T.O. 2G-GTCP85-43-12 TECHNICAL MANUAL DEPOT MAINTENANCE MANUAL (PARTIALLY VERIFIED) LUBRICATION COMPONENTS MAINTENANCE PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE MODELS GTCP85-180 GTCP85-180L GTCP85-180(C) GARRETT N00019-80-6.0602 BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICA- TION. ‘This publication is one of thirteen manuals covering Depot Maintenance. They are numbered 7.0. 2G-GTCP85-41-1 and T.O. 2G-GTCP85-43-1 through T.0. 2G-GTCP85-43-12. DISTRIBUTION STATEMENT - Distribution authorized to U S Government agencies only for administrative operational use. Other requests fr this document shal be reterredto’San Anton ALC/ MMOD, Kelly AFB TX 78241-5000. Warning This document contains technical data whose export is restricted by the Arms Export Control Act {Tite 22, USC, See 2751 et. seq.) or the Export Administration Act of 1979, as amended (Tite 50, U.S.C. ‘App. 2461 et. seq). Violations of these export laws are subject to severe criminal penalties. Handing and Destruction Notice - For unclassified, limited documents, destroy by any method that will prevent disclosure of the contents or reconstruction of the document. Published under authority of the Secretary ofthe Alr Force 14 MAY 1986 CHANGE 2 - 15 APRIL 1989 ‘AIR FORGE 29 Mer 90-900 REPRINT7.0, 26-GTCP85.43:12 RECORD OF CHANGES Total number of pages in this manual is 104 Page Change No. No. Title. 1 2 NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES NOTE Only those work packages and subordinate work packages assigned to this manual are listed in this index. Change pages are issued to a work package (WP) or subordinate work package (SWP). Insert the changed pages in the applicable work package or subordinate work package. The portion of the text affected in a change or revised WP or SWP is indicated by change bars or the change symbol “R” in the outer margin of ‘each column of text. Changes to illustrations are indicated by pointing hands or change bars, as applicable. Changes to wiring diagrams are indieated by shaded areas. NOTE: This change was produced through the Automated Technical Order System (ATOS). Backup pages Produced in ATOS are shown as being changed, although no changes have been effected. ‘These pages will Not contain change symbols. The list of etectve pages shows allthe peges in this publication and the latest change Issued to each page. Insert latest changed pages; destroy superseded pages. WP/SWP *Change Number Title Number 00100 Alphabetical Index. 002.00 Introduction 008.00 Oil Cooler Assembiy Part No. 152050-4 and Oil ‘Temperature Regulator Assembly Part No. 87520. 00400 Oil Pump Assembly Part No. 371976-14/-18/-24.. 005.00 Nonrecoverable Component... ‘Zero in this column indicates an original WP/SWP. A Chenge 27.0. 2G-GTCP85-43-12 WP 004 00 WORK PACKAGE TECHNICAL PROCEDURES LUBRICATION COMPONENTS MAINTENANCE, OIL PUMP ASSEMBLY PART NO. 871976-14/-18/-24 EFFECTIVITY: ENGINE MODELS GTCP865-180 GTCP85-180L, GTCP85-180(C) LIST OF EFFECTIVE WP PAGES RECORD OF CHANGES Original .. 14 May 86 Change . 80 Sep 88 Change “15 Apr 89 ‘Total Number of Pages in this WP is 46 PAGE CHANGE NO. NO. Change 2 11.0, 2G-GTCP85-43-12 WP 004 00 1, APPLICABLE SUPPORT EQUIPMENT, ‘Tool No. PEC9087-1/-2 T2R1810 25-241 284584-1-1 296987-1 Nomenclature Seal Mold (Naval Air Rework Facility, Marine Corps Air Station, Cherry Point, NC 28533) Test Block (Crissar Ine, 38905 10th St, E Palmdale, CA 93550 or equivalent) Dial Indicator Cover, Filter Puller, Mechanical, Seal (Puller) V-Block 2. APPLICABLE TCTO’S. None. 8, REFERENCE MATERIAL REQUIRED. Aireraft and Missile Repair, Structural Hardware Anodic Coatings for Aluminum and Al inum Alloys Chemical Conversion Coatings on Aluminum and Aluminum Alloys: General Information, Depot Maintenance Manual General Maintenance Instructions for Support, Equipment ‘Methods of Preservation-Packagi Non-Destructive Inspection Methods 2 Change 2 Item/Figure No. vt 2/TL TO. 11A8 MIL-A-8625 MIL-C-5541 7.0. 2G-GTCP85-43-1, WP 003 00 7.0. 11A-15 MIL-P-116 7.0. 333-14T.0. 2G-GTCP85-43-12 TECHNICAL MANUAL DEPOT MAINTENANCE MANUAL (PARTIALLY VERIFIED) LUBRICATION COMPONENTS MAINTENANCE PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE MODELS GTCP85-180 GTCP85-180L GTCP85-180(C) ‘OARRETT Nooo1s80-00602 This publication le one of thirteen manuals coverlng Depot Maintenance. They are numbered 7.0. 26-GTCPRS- 44-1 and T.0. 26.4TCP85-43-1 through .0. 20-aTCPES-43.12, Distribution - Authorized to the Dopartmont of Defense and US DoD contractors only (Administrative and Opers- tlonal Use). Other requests for thls document shall be referred to SA-ALG/TIRT, Kelly AFB TX 762445000, nlcal data whose export is restricted by the Arms Export Control Act Exort Annan fet of 1878, 8 amanda (le 80, US. xport laws are subject to severe criminal porate ‘and Destruction Notice - For unclassified, limited documents, destroy by any method that will prevent Glcloure of tho contents or teconsuucion ote document, Published under authority ofthe Secretary of the Al Force 14 MAY 1986 CHANGE 2 |. 15 app 1aqad7.0, 26-6TCP85-43-12 RECORD OF CHANGES Original ° 14 May 86 Change... 1 80 Sep 88 Change vernon 15 Apr 89 Change ve ynee Bo