generator case, aligning vane ring inner
lugs with slots in No. 2 bearing housing cover flange, as index marked (Pre-SB5314
and Post-SB5321), and offset holes in lockplate and flange.
(7) Install bolts (5) with new keywashers (6). Torque 32 to 36 lb.in. (Pre-SB5358) or 24
to 36 lb. in. (Post-SB5358) and lock keywashers.
(8) Position No. 2 bearing housing cover (4) on flange in centerbore and press fully
home over flange lip.
(9) Position baffle (3) on cover and install bolts (1) with new keywashers (2).
(10) Post-SB5314: Centralize baffle (3) in vane ring (10) to maintain a radial gap of
0.005 to 0.011 inch.
(11) Torque bolts (1) 44 to 48 lb.in., slacken to zero, retorque 32 to 36 lb.in. and lock
keywashers.
72-50-01
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Page 406
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
D. Reassembly of Engine
72-50-01
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Page 407/408
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
As the compressor turbine vane ring and shroud and the combustion exit ducts are
inspected during the performance of an engine hot-section inspection, all inspection
information and data pertaining to these components are detailed in 72-00-00,
INSPECTION/CHECK, Hot Section Inspection.
NOTE: Contents of 72-50-01 (T5 Temperature Sensing System) can be found in 77-20-01.
1. General
NOTE: Contents of 72-50-01 (T5 Temperature Sensing System) can be found in 77-20-01.
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
The special tools listed below are used in the following procedures.
Not Applicable
A. General
To avoid the possibility of air leakage during engine operation, prior to assembly, mating
faces of vane ring, shroud housing, exit duct support flange and vane ring lockplate
must be lapped to obtain the required surface contact.
72-50-01
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
NOTE: Prior to lapping compressor turbine vane ring, check for interference when
installing lockplate. If necessary, grind off weld bead high spots on any two
opposing lugs and if interference is still present, remove one air exit lug by
grinding flush with inner ring using suitable tooling.
(1) Lap faces A through E using suitable lapping tools and lapping compound
(PWC05-145) to obtain the required surface contact.
(2) Thoroughly clean all parts to remove all traces of lapping compound as follows:
(c) Allow solvent to drain from part and blow off residue with compressed air.
A. General
(1) Using an 8 to 9 in. micrometer, measure the O.D. of compressor turbine disk
assembly.
(2) From Table 801 following, select shroud segment class required and install as
detailed in Page Block 401.
72-50-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
0.001L − 0.003T
COMPRESSOR
TURBINE VANE 3
LUG THICKNESS RING
GAGE POINT
9.370 DIA. REF. 9.370 DIA.
MAXIMUM
2
FACE C LAP TO
OBTAIN 100%
AIR EXIT LUG CONTACT SECTIONAL VIEW OF LAPPED ASSEMBLY
6.480 DIA.
MINIMUM
0.101 MINIMUM
AFTER LAPPING EXIT DUCT
SUPPORT
FLANGE
FACE D LAP TO OBTAIN
90 − 100% CONTACT
COMPRESSOR TURBINE
SHROUD HOUSING 0.190 MAXIMUM
AFTER LAPPING
0.156 MINIMUM
AFTER LAPPING
FACE E LAP TO
OBTAIN 100%
CONTACT
COMPRESSOR TURBINE
VANE RING LOCKPLATE
C22097A
Compressor Turbine Vane Ring, Shroud Housing and Exit Duct Support Flange - Lapping
Requirements
Figure 801
72-50-01
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Page 803
COMPRESSOR TURBINE VANE RING - APPROVED REPAIRS Dec 02/2013
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
8
1
10
C41426
72-50-01
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Page 804
COMPRESSOR TURBINE VANE RING - APPROVED REPAIRS Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Hand Crank
2. Tip
3. Contact Point
4. Shroud Segment
5. Bolt
6. Adapter
7. Bolt
8. Gage
9. Gage Body
10. Dial Indicator
(3) Install adapter (PWC32209) on compressor stubshaft and secure with bolt (5).
(4) Use radius gage (PWC32380) or (PWC71568) position gage body (9) on master
(8). Rotate hand crank (1) clockwise to ensure dial indicator (10) is at lowest
position.
(6) Ensuring that dial setting is not disturbed, remove indicator from master and install
on adapter (6) with indicator plunger on inner diameter of shroud segments (4).
(7) Secure gage body to adapter with bolts (7). Torque bolt 20 to 30 lb.in.
(8) By rotating gage body and adapter on compressor stubshaft, obtain and record the
average dial indicator reading from all shroud segments. Note whether indicator
reading is on plus or minus side of gage zero as shown in examples given in Para.
C. following.
72-50-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The data obtained in Paragraph B. preceding are identified and defined as follows and
grinding requirements calculated in the example using the following definitions:
In this example, 0.016 in. must be ground from shroud segments to provide a blade tip
clearance of 0.019 in.
(1) Install flexible blanking material (3 and 10) around exit duct and vane ring and
blank vane ring by fitting a cardboard disk of suitable diameter over adapter
(PWC32209) on compressor stubshaft.
(a) Install grinding wheel (PWC34128) on grinder (7) and install grinder on adapter.
Secure with bolts and torque 20 to 30 lb.in. Check 0.001 in. shim stock will not
fit between grinder and adapter to ensure correct mounting.
(b) Position wheel (1) in line with and slightly overlapping segments, using
handcrank (6). Allow wheel to touch vane ring. Back off handcrank (6) one turn
and lock using screw (8).
(c) Rotate grinder around segments adjusting radial adjuster (9) until wheel (1)
contacts high spots. Back off adjuster one turn.
(d) Connect grinder air line (4) to shop air of 90 psig with flow rate of 36 SCFM.
NOTE: Where pronounced high spots exist, rotate shroud grinder, back and
forth, through an arc of 40 to 50 degrees to reduce high spots before
carrying out normal 360 degree grinding.
72-50-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(e) Operate grinder. Adjust wheel (1) with radial adjuster (9) until wheel contacts,
and grind upper segments ID to required dimension.
NOTE: When grinding upper segments do not load grinder to compensate for
any compressor rotor bearing play. Support grinder when grinding
lower segments to prevent taper grinding.
(f) Back off radial adjuster until grinding wheel contacts high spots on lower
segments and continue grinding using complete revolutions until required
dimensions are met.
(g) Disconnect air hose (4) and remove grinder from adapter.
(h) Install radius gage and recheck shroud segment diameter (Ref. Para. B.,
preceding). Check segment taper by running contact point across width of
segments.
(j) Using suitable suction cleaner, remove all grinding residue from gas generator
case.
(m) If grinding has produced a lip with sharp edge on inner edge of segment, or is
proud of the ground surface by more than 0.005 in., remove by local grinding
with hand held rotary tool, grinding wheel attachment and flexible drive, or similar
equipment.
72-50-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
3
1
13
12
11
4
6 5
9 8 7
10
C22989
72-50-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Grinding Wheel
2. Bolt (Shroud Housing)
3. Blanking Material (Exit Duct)
4. Air Hose
5. Gas Generator Case
6. Handcrank
7. Grinder
8. Axial Adjuster Lockscrew
9. Radial Adjuster
10. Blanking Material (Stator Assembly)
11. Blanking Disk
12. Bolt
13. Diamond Wheel Dresser
72-50-01
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
NOTE: Contents of 72-50-02 (Power Turbine Stator Assembly) can be found in 72-50-03.
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
5. Removal/Installation
A. Removal
72-50-02
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COMPRESSOR TURBINE DISK ASSEMBLY - MAINTENANCE PRACTICES Nov 16/2012
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
2 4 3
5
C22143
72-50-02
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MANUAL PART NO. 3040592
1 Wrench
2. Flange C
3. Protector Sleeve
4. Spreader
5. Keywasher
6. Turbine Stubshaft Bolt
(a) Install wrench (PWC30331) in gas generator case so that pins in arm
extensions locate in two bolt holes in flange C (2). Ensure that wrench is fully
engaged with compressor turbine disk.
(b) Insert protector sleeve (PWC30336) and spreader (PWC30335) into disk center
bore and screw spreader center bolt into internal thread in head of stubshaft
bolt (6) until keywasher (5) is unlocked. Remove spreader.
4 Set drill at slow speed and drill through bolt until drill stop contacts bolt
head. Use cutting oil, and remove debris at regular intervals.
6 Fill oil injector (PWC50060): turn knob cw until plunger bottoms. Place
injector tip in penetrating oil (50 % kerosene, 50 % engine oil is suitable),
and turn knob ccw to draw in oil.
7 Install injector in CT bolt. Make sure packing seals between injector and
bolt head.
10 If bolt does not move, repeat steps 6 through 9 until bolt is removed.
(d) Remove stubshaft bolt (6) and keywasher (5) using conventional socket and
wrench. If difficulty is encountered during removal of stubshaft bolt, proceed
as follows:
72-50-02
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4.270
DRILL STOP
DRILL BIT
C T BOLT
BUSHING
OIL INJECTOR
PREFORMED PACKING
C T BOLT
C25663
Removal of CT Bolt
Figure 202
72-50-02
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2 Using oil injector, inject liberal quantity of approved penetrating oil (50%
fuel PWC01-001, 50% engine oil PWC03-001) through center hole in
bolt to flood cavity in stubshaft. Rotate turbine several times to allow oil to
transfer along slots in bolt threads. Allow to stand for 20 minutes.
Remove oil injector.
4 If bolt still does not loosen, apply sufficient torque to just move bolt, do not
exceed 150 lb.ft. Reverse the torque and work back and forth until bolt is
free and can be unscrewed normally.
(a) Insert puller (PWC30403) in disk center bore and engage lugs (2) with slots (3)
(Ref. View A).
(b) Ease body (4) downwards until lug (2) is below slot (3) (Ref.View B).
(c) Rotate body and lug to contact underside of disk (Ref. View C).
(d) Position lock (5) in disk slot and turn nut (6) until turbine disk snap fit is broken
(evidenced by freedom of puller operation).
(2) Align master splines and press turbine disk (1) onto stubshaft.
(3) Ensure that new keywasher (3) is dry and free from burrs.
(4) Apply light coat of compound (PWC06-004) to bore surfaces of keywasher and to
shoulder and threads of turbine stubshaft bolt (4).
(5) Insert keywasher and mounting bolt into disk center bore.
72-50-02
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5 4 6
1
B
7
2 5
C3423
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MANUAL PART NO. 3040592
1. Puller
2. Lug
3. Turbine Disk Slot
4. Body
5. Lock
6. Nut
7. Turbine Disk
(6) Install protector sleeve (PWC30336) in disk center bore and wrench (PWC30331)
on Flange C (9).
(7) Using conventional socket wrench, torque turbine stubshaft bolt (4) 600 to 650 lb.in.
Slacken to zero and retorque 500 to 550 lb.in.
(9) Unscrew nut (6) of locking tool (PWC30458) to top of threads (8) and install in disk
center bore.
(10) Engage screw (7) in threads of turbine stubshaft bolt (4) and tighten until resistance
is felt.
(12) Slacken nut (6) and turn screw (7) counterclockwise until released from turbine
stubshaft bolt threads.
(15) Inspect center bore for presence of metal swarf. If necessary, remove with a clean
lint-free cloth.
(16) Check blade tip clearance using wire or tapered feeler gage. Clearance as detailed
in 72-50-01, Page Block 801 .
6. Inspection/Check
Inspection procedures and damage limits applicable to the compressor turbine disk are
covered in the engine hot-section inspection procedures (Ref. 72-00-00, INSPECTION/CHECK).
72-50-02
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2
1
5
1
7 8 6 5 3
C3819
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MANUAL PART NO. 3040592
1. Turbine Disk
2. Wrench
3. Keywasher
4. Turbine Stubshaft Bolt
5. Locking Tool
6. Nut
7. Screw
8. Thread
9. Flange C
72-50-02
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
NOTE: Contents of 72-50-03 (Power Turbine Disk Assembly) can be found in 72-50-04.
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
A. General
Removal/Installation of the stator assembly for replacement of the vane ring may be
necessary for the following reasons.
(a) Damage/wear limits are exceeded (Ref. 72-00-00, INSPECTION/CHECK, Hot
Section Inspection).
NOTE: In this case it is advisable to replace the vane ring with one having a
class within + 0.2 to - 0.1 of class of removed vane ring.
(b) After replacement of compressor turbine vane ring, engine fails to meet
performance check limits (Ref. 72-00-00, FAULT ISOLATION, Performance
Check Problems).
72-50-03
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
5
FACE A D E
3
1
5 COMPRESSOR TURBINE
SHROUD HOUSING (REF.) 11
SECTION A−A
7
FACE B
INSTALLATION DETAIL
( PT6T−3D/−3DE ONLY )
8 A
2
A
9
1
11
4
5
10
6
7
3
( PT6T−3D/−3DE ONLY )
C22112B
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MANUAL PART NO. 3040592
1. Exhaust Duct
2. T5 Harness
3. Nut
4. Bolt
5. Stator Housing Assembly
6. Stator Assembly
7. Power Turbine Shroud
8. T5 Probes
9. Probe and Harness Assembly
10. Dowels
11. Interstage Sealing Ring
12. Bolt
72-50-03
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MANUAL PART NO. 3040592
5
FACE A D E
12
1
5 COMPRESSOR TURBINE
SHROUD HOUSING (REF.) 11
SECTION A−A
7
FACE B
INSTALLATION DETAIL
( PT6T−3DF ONLY )
8 A
2
A
9
1
11
5
10
6
7
( PT6T−3DF ONLY )
12
C28702
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MANUAL PART NO. 3040592
B. Removal
NOTE: The stator assembly comprises a vane ring and an interstage baffle assembly
which is riveted within the vane ring. This baffle assembly must not be
removed.
(3) Cut and remove lockwire and release T5 harness from clip on exhaust duct (1).
(4) For PT6T-3D/-3DE engines, remove nuts (3) and bolts (4).
(6) Remove complete assembly of shroud, stator and stator housing from exhaust duct.
NOTE: Care must be exercised when withdrawing stator assembly (6) from stator
housing assembly (5). Stator assembly must be withdrawn straight so that
sides of slots do not contact T5 probes.
(7) Separate power turbine shroud (7), stator assembly (6) and stator housing
assembly (5).
C. Installation
NOTE: To avoid the possibility of air leakage during engine operation the mating faces
of stator assembly (6) and power turbine shroud (7) must be lapped as detailed
in Approved Repairs, Page Block 801.
(1) Insert stator assembly (6) in stator housing (5), ensuring that sides of slots in stator
do not contact probes (8).
(a) Install selected interstage sealing ring (8) in stator housing contacting area on
Face D.
(b) Hold suitable light source behind ring around contact area, ensuring that gap
between ring and contact area does not exceed 0.001 inch over an arc of 30°
maximum length. Rotate sealing ring, if necessary, to achieve maximum
contact. Index ring gap at new position.
(3) Clean faces A and B of exhaust duct and power turbine stator housing with
abrasive cloth (PWC05-101) and then clean with isopropyl alcohol (PWC11-014).
(4) Apply thin layer of coating (PWC07-023) to faces A and B and let dry 5 to 10 minutes.
72-50-03
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(5) Apply second layer of coating (PWC07-023) to faces A and B to obtain 0.002 to
0.003 thickness. Let dry 5 to 10 minutes.
(6) Position power turbine shroud (7) in stator housing assembly (5), engaging lugs
with slots in stator assembly and dowels (10) in holes in shroud housing.
(7) Position assembly on exhaust duct (1) and align offset holes.
(8) For PT6T-3D/-3DE engines, install bolts (4) and nuts (3). Torque 32 to 36 lb.in. and
lockwire.
(9) For PT6T-3DF engines, install bolts (12) and torque 32 to 36 lb.in. and lockwire.
72-50-03
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
Inspection procedures and damage limits applicable to the power turbine stator assembly are
covered in engine hot-section inspection procedures, as detailed in 72-00-00,
INSPECTION/CHECK, Hot Section Inspection.
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
5. Procedure
Repair of stator assembly is restricted to lapping of mating face of vane ring to obtain
optimum surface contact with shroud and thus minimize the possibility of air leakage during
engine operation.
(1) Lap face A using suitable lapping tools and lapping compound (PWC05-145) to
obtain the specified surface contact.
(c) Allow solvent to drain and blow off residue with compressed air.
0.100 MINIMUM
POWER TURBINE
STATOR ASSEMBLY
0.300 MIN.
POWER TURBINE
STATOR ASSEMBLY
C9323
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
5. Removal/Installation
Power turbine disk assembly may only be removed for inspection purposes at maintenance
level. Disk replacement involves balancing procedures that may only be carried out at an
overhaul facility.
A. Removal
72-50-04
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(b) Insert protector sleeve (PWC30336), and spreader (PWC30335) into disk
centerbore and screw spreader center bolt into internal thread in head of
stubshaft bolt (5) until keywasher (4) is unlocked.
(c) Remove stubshaft bolt and keywasher using a conventional socket. If difficulty
is encountered during removal of stubshaft bolt proceed as follows:
2 Using oil injector, inject liberal quantity of approved penetrating oil (50%
kerosene, 50% engine oil) through center hole in bolt to flood cavity in
stubshaft. Rotate turbine several times to allow oil to transfer along slots in
bolt threads. Allow to stand for 20 minutes. Remove oil injector.
4 If bolt still does not loosen, apply sufficient torque to just move bolt, do not
exceed 150 lb.ft. Reverse the torque and work back and forth until bolt is
free and can be unscrewed normally.
(a) Insert puller (PWC30403) into disk centerbore and engage lugs (2) with slots
(3) (Ref. View A).
(b) Ease body (4) downwards until lug (2) is below slot (3) (Ref. View B).
(c) Rotate body and lug to contact underside of disk (Ref. View C).
(d) Position lock (5) in disk slot and turn nut (6) until turbine disk snap fit is
released (evidenced by freedom of puller operation).
72-50-04
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NOTE: Ensure power turbine rotor air seal is installed prior to power turbine installation.
(2) Align master splines and press turbine disk onto shaft.
(3) Ensure that new keywasher (7) is dry and free from burrs.
(4) Apply light coat of compound (PWC06-004A) to bore surfaces of keywasher and to
shoulder and threads of stubshaft bolt (8).
(6) Install wrench (PWC30811) or (PWC51409) on exhaust duct and insert protector
sleeve (PWC30336) into centerbore of wrench and disk.
(7) Using a conventional socket wrench, torque stubshaft bolt 600 to 650 lb.in. Slacken
to zero and re-torque 500 to 550 lb.in.
(9) Unscrew nut (5) to top of threads (4) and install locking tool (PWC30458) in disk
centerbore.
(10) Engage screw (3) in thread of stubshaft bolt and tighten until resistance is felt.
(12) Slacken nut (5) and turn screw (3) until it is released from stubshaft bolt threads.
(15) Inspect centerbore for presence of metal swarf and if necessary, remove with clean
lint-free cloth.
6. Inspection/Check
Inspection procedures and damage limits applicable to the power turbine disk are covered in
the engine hot section inspection procedures (Ref. 72-00-00, INSPECTION/CHECK, Hot
Section Inspection).
72-50-04
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4
5
C3101A
72-50-04
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MANUAL PART NO. 3040592
1. Wrench
2. Protector Sleeve
3. Spreader
4. Keywasher
5. Stubshaft Bolt
6. Mount Ring (PWC30269) (Ref.)
72-50-04
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6
5
2
4
1
VIEW A
3 7
VIEW B
2
VIEW C 4
C3102
72-50-04
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1. Puller
2. Lug
3. Disk Slot
4. Body
5. Lock
6. Nut
7. Turbine Disk
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3
4 NOTE: POSITION TOOL ON
3 DOGS LOCATED
5 WITHIN BALANCING RING
2
1
6
7
8
10
9
11
CAUTION: ENSURE LEGS (10) OF KEY−WASHER SEAT IN SLOTS (9)
C3103A
72-50-04
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MANUAL PART NO. 3040592
CHAPTER
SECTION PAGE DATE
LEP 1 Nov 23/2015
2 blank Nov 23/2015
TABLE OF CONTENTS
SUBJECT PAGE
5. Removal/Installation 201
A. Removal of Accessory Drive Seals 202
The accessory gearbox comprises a cast magnesium alloy cover and a housing containing
the various gears, shafts and mounting pads associated with the engine fuel and oil system
pumps, the tachometer generator, the starter generator and the centrifugal breather. The
cover is secured to the housing by studs and the complete assembly is secured to the
compressor inlet case by studs at Flange G. The gearbox is driven by the compressor through
a coupling shaft which is supported by a ball-type bearing in the cover. The remainder of
the gearshafts are supported by roller-type bearings in the cover and the housing. The upper
part of the gearbox contains the tachometer generator drive gear, the fuel pump and fuel
control unit (FCU) gear and the centrifugal breather and starter-generator gears. These gears
are driven from the coupling shaft via two idler gears. The lower part of the gearbox
contains three oil scavenge and one main pressure pump, which are driven from the lower
idler gear and are mounted on a common shaft. The housing also contains an integral oil tank.
Oil filler tubes and apertures for visual contents gages are provided on both sides of the
gearbox and those not in use when the gearbox is installed on the engine (i.e. the inner ones)
are blanked off.
Internal cored passages and pressure tubes take pressure oil to No.1 bearing in the inlet
case, oil being returned by gravity to the accessory gearbox sump. Pressure oil to power
section and reduction gearbox input section bearings and scavenge oil from them, is
conveyed through external pipes. A centrifugal breather impeller mounted on the
starter-generator drive gearshaft separates oil from breather air in the gearbox housing, the
air being vented from a cored passage in the top of the housing.
A carbon face seal on the gearbox housing end of the gearshaft prevents oil leakage through
the bearing assembly. An external line takes pressure oil from the check and regulating
valve on the lower part of the gearbox to a boss on the gearbox cover, which is connected to
the oil-to-fuel heater by an internal passage. An oil pressure adjustment valve assembly is
installed at the top of the gearbox and a boss on the lower part of the gearbox houses a
magnetic chip detector assembly.
72-60-00 Page 1
ACCESSORY GEARBOX - DESCRIPTION AND OPERATION Aug 12/96
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
PRESSURE
ADJUSTMENT FUEL PUMP
VALVE BOSS AND FCU DRIVE
CENTRIFUGAL
STARTER BREATHER
TACHOMETER
GENERATOR GENERATOR
MOUNTING DRIVE
PAD CARBON SEAL
STARTER
OIL GENERATOR
FILLER OIL−TO−FUEL HEATER
LINE BOSS DRIVE
IDLER GEARS
COVER
MAGNETIC CHIP
DETECTOR
COUPLING SHAFT
FUEL PUMP AND CENTRIFUGAL
FCU GEARS BREATHER AND
STARTER
GENERATOR
GEARS
CONTENTS
GAGE
SCAVENGE
PUMPS
HOUSING
TACHO−GENERATOR PRESSURE
GEAR PUMP
COUPLING SHAFT
LUBRICATING
OIL PUMPS
C9358
72-60-00 Page 2
ACCESSORY GEARBOX - DESCRIPTION AND OPERATION Aug 12/96
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
Locking Tool TD1032L
5. Removal/Installation
Removal and disassembly of the accessory gearbox assembly is not required at maintenance
(Ref. Overhaul Manual).
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(3) Remove unserviceable oil seal (3) and seal carrier (2) from gearbox housing with
starter puller (PWC30046-52) or fuel pump puller (PWC30046-54) or Ng
Tacho-generator puller (PWC30046-57) or puller (PWC30052).
(4) Remove seal (3) and preformed packing (4) from oil seal carrier with base and drift
(PWC37088-1), (PWC37088-002) or (PWC37088-003). Discard seal (3) and
preformed packing (4).
(3) Lubricate and install new preformed packing (4) on OD of oil seal carrier.
(4) Install assembled oil seal (3) and seal carrier (2) in boss of gearbox housing. Press
into position with drift (PWC30075).
(2) Withdraw seal carrier (2) and carbon seal assembly (3) from housing, using puller
(PWC30046-52).
(3) Insert fingers of puller (PWC32810) fully home in bore of seal retainer and withdraw
carbon seal assembly from seal carrier by turning extractor screw clockwise using
suitable Allen key.
(1) Immerse seal carrier (2) in clean oil heated to 121°C (250°F) for 10 to 15 minutes.
(2) Lubricate carbon seal assembly and ensure that carbon seal (5) moves freely in
and out against spring (6).
(3) Remove seal carrier (2) from oil, allow excess oil to drain and install carbon seal
assembly (3) in carrier, using drift (PWC30675).
72-60-00
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E. Removal of Oil Filler Neck and Oil Level Indicator (Ref. Fig. 203)
(2) Remove and discard preformed packing (12) from the oil filler cap (11).
(3) Remove bolts (18), washers (19) and oil filler neck (13) from housing.
(4) Pre-SB5459: Remove strainer (16), retaining ring (17) and preformed packings (14
and 15). Discard preformed packings (14 and 15).
(5) Post-SB5459: Remove oil filler tube (21), ball (22), retaining ring (23), retaining ring
(17) and preformed packings (14 and 15). Discard preformed packings (14 and 15).
(6) Remove bolts (9), washers (10), blanking plate (5) and gasket (6) at inboard side of
housing.
(7) Remove bolts (7), washers (8), oil level indicator (1), gasket (2), reflector (3) and
gasket (4) at outboard side of housing.
F. Installation of Oil Filler Neck and Oil Level Indicator (Ref. Fig. 203)
(1) Install gasket (4), reflector (3), gasket (2) and oil level indicator (1) at outboard side
of housing with washers (8) and bolts (7). Torque bolts 24 - 36 lb.in. and lockwire.
(2) Install gasket (6) and blanking plate (5) at inboard side of housing with washers
(10) and bolts (9). Torque bolts 24 - 36 lb.in. and lockwire.
(3) Pre-SB5459: Assemble retaining ring (17), strainer (16), preformed packings (14
and 15) and oil filler neck (13) together and install the part with bolts (18) and
washers (19). Torque bolts 24 - 36 lb.in. and lockwire.
(4) Post-SB5459: Assemble retaining ring (17), oil filler tube (21) , ball (22), retaining
ring (23), preformed packings (14 and 15) and oil filler neck (13) together and
install the part with bolts (18) and washers (19). Torque bolts 24 - 36 lb.in. and
lockwire.
6. Inspection/Check
(1) Inspect sealing face for chips, nicks and scratches. Seal is acceptable provided
that:
72-60-00
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4
3
2
1
4
3
2
C3077A
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1. Retaining Ring
2. Seal Carrier
3. Seal
4. Preformed Packing
(b) A circular strip not less than 45% of original face width makes sealing contact.
(c) Scratches extending across sealing face are less than 0.005 in. deep
and 0.010 in. wide.
(2) Inspect condition of remaining areas of seal. Seal is acceptable provided that:
(c) Scratches are less than 0.005 in. deep and 0.010 in. wide.
7. Approved Repairs
NOTE: The following procedure applies only to specific sized inserts used in the accessory
gearbox to airframe mounting pad. Refer to Illustrated Parts Catalog for approved
location and particular part number of insert.
(1) Drill out insert material between keys to depth shown using 13/32 inch diameter drill
(Ref. Detail A).
(2) Using small pin punch, bend keys inward and break them off (Ref. Detail B).
(3) Remove insert with a standard ‘‘E-Z Out’’ type tool (Ref. Detail C).
(4) Screw in new insert, using fingers, to a depth of 0.010 to 0.030 in. below surface of
parent component (Ref. Detail D).
(5) Using a ‘‘Kee’’ driving-tool (TD1032L) and a hammer, drive down keys with several
light taps (Ref. Detail E).
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4
4
5
1
C3073A
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1. Retaining Ring
2. Seal Carrier
3. Carbon Seal Assembly
4. Preformed Packing
5. Carbon Seal
6. Carbon Seal Spring
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20
18
19
14
INBOARD SIDE
11
PRE−SB5459
12
13 15
16 9
10
7 8 17
OUTBOARD SIDE
6 5
21
22 1 4
2 3
23
POST−SB5459
C165004
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
13
32 IN. DRILL
LOCKING KEYS
0.200 INCH
DETAIL E
C3559
72-60-00
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
CHAPTER
SECTION PAGE DATE
LEP 1 Mar 09/2001
2 blank Mar 09/2001
Page 1/2
73-00 LEP Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
TABLE OF CONTENTS
SUBJECT PAGE
A. System Components 1
B. System Operation 15
Page 1/2
73-00 CONTENTS Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The engine fuel system comprises two separate identical power section fuel control systems
with their associated fuel pumps and a common torque limiter. Each system has two
operating modes, automatic (normal flight) or manual (emergency) which may be selected by
the pilot at his discretion for individual power sections.
The power section control system comprises a fuel pump, a manual fuel control unit
(MFCU), an automatic fuel control unit (AFCU), a flow divider and dump valve, a power
turbine (Nf) governor, an oil-to-fuel heater, a dual fuel manifold and 14 duplex nozzles.
System fuel pumps are engine driven and are designed to operate at altitude without cavitating.
Manual and automatic fuel control units on each power section are mechanically
interconnected and are linked to pilot-operated airframe controls.
At start the levers are moved from their minimum stops, which correspond to no-flow, to a
no-load position through 50 degrees approximately. In flight, the levers are set to their
fully-open position. If manual control is selected, the levers are moved within the 50
degree to fully open range until shutdown. Servo-pressure is always available for transfer to
manual control.
During transfer from automatic to manual modes, a surge accumulator located between the
MFCU and the flow divider and dump valve, ensures that delivery pressure is maintained
constant by absorbing any surges.
After shutdown, residual fuel is drained by two drain valves installed at the bottom of the gas
generator case.
The positive displacement gear type pump, which incorporates spring and fuel
pressure loaded bushings, is mounted on the accessory gearbox. A splined coupling
is used to transmit the geartrain drive to the pump gears; the coupling splines are
lubricated by oil mist from the gearbox through a hole in the gearshaft.
Fuel enters the pump through a 10 micron strainer element and passes to the
pump gear chamber. Fuel pressure upstream and downstream from the strainer is
monitored by two pressure taps.
Bypass fuel from the fuel controls is returned to the pump inlet through an injector
pump downstream from the strainer. This non-mechanical injector pump takes
the excess flow from the fuel control and transmits the energy contained in the higher
pressure bypass fuel to the pump inlet.
C22131
Fuel Control System Schematic
Figure 1
The solenoid valve is spring-loaded to a closed position and seals the space
above the transfer valve piston while de-energized. When electrical power is
applied to the solenoid valve, it opens against spring pressure to allow fuel
from the transfer valve into the bypass line. The resultant drop in pressure above
the transfer valve piston causes it to move against spring pressure and block
the fuel outlet port to the AFCU. At the same time, it opens a port to the metering
valve.
The manual throttle lever also controls a piston in a ported cylinder. In the
‘‘OFF’’ position fuel flow to the manifold is cut-off by the piston and is directed
to a bypass line. The two inlet lines to the cylinder, one from the AFCU, the
other from the metering valve, each contain a check valve. Depending on which
mode is being used, back pressure on the check valve in the inoperative line
closes the valve, thus sealing off the system not in use.
The pressurizing valve in the line between the cut-off valve and the manifold
ensures that no fuel flows to the manifold until a pre-set minimum pressure has
been attained.
73-00-00
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ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The AFCU, which is mounted on the fuel pump, basically comprises three sections;
a fuel section, a power input, speed governor and bias section and a bellows
section.
The unit is driven at a speed proportional to gas generator speed (Ng) and
establishes a proper fuel schedule, in response to power requirements, by controlling
Ng through regulation of fuel flow.
The AFCU is supplied with fuel from the pump through the transfer valve in the
MFCU.
Flow is established by a metering valve and bypass valve system, fuel at pump
(P1) pressure being applied to the entrance of the metering valve. Fuel
pressure immediately after the valve, metered fuel (P2) pressure, is compared
with P1 pressure by the bypass valve, and a constant differential (P1 - P2)
is maintained. The orifice area of the metering valve changes to meet specific
power section requirements, and fuel pump output in excess of those
requirements is returned to the pump inlet. Returned fuel is referred to as Po.
The bypass valve consists of a sliding valve in a ported sleeve, actuated
by a diaphragm and spring. In operation, spring force is balanced by P1 - P2
pressure differential working on the diaphragm.
(b) Power Input, Speed Governor and Enrichment Section (Ref. Fig. 3)
The speed bias lever provides a mechanical link between the governor spool
and governor lever.
73-00-00
Page 6
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
SPRING
METERING VALVE
DIAPHRAGM
GOVERNOR BELLOWS
BYPASS VALVE
BYPASS
EVACUATED BELLOWS
RETURN (P0)
REGULATOR VALVE BODY
Pr GOVERNOR LEVER
Pg OUTLET
GOVERNOR SPRING
TO Nf GOVERNOR
SPEED BIAS LEVER
THROTTLE SHAFT AND LEVER ASSY
AIR INLET
GOVERNOR SPEED SCHEDULING CAM
GOVERNOR WEIGHTS A
BEARING ASSY Py GOVERNOR RESTRICTOR
C22133
Automatic Fuel Control Unit
Figure 2
73-00-00
Page 7
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
Pa
Px
Py
GOVERNOR LEVER SPEED BIAS LEVER
GOVERNOR VALVE
CLOSED
SMALL SPRING
DRIVE SHAFT
GOVERNOR SPRING
POWER
INPUT SHAFT
SPEED SCHEDULING CAM
C5649
73-00-00
Page 8
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The power input shaft incorporates a speed scheduling cam which depresses
the governor cam lever when power is increased. A spring connects the cam
lever to the governor lever which is pivoted at one end and operates against
an air flow restrictor to form the governor valve.
The speed bias lever, pivoted at the same point as the governor lever, has two
extensions which straddle a portion of the governor lever so that, after a
slight movement, a gap closes and both levers move together. A small spring
connects the speed bias and governor levers. A roller on the arm of the speed
bias lever contacts the end of the governor spool.
The speed scheduling cam applies tension to the governor spring through the
cam lever; this applies a force to close the governor valve.
The drive shaft is driven at a speed proportional to gas generator speed (Ng).
As the shaft turns it rotates a table on which the governor weights are
mounted. Small levers on the inner race of the weights contact the base of the
governor spool. As Ng increases, centrifugal force causes the weights to
move outwards and apply an increasing force against the spool. This force
moves the spool forward on the drive shaft against the roller at the end of the
speed bias arm. If Ng continues to increase, the speed bias lever will move
until it contacts the governor lever; further increase in Ng will allow the bias lever
to overcome the governor spring and both levers will move to open the
governor valve, bleeding off modified compressor discharge pressure (Py).
Pr is also applied to one side of the governor reset diaphragm and passed
through the reset bleed to the other side of the diaphragm where it is designated
Pg. The reset section Pg outlet is connected to the power turbine governor
by an external line.
Opening of the governor reset valve causes a flow through the reset bleed with
pressure drop of Pr - Pg. and Pg will be reduced. Movement of the reset
diaphragm will then cause the reset rod to apply a force to the governor lever
which overcomes governor spring tension and increases bleed-off of Py.
73-00-00
Page 9
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The acceleration bellows, one end of which is attached to the body, provides
an absolute pressure reference. The governor bellows, which is secured within
the body, functions in a similar manner to a diaphragm and is represented
as such in the figure.
The valve receives pressurized fuel (P1) from the MFCU transfer valve. P1
pressure is applied to one side of the valve through the P1 inlet. Valve spring
tension and fuel bypass pressure (P0) is applied to the other side of the valve. When
pressure differential P1 - P0 reaches 100 to 120 psi., the valve opens and allows
fuel to flow through holes in the sleeve and passages in the body to the P0 outlet. This
ensures that P0 upstream of the valve is at least 100 psi above P0.
73-00-00 Page 10
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
AREA OF Px PRESSURE
CANCELLATION
Px
Py
Px
EVACUATED (ACCELERATION)
DIAPHRAGM REPRESENTING BELLOWS
GOVERNOR BELLOWS
C3029
Bellows Operation - Schematic
Figure 4
73-00-00 Page 11
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
P INLET
1
P 0 PORT
SHIMS
VALVE SPRING
VALVE
SLEEVE
P OUTLET
1 VALVE BODY
C3143A
73-00-00 Page 12
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The surge accumulator is connected to the fuel delivery line between the MFCU
and the flow divider and dump valve.
Fluctuations in fuel pressure are prevented from reaching the flow divider by the
accumulator which absorbs these changes.
(6) Flow Divider and Dump Valve, Manifold Adapters and Nozzles (Ref. Fig. 6)
The flow divider and dump valve, which is installed between the fuel control units
and the manifold, receives metered fuel from the MFCU and delivers it to the primary
and secondary manifolds. Initially, fuel enters the unit and exerts sufficient
pressure on the divider cylinder piston to allow fuel to flow to the primary manifold.
When pressure has built up sufficiently, the inner piston is pushed back against
spring tension to allow fuel to flow to the secondary manifold.
When fuel flow to the unit is cut off, the piston moves under spring tension to block
the inlet. Fuel in the primary and secondary manifolds thus drains out through
the dump outlet.
The power turbine governor of each power section fuel control system is mounted
on the appropriate side of the reduction gearbox and is driven at a speed
proportional to the power turbine. The governor supplies a signal to the AFCU to
change compressor speed whenever it senses a power turbine load change, and
employs a drive body similar to that of the AFCU. A difference is the elimination
of the enrichment mechanism. Normally, the Nf governor lever positions the governor
so as to fully close the governor valve. Any tendency of the power turbine to
change load or speed results in the governor valve bleeding off more or less Pg. If
Nf overspeeds, the valve bleeds off more Pg, and the Pr - Pg differential increases
causing the governor reset rod to increase its force on the AFCU governor lever to
lower Py and reduce fuel flow. The reverse sequence would occur if Nf were
caused to underspeed.
Application of load requires increasing the pitch of the helicopter rotor blades. A
load application will tend to cause a decrease in Nf. The power turbine governor will
sense this decrease in Nf and remove reset force from the main fuel control and
cause Ng to increase. As load is increased by movement of the pilot’s collective pitch
control, the power turbine governor throttle lever is advanced to compensate for
the ‘‘droop’’ characteristic of the system.
If the load is decreased, Nf will tend to overspeed and the power turbine governor
will again reset the main fuel control to lower Ng.
Various power turbine speeds (Nf) may be selected by repositioning the throttle
lever on the power turbine governor through manipulation of a ‘‘beeper’’ switch.
73-00-00 Page 13
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
FUEL NOZZLE
COMBUSTION CHAMBER LINER
FLOW DIVIDER
DUMP POSITION
C22101
73-00-00 Page 14
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The oil-to-fuel heater assembly is basically a plate and fin constructed heat
exchanger which utilizes heat from the power section oil to maintain fuel temperatures
within a specified range. The assembly consists of collectors, heat exchanger
core, and a valve body, which are integral with the heat exchanger. A thermal element,
guide, valve sleeve, and spring are contained in the valve body by a retaining
cap which is secured by lockwire.
Fuel flow through the oil-to-fuel heater passes from inlet to outlet connections via a
thermal element. The element consists of a highly expansive material sealed in
a metallic chamber, the expansion force being transmitted through a diaphragm and
rod to the heater valve sleeve. Since the element exerts an expansive force only,
it is counter-balanced by a spring which provides a force to return the sleeve when the
fuel temperature decreases. When fuel temperature decreases below 21.1°C
(70°F), all oil entering the heater is circulated through the core to increase fuel
temperature. The element senses outlet fuel temperature and as temperature rises
above 21.1°C (70°F), the valve moves to reduce flow through the core and at
the same time, opens a bypass port between the oil inlet and outlet connections. At
fuel outlet temperatures above 32.2°C (90°F), the core exit is fully closed forcing
the entire oil flow to bypass the core.
The common torque limiter is mounted on the reduction gearbox. The unit receives
torquemeter oil pressure signals proportional to the torque outputs of the two
power sections. The combined power section torque is limited, when the sum of
torque output overcomes servo lever spring force and equal amounts of Pg air bleed
off.
In manual mode, fuel from the airframe booster pump passes through the strainer
to the fuel pump. The pump delivers fuel to the transfer valve in the MFCU. In this
mode the solenoid valve is energized and the transfer valve directs fuel to the
metering and cut-off valve. The metering section of the valve and the bypass restrictor
establish a suitable minimum flow through the MFCU as a function of manual
throttle lever position. The metered flow then passes through the cut-off section of
the valve to the pressurizing valve which, as soon as a pre-set minimum pressure
is attained, opens, allowing fuel to pass via the delivery line to the flow divider and
on to the fuel manifold.
In this mode flow control is an MFCU function upon which torque limiter and Nf
governor functions have no effect.
Selection of automatic mode de-energizes the MFCU solenoid valve and the
transfer valve directs fuel flow through the pressure regulating valve to the AFCU.
73-00-00 Page 15
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
FUEL INLET
NORMAL CONDITION
FUEL OUTLET
PUSH ROD
OIL INLET OIL OUTLET
BYPASS CONDITION
C3023A
Oil-to-fuel Heater
Figure 7
73-00-00 Page 16
ENGINE FUEL AND CONTROL - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The metering valve in the AFCU, is controlled by pneumatic signals supplied by the
power input and speed governor section, the bellows section, the Nf governor
and the torque limiter.
Metered fuel from the AFCU is directed via the check valve in the MFCU to the
pressurizing valve which opens when the pre-set minimum pressure is attained and
directs fuel into the delivery line to the flow divider and fuel manifold.
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
LEP 1 Jul 18/2016 73-10-05 201 Jul 18/2016
2 Jul 18/2016 Maintenance 202 Jul 18/2016
Practices 203 Jul 18/2016
Contents 1 Jul 18/2016 204 Jul 18/2016
2 Jul 18/2016 205 Jul 18/2016
3 Jul 18/2016 206 Jul 18/2016
4 Jul 18/2016 207 Jul 18/2016
208 Jul 18/2016
73-10-01 201 Jul 18/2016 209 Jul 18/2016
Maintenance 202 Jul 18/2016 210 Jul 18/2016
Practices 203 Jul 18/2016 211 Jul 18/2016
204 Jul 18/2016 212 Jul 18/2016
205 Jul 18/2016 213 Jul 18/2016
206 Jul 18/2016 214 Jul 18/2016
207 deleted 215 Jul 18/2016
208 deleted 216 Jul 18/2016
209 deleted 217 Jul 18/2016
210 deleted 218 Jul 18/2016
211 deleted 219 Jul 18/2016
212 deleted 220 Jul 18/2016
221 Jul 18/2016
73-10-02 201 Dec 02/2013 222 Jul 18/2016
Maintenance 202 Dec 02/2013 223 Jul 18/2016
Practices 203 Dec 02/2013 224 Jul 18/2016
204 Dec 02/2013 225 Jul 18/2016
205 Dec 02/2013 226 Jul 18/2016
206 Dec 02/2013 227 Jul 18/2016
207 Dec 02/2013 228 blank Jul 18/2016
208 Dec 02/2013
73-10-06 201 Mar 09/2001
73-10-03 201 Mar 09/2001 Maintenance 202 Mar 09/2001
Maintenance 202 Mar 09/2001 Practices 203 Mar 09/2001
Practices 203 Mar 09/2001 204 blank Mar 09/2001
204 blank Mar 09/2001
73-10-07 201 Jul 18/2016
73-10-04 201 Mar 09/2001 Maintenance 202 Jul 18/2016
Maintenance 202 Mar 09/2001 Practices 203 Jul 18/2016
Practices 203 Mar 09/2001 204 Jul 18/2016
204 Mar 09/2001 205 Jul 18/2016
CHAPTER
SECTION PAGE DATE
206 Jul 18/2016
207 Jul 18/2016
208 blank Jul 18/2016
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
5. Removal/Installation 201
A. Removal 201
B. Installation 201
6. Repair 203
1. General 201
5. Removal/Installation 201
6. Inspection/Check 206
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
5. Removal/Installation 201
A. Removal 201
B. Installation 201
6. Inspection/Check 203
A. Procedure 203
B. Check 203
FLOW DIVIDER AND DUMP VALVE - MAINTENANCE PRACTICES 73-10-04
1. General 201
5. Removal/Installation 201
A. Removal 201
B. Installation 203
1. General 201
5. Removal/Installation 202
A. Removal 202
TABLE OF CONTENTS
SUBJECT PAGE
B. Installation 209
6. Adjustment/Test 213
A. Preparation 213
7. Cleaning 225
5. Removal/Installation 201
A. Removal 201
B. Installation 201
1. General 201
5. Removal/Installation 201
TABLE OF CONTENTS
SUBJECT PAGE
6. Cleaning 204
7. Adjustment/Test 205
1. General 201
2. Consumable Materials 201
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
A. Removal
(1) Disconnect fuel inlet tube from inlet connection (1). Cap tube end and connection.
(2) Remove bolts (4) securing elbow connection (3) to fuel pump. Remove elbow
(3) and transfer tube (9).
(3) Remove bolts (11) securing oil-to-fuel heater (10) to accessory gearbox.
(4) Withdraw oil-to-fuel heater (10) and transfer tubes (13) from mounting face on
accessory gearbox.
B. Installation
(1) Lubricate new preformed packings (2) and install on transfer tubes (13).
(2) Insert oil transfer tubes (13) in ports on oil-to-fuel heater mounting face of accessory
gearbox.
(3) Install oil-to-fuel heater (10) over transfer tubes (13) aligning the bolt holes,
exercising care to prevent damage to preformed packings (2).
(4) Secure oil-to-fuel heater (10) to accessory gearbox with bolts (11) and washers
(12). Tighten bolts, torque 32 to 36 lb.in., and lockwire.
73-10-01
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PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
12
11 2 3
10 13
2
4
5
6
8
9
8
C9295
Oil-to-Fuel Heater
Figure 201
73-10-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(5) Lubricate new preformed packings (8) and install on fuel transfer tube (9). Insert
transfer tube (9) into fuel outlet port on oil-to-fuel heater; exercise care to prevent
damage to preformed packings (8).
(6) Lubricate new preformed packing (6) and install in groove on inlet port face (7) of
fuel pump. Install elbow connector (3) over fuel transfer tube (9) exercising care to
prevent damage to packing. Secure elbow (3) to fuel pump with two washers
(5) and bolts (4). Torque bolts 36 to 40 lb.in. and lockwire.
(8) If new or overhauled oil-to-fuel heater has been installed, perform depreservation
procedure.
6. Repair
A. Repair of the Fuel Heater Thermal Element (Ref. Figs. 202 and 203)
(1) DELETED.
(1) DELETED.
73-10-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
DELETED
C00000
73-10-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
DELETED
C00000
Installation of Fuel Heater Thermal Element
Figure 203
73-10-01
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OIL-TO-FUEL HEATER - MAINTENANCE PRACTICES Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
DELETED
C00000
Temperature Plate
Figure 204
73-10-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
5. Removal/Installation
(1) Remove complete assembly of AFCU, MFCU, and fuel pump from accessory
gearbox (Ref. 73-20-01).
(6) Remove preformed packings (4, 5 and 12) from recesses in fuel pump.
(7) Remove and inspect coupling (3) for wear. Replace if splines are worn.
(8) If replacement fuel pump is to be installed, slacken locknut (9) and remove elbow
(10), packing retainer (8) and preformed packing (7).
73-10-02
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Page 201
FUEL PUMP - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
3
AFCU
5
5
2
1 7
12 8
9
10
11
13
14
MFCU
C22087A
73-10-02
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FUEL PUMP - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Nut
2. Washer
3. Coupling
4. Preformed Packing
5. Preformed Packing
6. Fuel Pump
7. Preformed Packing
8. Packing Retainer
9. Locknut
10. Elbow
11. Seal Drain Tube Connector
12. Preformed Packing
13. Washer
14. Nut
(1) Remove drain plug (9) from filter cover (11). Drain any residual fuel into suitable
container.
(2) Remove bolts (8) and washers (7) securing cover (11) to fuel pump.
(3) Withdraw filter cover complete with filter element (3) from fuel pump.
(4) Withdraw filter element from cover and remove preformed packings (2, 4, 5 and 6).
(1) Install new preformed packings (5 and 6) on boss inside fuel filter cover (11). Install
filter element (3) into cover (11).
(2) Install new preformed packing (2) on filter seating location in pump body.
(3) Install new preformed packing (4) on cover (11) and install assembled element and
cover on fuel pump (1).
(4) Secure with washers (7) and bolts (8). Torque 100 to 115 lb.in. and lockwire.
(5) Install new preformed packing (10) on drain plug (9) and insert in filter cover (11).
Torque plug 40 to 65 lb.in. and lockwire.
73-10-02
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FUEL PUMP - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1 8
11
10
C9340A
73-10-02
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Page 204
FUEL PUMP - MAINTENANCE PRACTICES Dec 02/2013
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Fuel Pump
2. Preformed Packing
3. Filter Element
4. Preformed Packing
5. Preformed Packing
6. Preformed Packing
7. Washer
8. Bolt
9. Plug
10. Preformed Packing
11. Filter Cover
NOTE: If recesses in fuel pump contain preformed packing which were not discarded
at removal or which were installed under the shipping plate on a new pump,
these preformed packings must be replaced with new items of correct part
number.
(1) If a replacement fuel pump is being installed, install new preformed packing (7),
new packing retainer (8) and locknut and elbow (9) and (10). Do not torque
locknut at this stage.
(6) Connect seal drain tube connector (11). Torque 90 to 100 lb.in. and lockwire.
Torque locknut (9) 38 to 42 lb.in. and lockwire.
73-10-02
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(7) Install complete assembly of AFCU, MFCU and fuel pump on accessory gearbox
(Ref. 73-20-01, MANUAL FUEL CONTROL UNIT (MFCU) - MAINTENANCE
PRACTICES).
(8) If a new or overhauled pump has been installed, carry out depreservation
procedure (Ref. 72-00-00, SERVICING).
6. Inspection/Check
(1) Remove drain line fitting or plug from pump drain port, to gain access to sump
area.
(2) Insert suitable cotton swab or equivalent through the drain port into the sump area,
positioning tip of swab against pump housing.
NOTE: 2. Blue or black residue indicates possible AFCU bearing washout (Ref.
73-20-02).
(b) Examine the input coupling shaft area of the pump face for residue from
fretting corrosion (iron oxide deposit). If none is present, the pump may remain in
service.
(c) Evidence of corrosion residue indicates possible spline wear. Return the fuel
pump to an approved overhaul facility.
73-10-02
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
DRIVE COUPLING
AREA TO BE EXAMINED
FOR IN−SITU INSPECTION
C203868
Fuel Pump (Typical)
Figure 203
73-10-02
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(1) Check for oil leakage from fuel pump drain port, maximum allowed (3 cc/hour). If
limit exceeded replace the accessory drive seal (Ref. 72-60-00).
(2) Check for fuel leakage from fuel pump drain ports, maximum allowed (30 cc/hour).
(a) If limit exceeded through fuel pump drain port (AGB side), send fuel pump for
repair/overhaul.
(b) If limit exceeded through fuel pump drain port (AFCU side), inspect AFCU drive
shaft bearing for fuel contamination (Ref. 73-20-02, Inspection/Check).
(1) Remove the fuel pump from the accessory gearbox (Ref. 73-10-02).
(2) Examine the input coupling shaft area of the pump face and drive spline for residue
from fretting corrosion (iron oxide deposit). If none is present, the pump may remain
in service.
(3) Evidence of corrosion residue indicates possible spline wear. Return the fuel pump
to an approved overhaul facility.
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1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
5. Removal/Installation
(2) Pre-SB5398: Remove nut and bolt (2) and accumulator (6), complete with clamp
(5). Remove clamp.
(3) Post-SB5398: Remove nut and bolt (9) securing accumulator (6) to bracket support
assembly (10).
(2) Pre-SB5398:
(b) Secure assembly to bracket (4) with bolt and nut (2). Torque nut 36 to 40 lb.in.
(3) Post-SB5398: Secure bracket support assembly (10) to accumulator (6) with nut and
bolt (9). Torque nut 36 to 40 lb.in.
6
1
POST−SB5341 3
4
4
7 1 6
2
5
8
5 6
PRE−SB5398 8
3 10
6
7 1 9
8
POST−SB5398
C22184D
1. Coupling Nut
2. Nut and Bolt (Pre-SB5398)
3. Flange C
4. Bracket (Pre-SB5398)
5. Clamp (Pre-SB5398)
6. Surge Accumulator
7. Tee
8. Fuel Tube
9. Nut and Bolt (Post-SB5398)
10. Bracket Support Assembly (Post-SB5398)
(4) Connect coupling nut (1) to fuel delivery pipe and torque 90 to 100 lb.in. Lockwire
coupling nut.
6. Inspection/Check
A. Procedure
(1) Pre-SB5398: Visually inspect the accumulator for signs of metal distortion on the
sides and ends. The distortion will show up as bulging of the sides or doming of
the end cap. Replace the accumulator, if any metal distortion is found.
NOTE: Bulging or doming can be verified using a metal straightedge on the sides
and ends of the accumulator.
(2) Post-SB5398: Visually inspect the accumulator. If the pop-out indicator is extended
replace the accumulator.
B. Check
(1) Apply clean, dry compressed air at 100 psig to the surge accumulator and check
for leakage.
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
A. Removal
NOTE: For ease of access, ignition cables may be disconnected at spark igniters (Ref.
74-10-00).
1
2
3
4
5
6
7
8
C74408
1. Elbow
2. Jam Nut
3. Back-up Ring
4. Preformed Packing
5. Fuel Manifold Adapter
6. Preformed Packing
7. Flow Divider and Dump Valve
8. Gas Generator Case
9. Bolt
(a) If flow divider (7) is being removed with engine installed, disconnect dump or
purge line as applicable from elbow (1). Suitably cap line connection and
elbow.
(b) Disconnect fuel inlet line from elbow (1) and suitably cap line connection and
elbow.
(c) Support flow divider (7), remove bolts (9) fastening valve to fuel manifold inlet
adapter (5).
(d) Remove and discard preformed packings (6) from recesses in mounting face of
valve.
2 Loosen nut (2) and remove elbow (1). Discard back-up ring (3) and
preformed packing (4). Install blanking plugs in dump/drain and/or inlet
ports.
B. Installation
(a) When a replacement flow divider (7) is being installed, depreserve, and install
elbows or elbow and nipple as follows:
1 Remove shipping plugs from inlet and dump ports and drain as much
preservation oil as possible.
2 Flush out valve from dump/drain port or air inlet end with fuel (PWC01-001),
to remove all residual preservation oil. Continue flushing until clear fuel
flows from manifold ports. Temporarily reinstall plug in dump or air inlet port.
3 Install back-up ring (3) and preformed packing (4) on elbow (1).
4 Remove plugs from inlet ports, install elbow (1), and position at angle
noted during removal. Tighten jam nuts (2) 38 to 42 lb.in., and lockwire.
5 To prevent ingress of foreign material, cap elbow and nipple until valve is
ready for installation.
(b) Press preformed packings (6) into recesses at manifold ports in mounting face
of valve.
(c) Position valve on base of fuel manifold inlet adapter (5), align attachment holes
and install bolts (9). Tighten bolts 32 to 36 lb.in., and lockwire bolts in pairs.
(d) Remove blanking caps from fuel inlet tube and elbow (1) and connect tube to
elbow. Tighten coupling nuts 90 to 100 lb.in., and lockwire.
(e) If installation of flow divider has been carried out with engine installed, proceed
as follows:
1 Remove blanking caps from dump/drain line and elbow (1), and connect
appropriate line.
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
The special tools listed below are used in the following procedures.
73-10-05
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
ANS929 Blanking Cap (2)
Flushing Fixture
Stainless Steel Container, Perforated
Ultrasonic Cleaner
5. Removal/Installation
A. Removal
NOTE: For ease of access, ignition cables may be disconnected at spark igniters
(REF. 74-10-00).
NOTE: 3. Remove four fuel manifold adapter assemblies and temporarily install
four fuel nozzle sheaths (bolts tightened) equi-distanced around the gas
generator case at the 2, 4, 8 and 10 o’clock positions. This will maintain
combustion chamber liner alignment while the other fuel manifold adapter
assemblies are removed.
(a) Number fuel manifold adapters for ease of identification and correct re-location.
(b) Remove bolts (5, Fig. 201) and locking plate (6) from inlet manifold adapter
and both adjacent manifold adapters.
(c) Remove fuel manifold transfer tubes (1) from both sides of inlet manifold with
pusher (PWC32366) or (PWC50074) in direction of arrow.
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(f) Remove bolts (5) and locking plates (6) from remaining fuel manifold adapters
as required, and withdraw tubes and adapter assemblies.
(g) If required, remove strainer elements (4) using puller (PWC30128-14). Remove
and discard preformed packings (3).
NOTE: Do not remove strainer elements before testing fuel nozzle assemblies
(Ref. 73-10-05, Adjustment/Test).
(2) Remove fuel nozzle sheaths (10, Fig. 201) from inlet adapter and all other manifold
adapter assemblies using puller (PWC30416) (Ref. Fig. 205).
(a) For PT6T-3D/-3DE/-3DF Engines with tapered fuel manifold adapters (Ref. Fig.
201), proceed to Para. 5.A.(3).
(b) For PT6T-3D/-3DE/-3DF Engines with cylindrical fuel manifold adapters (Ref.
Fig. 201):
2 Visually inspect fuel nozzle tips for concentricity with fuel exit hole of
sheath (Ref. Fig. 203).
NOTE: Fuel nozzle tip should be centered with fuel exit hole of sheath.
3 If concentricity is acceptable, remove sheath (10, Fig. 201) from inlet adapter
and all other manifold adapter assemblies using puller (PWC30416) (Ref.
Fig. 205) and proceed to Para. 5.A.(3).
73-10-05
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MANUAL PART NO. 3040592
1 2
3 4
6
4
3
12
11 2
1
10
9
8 A
7
15
MANIFOLD ADAPTER
ASSEMBLY (TYPICAL)
14
13
C232723
73-10-05
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1. Transfer Tube
2. Preformed Packing
3. Preformed Packing
4. Strainer Element
5. Bolt
6. Lockplate
7. Keywasher
8. Gasket
9. Gasket
10. Sheath
11. Locating Pin
12. Manifold Adapter
13. Cone
14. Distributor
15. Nozzle Body
(a) Unlock the keywasher (7) and remove the nozzle tip assembly (comprised of
items 13, 14 and 15) and the gasket (8) from the the adapter (12). Discard the
keywasher and the gasket.
(b) Remove strainer element (4). Remove and discard preformed packing (3).
(c) Clean fuel manifold adapter and strainer element thoroughly (Ref. 73-10-05,
Cleaning).
(5) To prevent exposure to dust and dirt, place manifold components in clean, covered
containers or polyethylene bags until required for use.
(6) Send rejected nozzle assemblies for repair or overhaul in original packaging to
prevent parts contacting each other during shipment.
73-10-05
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C81294A
73-10-05
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
FUEL FUEL
NOZZLE NOZZLE
SHEATH SHEATH
CENTERED
ORIFICE OFF−CENTER
ORIFICE
FUEL FUEL
NOZZLE NOZZLE
TIP TIP
C81717A
Inspection of Fuel Nozzle Tip Concentricity
Figure 203
73-10-05
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MANUAL PART NO. 3040592
PRIMARY SECONDARY
FLOW FLOW
SECONDARY
FLOW
GASKET
PRIMARY
FLOW
C67070
73-10-05
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
B. Installation
NOTE: When you install the new nozzle tip assembly, make sure that the cone
(13) and the distributor (14) are installed in the nozzle body.
(2) If strainer elements (4) were removed, install new preformed packings (3) on
strainer elements (new or cleaned) (4) and insert into manifold adapters.
(3) Function and leak test each nozzle and adapter assembly (Ref. 73-10-05,
Adjustment/Test).
(a) Install sheath (10) on inlet adapter, ensuring that locating pin (11) engages hole
in sheath.
(b) Using feeler gage check gap between fuel nozzle adapter and sheath, all
around maximum gap should be 0.003 inches (Ref. Fig. 206). Larger gap
suggests one or both parts are distorted. Replace part(s) as necessary.
(c) Carefully check gap between fuel nozzle tip and side of hole in sheath,
clearance of 0.020 inch is required. If clearance is less at any point suggests one
or both parts are distorted. Replace part(s) as necessary.
73-10-05
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1 2 3
5 4
C859A
73-10-05
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1. Puller
2. Sheath
3. Pin
4. Manifold Adapter Assembly
5. Hexagon Bolt
(d) Lubricate new preformed packings (2) with engine oil (PWC03-001) and install
on four fuel transfer tubes (1 , Fig. 201), and insert tubes into ports of inlet
manifold adapter. With pusher (PWC32366) or (PWC50074), push tubes into full
depth of bore in adapter ports in direction of arrow.
(e) Position gasket (9) over sheath (10) on inlet manifold adapter and align bolt
holes. Sheath flange must be flat.
NOTE: 1. Do not force fuel nozzle sheath into the gas generator case.
Investigate any cause of resistance.
(f) Insert sheath on inlet manifold adapter into boss at 6 o’clock position on gas
generator case, align bolt holes, and secure adapter to case with two bolts.
Do not torque bolts at this stage.
(a) Install sheaths (10) on manifold adapters (12) ensuring that locating pins (11)
engage with respective holes in sheaths.
73-10-05
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(b) Position gaskets (9) over sheaths (10) on manifold adapters (12) and align bolt
holes.
NOTE: 1. Do not force fuel nozzle sheath into the gas generator case.
Investigate any cause of resistance.
(c) Lubricate new preformed packings (2) with engine oil (PWC03-001) and install
on remaining fuel transfer tubes (1).
(d) Install fuel manifold adapter assemblies (12) and sheaths (10) on gas
generator case, progressively, starting on each side of inlet manifold adapter
(12). As each adapter assembly is positioned, with pusher (PWC32366) or
(PWC50074), insert fuel transfer tubes (1) to interconnect with adjacent
adapter, install locking plate (6), and secure adapter and plate to gas generator
case with two bolts (5) at each location. Do not torque bolts at this stage.
NOTE: 1. Make sure that the locking plate is correctly positioned (Ref. Fig. 207).
The plate must be installed between the flange of the transfer tube
and the fuel nozzle adaptor. P&WC recommends to use a mirror to
make sure the installation is correct on the inboard side of the
engine.
(e) When all fuel manifold adapter assemblies (12) are positioned, remove bolts
from inlet manifold adapter, install locking plate (6), and reinstall bolts (5).
73-10-05
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(a) Torque all bolts 15 to 20 lb.in., in sequence, then continue torquing in sequence
32 to 36 lb.in., and lockwire using single strand method with 0.032 inch
lockwire (PWC05-090).
NOTE: ‘‘Single’’ strand type lockwiring is acceptable (Ref. Fig. 208) for fuel
manifold adapters, providing that 0.032 inch lockwire is used.
6. Adjustment/Test
(1) Install blanking caps (10) on adapter and elbow. Torque caps 40 to 45 lb.in.
NOTE: If adapter and elbow are removed from flow divider install blanking plug
(PWC30530) (11) in lieu of caps (10).
(1) Back off torque screw (6) and set screw (4) on test fixture (PWC30405). Loosen
pivot screw (8) and rotate pivot block (7) to provide adequate space for installation
of fuel manifold adapter between pivot block and end block.
(2) Position fuel manifold adapter assembly (3) between pivot and blocks of fixture (2),
with nozzle orifice towards plastic pad (5).
(3) Insert plugs of pivot block (7) into manifold adapter ports and, by rotating block,
insert two plugs of fixture end block into opposite ports of adapter. Make sure that
preformed packings are not dislodged from grooves in fixture plugs during this
operation.
(4) With plugs fully inserted in manifold adapter ports, hold parts firmly in position and
tighten pivot screw (8).
(5) Turn set screw (4) inward until it seats on rear of adapter, behind nozzle.
(6) Turn torque screw (6) until plastic pad (5) seats on nozzle orifice face.
73-10-05
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ADAPTER
MAX. ALLOWABLE
GAP 0.003 INCH
AT ANY POSITION
SHEATH
ADAPTER
MAX. ALLOWABLE
GAP 0.001 INCH
AT ANY POSITION
METAL GASKET
C41914
73-10-05
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ADAPTER
LOCKING
PLATE
FLANGE
CORRECT INSTALLATION
INCORRECT INSTALLATION
INCORRECT INSTALLATION
C111468
Locking Plate Positioning
Figure 207
73-10-05
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PARTIAL SECTION TO
SHOW LOCKWIRE ROUTE
LOCKWIRE
NOT TWISTED
C23094A
73-10-05
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(7) Tighten screws (4 and 6), simultaneously, to ensure that pad closes nozzle orifice
without distorting adapter. Tighten set screw locknut.
(8) External Leak Test: Check for leaks (external) between fuel nozzle and adapter with
one of the following methods:
(a) Method A:
(b) Method B:
1 Connect hose assembly (1) to a pressure tester fitted with a 0 to 600 psig
gage and filled with fuel (PWC01-001). Apply compressed air or nitrogen at
500 psig to fixture (2) and check for leaks. Leakage is not permitted.
(c) If the leak check is successful, lock the keywasher on the nozzle adapter
assembly and do the test again.
(d) Reduce pressure to zero as indicated on gage (6, Fig. 210), by adjusting
pressure regulator (3). Disconnect hose assembly (1) from test fixture (2).
(e) Disconnect air supply line (2) from pressure regulator (3) on test rig (1).
(f) Remove fuel manifold and adapter assembly (13) from test fixture (2).
(a) Check for leaks (Internal) between primary and secondary passages as follows:
1 Partially fill fuel container (4, Fig. 210) of test rig (1) with clean fuel
(PWC01-001).
2 Insert one blanking tube assembly (13) and connecting tube (9) of fuel
nozzle fixture (12) into fuel manifold adapter (11) as shown. The two
remaining blanking tubes (13) are not required.
3 Place manifold adapter (11) in fuel nozzle fixture (12) and put collars of
blanking tubes (13) inside of fixture flanges with tubes in appropriate
slots. Fasten adapter to fixture with screws and nuts.
4 Connect tube (9) to fitting (19) and ball valve (8) on hose assembly (7) and
tighten coupling nuts to prevent leakage.
5 Connect air supply line (2) with 100 psig maximum to pressure regulating
valve (3) on test rig (1).
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1
1
2 2
3 11
11
9
10
10 9
8 1
6 5 4
C9339
73-10-05
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1. Hose Assembly
2. Test Fixture
3. Fuel Manifold Adapter Assembly
4. Set Screw
5. Plastic Pad
6. Torque Screw
7. Pivot Block
8. Pivot Screw
9. Flow Divider
10. Blanking Cap
11. Blanking Plug
7 Check for leaks at secondary port using pressure air to dry the manifold
passage which is open to atmosphere and visually inspect for any fuel
leaks. No leakage permitted.
9 Disconnect air supply line (2) from pressure regulating valve (3) on test rig
(1).
10 Remove fuel manifold adapter (11) and fuel nozzle (10) from fuel nozzle
fixture (12) and withdraw connecting tube (9) and blanking tube (13) from
ports in adapter.
(10) Remove plugs (12) or blanking caps (11) from flow divider.
C. Inspect Sheaths
(2) Inspect sheaths for fretting wear to a maximum depth of 0.010 inch. If worn beyond
0.010 inch. also inspect igniters for fretting wear (Ref. 74-20-00).
(3) If igniters are also worn beyond limits, remove power section and inspect combustion
liner components for cracking and/or evidence of distortion. Replace liner as
required. If condition of liner is acceptable, send power section to an overhaul facility
for investigation of gas generator.
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NOTE: 2. Nozzles should be examined for carbon buildup on the tips and, if necessary,
cleaned (Ref. Para. 7., following).
(1) Definitions of terms used in text to describe specified test conditions for nozzles are
as follows:
(a) ‘‘Onion’’ describes a spray condition which sometimes occurs at low flow rates
when spray exhibits a distinct ‘‘onion’’ bulb shape.
(c) Spitting is a condition which exists when large drops of unatomized fuel occur
intermittently and usually on outside of spray cone.
(d) Drooling is a condition which occurs when large drops of unatomized fuel form
on nozzle face.
(2) Set pressure regulating valve (3) of test rig (1) (PWC30506) or (PWC90086), or
equivalent, to zero pressure position and wait until gage (6) shows zero pressure;
open ball valve (8) to confirm, then close ball valve.
(3) Remove filler plug (17) and fill fuel container (4) with 48 fluid ounces of clean fuel
(PWC01-001).
(4) Inspect filler plug preformed packing seal for condition and screw filler plug into fuel
container (4).
(5) Carefully insert blanking tube (13) and connecting tube (9) in fuel manifold adapter
(11) assembly and connect fitting (19) to connecting tube (9). Tighten coupling nut
securely.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
5
4
17 6
2
19
MAXIMUM INLET
AIR PRESSURE 11 7
100 PSIG
8
13
9
12
18 14
10
16
14
15
C3084C
Fuel Nozzle Functional Check
Figure 210 (Sheet 1 of 2)
73-10-05
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Test Rig
2. Air Supply Line
3. Pressure Regulating Valve
4. Fuel Container
5. Filter
6. Pressure Gage
7. Hose Assembly
8. Ball Valve
9. Connecting Tube
10. Fuel Nozzle
11. Fuel Manifold Adapter
12. Fuel Nozzle Fixture
13. Blanking Tube
14. Blanking Caps AN929
15. Fuel Inlet Adapter
16. Flow Divider
17. Filler Plug with Relief Valve
18. Ground Cable
19. Fitting
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
ACCEPTABLE
NOT ACCEPTABLE
25%
A
10%
FUEL NOZZLE A
THE ADDITION OF THE STREAKS MUST NOT
BE MORE THAN 10% OF THE TOTAL FUEL SPRAY. FUEL SPRAY UNDER VIEW
VIEW A
C241173
Fuel Nozzle Functional Check
Figure 210 (Sheet 2)
73-10-05
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MANUAL PART NO. 3040592
(6) Place the assembly of adapter (11) and nozzle (10) in fixture (12) (PWC32811) and
secure. Position drip tray underneath.
NOTE: The fuel inlet adapter (15) and flow divider (16) assembly is functionally
checked in the same manner as for the fuel manifold adapter (11), except
that the flow divider connections are blanked with blanking caps (14).
Alternatively, if these connections are removed, the flow divider ports may
be blanked with suitable blanking plugs.
(7) Adjust pressure regulator (3) gradually until 20.0 psig is indicated on pressure gage
(6). A full conical spray, free from spitting or drooling, must appear from nozzle at
20.0 psig and a distinct onion shape may or may not form before the open spray. If
spitting or drooling occurs at 20.0 psig, reject nozzle.
(8) Adjust pressure regulator (3) to increase pressure to 60 psig as indicated on gage
(6). Volume of spray must increase and be spread evenly about the center axis of
nozzle orifice. If the addition of the streak more than a total of 10% of total fuel
spray then reject the nozzle.
(9) Close ball valve (8) and uncouple connecting tube (9) from fitting (19).
(10) Disconnect air supply line (2) from pressure regulator (3) on test rig (1).
(11) Remove adapter (12) and nozzle assembly (13) from flow fixture (11) and withdraw
connecting tube assembly (10) and blanking tube assembly (18) from ports in
adapter.
(12) Function test secondary passage of adapter (12) and nozzle assembly (13) (Ref.
Steps (5) thru (11)). Note that connecting tube assembly (10) and blanking tube
assembly (18) are inserted into ports on opposite side of adapter (12).
(13) Remove external carbon by lightly brushing orifice face with a brush having either
bronze or non-metallic bristles, while fuel flows through orifice.
(14) Close ball valve (8) and uncouple connecting tube (9) from fitting (19).
(15) Remove the assembly of fuel adapter (11) and nozzle (10) from fixture (12), and
withdraw blanking tube (13) and connecting tube (9) from adapter (11).
(16) Place adapter and nozzle assembly in a clean, dust-proof container until required
for installation on engine.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
7. Cleaning
(1) Clean by introducing dry, clean compressed air into the nozzle adapter fuel inlet
and brushing the orifice lightly with a soft bristled nylon or bronze brush.
CAUTION: EXTREME CARE MUST BE USED WHEN THE FUEL NOZZLE ASSEMBLIES
ARE HANDLED SINCE EVEN FINGERPRINTS ON THE ORIFICE MAY
PRODUCE POOR SPRAY PATTERN. CLEAN, LINT-FREE COTTON GLOVES
OR SURGICAL GLOVES SHOULD BE WORN AT ALL TIMES WHEN
THESE PARTS ARE HANDLED.
(3) Suspend the perforated stainless steel container containing nozzle assemblies in
the cleaner tank solution. Make sure that all nozzles are completely immersed.
(4) Cover tank and activate ultrasonic cleaner for approximately one hour.
(5) After cleaning, immediately wash assemblies thoroughly in very hot water.
NOTE: 1. Fuel nozzle flushing fixture may be locally manufactured (Ref. Fig. 211).
NOTE: 2. Use suitable blanking plugs if all 14 positions are not filled.
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MANUAL PART NO. 3040592
(7) Connect the hot water supply to the flushing fixture and flow clean, very hot water
through the nozzles for one minute at normal tap water pressure up to 30 psig.
(8) Disconnect the flushing fixture from the hot water supply, connect to a supply of
clean filtered compressed air or nitrogen and dry thoroughly. Disconnect the
flushing fixture from the air supply.
(9) Connect the flushing fixture to the fuel manifold adapter assembly test rig and flow
fuel through the nozzles for one minute at 30 psig.
(10) Remove the nozzles from the flushing fixture and store in a clean container until
required for reinstallation and test in the adapter assemblies.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
7 INCHES
TAP TO SUIT
DRILL AND TAP FITTING
DRILL 6.75 IN. DEEP
0.3125 IN. X 32 UNJEF
1.50 IN. X 1.50 IN. BAR STOCK, OR 14 PLACES
1.50 IN. DIA. STOCK STAINLESS STEEL
C72872
Fuel Nozzle Flushing Fixture
Figure 211
73-10-05
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
Not Applicable
Not Applicable
A. Removal
(1) Remove adapter (6) from boss (1) in gas generator case.
(3) Remove retaining ring (3), drain valve (4) and spring (5) from adapter.
B. Installation
(1) Install spring (5), drain valve (4) and retaining ring (3) in adapter (6).
(3) Install drain valve assembly in boss (1) in gas generator case. Torque 450 to
550 lb.in.
A A
C22113
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
Cleaning Tank, Electrosonic Model KS5518 or Equivalent
5. Removal/Installation
NOTE: During removal of filter element inspect drain valve for proper operation.
(1) Remove lockwire and, using a suitable wrench, unscrew cover (6).
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P3 AIR FILTER - MAINTENANCE PRACTICES Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
12
11
10
8
7
5
4
3
2
DETAIL A
C33786
73-10-07
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MANUAL PART NO. 3040592
CAUTION: THE P3 FILTER COVER IS MADE FROM ALUMINUM ALLOY. TAKE CARE
NOT TO DAMAGE THE COVER WHEN LOCKWIRING THE DRAIN VALVE
ASSEMBLY ON POST-SB5367 P3 FILTER COVER ASSEMBLIES. BEFORE
LOCKWIRING THE DRAIN VALVE ASSEMBLY, EXAMINE THE LOCKWIRE
ATTACHMENT HOLES ON THE COVER ASSEMBLY FOR EVIDENCE OF
TEARING. IF TEARING IS EVIDENT, SECURE LOCKWIRE TO AN
ALTERNATIVE SERVICEABLE LOCATION (REF. 70-00-00, STANDARD
PRACTICES - REMOVAL/INSTALLATION).
(1) Hold cover (6) with suitable wrench and unscrew drain valve adapter (1). Discard
preformed packing (2).
(2) Remove retaining ring (5), drain valve (4) and valve spring (3).
(1) Install valve spring (3) and drain valve (4) into drain valve adapter (1). Secure with
retaining ring (5).
(2) Install preformed packing onto drain valve adapter (1) and screw adapter into cover
(6), torque 225 to 250 lb.in. and lockwire (PWC05-089).
CAUTION: BEFORE THE NEW PREFORMED PACKINGS ARE INSTALLED, MAKE SURE
THAT THE AREA INSIDE THE FILTER HOUSING ASSEMBLY, COVER AND
FILTER IS CLEAN AND FREE FROM DEBRIS.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
(3) Install new preformed packing (8) onto boss of element (9).
NOTE: Ensure preformed packing (8) is installed on first groove (furthest from
face of element).
(4) Position element over spigot inside filter housing assembly (12).
(5) Lubricate new preformed packing (7) with silicone compound (PWC09-003) and
install on cover (6).
(6) Apply engine oil on threads and install cover in housing, torque 60 to 70 lb.in. and
lockwire.
6. Cleaning
(1) Put the filter element vertically in an electrosonic cleaning tank (Model KS5518) or
equivalent with open end at the bottom.
NOTE: Make sure that there is no plug installed at the open end of the element.
NOTE: To avoid spillage during operation, level must be kept at 1/4 in. below top
of tank.
NOTE: Cleaning duration should be adjusted to suit condition of filter element. For
best results, cleaning solvent should be changed every 20 minutes.
(8) Remove element from tank, using clean lint-free gloves and dry with clean low
pressure compressed air.
(9) Store cleaned element in polyethylene bag until required for installation.
NOTE: This cleaning can also be done at a PWC approved overhaul facility.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
NOTE: Cleaning of drain valve components is required at 100 hour intervals, however,
it is recommended that drain valves on engines operating in dirty or desert
conditions be cleaned and inspected at 50 hour intervals .
(1) Clean drain valve components and cover (6) using isopropyl alcohol (PWC11-014).
7. Adjustment/Test
NOTE: The P3 Filter Pressure Drop check is performed at the 900 hour level.
Ultrasonically clean the P3 Filter prior to performing this check.
(2) Connect P3 filter housing or fixture to the test set up as shown in figure.
(3) Pressurize the filter housing or the fixture to an indicated pressure of 150 psig
(approx. air flow 0.15 lb/min) and record the pressure drop across the housing
or fixture.
(4) Install the cleaned P3 filter element in the housing or fixture and record pressure
drop across the housing or fixture again when pressurized to 80 psig.
(5) The pressure drop differential (delta P) between the readings in steps (3) and (4)
shall not be more than 0.5 in. Hg. In the event delta P exceeds 0.5 in. Hg, the P3
element must be recleaned and tested.
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
P3 AIR FILTER
ELEMENT
CLEANING SOLVENT
LOW FREQUENCY
CLEANER
THROUGH HOLE
DO NOT PLUG
C7153A
73-10-07
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
SUPPLY PRESSURE
GAGE
TO AMBIENT 0 − 100 PSIG
AIR FLOWMETER
0.10 − 2.40 LB/MIN
OR A CALIBRATED ORIFICE REGULATOR
OUT IN
AIR SUPPLY
P
MANOMETER
0 − 30 INCH Hg
C8369
P3 Filter Check
Figure 203
73-10-07
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
P3 / PG - MAINTENANCE PRACTICES
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
Not Applicable
Not Applicable
(1) Use a suitable ohmmeter or resistance bridge, measure resistance of element and
lead assembly across Pins A and B. Resistance must be 20±1.4 ohms.
B. For Post-SB5409 engines: Pg and P3 tubes (Engine mounted on the aircraft) (Ref. Fig.
201)
(1) With the tubes installed and connected together, use a suitable ohmmeter or
resistance bridge, measure resistance of the tubes and lead assembly across Pins A
and B of the Pg tube connector. Resistance must be 10±0.7 ohms.
C. For Post-SB5409 engines: Pg and P3 tubes (Engine not mounted on the aircraft) (Ref.
Fig. 201)
(1) Use a suitable ohmmeter or resistance bridge, measure resistance of the individual
tube elements and leads assembly across Pins A and B. Resistance must be
20±1.4 ohms for each tube.
D. For Post-SB5458 engines: Pg tube (Engine mounted or not mounted on the aircraft)
(Ref. Fig. 202)
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
B B A
D VIEW D
A
VIEW C
A B
B A
VIEW E VIEW F
C139047
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MAINTENANCE MANUAL
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B A
G
VIEW G
C242273
Checking Resistance of Pg Heated Tube (Post-SB5458)
Figure 202
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
CHAPTER CHAPTER
SECTION PAGE DATE SECTION PAGE DATE
LEP 1 Jul 18/2016 204 blank Mar 09/2001
2 blank Jul 18/2016
73-20-04 201 Jun 05/2009
Contents 1 Jul 18/2016 Maintenance 202 Jun 05/2009
2 Jul 18/2016 Practices 203 Jun 05/2009
3 Jul 18/2016 204 blank Jun 05/2009
4 blank Jul 18/2016
73-20-06 201 Mar 09/2001
73-20-01 201 Dec 02/2013 Maintenance 202 Mar 09/2001
Maintenance 202 Dec 02/2013 Practices 203 Mar 09/2001
Practices 203 Dec 02/2013 204 Mar 09/2001
204 Dec 02/2013 205 Mar 09/2001
205 Dec 02/2013 206 Mar 09/2001
206 Dec 02/2013
207 Dec 02/2013 73-20-07 201 Dec 02/2013
208 Dec 02/2013 Maintenance 202 Dec 02/2013
209 Dec 02/2013 Practices 203 Dec 02/2013
210 Dec 02/2013 204 blank Dec 02/2013
211 Dec 02/2013
212 Dec 02/2013
213 Dec 02/2013
214 Dec 02/2013
215 Dec 02/2013
216 blank Dec 02/2013
TABLE OF CONTENTS
SUBJECT PAGE
5. Removal/Installation 201
5. Removal/Installation 201
6. Inspection/Check 205
A. Procedure 205
TABLE OF CONTENTS
SUBJECT PAGE
7. Storage 207
5. Removal/Installation 201
A. Removal 201
B. Installation 201
1. General 201
5. Removal/Installation 201
A. Removal 201
B. Installation 201
1. General 201
2. Consumable Materials 201
TABLE OF CONTENTS
SUBJECT PAGE
5. Removal/Installation 201
A. Removal 201
B. Installation 203
6. Re-priming 204
A. Procedure 204
1. General 201
5. Removal/Installation 201
A. Removal 201
B. Installation 201
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
5. Removal/Installation
NOTE: It is advisable to remove the complete assembly of fuel control units, fuel pump,
and oil-to-fuel heater as detailed in Subpara.A., following, before attempting to
remove the MFCU, AFCU or fuel pump.
(7) Remove bolts (6) and washers (7) and withdraw fuel inlet elbow (8). Remove
transfer tube (4) and preformed packings (3 and 5).
(8) Remove nuts and washers (9) and withdraw complete assembly from accessory
gearbox studs.
73-20-01
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
OIL−TO−FUEL ACCESSORY
HEATER (REF.) 6 GEARBOX (REF.)
3
10
7
1
5 8
9
4
AFCU 3
A 2
C
COUPLING
17
MFCU
FUEL PUMP
11
16
B
SOLENOID VALVE
25
12
13
PVR
C22085B
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MANUAL PART NO. 3040592
1. Pg Tube Connector
2. P3 Tube Connector
3. Preformed Packing
4. Transfer Tube
5. Preformed Packing
6. Bolt
7. Washer
8. Fuel Inlet Elbow
9. Nut and Washer
10. Gasket
11. Electrical Connector
12. Fuel Delivery Tube Connector
13. MFCU Throttle Shaft
14. Seal Drain Tube Connector
15. Py Tube Connector
16. P3 Tube Connector
17. Seal Drain Tube Connector
18. Pin
19. Cotterpin
20. AFCU Lever Arm
21. Nut and Cotterpin
22. Interconnect Linkage
23. MFCU Lever Arm
24. Nut
25. Spacer
26. Straight Pin
27. Sleeve Spacer
(1) Move throttle shaft (13) until indicator shows zero degrees.
(2) Move AFCU lever arm (20) to compress spring on linkage (22). Remove nut (24)
and spacer (25).
(3) Move AFCU lever arm so that linkage (22) is withdrawn from straight pin (26) and
remove straight pin from MFCU lever arm.
(4) Reinstall straight pin (26), spacer (25) and nut (24) on linkage (22) until replacement
MFCU is installed and linkage is to be reconnected.
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MANUAL PART NO. 3040592
(1) Disconnect bypass tube (12) at connector (20) on MFCU and connector (11) on
PRV (14). Remove tube.
NOTE: Due to difficulty in gaining access to bolts (24), fuel outlet tube is
disconnected from AFCU after removal of MFCU from pump.
(a) Disconnect fuel outlet tube connector (17) from straight nipple (15) on PRV.
(a) Remove bolts (16 and 26). Remove retaining plate (27) and withdraw inlet tube
from AFCU and MFCU.
(4) Disconnect seal drain tube (6) at fuel pump and connector (10).
(6) If interconnect linkage has not been disconnected, proceed as detailed in Subpara.
B. preceding.
(7) Remove nuts and washers (1) and withdraw MFCU from fuel pump studs (3)
Remove preformed packings (2).
(8) Remove bolts (24), withdraw inlet tube and remove preformed packing (25).
NOTE: Exercise care when withdrawing outlet tube (Ref. Detail A). Seat (29) and
screen assembly (30) are under spring pressure. Ensure that seat and
screen assembly remain with AFCU.
(b) Remove elbow and locknut (21), back-up ring (22) and preformed packing (23).
NOTE: Prior to installation, check MFCU lockwiring and locking seals for integrity. If
any are broken, send unit to an overhaul facility for serviceability check.
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MANUAL PART NO. 3040592
(a) Install connector (7), two new gaskets (8) and bolt (9) in MFCU seal drain port.
Do not torque at this stage.
(b) Install elbow and locknut (21), new preformed packing (23) and back up ring
(22) in fuel bypass port. Do not torque locknut at this stage.
(c) Install straight nipple (5) and new preformed packing (4) in MFCU fuel delivery
port. Torque 65 to 75 lb.in.
(2) Install new preformed packing (25) on fuel outlet tube. Ensure that screen assembly
(30) and seat (29) are installed and insert tube in AFCU port. Secure with bolts (24)
and torque 32 to 36 lb.in. and lockwire.
(3) Install new preformed packings (2) in recesses in MFCU/fuel pump mating face.
NOTE: If recesses in pump contain preformed packings which were not discarded
at MFCU removal or which were installed under the shipping plate on a
new pump, these preformed packings, must be replaced with new items of
the correct part number.
(4) Position MFCU on studs (3) and secure with nuts and washers (1). Torque 75 to
85 lb.in.
(b) Position PRV on MFCU and secure with bolts (13). Torque 32 to 36 lb.in. and
lockwire.
(c) Connect fuel tubes to PRV at connectors (11 and 17). Torque 90 to 100 lb.in.
and lockwire.
(7) Install the fuel inlet into boss of the AFCU. Install retaining plate (27) on the fuel
inlet tube with slot facing downwards and attach with bolts (26). Torque the bolts
32 to 36 lbf.in. and lockwire.
(8) Connect tube connector (20) to elbow (21). Torque connector (20) 90 to 100 lb.in.
Torque locknut on elbow (21) 38 to 42 lb.in. Lockwire connector and locknut.
(9) Install new preformed packing (19) and secure fuel inlet tube to MFCU with bolts
(16). Torque 32 to 36 lb.in. and lockwire.
(10) Connect seal drain tube (6) to fuel pump drain and at connector (10), to connector
(7) on MFCU. Torque connector (10) 90 to 100 lb.in. and connector bolt (9) 65 to
75 lb.in. Lockwire connectors.
(11) Connect linkage and install complete assembly of pump, AFCU and MFCU on
accessory gearbox (Ref. Subpara. E., following).
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
30
29
28 DETAIL A
A
FUEL PUMP
25 FUEL OUTLET 1
27 TUBE
26
2 3
23
6
22
21
20 19
18
8
17
15 7
12 8
16 9
14
10
11
6
13
12
C203298
Removal/Installation of MFCU
Figure 202
73-20-01
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(a) Before connection of linkage, fits and clearances must be checked (Ref. Table
201).
(a) Remove nut (24), spacer (25) and straight pin (26) from linkage (22).
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(c) Insert end of linkage (22) through straight pin and install spacer (25).
NOTE: If there is interference between spacer (25) and lever arm (23), chamfer
corners of spacer (Ref. Detail D).
(e) With AFCU lever arm (20) held against maximum stop, tighten nut (24) until
indicator on throttle shaft registers 95 degrees.
NOTE: 1. Each time adjustment of nut (24) is required, AFCU lever arm must
be moved to compress spring and free nut from tangs of spacer
(25). When 95-degree reading is achieved, ensure that nut flats
engage correctly in spacer tangs.
NOTE: 2. Final adjustment of interconnect lever is carried out during test (Ref.
71-00-00, POWER PLANT - ADJUSTMENT/TEST).
(6) Install new preformed packing (5) on inlet port face of fuel pump.
(8) Insert one end of transfer tube into oil-to-fuel heater boss and the other end into
elbow (8).
(9) Position elbow (8) on fuel pump and install bolts (6) and washers (7). Torque 36 to
40 lb.in. and lockwire.
(10) Connect fuel delivery tube connector (12) to straight nipple on MFCU. Torque 90 to
100 lb.in. and lockwire.
(11) Connect pneumatic tube connectors (16, 15, 2 and 1). Torque 90 to 100 lb.in. and
lockwire.
(12) Connect electrical connector (11) to solenoid valve. Tighten connector fingertight
plus five degrees and lockwire.
(14) Connect seal drain connector (14). Torque 90 to 100 lb.in. and lockwire.
(15) If new or overhauled MFCU has been installed, carry out depreservation procedure.
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Limits
REF.
NO. Name Min. Max.
Not Applicable
Limits
REF.
NO. Name Min. Max.
Not Applicable
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Limits
REF.
NO. Name Min. Max.
Not Applicable
7. Approved Repairs
(1) Disconnect fuel inlet tube connector (1) from straight nipple (2).
(2) Disconnect fuel bypass tube connector (5) from nipple on PRV (3).
(5) If replacement PRV is to be installed, remove straight nipple (2) and preformed
packing from PRV.
(6) Install new preformed packing and straight nipple (2). Torque 65 to 75 lb.in.
(8) Position PRV on MFCU and secure with bolts (4). Torque 32 to 36 lb.in. and
lockwire.
(9) Connect fuel bypass tube connector (5) to nipple on PRV. Torque 90 to 100 lb.in.
and lockwire.
(10) Connect fuel delivery tube connector (1) to straight nipple (2). Torque 90 to
100 lb.in. and lockwire.
(11) If new or overhauled PRV has been installed, carry out depreservation procedure.
NOTE: The solenoid can be removed with MFCU installed on the engine to facilitate
line maintenance requirements.
(2) Remove screws (3) and washers (4) securing solenoid valve (2) to MFCU. Remove
valve and discard preformed packings (5).
(3) Lubricate new preformed packings (5) with engine oil and install in ports on
solenoid valve block.
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(4) Install solenoid valve assembly on MFCU and secure with two screws (3) and plain
washers (4). Tighten screws, torque 20 to 25 lb.in. and lockwire.
(5) Connect solenoid electrical connection (1) tighten fingertight plus 5 degrees and
lockwire.
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MFCU
C9348
73-20-01
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5 3
C9341B
73-20-01
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MANUAL PART NO. 3040592
1. Electrical Connection
2. Solenoid Valve
3. Screw
4. Washer
5. Preformed Packing
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MAINTENANCE MANUAL
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1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this sectionrefer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
FCU Shipping Stand P/N 2529654
5. Removal/Installation
NOTE: If the AFCU is to be stored off the engine, prepare the AFCU for short or long
term storage (Ref. Storage) after removal is complete.
(1) Remove complete assembly of AFCU, MFCU and fuel pump from accessory
gearbox.
(2) Remove bolts (10 and 12) and retaining plate (13).
(3) Withdraw fuel tube (9) and remove preformed packings (11 and 14).
(4) Disconnect fuel tube connector (7) from nipple (8) on PRV.
NOTE: Due to difficulty in gaining access to bolts (17), fuel tube (16) is disconnected
from AFCU after removal from pump.
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AUTOMATIC FUEL CONTROL UNIT (AFCU) - MAINTENANCE PRACTICES Jul 18/2016
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
23
21
22
20 24
AFCU
DETAIL A 4
3
2 INTERCONNECT
1 LINKAGE 25
DETAIL C
6 FUEL PUMP
AFCU
5
NOTE:
C AFCU, MFCU AND FUEL PUMP
19 SHOWN SEPARATED FOR CLARITY
14 18
15
17
13
A
12 MFCU
16
9 16
11 8
B PRV
10
9
VIEW ON B
C165926
Removal/Installation of AFCU
Figure 201
73-20-02
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MANUAL PART NO. 3040592
1. Preformed Packing
2. Packing Retainer
3. Locknut
4. Elbow
5. Preformed Packing
6. Coupling
7. Fuel Tube Connector
8. Straight Nipple
9. Fuel Tube
10. Bolt
11. Preformed Packing
12. Bolt
13. Retaining Plate
14. Preformed Packing
15. Preformed Packing
16. Fuel Tube
17. Bolt
18. Nut
19. Washer
20. Seat
21. Screen
22. Pin
23. Cotterpin
24. AFCU Lever Arm
25. Cotterpin and Nut
(6) Remove nuts (18) and washers (19) and withdraw AFCU, complete with fuel tube
(16), from fuel pump studs.
(8) Remove coupling (6) and inspect for wear. Replace if splines are worn.
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NOTE: Exercise care when withdrawing tube (16) from AFCU (Ref. Detail A). Seat
(20) and screen (21) are under pressure of spring. Make sure that seat
and screen remain with AFCU.
(11) If a replacement AFCU is to be installed, slacken locknut (3) on elbow (4). Remove
elbow (4), packing retainer (2) and preformed packing (1).
(12) If original AFCU is to be reinstalled and AFCU lever arm (24) has been inadvertently
removed, lever must be reinstalled as detailed in Subparagraph B. following.
NOTE: 1. Prior to installation, check AFCU lockwiring and locking seals for integrity. If
any are broken, send unit to an overhaul facility for serviceability check.
NOTE: 2. When a replacement FCU is being installed, check the length of storage and
do reconditioning after storage (Ref. Storage).
(1) If a replacement AFCU is being installed, install elbow (4) and locknut (3) with new
packing retainer (2) and new preformed packing (1). Do not torque locknut (3) at
this stage.
(3) Make sure that screen (21) and seat (20) are installed in AFCU.
(5) Insert tube into AFCU boss and retain with bolts (17). Torque 32 to 36 lb.in. and
lockwire.
NOTE: If recess in fuel pump contains a preformed packing which was not
discarded at AFCU removal, or which was installed under the shipping
plate on a new pump, this preformed packing must be replaced with a new
item of the correct part number.
(7) Position AFCU on fuel pump studs, aligning coupling shaft with drive in AFCU.
(8) Install four nuts (18) and washers (19). Torque 75 to 85 lb.in.
(9) Connect tube connector (7) to nipple (8) on PRV. Torque 90 to 100 lb.in. and
lockwire.
(10) Install new preformed packings (11 and 14) on fuel tube (9).
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(11) Install the fuel inlet tube into boss of the AFCU. Install retaining plate (13) on the
fuel inlet tube with slot facing downwards and attach with bolts (12). Torque the
bolts 32 to 36 lbf.in. and lockwire.
(12) Secure tube (9) to MFCU with bolts (10). Torque 32 to 36 lb.in. and lockwire.
(13) If original AFCU is being reinstalled and lever arm (24) has been inadvertently
removed, reinstall lever arm as follows:
(a) Insert dowel pin in throttle shaft and install lever arm on shaft, aligning slots in
lever arm with tangs of cam and dowel pin.
(b) Rotate lever arm towards the maximum stop. If torque resistance is felt as per
NOTE preceding and lever is pointing upwards, install nut (24), torque 65 to
85 lb.in. and secure with cotterpin.
(c) If no torque resistance is felt, disengage lever arm from tangs and rotate tangs
from 180 degrees towards maximum stop. Reinstall lever arm and repeat step
(b) preceding.
(15) Install pin (22) and secure with new cotterpin (23).
(16) Install complete assembly of AFCU, MFCU and fuel pump on accessory gearbox.
(18) If new or overhauled AFCU has been installed perform depreservation procedure.
6. Inspection/Check
A. Procedure
(1) Check for fuel leakage between AFCU and fuel pump flanges or interconnect line.
No leakage is permitted.
(2) Check for fuel leakage or blue stain at AFCU vent hole (Ref. Fig. 202). No leakage
is permitted.
(a) Separate AFCU from fuel pump. Check for leakage at bypass port preformed
packing (5, Fig. 201). Replace preformed packing.
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BLUE GREASE ON
RETAINER PLATE IS
ACCEPTABLE
BLUE STAIN OR
FUEL AROUND VENT
HOLE − NOT ACCEPTABLE
C41931
73-20-02
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MANUAL PART NO. 3040592
(b) Inspect drive shaft bearing for blue grease. If grease has been washed away
by leaking fuel, send AFCU for repair/overhaul.
NOTE: Blue stain will be evident around the vent hole at the bottom of AFCU
7. Storage
A. Preservation of AFCU
(a) Fill the fuel section of the AFCU with calibrating fluid (PWC03-002) filtered
through a 10 micron filter.
(b) Install caps and plugs in all ports of the fuel section of the AFCU.
(c) Check the security of all caps and plugs in all ports of the air section of the
AFCU to prevent the entrance of dirt or other contaminates.
(e) Refer to Para. C., Packaging and Shipping, for protection from dirt and other
contaminants.
(f) Every ten days, check the fluid level in the fuel section of the unit and refill as
necessary.
(b) Fill the fuel section of the AFCU with preservative oil (PWC05-077) filtered
through a 10 micron filter.
NOTE: Tip the AFCU as necessary to make sure that a complete film of oil
goes into all ports and passages of the fuel section of the unit.
(c) Drain the excess oil as required and install caps and plugs in all ports of the
fuel section of the unit.
(d) Check the security of all caps and plugs in all openings of the air section of the
AFCU to prevent the entrance of dirt or other contaminates.
(f) Refer to Para. C., Packaging and Shipping, for protection from dirt and other
contaminants.
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CAUTION: DO NOT PERMIT FUEL OR OIL TO ENTER THE DRIVE BODY CAVITY OR
ANY AIR PRESSURE PORTS.
CAUTION: DO NOT ATTEMPT TO REPLACE ANY LOCKWIRE SEAL UNTIL THE AFCU
HAS BEEN CHECKED TO BE CERTAIN THAT CALIBRATION OR OPERATION
HAS NOT BEEN EFFECTED.
(1) Inspect all lockwire and lockwire seals. Replace broken lockwire after checking the
torque value of nuts, plugs, caps or screws that were lockwired.
(2) Return the unit for recalibration if any lockwire seal indicates tampering or if the
lockwire is broken.
(3) For units in storage three years or less, remove the plugs and drain preservation
fluid prior to the return to service. No further action is required.
(a) For units in storage three years or more but less than six years, ship the unit to
an approved overhaul facility (Ref. Step (7)) for the following:
(a) For units in storage more than six years, ship the unit to an approved overhaul
facility for reconditioning (Ref. step (7)) for the following:
4 Lubrication of unit.
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(a) For units installed on the engine and not used for up to 28 days, no specific
action is required.
(b) For units installed on the engine and not used for more than 29 days, remove
the AFCU from the engine and ship the unit to an approved overhaul facility for
reconditioning (Ref. step (7)) for the following:
(7) DELETED.
(1) When the AFCU is to be shipped or stored near salt water, prepare the unit as
follows:
(a) Make sure that all shipping plugs and caps are secure.
(b) Place the AFCU (2) on the shipping base (5) and secure with bolts (4).
(d) Put the AFCU and stand into a moisture and vapor proof container or plastic
bag and seal the opening. Attach a tag to the unit indicating the date of
storage.
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FUEL
1
OUT
9
2
FUEL
OUT
FUEL
IN 3
7
4
6 5
C88316
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
A. Removal
(1) Disconnect tubes (1) from tube cross (3). Cap open tubes and tube cross.
(2) Remove nut(s) (2) and withdraw accumulator (4) and clamps (5), or sealing cap (7)
and clamps (8), as applicable.
B. Installation
(1) Position accumulator (4) and clamps (5) or sealing cap (7) and clamps (8), as
applicable.
(3) Remove all caps from tubes (1) and tube cross (3).
(4) Connect tubes to tube cross and tighten coupling nuts (6) fingertight.
(6) Torque coupling nuts (6) 90 to 100 lb. in. and lockwire.
8
4
1
2 3
6 6
7
1
C22105A
Pg Accumulator - Removal/Installation
Figure 201
1. Tube
2. Nut
3. Tube Cross
4. Pg Accumulator
5. Clamps
6. Coupling Nuts
7. Sealing Cap
8. Loop Clamp
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
A. Removal
B. Installation
(1) If replacement governor is being installed, install new preformed packing (10),
back-up ring (11), locknut (12) and elbow (2). For installation of lever, refer to
the airframe maintenance manual.
NOTE: To prevent Nf governor cotter pin being damage (fractured), other end of
shaft should be held during torquing process.
1 2
13
12
11
10
9
14
8
3
7
4
6
5
C3063A
1. Pg Tube
2. Elbow Connection
3. Minimum Stop
4. Maximum Stop
5. Self-locking Nut
6. Lever Control Arm (airframe part)
7. Nut (airframe part)
8. Gasket
9. Mounting Studs
10. Preformed Packing
11. Backup Ring
12. Locknut
13. Coupling
14. Cotter Pin (airframe part)
(4) Position governor on studs and install nuts (5) and washers. Torque 75 to 85 lb.in.
(5) Connect Pg tube (1) to elbow (2). Torque connector 90 to 100 lb.in. and lockwire.
Torque locknut (12) 38 to 42 lb.in. and lockwire.
(6) If replacement governor has been installed, set minimum and maximum stops (3
and 4) as per applicable aircraft manual.
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
Not Applicable
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
Hypodermic Syringe 20cc capacity with No. 18 needle
Plastic Tubing 20 to 24 in. length of 1/4 in. I.D. capable of
withstanding 75 psi.
Adapter 7/16 - 20 UNF-3A
5. Removal/Installation
(3) Disconnect oil tube assemblies (15) from tees (2 and 6).
(4) Disconnect oil tube assemblies (1) from tees (2 and 6).
(6) Slacken locknuts (7 and 14) and remove tees (2 and 6), back-up rings (8) and
preformed packings (9).
6
2 15
1
15 5
7
4
8
14 9
5
TP2 PORT
4
TP1 PORT
3
10
13
13
11
12
13
10
C22100
(7) Install plugs (5) and preformed packings (4) in TP1 and TP2 ports.
(8) Remove three nuts and washers (3) from studs (13).
(10) Remove adapters (12) and preformed packings (11) and install blanking plugs in
open ports.
NOTE: Torque limiters are primed at manufacture and overhaul and do not require
re-priming at installation. However, if torque problems are encountered and
re-priming is necessary (Ref. 72-00-00, FAULT ISOLATION), prior to installation
carry out procedures detailed in Paragraph 6. following.
(3) Remove plugs (5) and preformed packings (4) from TP1 and TP2 ports.
(4) Top up with approved turbine engine oil to the first thread from top of ports.
(5) Install tees (2 and 6) complete with new preformed packings (9), back-up rings (8)
and locknuts (7 and 14) in TP1 and TP2 ports. Tighten fingertight.
(6) Remove blanking caps from oil tube assemblies (15) and connect to tees (2 and 6).
(7) Remove blanking caps from oil tube assemblies (1) and connect to tees (2
and 6).
(9) Torque connections on tube assemblies (1 and 15) 90 to 100 lb.in. and lockwire to
locknuts (7 and 14).
(10) Install adapters (12) and new preformed packings (11). Torque 65 to 75 lb.in. and
lockwire.
(11) Connect two Pg tube assemblies (10) to adapters (12), torque connections 90 to
100 lb.in. and lockwire.
6. Re-priming
Re-priming of torque limiter is carried out only when required following fault isolation (Ref.
72-00-00, FAULT ISOLATION) with unit removed from engine as detailed in Para. 5. A..
(2) Set up air supply as shown on figure and connect transparent tube to TP2 port.
(3) Fill tube with approved turbine engine oil and tap tube to release any trapped air.
(4) With TP2 port uppermost and tube vertical, slowly increase air pressure to 47 ± 2 psi.
(5) Maintain this position for 10 seconds and tap unit and tube to free entrapped air
from bellows.
(6) Turn unit so that Pg1 port is uppermost and repeat step (5).
(7) Maintain Pg1 port uppermost and slowly release air pressure (approximately 30
seconds).
(8) Turn unit so that TP2 port is uppermost and repeat step (5).
(9) Repeat steps (3) through (5) until bellows are completely filled with oil.
NOTE: Bellows are full when air bubbles are no longer seen in oil in transparent
tube.
(11) Check that oil level is between bottom and third thread in TP2 port. Adjust as
necessary.
PRESSURE GAGE
(0 TO 75 PSIG)
TUBE TRANSPARENT
(22 2 INCH INCH I.D.)
TP2 PORT
ADAPTER 7/16−20 UNF−3A THD
TP1 PORT
PG1 PORT
PG2 PORT
C22134
Torque Limiter Priming
Figure 202
(14) Repeat above procedure to prime TP1 bellows substituting TP1 for TP2 and Pg2
for Pg1.
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
Not Applicable
A. Removal
(1) Disconnect coupling nut (1) at elbow (2) and protect elbow and coupling nut with
blanking caps.
B. Installation
(1) Install accumulator (4) and temporarily secure with nut (3).
(3) Connect coupling nut (1) to elbow (2). Tighten nut, torque 90 to 100 lb.in., and
lockwire.
73-20-07
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3
2
C3066A
Py Accumulator - Removal/Installation
Figure 201
73-20-07
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1. Coupling
2. Elbow
3. Nut
4. Accumulator
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CHAPTER
SECTION PAGE DATE
LEP 1 Jan 26/2015
2 blank Jan 26/2015
TABLE OF CONTENTS
SUBJECT PAGE
A. System Components 1
B. System Operation 1
1. General 201
5. Adjustment/Test 201
A. General 201
The ignition system has been developed and adapted to provide quick light-ups over a wide
temperature range.
The system consists of two spark igniter systems; one for each power section.
Each spark igniter system comprises an exciter, two ignition leads and two spark igniters and
will operate from a 9 to 30 VDC supply.
The two spark igniters are mounted in floating housings at the 4 o’clock
and 11 o’clock positions on the gas generator case and protrude into the domed
end of the combustion chamber liner. The igniters are connected to the ignition exciter
by the two ignition leads.
B. System Operation
When the energy in a storage capacitor in the exciter reaches a level equivalent to four
joules, an arc is produced across a gap. This allows the stored energy to be discharged
to the igniters through a dividing and step-up transformer network. The network is such
that if one igniter is open or short circuited the remaining igniter will continue to
function.
74-00-00 Page 1
IGNITION - DESCRIPTION AND OPERATION Mar 09/2001
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MANUAL PART NO. 3040592
TYPICAL CONNECTION
A
IGNITION LEAD
GAS GENERATOR
CASE
SPARK
COMBUSTION IGNITER
CHAMBER LINER
DETAIL A
COMBUSTION
CHAMBER LINER
GAS GENERATOR
CASE
IGNITION LEADS
SPARK
IGNITER
EXCITER UNIT
C3025
Ignition System
Figure 1
74-00-00 Page 2
IGNITION - DESCRIPTION AND OPERATION Mar 09/2001
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
Not Applicable
Not Applicable
5. Adjustment/Test
A. General
The ignition system may be tested for correct operation while the engine is installed in
the airframe or with the engine installed in the maintenance stand.
B. Operational Check
(1) Disconnect coupling nut of one ignition cable from output connector on ignition
exciter.
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(3) Reconnect coupling nut of ignition cable to ignition exciter and remove other cable
coupling nut. Repeat step (2), preceding.
(4) If ‘‘snapping’’ sound is not heard on either check, replace ignition exciter and repeat
steps (1) through (3) preceding.
(5) If ‘‘snapping’’ sound is not heard on one check only, replace associated spark
igniter and repeat check. If spark igniter still fails, replace ignition exciter.
WARNING: PUT ON EYE PROTECTION WHEN YOU CUT THE LOCKWIRE. PIECES
CAN BREAK OFF AND CAUSE INJURY.
(6) Tighten the coupling nuts with your fingers, plus 45 degrees. Lockwire the coupling
nuts.
6. Fault Isolation
For detailed fault isolation of ignition system, refer to Chapter 72-00-00, FAULT ISOLATION.
74-00-00
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CHAPTER
SECTION PAGE DATE
LEP 1 Jan 26/2015
2 blank Jan 26/2015
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
5. Removal/Installation 201
7. Inspection/Check 204
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
Not Applicable
Not Applicable
5. Removal/Installation
(2) Remove supply cable (1 , Fig. 201) from input connector (2) on ignition exciter (3).
(3) Remove ignition cable couplings (6) from output connectors (5) on ignition exciter.
(4) Remove bolts, washers (4) and ignition exciter from the airframe.
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1
2
WARNING
4
VOLTAGE HIGH AMPERAGE
OUTPUT
DISCONNECT INPUT CURRENT
BEFORE SERVICING.
BEFORE OPERATING
CONNECT OUTPUT LEADS
AND IGNITER PLUGS.
C61A
74-10-00
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1. Supply Cable
2. Input Connector
3. Ignition Exciter
4. Bolt, Washer and Nut (Airframe-supplied)
5. Ignition Output Connectors
6. Ignition Cable Couplings
(2) Lightly coat threads of ignition exciter connectors with lubricant (PWC06-005).
WARNING: PUT ON EYE PROTECTION WHEN YOU CUT THE LOCKWIRE. PIECES
CAN BREAK OFF AND CAUSE INJURY.
(3) Connect the coupling nuts of supply cable (1, Fig. 201) and two high tension
ignition cable couplings (6) to the respective connectors (2 and 5) on the ignition
exciter (3). Tighten the coupling nuts with your fingers, plus 45 degrees. Lockwire the
coupling nuts.
(4) DELETED.
6. Cleaning/Painting
(1) Remove all corrosion residue using a stainless steel wire brush.
(2) Clean affected surfaces thoroughly using a clean lint free cloth moistened with
solvent (PWC11-023) or (PWC11-025).
74-10-00
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7. Inspection/Check
(2) Inspect ignition exciter input and output connectors for signs of corrosion. If
corrosion is evident clean and reprotect as detailed in Paragraph 6. A..
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CHAPTER
SECTION PAGE DATE
LEP 1 Jan 26/2015
2 blank Jan 26/2015
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
5. Removal/Installation 202
A. Removal 202
B. Installation 202
6. Inspection/Check 203
A. Inspection 203
7. Cleaning 203
A. Igniters 203
9. Adjustment/Test 207
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
Ohmmeter Model 260
74-20-00
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A. Removal
(1) Disconnect coupling nuts (4) of each cable (1) at ignition exciter (2), then at each
spark igniter (3).
(2) Remove self-locking nuts and bolts securing clamps (6) to gas generator case (5).
Remove cables.
(3) Remove spark igniters (3) from bosses on gas generator case (5). Remove
gaskets.
B. Installation
(1) Fit new gaskets on spark igniters (3) and install in bosses on gas generator case
(5). Torque igniters 300 lb.in., loosen to 0 lb.in. and retorque 300 to 360 lb.in.
(2) Lightly spray threaded portions of igniter plugs (3) and exciter unit (2) connections
with lubricant (PWC06-005).
WARNING: PUT ON EYE PROTECTION WHEN YOU CUT THE LOCKWIRE. PIECES
CAN BREAK OFF AND CAUSE INJURY.
(4) Install the coupling nuts (4) at the other end of the cables (1) on the respective
spark igniter (3). Tighten the coupling nuts (4) with your fingers, plus 45 degrees.
Lockwire the coupling nuts (4).
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(5) Locate clamps (6) on gas generator case and secure with bolts and self-locking
nuts. Tighten nuts and torque 36 to 40 lb.in.
6. Inspection/Check
A. Inspection
(b) Check for erosion in accordance with Table 201. Failure to meet the stated limit
will be cause for rejection.
(c) Inspect exterior of cylindrical area of firing end of igniter shell for chafing wear.
Wear is acceptable to a depth of 0.015 inch. If worn beyond 0.015 inch. also
inspect fuel nozzles sheaths for fretting wear (Ref. 73-10-05).
(d) If fuel nozzle sheaths are also worn beyond limits, remove power section and
inspect combustion liner components for cracking and/or evidence of distortion.
Replace liner as required. If condition of liner is acceptable, send power
section to an overhaul facility for investigation of gas generator.
7. Cleaning
A. Igniters
(1) Insert rubber stopper in cable terminal end of igniter to prevent entry of foreign
material during cleaning.
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5 3 6
1 6
C3056B
74-20-00
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1. Ignition Cables
2. Ignition Exciter (Airframe Mounted)
3. Spark Igniter
4. Coupling Nut
5. Gas Generator Case
6. Loop Clamps
(2) Clean igniter barrel with soft wire brush, and igniter threads with soft bristle brush.
(3) Remove rubber stopper from terminal end of igniter and clean igniter with clean
lint-free cloth moistened with envirosolv 655 (PWC11-005+) or acetone
(PWC11-012) or isopropyl alcohol (PWC11-014) or ardrox leeder 1064K
(PWC11-023+) or desoclean 45 (PWC11-025+) or as per SPOP 209.
(4) Dry igniter with clean lint-free cloth and dry, filtered, compressed air.
8. Approved Repairs
(1) Examine damaged area to make sure damage is not more than 0.375 in. in length,
edge of damage is at least 0.500 in. from nearest connector or flange and there is
no damage to underlying insulation.
CAUTION: SOLDERING IRON MUST NOT BE MORE THAN 250 WATTS. APPLY
ONLY ENOUGH HEAT TO FLOW SOLDER.
(3) Use solder (PWC05-058) with flux (PWC05-029) to solder damaged area. Overlap
damaged area by approximately 0.125 in.
74-20-00
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DIM. A
A A
CAUTION
SHOULD A SPARK IGNITER BE DROPPED, INTERNAL DAMAGE
POSSIBLY NOT DETECTABLE BY TEST CAN OCCUR.
RECOMMENDATION IS TO REPLACE THE SPARK IGNITER
C6312A
74-20-00
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(4) Clean braiding with clean cloth dampened with envirosolv 655 (PWC11-005+) or
acetone (PWC11-012) or isopropyl alcohol (PWC11-014) or ardrox leeder 1064K
(PWC11-023+) or desoclean 45 (PWC11-025+) or equivalent or as per SPOP 209
and then dry repaired area with filtered, compressed air not to be more than 30
psi.
(5) Smooth repaired area with abrasive cloth (PWC05-013) to blend with braided
surface. Repeat step (4), as required.
(6) Check cable assembly for continuity and insulation resistance prior to installation
(Ref. Para. 9.).
(1) Examine damaged area to make sure that damage that is more than 0.375 in. (Ref.
Subpara. A.) is not more than 1.000 in. in length and is at least 0.500 in. from
nearest connector, flange or existing repair. Replace ignition cable assembly if
damage is more than these limits.
(3) Wrap fiberglass insulating tape (PWC05-070) around cable braiding, covering all of
damaged area as shown.
(4) Wrap repaired area with stainless steel wire as shown. Hold wrapping wire snugly
along length of cable braid beginning from the left. Starting at opposite end, wrap
wire tightly and uniformly over cable braiding and repaired area.
NOTE: Make sure wire overlaps tape and contacts cable braiding at each end of
repair.
(5) When approximately two-thirds of wrapping is completed, allow short end of loop to
remain exposed. Continue wrapping wire to complete remaining distance, shown as
’’1/3X‘‘.
(6) After final turn of wrapping, insert wire ’’A‘‘ through loop as shown. Cut off surplus
end ’’B‘‘ of wire so that length is approximately one-third of repair length. Pull loop
end ’’C‘‘ until wire at ’’A‘‘ is snug and end ’’B‘‘ of wire disappears immediately
below the final turn of wrapping. Cut wire end ’’C‘‘ flush.
(7) Test cable assembly for continuity and insulation resistance prior to usage (Ref.
Para. 9., Adjustment/Test).
9. Adjustment/Test
A. Ignition Cables
(1) Check for continuity with an ohmmeter Model 260, or other low voltage continuity
device. Resistance from terminal to terminal must be 0.5 Ω max.
74-20-00
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INSULATING TAPE
B X
1/3 X
C
C4960C
74-20-00
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(2) Insulation resistance between metal braiding and inner cable must be 100 KΩ min.
NOTE: Return defective cables to an approved repair shop for inner cable
replacement.
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CHAPTER
SECTION PAGE DATE
LEP 1 Mar 09/2001
2 blank Mar 09/2001
Page 1/2
75-00 LEP Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
TABLE OF CONTENTS
SUBJECT PAGE
1. General 1
3. Fault Isolation 6
Page 1/2
75-00 CONTENTS Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
Three separate air systems are provided for the engine; one system for bearing compartment
sealing, a second for cooling air, and the third for compressor bleed valve and airframe
services.
Besides providing air for combustion and turbine drive, the airflow through the gas generator
section of the engine has various other functions in the peripheral systems associated
with engine operation.
Compressor interstage air (P2.5) is used to seal No. 1 bearing and, with compressor
discharge air (P3), is used to operate a compressor bleed valve which provides optimum
anti-stall characteristics at low compressor rotor speeds.
P3 air is also used to seal No. 2 and 3 bearing compartments, to cool compressor and
power turbine disks and the compressor turbine vane ring, to operate the pneumatic section
of the fuel control system and to pressurize the carbon seals in the reduction gearbox.
A P3 cabin air bleed port is provided by a boss at the 11 o’clock position on the gas generator
case. This boss may be blanked off if not required.
This system consists of a bleed valve which is bolted over a port at the 5 o’clock
position on the gas generator case inner section.
At low compressor speeds the valve opens to vent P2.8 air to atmosphere. At
higher speeds the valve remains closed.
Compressor interstage air is supplied directly to the valve from slots in the impeller
housing, and compressor delivery air (P3) is supplied from gas generator case
diffuser pipes through an internal pressure tube.
Compressor interstage air (P2.8) pressurizes the top side of the piston; P3 air is
taken through a primary orifice to a convergent-divergent orifice, which vents to
atmosphere. The control pressure (Px) arrived at between primary and
convergent-divergent orifice is used to pressurize the underside of the piston. When
P3 reaches a pre-selected value, the convergent-divergent orifice becomes
choked and pressure below the piston increases to close the valve. Below the
pressure at which the orifice becomes choked, interstage pressure moves the piston
75-00-00 Page 1
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C3002A_1
75-00-00 Page 2
AIR - DESCRIPTION AND OPERATION Mar 09/2001
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
C3002A_2
Engine Main Airflow
Figure 1 (Sheet 2)
75-00-00 Page 3
AIR - DESCRIPTION AND OPERATION Mar 09/2001
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
COMPRESSOR
DISCHARGE AIR
P2.8 INTERSTAGE AIR GAS GENERATOR CASE
P2.8 INTERSTAGE AIR
P3 P3
ROLLING
DIAPHRAGM DISCHARGE TO
ATMOSPHERE
PRIMARY COVER
ORIFICE Px
Pa Pa
NO.3 BEARING
C22142A
75-00-00 Page 4
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Pressurized air is used to seal No.1, 2 and 3 bearing compartments, and to cool
compressor and power turbines and compressor turbine guide vanes. Labyrinth
airseals protect bearing compartments, and consist of plain rotating surfaces
within stationary circular seals with deep annular grooves machined inside the bore.
When parts are matched, and the clearance between rotating and stationary
parts kept as small as possible, the air pressure drop across the seal prevents
passage of oil when the power section is running.
Compressor interstage air is used to provide a pressure drop across the No.1
labyrinth air seal. The air is taken, through holes in the third-stage compressor spacer
disk through the center of the compressor disks to outlet holes in the compressor
hub. The compressor hub and sleeve have slots which allow air to the center of the
double stator seal assembly, and air passes outward across both halves of the
seal. Air across one half of the seal is returned to the main airflow before the
compressor first-stage rotor. Air across the other half seal passes through holes in the
air seal stator, and matched holes in the compressor inlet case centerbore flange,
to the accessory gearbox housing.
No.2 bearing compartment is sealed by a double labyrinth air seal, and a single
labyrinth air seal. P3 air from around the combustion chamber outer exit duct pases
through holes in the gas generator case centerbore outer flange, and pressurizes
the double labyrinth air seal via hollow struts in the bearing compartment support
housing. Air passes from the seal central groove outward through half the seal to
rejoin the main air stream at the centrifugal impeller exit, and inward through half of
the seal, to be scavenged with oil.
The P3 air stream which pressurizes the seal, also passes down the leading face of
the compressor turbine to cool it. Pressure differential across No.2 bearing seal is
provided by part of this air stream flowing into the bearing compartment. The main
airflow is through holes in the compressor stub shaft to the centerbore of both
turbine disks. Air passes outward between the disks to cool their surfaces, and
through holes in the power turbine stub shaft to pressurize No.3 bearing labyrinth
seal.
No.3 bearing compartment is sealed from the power turbine by a double labyrinth
seal. Air passes outward through half the stator to join the main air stream through the
power section, and inward to seal the bearing compartment.
Compressor discharge air for the fuel control system is taken from a diffuser pipe to
a boss at the 7 o’clock position on the gasgenerator case to an air manifold
adapter and the reset regulator of the AFCU. Metered air from the regulator is
75-00-00 Page 5
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
taken to the power turbine governor and torque control unit on the reduction
gearbox. Compressor discharge air for pressurization of clutch carbon seals in the
reduction gearbox is taken from a second boss at the 7 o’clock position on the
gas generator case, directly to the reduction gearbox.
3. Fault Isolation
For detailed fault isolation of the air system, refer to Chapter 72-00-00, FAULT ISOLATION.
75-00-00 Page 6
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MANUAL PART NO. 3040592
CHAPTER
SECTION PAGE DATE
LEP 1 Jun 05/2009
2 blank Jun 05/2009
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
5. Removal/Installation 201
A. Removal 201
B. Installation 203
6. Adjustment/Test (Pre-SB5444) 203
C. Test 205
D. Check 206
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
A. Removal
(2) Remove bolts (2) and washers (3) securing bleed valve (1) to gas generator case.
(3) Withdraw bleed valve assembly together with spring pin (5).
(4) Pre-SB5318/Post-SB5339: Remove spring pin (5) and discard preformed packing
(4).
(5) Post-SB5318: Remove spring pin (5) and discard gasket (7).
1
5
2 1
PRE−SB5318
POST−SB5339 3
POST−SB5318
2
C3830D
B. Installation
(1) Pre-SB5318/Post-SB5339: Install spring pin (5) with new preformed packing (4) in
bleed valve (1).
(2) Post-SB5318: Install spring pin (5) in bleed valve (1). Install gasket (7) on bleed
valve (1).
(3) Ensure piston is free to travel. Install bleed valve assembly on gas generator case
and secure with bolts (2) and washers (3). Torque bolts (2) 16 to 20 lb.in.
6. Adjustment/Test (Pre-SB5444)
NOTE: 1. Pre-SB5380: The classified sets are introduced to control the valve closing point
to suit individual power sections. The lower the class number the later the valve
closes.
NOTE: 2. Post-SB5380: The compressor bleed valve assembly is provided with a secondary
metering orifice plug which controls the closing point on individual engines and
prevents engine surge. The lower the part number suffix (smaller orifice size), the
earlier the bleed valve closes.
(1) Obtain plug set required to solve problem (Ref. 72-00-00, ENGINE - FAULT
ISOLATION).
NOTE: On valves not provided with classified metering plugs sets, replacement
metering plugs must be the same size as original.
5 2
4
C7739A
1. Cover
2. Plug
3. Primary Metering Plug
4. Final Metering Plug
5. Preformed Packing
6. P3 Air Inlet
(a) Cut lockwire, remove final metering plug (4), blanking plug (2) and preformed
packings (5).
(1) Obtain plug required to solve problem (Ref. 72-00-00, ENGINE - FAULT ISOLATION).
(a) Cut lockwire, remove final metering plug (4) and preformed packing (5).
(1) Remove bleed valve and check that piston moves freely through its full travel in
housing bore.
(2) Blank off P3 air inlet (6) in valve housing and remove final metering plug (4).
(3) Inspect plug (4) for contamination. If necessary, clean with solvent (PWC11-027)
using a small artist-type brush.
(4) Remove blanking plug (2) and primary metering plug (3) (Ref. Subpara. A.,
preceding).
(5) Clean metering plug (3) with solvent (PWC11-027) using a wooden dowel to clean
orifice.
(8) Install test adapter, complete with preformed packing (5), in final metering plug port.
Pressurize unit to 40 ± 5 psig with clean, filtered shop air or nitrogen. Seal off valve
at this pressure.
(10) Remove test adapter and reinstall final metering plug (4), complete with new
preformed packing (5). Torque plug 35 to 40 lb.in. and lockwire.
D. Check
(a) Secure compressor bleed valve (3) and bracket assembly (1) (PWC50041) with
four bolts (2) and washers. Torque bolts 16 to 20 lb.in.
(a) Start engine (Ref. 71-00-00) and allow gas generator speed to stabilize at
ground-idle.
(c) Slowly accelerate engine until bubbles cease to flow through water in container.
(d) Plot closing point of bleed valve on graph (Ref. Fig. 204). Closing point shall
be within the gas generator speed band for indicated air temperature.
NOTE: If closing point exceeded, slowly decelerate gas generator speed until
bubbles are observed and repeat steps (c) and (d).
7. Adjustment/Test (Post-SB5444).
A. Initial Setting
(1) Turn the adjustment screw 11⁄2 turns or 9 flats of the screw clockwise to change the
manufacturer’s original factory setting.
NOTE: The manufacturer’s original factory setting is preset for general engine
applications. The adjustment screw requires a different setting to obtain
satisfactory closing point check.
NOTE: Refer to Figure 207, for details for manufacturing test fixture.
(1) Install new preformed packing (4, Fig. 201) on spring pin.
(2) Secure bleed valve to the test fixture (Ref. Fig. 207) with bolts and torque 16 to
20 lb.in.
(3) Remove final metering plug (1, Fig. 206) and preformed packing (7) from bleed
valve cover.
(4) Install a suitable blanking plug with preformed packing and torque plug 15 to 20 lb.
in.
1.5 IN.
(38.10 mm)
4 MAX. DEPTH
OF TUBE
IMMERSION.
5
1 WATER
3 2
DETAIL A (TYPICAL)
PRE-SB5444 C24665A
(7) Open the shut-off valve. Increase the pressure regulator setting until the pressure
gage indication is 35 to 45 psig.
(8) Apply leak-test fluid (PWC05-007) to all air line connections, blanking plugs and
bleed valve cover flange. Check for leakage. Rectify as required.
(9) With the gage reading 35 to 45 psig, note the reading and close the shut-off valve.
A pressure drop over a period of five minutes must not exceed 10 psig.
(a) If the leakage rate is exceeded, send complete compressor bleed valve to an
authorized accessory repair facility.
(10) Disconnect the air supply from regulator. Set pressure regulator to zero to release
pressure from bleed valve.
(11) Remove bleed valve from fixture. Remove blanking plug. Install new preformed
packing (7) on metering plug (1) and install metering plug in valve cover. Torque
plug 15 to 20 lb. in. and secure with lockwire (PWC05-089).
NOTE: Bleed valve closing point check is recommended when troubleshooting engine
performance/surge problems (Ref. 72-00-00, Fault Isolation).
(a) Turn the adjustment screw 1.5 turns or nine flats of the screw, clockwise to
change the manufacturer’s adjustment screw setting.
(b) Insert a piece of 0.001 inch shim stock between the bracket assembly tube end
and the compressor bleed valve flange and adjust bracket assembly accordingly
by loosening the hexagonal cap screws (2).
98
97
96
95
94
PERCENTAGE OF GAS GENERATOR SPEED (% Ng)
93
AREA ’B’ − REJECT
92
91
E
90 ABL
PT
CCE
89
’ −A
’A
88 ND
BA
87
86
85
83
82
81
−40 −30 −20 −10 0 10 20 30 40 50 60 70 80 90 100 ( °F)
−40 −30 −20 −10 0 10 20 30 35 ( °C)
OUTSIDE AIR TEMPERATURE (OAT)
96%
95%
94%
93%
TOLERANCE = −0.0%
+2.1%
92%
PERCENTAGE OF GAS GENERATOR SPEED (%Ng)
91%
90%
89%
88%
87%
86%
Alt = 0Kft
85% Alt = 5Kft
Alt = 10Kft
84%
Alt = 15Kft
83% Alt = 20Kft
82%
81%
80%
79%
−50 −40 −30 −20 −10 0 10 20 30 40 50 ( °C )
(POST-SB5444) C75363F
Compressor Bleed Valve Closing Point
Figure 204 (Sheet 2)
Px DIAGNOSTIC
PORT
DIFFUSER
FIXED
SECONDARY
VENTURI 0−40 PSI
THIS GAGE IS REQUIRED
FOR CALIBRATION
ADJUSTABLE TEST ONLY.
PRIMARY REMOVE FOR LEAK TEST.
ORIFICE
TEST FIXTURE
0−75 PSI
SHUT−OFF
VALVE
REGULATOR
FILTER
SHOP AIR
C71848
(c) Ensure the tube end secures the shim to the compressor bleed valve flange
and the flared end of the tube of the bracket assembly is in the groove made
by the compressor bleed valve and the seat. Re-torque the hexagonal cap
screws (2) using 16 to 20 lb.in.
(d) Secure the compressor bleed valve and bracket assembly with the four bolts
and washers. Torque bolts 16 to 20 lb.in.
(f) Insert other end of tube into clear container of water (5) where maximum depth
of tube immersion shall not exceed 1.5 inches. Ensure the container is vented.
(h) Start engine (Ref. 71-00-00) and allow gas generator speed to stabilize at
ground idle.
(j) Slowly accelerate engine until bubbles cease to flow through the water in
container. Do not exceed 97% (37,000 rpm). If bubbles continue at 37,000
rpm, adjust compressor bleed valve by 3 flats counterclockwise and repeat.
(k) Plot closing point of bleed valve on graph (Ref. Fig. 204).
1 Closing point shall be within the gas generator speed range for indicated
air temperature.
NOTE: A BOV set to close too soon or too late may contribute to
compressor stalls.
(l) Remove and adjust bleed valve closing point as required. Repeat Steps C.(f)
through C.(k) in order that Ng at the bleed valve closing point falls within limits
(Ref. Fig. 204):
NOTE: If closing point exceeded, slowly decelerate gas generator speed until
bubbles are observed and repeat steps above.
ADJUSTMENT
STEM
7 NOTCH
LOCK
6 BOLT
2
5
3
C73673A
(m) Remove bracket assembly (1) from compressor bleed valve (3) and secure
bleed valve (Ref. 5.B.(3)).
8. Approved Repairs
(4) Remove retaining plate (5) and diaphragm (6) from piston. Discard diaphragm.
(5) Using cotton swab moistened with petroleum solvent (PWC11-027) lightly wipe bore
of spacer sleeve (7).
(6) Using cloth moistened with solvent (PWC11-027) wipe inside of cover (3).
(7) Lightly smear piston top and mating flange of housing with compound (PWC09-003),
particularly the area around metering plug (8). Ensure metering plug remains dry
and orifice is unobstructed. Remove any excess compound inadvertently applied to
other surfaces.
(8) Install new diaphragm (6) with fabric side towards piston. Align bolt holes.
(9) Install retaining plate (5) on diaphragm and secure with bolts (4). Torque bolts 11 to
15 lb.in. and lockwire.
(11) Lightly smear cover mating flange with compound (PWC09-003). Locate cover on
valve housing, move piston up and down to ensure that diaphragm rolls correctly
between piston and housing. Secure cover with four self-locking nuts (1) and washers
(2). Check run-on torque and add 24 to 28 lb.in.
2.750 DIA.
4.100 DIA.
BOLT HOLE
0.190−32 UNJF
22 ° 30’
3.250
DIA. 22 ° 30’
PIN HOLE
13/64 DIA. (0.203)
0.750 0.750
1.500
DRILL AND TAP TO
ACCOMODATE AIR
SUPPLY EQUIPMENT
4.100 DIA.
MATERIAL: ALUMINUM
(4) Remove retaining plate (5) and diaphragm (6) from piston. Discard diaphragm.
(5) Remove two screws (12) and compressor bleed valve seat (11).
(6) Locate the three piston dampers on piston (insitu). Using an approved marker,
identify each one by writing a number on the piston surface next to each damper.
(7) Remove damper components and store in separate plastic bags identified with
corresponding location number (on piston surface) as follows:
(b) Remove damper retainer (13) from piston. Record the number of turns and
fraction of a turn from index mark (on piston) until retainer is fully released
from the piston.
(c) Place retainer in respective plastic bag. Remove spring (14) and bushing (15)
from piston and place in bag with retainer.
(9) Using cotton swab moistened with petroleum solvent (PWC11-027) lightly wipe bore
of spacer sleeve (7).
(10) Using cloth moistened with solvent (PWC11-027) wipe inside of cover (3).
(11) Lightly smear piston top and mating flange of housing with compound (PWC09-003),
particularly the area around metering plug (8). Ensure metering plug remains dry
and orifice is unobstructed. Remove any excess compound inadvertently applied to
other surfaces.
(12) Install new diaphragm (6) with fabric side towards piston. Align bolt holes.
(13) Install retaining plate (5) on diaphragm and secure with bolts (4). Torque bolts 11 to
15 lb.in. and lockwire.
(14) Lightly smear cover mating flange with compound (PWC09-003). Locate cover on
valve housing, move piston up and down to ensure that diaphragm rolls correctly
between piston and housing. Secure cover with four self-locking nuts (1) and washers
(2). Check run-on torque and add 24 to 28 lb.in.
WATER
5
3 2
1
DETAIL A (TYPICAL)
(POST-SB5444) C76914A
(a) Withdraw piston towards seat end of housing until damper orifices are
exposed.
(b) Install three damper bushings (15) and springs (14) in respective retainers.
Apply sealing compound (PWC09-002A) to threads.
(c) Adjust retainers equally. Turn each retainer the same number of turns that were
necessary to remove them.
NOTE: When installed, retainers must be 0.020 to 0.100 in. below surface of
piston.
(d) Before sealant has time to cure, adjust helical compression spring retainers
until a force of 1.0 to 2.0 lb. is required to move the compressor bleed valve
piston.
(e) Allow sealant to cure at room temperature for 24 hours. As an alternative, one
of the following methods can be used to reduce the time required to cure the
sealant:
1 Allow to stand at room temperature for one hour, then bake at 212 °F (100
°C) for 15 minutes.
2 Allow to stand at room temperature for one hour, then bake at 300 °F (149
°C) for 10 minutes.
3 Allow to stand at room temperature for one hour, with the compressor
bleed valve installed in the engine, run the engine at idle for five minutes.
(f) Push compressor bleed valve piston into compressor bleed valve housing
assembly. Install compressor bleed valve seat (11) and two screws (12).
Torque screws 6 to 7 lb. in.
8
7
A
10
NOTE: SURFACE A IS
OVERALL FABRIC
WITH IDENTIFICATION
INK STAMP
Pre-SB5330 C3930A
1. Self-locking Nut
2. Washer
3. Cover
4. Bolt
5. Retaining Plate
6. Diaphragm
7. Spacer Sleeve
8. Primary Metering Plug
9. Piston
10. Housing
11. Compressor Bleed Valve Seat
12. Screw
13. Damper Retainer (Post-SB5330)
14. Spring (Post-SB5330)
15. Bushing (Post-SB5330)
10
7 15
14
9 13
11
12
Post-SB5330 C71179
CHAPTER
SECTION PAGE DATE
LEP 1 Nov 16/2012
2 blank Nov 16/2012
TABLE OF CONTENTS
SUBJECT PAGE
1. General 1
2. Engine Monitoring 1
A. Gas Generator (Ng) and Power Turbine (Nf) Speed 1
1. General
The engine is equipped with the following monitoring devices to monitor engine performance
in flight, to ascertain engine mechanical condition and to ground check power output.
2. Engine Monitoring
Both torquemeters in the reduction gearbox are individually calibrated at engine test and
an associated index number is established for each and stamped on the reduction
gearbox plate. When each airframe supplied calibrated torque pressure transmitter is
installed on the reduction gearbox it must be adjusted to the associated torquemeter index
number.
Transmission of drive from third-stage to output shaft through helical gears results in
axial movement of the clutch drive shaft in response to torque changes (Ref. 72-10-00).
Axial movement is transmitted through No.10 ball bearing to the torquemeter piston
and piston cover, and then to the torquemeter valve. An increase in torque moves the
torquemeter valve inward in its sleeve and increases the coincidence of ports in (inlet)
sleeve and valve. Oil flow into the torquemeter chamber is thus increased and
pressure raised to a corresponding higher value. Conversely, when torque decreases
the ports become less coincident and oil flow decreases. A constant bleed of oil from the
torquemeter chamber ensures that no hydraulic lock occurs.
Airframe supplied oil pressure and temperature transducers are installed on the engine
to monitor power section and reduction gearbox oil systems. Power section oil
pressure and temperature are sensed by a transducer in the pressure oil return line in
the accessory gearbox. Reduction gearbox output section oil pressure is sensed by a
transducer above the output shaft in the pressure oil annulus surrounding the shaft.
Oil temperatures are sensed by airframe supplied thermocouple probes in accessory and
reduction gearboxes.
77-00-00
P&WC Proprietary Information. Subject to the restriction on the title page.
The export control classification with respect to this document is contained on the back of the title page.
Page 1
ENGINE INDICATING SYSTEM - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
77-00-00
P&WC Proprietary Information. Subject to the restriction on the title page.
The export control classification with respect to this document is contained on the back of the title page.
Page 2
ENGINE INDICATING SYSTEM - DESCRIPTION AND OPERATION Nov 16/2012
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
CHAPTER
SECTION PAGE DATE
LEP 1 Jan 07/2005
2 blank Jan 07/2005
Page 1/2
77-20 LEP Jan 07/2005
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
TABLE OF CONTENTS
SUBJECT PAGE
5. Removal/Installation 201
6. Inspection 205
A. Inspection/Check 205
B. Functional Check 206
7. Repair 206
Page 1/2
77-20 CONTENTS Jan 07/2005
PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name
Turbine Temperature Indicating System Test Set (Barfield 2312G-8)
5. Removal/Installation
(3) Cut and remove lockwire lacing from clips (1) on power turbine stator housing and
exhaust duct.
2
6
1
3
7
A
LOCKWIRE
DETAIL A 8
C12233
1. Clips
2. Power Turbine Stator Housing
3. T5 Thermocouple Installation
4. Probe Retaining Nut and Washer
5. T5 Thermocouple Wiring Harness Assembly
6. T5 Terminal Block
7. Terminal Posts
8. Bolt
9. Junction Box
(1) Position harness on power turbine stator housing with junction box at 6 o’clock
position.
(2) Install new washers on probes and partially insert probes at 8 o’clock and 4 o’clock
positions into bosses.
(3) Partially insert the next two probes into bosses simultaneously bending harness
around stator housing.
(4) Insert the remaining probes in the same manner until all probes are seated in
bosses.
(7) Torque nuts (4) and bolts (8) 40 to 50 lb.in. and lockwire.
(8) Secure harness in clips (1) with lockwire lacing (Ref. Detail A).
(9) Carry out continuity, insulation and probe heat response checks as detailed in
Inspection/Check (Ref. Para. 6.).
1
6
C3062A
(2) Remove bolts and self-locking nuts (4) securing compensator to mounting
brackets (6).
6. Inspection
A. Inspection/Check
(1) Inspect the installed probe and harness installation for security and signs of
damage.
(2) Check security of the two harness retaining clips on stator housing. One loose clip
is acceptable but must be removed. Rebrazing of a loose clip is not allowed.
(b) Apply heat to each probe tip in turn and check for a positive temperature
indication.
NOTE: A heat source such as a 100 watt soldering iron capable of heating
individual probes to 94°C (200°F) but not exceeding 540°C (1000°F)
may be used.
(c) Before proceeding to next probe, allow previously heated probe to cool to room
temperature.
(4) Check insulation by connecting one lead of test set to one of the terminal posts on
terminal block and the other lead to stator housing.
B. Functional Check
(1) Remove external leads from terminal block on gas generator case.
(2) Using Barfield Test Set Model 2312G-8 or equivalent, check insulation resistance of
harness when measured between either chromel or alumel terminal and ground.
Minimum acceptable resistance is 5000 ohms.
(3) Check continuity and loop resistance measured across chromel and alumel
terminals. Acceptable loop resistance is 1.8 to 2.6 ohms.
7. Repair
NOTE: The cement used for repair is supplied in two parts; a filler in powder form
and a binder in liquid form.
(2) Clean repair areas to ensure that all surfaces are free of grease and other
contaminants.
NOTE: The presence of any contaminant will adversely affect the physical and
electrical insulating properties of the cement mixture.
(4) If terminals on probe or terminal block are loose, apply a few drops of liquid binder
(PWC08-009) at junction of loose terminal.
(6) Cure for 24 hours at ambient temperature or heat in oven as applicable below.
CHAPTER
SECTION PAGE DATE
LEP 1 Sep 19/2008
2 blank Sep 19/2008
TABLE OF CONTENTS
SUBJECT PAGE
A. System Components 1
B. System Operation 7
The engine has three separate lubrication systems. Identical systems lubricate each power
section and the associated input section of the reduction gearbox. A third system lubricates the
reduction gearbox output section and additional lubrication for No.10-1/2 bearing.
Calibrated oil nozzles are used on main engine bearings to maintain optimum oil flow.
Each system is supplied by its main pressure pump. Oil is retrieved from power section
bearings by scavenge pumps. Each engine includes five detectors; three in the reduction
gearbox and one in each accessory gearbox. The chip detectors incorporate self-closing valves
which eliminate the need to drain oil when removing detectors for inspection.
Each system includes an oil filter. All three filters are mounted on the reduction gearbox.
The power section lubrication system pressure pump and three scavenge pumps
are mounted in the accessory gearbox which also houses an integral oil tank. The
filter assembly is mounted on a cover of the reduction gearbox.
The combined check and regulating and pressure relief valve assembly, the
oil-to-fuel heater and the centrifugal breather are all accessory gearbox mounted.
Pressure oil is circulated from each integral oil tank through its respective
power section lubricating system by a self-contained pressure pump mounted
on a boss on the rear face of the accessory gearbox housing casting. A screened
oil pump inlet is supplied with oil from the lowest part of the tank. An outlet
supplies pressure oil to a cored internal passage on the housing which connects
with the main check and pressure regulating valve mounted underneath the
housing.
The scavenge oil system for each power section includes three scavenge
pumps. One pump scavenges oil from No.3 and No.4 bearings and the reduction
gearbox input section, a second scavenges oil from No.2 bearing, and the
third scavenges oil from accessory gearbox sump to main oil tank. One scavenge
pump is mounted externally on the accessory gearbox cover, the other two
are mounted inside the gearbox.
The main pressure pump and the three scavenge pumps are gear-type and are
all mounted on a common shaft.
PRESSURE LINE TO
OIL FUEL HEATER
PRESSURE SENSE
LINE FOR RELIEF
VALVE OPERATION
PRESSURE OIL
CASTING PASSAGE TAKING SCAVENGE OIL TO COOLER
OIL TO ACCESSORY FROM NO.2 BEARING SCAVENGE FROM NO.3 & 4
GEARBOX BEARING BEARINGS AND REDUCTION
GEARBOX
UNDERSIDE VIEW
C3730B
TORQUEMETER SCAVENGE
PUMPS
CHECK VALVE
PRESSURE
REGULATING
VALVE
SCAVENGE OIL FROM
NO.2 BEARING
BYPASS VALVE
SCAVENGE OIL FROM
NO.3 & 4 BEARINGS
POWER SECTION
OIL FROM COOLER FILTER
EJECTOR TYPE
TO COOLER SCAVENGE PUMP
SCAVENGE OIL
SUMP AREA LUBRICATION FOR
OUTPUT GEAR MESH
LUBRICATION FOR
12 1_2 BEARING
PUMP LUBRICATION FOR
CLUTCH GEAR
BEARINGS
PRESSURE OIL
FROM
COOLER TO
COOLER
OUT PUT SECTION REDUCTION GEAR BOX OIL SYSTEM
C5645A
Engine Oil Systems - Component Location
Figure 1 (Sheet 2)
The oil tank is an integral part of the accessory gearbox assembly, its faces
being formed by the compressor inlet case and the accessory gearbox housing
casting (lower half). The tank has a total capacity of 1.6 U.S. gallons of
which 0.75 U.S. gallon is usable oil. An expansion space of 0.5 U.S. gallon is
provided.
The tank is provided with two filler necks and visual oil level indicators located
on either side of the gearbox. The inboard neck and indicator is blanked off.
A snap-type filler cap and strainer element is installed in the neck in use. A drain
plug in the bottom of the tank facilitates oil drainage.
Pressure oil from the pump normally holds open a check valve to allow oil
through an outlet port and two external pressure lines, one via the cooler to the
system filter and the other to the oil/fuel heater.
When return line pressure from oil system filter exceeds pre-set value, the
regulating valve is moved against spring pressure to open a port and allow
pressure oil to flow through a cored passage in the gearbox housing back to the
main oil tank. Oil flow to cooler is, therefore, limited by demand rather than
pump capacity.
TRANSFER TUBE
REDUCTION GEARBOX
INPUT HOUSING
REDUCTION GEARBOX
OUTPUT HOUSING
C3019A
Oil Filter and Bypass Valve - Schematic
Figure 2
C3020A
A single gear-type pressure pump driven from the output shaft supplies
lubricating oil to output shaft bearings and two gearbox composite third-stage
shaft bearings.
A spring loaded pressure relief valve, installed within the pump inlet housing,
regulates system pressure by allowing oil into the pump inlet when pressure
becomes excessive. This feature prevents cavitation and reduces the risk of
bearing erosion.
Oil is drawn through an inlet screen from an oil tank formed between input and
output housings and delivered to an oil cooler. Return oil from the cooler is
passed through a filter identical to those in power section oil systems, and
delivered to bearings.
(a) Lubrication
Lubricating oil for power section bearings, other than No.3 and 4 bearings, is
supplied from the oil filter through an external transfer tube that runs the length
of the power section. Oil for accessory bearings in the accessory gearbox
and No.1 bearing is taken through internal passages in gearbox castings to two
oil jets. One jet sprays bearings in the upper part of the gearbox, and the
other sprays bearings in the lower part, and No.1 bearing. No.1 bearing oil is
sprayed through a fine strainer and nozzle assembly directly on the bearing
races, and on to the compressor hub assembly coupling shaft to run in
grooves to the split inner race.
PUMP GEARS
INPUT HOUSING
TRANSFER TUBES
OUTPUT HOUSING
CHIP DETECTOR
CHECK VALVE
OUTLET TO COOLER
CHIP DETECTOR
PUMP INLET HOUSING
C22125
No.2 bearing lubricating oil is taken from a tee-piece in the external transfer
tube through a boss on the gas generator case at the 7 o’clock position. It is
taken internally through a cored passage in the gas generator case
centerbore to an oil gallery with two nozzles to lubricate both faces of the
bearing.
Oil for No.3 and 4 bearings is taken through internal cored passages in
reduction gearbox castings through a minimum pressure valve to an oil gallery
at the 12 o’clock position in the bearing housing. Nozzles direct oil to both
faces of No.3 bearing and one face of No.4 bearing.
Pressure oil for reduction gearbox input section bearings is taken from a
collection point through four separate casting passages. One passage sprays
oil inside the reduction gearbox input shaft to lubricate No.4 and No.5 bearings
centrifugally, and an offshoot from this passage lubricates No.6 bearing.
Another passage takes oil to cool the meshing teeth of input and second-stage
gears. The third passage takes oil to cool the meshing teeth of second-stage
and clutch gears and lubricate bearings No.7 and No.8. A fourth passage takes
oil to pressurize the torquemeter chamber and lubricate accessory gearshaft
bearings.
(2) Scavenge
Oil from No.1 bearing is returned by gravity to the bottom of the compressor inlet
case, and from there through an internal cored passage to the accessory gearbox
sump. Oil from No.2 bearing is returned via an internal scavenge tube to the
bottom of the gas generator case, and from there via an external scavenge line, the
check and regulating valve block on the accessory gearbox, and a further
external scavenge line to the externally mounted scavenge pump. Oil from No.3
and 4 bearings is returned from the reduction gearbox output housing sump area via
external scavenge line, check and regulating valve block, and external and
internal passages to the large internally mounted scavenge pump.
A ball valve in the externally-mounted scavenge pump allows excess oil vapor from
No.2 bearing to bypass the pump. The pump delivers oil to the accessory
gearbox sump, to be scavenged together with oil from No.1 bearing and the
accessory gearbox bearings by the smaller of the two internal pumps, and returned
through an internal passage to the main oil tank. The larger pump also delivers
oil through the same internal passage directly to the main oil tank.
In addition to the three main scavenge pumps, an ejector pump boosts scavenge
oil from No.3 and 4 bearings. A schematic diagram of ejector pump operation is
shown on Figure 5.
The pump operates on the venturi principle and utilizes pressure oil from the supply
line to No.3 and 4 bearings. The pressure oil, flowing at high velocity through a
restrictor nozzle in the pump housing causes sufficient reduction in pressure at the
throat area to suck the scavenge oil along the scavenge tube from the bearing
area. Scavenge and pressure oil from the ejector pump are sprayed into the sump
area at the bottom of the reduction gearbox input section, and scavenged from
there by the pump in the accessory gearbox. A high velocity flow of pressure oil is
PRESSURE OIL
RESTRICTOR NOZZLE
SCAVENGE OIL FROM
NO.3 & 4 BEARINGS
TO SUMP
C3022
necessary for efficient operation of the ejector pump and a spring loaded check
valve is therefore provided to prevent oil flow which might otherwise flood the bearing
compartment during run-up and run-down.
Casting passages take pressure oil from the filter to an annulus in the output
housing, and an offshoot from these passages supplies cooling oil to the mesh of
two reduction gearbox third-stage gears and output shaft gear. Two passages from
the annulus take oil to nozzles spraying inside the two No.10 bearings under
centrifugal flow, and to collect in integral reservoirs of each sprag clutch. From clutch
reservoirs, oil flows outward to lubricate bearings No. 10-1/2, 11, 12 and 12-1/2.
Additional lubrication for each 10-1/2 bearing is provided by pressure oil tapped from
the reduction gearbox system and conducted by a series of transfer tubes and
internal lines to pockets machined in the input housing near each clutch gear bearing.
Drilled holes in the pockets, direct a jet of oil onto each No. 10-1/2 bearing.
No. 15, 16 and 17 bearings are lubricated from the annulus.
The system relies on gravity to scavenge lubricating oil from bearings, oil returning
directly to the reduction gearbox oil tank. Carbon seals mounted on the clutch
gear, and pressurized by P3 air, prevent oil entering either reduction gearbox input
section. Seals are pressurized by P3 air from whichever power section has the
higher operating pressure. A breather tube in the output housing vents to atmosphere.
CHAPTER
SECTION PAGE DATE
LEP 1 Jul 18/2016
2 blank Jul 18/2016
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
5. Removal/Installation 201
A. Removal 201
B. Installation 203
6. Inspection/Check 204
7. Cleaning 205
5. Removal/Installation 201
A. Removal 201
B. Installation 201
1. General 201
TABLE OF CONTENTS
SUBJECT PAGE
5. Removal/Installation 201
A. Removal 201
B. Installation 201
1. General 201
2. Consumable Materials 201
5. Removal/Installation 201
A. Removal 201
B. Installation 201
OIL SCAVENGE AND PRESSURE TUBES- MAINTENANCE
PRACTICES 79-20-06
1. General 201
5. Removal/Installation 201
6. Inspection/Check 203
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
Not Applicable
The fixtures, equipment and supplier tools listed below are used in the following procedures.
Name Remarks
Cleaning Tank, Electrosonic Model KS5518 or Equivalent
NOTE: Removal/Installation procedures for the three oil filters on the reduction gearbox are
identical.
A. Removal
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
2
1
C3071A
79-20-02
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MANUAL PART NO. 3040592
1. Cover
2. Nut
3. Preformed Packing
4. Filter Element
5. Retaining Ring
6. Preformed Packing
7. Mounting Studs
8. Spacer (Post-SB5350)
9. Washer
(4) Remove retaining ring (5) and withdraw element from cover.
NOTE: 2. For the presence of silver flakes in the oil only: Certain engine bearing
cages are silver plated to enhance lubrication. After a period of operation
some of this plating may separate from the bearing cages and introduce
silver flakes into the oil. The reverse side of the silver flakes may carry
traces of copper flash, and the copper flash may be present in the oil
filter element. The separation of this silver plating and traces of copper
flash is acceptable and does not affect bearing performance or the
engine oil system. Refer to Chapter 72-00-00, ENGINE -
INSPECTION/CHECK, Unscheduled Inspections for maintenance
recommendations.
(6) Post-SB5350: Remove spacer (8) from oil filter cover (1).
B. Installation
(2) Install new preformed packing (6) in groove in internal bore of filter element (4).
(3) Insert element into cover (1) with lugs facing outwards.
(5) Install new preformed packing (3) and position filter assembly on mounting studs
(7).
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6. Inspection/Check
(3) Using a 10-power (minimum) magnifying glass, inspect element for clogged
passages and broken wires.
NOTE: 1. If dents and/or broken wires are found, element must be replaced.
NOTE: 2. If more than five percent of visible passages are found to be clogged,
filter element must be shipped to the nearest authorized P&WC overhaul
facility for ultrasonic cleaning and bubble point testing.
B. Patch Making
NOTE: Operators may send the contaminated filter or debris to a qualified laboratory
for filter patch check and/or analysis (Ref. 70-00-00, MAINTENANCE
PRACTICES).
(2) Using suitable tapered rubber plugs, seal inner cavity of filter element.
(4) Fill container with solvent (PWC11-027) or cleaner (PWC11-054) to cover filter
element and keep some space for liquid movement when shaking. Install cover.
(5) Shake container for about three minutes manually or 30 seconds in a vibrator.
Remove cover.
NOTE: Make sure there are no deposits left on filter. If yes, install container cover
and continue shaking.
(6) Turn vacuum pump ON and pour liquid contents of container into the filter (patch)
holder.
(7) Fill the container with solvent (PWC11-027) or cleaner (PWC11-054). Shake the
container and empty the container into filter holder to flush out all the remaining
loose particles. Remove filter element from container.
(8) Remove filter paper from filter (patch) holder and place in receptacle. Identify
sample with type of filter, engine number and TSN.
(9) Send sample to a qualified laboratory for material spectrographic analysis (Ref.
70-00-00, MAINTENANCE PRACTICES).
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MANUAL PART NO. 3040592
(2) Install suitable rubber or plastic plug (2) in element center tube.
(4) Fill the tank to approximately 1/4 inch below edge with cleaner (PWC11-054) or
solvent (PWC11-032) or solvent (PWC11-074) or petroleum solvent (PWC11-027)
or isopropyl alcohol (PWC11-014).
(6) Rotate element 180 degrees and operate cleaner for another 15 minutes.
NOTE: Adjust cleaning duration to suit condition of element and for optimum results,
replace solvent every 20 minutes of cleaner operation.
(7) Using clean lint-free gloves, remove element from tank and remove plug (2).
(8) Visually inspect element (Ref. Para. 6.). If necessary, repeat above cleaning
procedure.
(9) Dry element with clean filtered air at 29 psig (200 kPa) maximum, or allow to stand
in a clean environment until dry.
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MANUAL PART NO. 3040592
1 3
C6386A
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. Filter Element
2. Plug
3. Cleaner Tank
4. Cleaning Solution
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MAINTENANCE MANUAL
MANUAL PART NO. 3040592
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
Not Applicable
Not Applicable
A. Removal
CAUTION: TWO IDENTICAL FILTER BYPASS VALVES ARE LOCATED ONE IN EACH
REDUCTION GEARBOX COVER (NO.1 AND NO.2). A THIRD FILTER
BYPASS VALVE IS LOCATED IN THE LOWER PART OF THE INPUT HOUSING
AND, ALTHOUGH VERY SIMILAR IN APPEARANCE, IS NOT
INTERCHANGEABLE WITH THE OTHER TWO VALVES. THE LOCATION OF
EACH VALVE MUST BE TAGGED AS IT IS REMOVED.
B. Installation
(1) Insert valve (6) and spring (5) into gearbox cover (2).
(4) Insert valve (10) and spring (9) into input housing (1).
6 5 4
3
6
10 5 4
3
C3072A
1. Input Housing
2. Gearbox Covers
3. Plug
4. Preformed Packing
5. Spring
6. Valve
7. Plug
8. Preformed Packing
9. Spring
10. Valve
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
Not Applicable
Not Applicable
A. Removal
(1) Place suitable container under housing (7) to catch residual oil.
(2) Restrain cover (12) to prevent loss of springs (5 and 10) and remove bolts (1) and
washers (2).
(3) Carefully remove cover (12), valve housing (4), spring (5), check valve (6), spring
(10), spacers (9) and regulating valve (8).
(4) Blank off all exposed openings and store removed parts in a clean container until
required for installation.
B. Installation
(1) Install new preformed packings (3) in grooves in valve housing (4).
(2) Install spring (5) on housing (4) so that spring abuts shoulder on housing.
(3) Insert check valve (6) through spring (5) into valve housing (4).
LOCATION
VIEW 7
6
5
3
2
1 8
10
11
12
10 3
4
12
3
8
11
1
6
7 2
C22102
1. Bolt
2. Washer
3. Preformed Packing
4. Valve Housing
5. Spring
6. Check Valve
7. Housing
8. Regulating Valve
9. Spacers
10. Spring
11. Preformed Packing
12. Housing Cover
(5) Install required number of spacers (9) into body of regulating valve (8).
NOTE: The addition of one spacer raises oil pressure 3 to 4 psi. Removal of one
spacer lowers oil pressure by 3 to 4 psi. Maximum number of spacers is
12 but total thickness of all spacers must not exceed 0.400 inch.
(8) Install new preformed packing (11) on face of housing cover (12).
(9) Position housing cover on housing (7), install four bolts (1) and washers (2). Torque
bolts 32 to 36 lb. in. and lockwire.
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
Not Applicable
Not Applicable
NOTE: Prior to removal, note position of adjusting washers (2) in relation to collar on valve
(3) (i.e. number of washers above and below collar as seen through cutout in cover
(1)).
A. Removal
(2) Remove valve (3), washers (2) and preformed packing (4).
(3) Remove valve housing (5) and preformed packings (6 and 7) from accessory
gearbox.
B. Installation
(3) Install washers (2) on valve (3) in locations noted prior to removal or if oil pressure
adjustment is required, transfer washers to achieve required increase or decrease.
NOTE: Maximum oil pressure is obtained with all four washers above collar.
Each washer transferred below collar will reduce oil pressure between 2
and 3 psi.
5
ACCESSORY GEARBOX (REF.)
C3750A
1. Cover
2. Washers
3. Valve
4. Preformed Packing
5. Valve Housing
6. Preformed Packing
7. Preformed Packing
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
Not Applicable
3. Special Tools
Not Applicable
Not Applicable
5. Removal/Installation
A. Removal of Oil Scavenge and Pressure Tubes from Reduction Gearbox (Ref. Fig. 201)
(1) Remove nuts (18) and bolts (14) securing retaining plate (15) to rear fireseal.
(2) Remove nuts (8 and 11) and bolts (1, 2 and 3) securing brackets (9 and 10) and
clamps. Remove brackets and clamps.
(3) Ease transfer tubes (12 and 13) away from RGB.
(4) Remove retaining plate (15) and plastic rings (16 and 17).
(5) Remove preformed packings (5 and 6) and retainers (4 and 7) from transfer tubes.
Discard preformed packings.
B. Installation of Oil Scavenge and Pressure Tubes from Reduction Gearbox (Ref. Fig. 201)
CAUTION: WHEN THE ENGINE IS NOT INSTALLED ONTO THE AIRFRAME, THE
FIRE WALL SEALS ARE NOT ATTACHED AND WILL FLEX/BEND WHEN TOO
MUCH AXIAL MOVEMENT IS APPLIED TO THE OIL SCAVENGE AND
PRESSURE TUBES. THIS CAN EXPOSE AND PINCH BOTH THE OIL TUBES
PREFORMED PACKING AT THE PRESSURE REGULATING VALVE
HOUSING (AGB SIDE) AND CAN RESULT IN LOSS OF OIL DURING ENGINE
OPERATION.
(1) Install retainers (4 and 7) and new preformed packings (5 and 6) on scavenge tube
assemblies (12 and 13).
79-20-06
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CENTER FIRESEAL
MOUNT RING
REAR FIRESEAL
MOUNT RING
CENTER FIRESEAL
MOUNT RING
5
2 4
1 3
REAR FIRESEAL
MOUNT RING
6
7
8
9
10
11
12
13
14
15
16
17
18
C22760A
79-20-06
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MANUAL PART NO. 3040592
1. Bolt
2. Bolt
3. Bolt
4. Retainer
5. Preformed Packing
6. Preformed Packing
7. Retainer
8. Nut
9. Bracket
10. Bracket
11. Nut
12. Transfer Tube (Pressure)
13. Transfer Tube (Scavenge)
14. Bolt
15. Retaining Plate
16. Ring (Pressure)
17. Ring (Scavenge)
18. Nut
(2) Install plastic rings (16 and 17) in retaining plate (15) and install plate assembly
over tube assemblies (12 and 13).
(3) Insert tube assemblies (12 and 13) through rear fireseal mount ring and carefully
ease forward to engage with previously installed tubes at center fireseal.
(4) Secure brackets and clamps (9 and 10) to positioning bracket at flange C with nuts
(8 and 11) and bolts (1, 2 and 3). Torque nuts 36 to 40 lb.in.
(5) Secure retaining plate (15) to rear fireseal with nuts (18) and bolts (14). Torque nuts
36 to 40 lb.in.
(6) Inspect the condition of oil pressure and scavenge tubes at pressure regulating
valve housing (AGB side). Make sure that the preformed packings are not
exposed or pinched.
6. Inspection/Check
A. Inspect Rings
NOTE: It is not necessary to remove the tubes to proceed with this inspection.
Removing nuts (18) and bolts (14) will allow retaining plate (15) to slide over
tubes (12 and 13) giving access to plastic rings (16 and 17).
79-20-06
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(1) Measure plastic rings (16 and 17, Fig. 201) both inside and outside diameters (Ref.
Table 201).
NOTE: 1. If dimensions are out of tolerance, the plastic ring must be replaced.
NOTE: 2. Out of tolerance plastic rings can cause fretting in the area where tubes
are situated in the retaining plate.
(1) Inspect smaller diameter tube (12, Fig. 201) for fretting in the area where the
retaining plate was originally positioned.
(2) If fretting is present, measure the depth of the wear (Ref. Detail A).
NOTE: The maximum wear allowed must not be more than 0.020 inches from the
original surface.
(1) Inspect large diameter tube (13, Fig. 201) for fretting in the area where the
retaining plate was originally positioned.
(2) If fretting is present, measure the depth of the wear (Ref. Detail B).
NOTE: The maximum wear allowed must not be more than 0.024 inches from the
original surface.
79-20-06
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0.000
0.020
DETAIL A
0.000
0.024
NOTE: MAXIMUM PREMISSIBLE
WEAR 0.000 − 0.024 IN.
DETAIL B
C86852A
Scavenge and Pressure Tube Wear
Figure 202
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MANUAL PART NO. 3040592
CHAPTER
SECTION PAGE DATE
LEP 1 Nov 23/2015
2 blank Nov 23/2015
TABLE OF CONTENTS
SUBJECT PAGE
1. General 201
5. Removal/Installation 201
6. Cleaning 208
A. Chip Detector 208
B. Strainer 208
7. Inspection/Check 208
1. General
B. For additional information regarding Special Tools and Fixtures, Equipment, and
Consumable Materials referred to in this section, refer to section TOOLS/FIX/EQUIP or
CONSUMABLE MATERIALS respectively.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.
3. Special Tools
The special tools listed below are used in the following procedures.
Not Applicable
5. Removal/Installation
(1) Push chip detector (1) while turning 90 degrees counterclockwise. Remove chip
detector from valve housing (3).
(3) Examine chip detector (1) for metal. Identify metal if found (Ref. 72-00-00).
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13
10
B
11 A A
12
2 8
7
1
DETAIL B
13
10 9
4
11
12
3 5
INCORRECT
SEATING
2 ENSURE STRAINER IS
1 LOCATED ON FLANGES
DETAIL A
(TYPICAL) CORRECT
SEATING
C22136B
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(b) Insert fitting (PWC38147) into housing and turn 90 degrees clockwise to open
valve and allow oil to drain.
(e) Remove bolt (5), washer (6), adapter (7) and preformed packing (8).
(f) Remove strainers (9) from the No. 1 and the No. 2 power section chip detectors.
(1) Cut lockwire and remove chip detector (12) from valve housing (10). Discard
preformed packings (11).
(b) Screw fitting (PWC30793) into housing to open valve and allow oil to drain.
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(3) Disconnect the torque control tube. Remove four bolts (5), washers (6), adapter
assembly (7), preformed packing (8) and strainers (9). Remove the strainers (9)
from the No. 1 and the No. 2 power section chip detectors.
(1) If strainer (9) has been removed install strainer in reduction gearbox with rim outward.
(2) Install preformed packing (8), adapter (7) and secure with bolt(s) (5) and washer
(6). Torque bolts 36 to 40 lb.in. and lockwire.
(4) Install valve housing (3) into adapter (7) or reduction gearbox, as applicable. Torque
housing 175 to 225 lb.in. and lockwire.
(6) Push chip detector into valve housing (3) and turn 90 degrees clockwise to lock in
position. The chip detector must move back when fully installed, and the scallop on
detector must align with flat on the valve housing.
D. RGB Chip Detectors - Installation (Post-SB5312 and Pre-SB5354) (Ref. Fig. 201)
(1) If strainer (9) has been removed, install strainer in reduction gearbox with rim
outward.
(2) Install new preformed packing (8) on adapter (7). Install adapter on reduction
gearbox. Secure with two bolts (5) and washers (6). Connect torque control oil
tube to adapter (7). Torque oil tube connection 65 to 75 lb.in. and bolts (5) 32 to
36 lb.in. Lockwire bolts and connection.
(4) Install valve housing into adapter (7) or reduction gearbox, as applicable. Torque
housing 175 to 225 lb.in. and lockwire.
79-30-01
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(6) Install chip detector (12) in valve housing (10). Torque 45 to 55 lb.in. and lockwire.
(a) From the housing, remove the incorrect identification painted stripes with paint
remover (PWC12-003).
(b) Align with the stripes on the connector and paint three equally spaced colored
identification stripes on housing with epoxy enamel paint (PWC07-015) or
suitable red paint.
(1) Push and turn chip detector (1) 90 degrees counterclockwise to remove from valve
housing (3).
NOTE: Removal of chip detector causes detector valve to close preventing loss of
oil.
(3) If complete assembly of detector (1) and valve housing (3) is to be replaced,
proceed as follows:
(b) Insert fitting (PWC38147) into housing and turn 90 degrees clockwise to open
valve. Allow oil to drain.
(1) Remove lockwire and chip detector (5) from valve housing (8).
(3) If complete assembly of detector (5) and valve housing (8) is to be replaced
proceed as follows:
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A A
8
7
6
5
2
1
DETAIL A
C22137A
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1. Chip Detector
2. Preformed Packing
3. Valve Housing
4. Preformed Packing
5. Chip Detector (Post-SB5312)
6. Preformed Packing (Post-SB5312)
7. Preformed Packing (Post-SB5312)
8. Valve Housing (Post-SB5312)
(b) Screw fitting (PWC30793) into housing to open valve. Allow oil to drain.
(b) Install valve housing in boss. Torque 175 to 225 lb.in. and lockwire.
(3) Push chip detector into valve housing and turn 90 degrees clockwise to lock in
position. The plug must move back when fully installed, and the scallops on plug
must align with flat on valve housing.
H. AGB Chip Detector - Installation (Post-SB5312 and Pre-SB5354) (Ref. Fig. 202)
(b) Install valve housing (8) in boss. Torque 175 to 225 lb.in. and lockwire.
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(a) From the housing, remove the incorrect identification painted stripes with paint
remover (PWC12-003).
(b) Align with the stripes on the connector and paint three equally spaced colored
identification strips on housing with epoxy enamel paint (PWC07-015) or
suitable red paint.
6. Cleaning
A. Chip Detector
B. Strainer
(1) Agitate strainer in clean unused petroleum solvent (PWC11-027) and clean with
soft-bristled brush.
(3) Dry with clean, dry, filtered compressed air or allow to stand in a clean environment
until dry.
(4) Repeat above procedure as necessary using clean unused solvent each time.
7. Inspection/Check
(1) Using suitable ohmmeter, check for electrical circuit continuity when the two poles
are shorted together. Reject component if no continuity.
(2) Check condition of pins and potting compound. Loose pins and/or broken potting
compound are cause for rejection.
(3) Do a check for minimum weight lift capacity of the magnet. The magnet must lift a
steel weight of 6 oz minimum. If the magnet does not lift the minimum weight,
replace the chip detector.
NOTE: Use a steel weight that allows a maximum surface contact of the chip
detector magnet (i.e. flat steel bar or circular weight with holes that
engage the detector magnet).
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(2) Put magnet end in solvent (PWC11-027) or cleaner (PWC11-054) to remove oil.
(3) Transfer debris at magnet end to clear adhesive tape and identify with engine S/N,
and TSN or TSO.
(a) Send debris to qualified laboratory for analysis (Ref. 70-00-00, MAINTENANCE
PRACTICES).
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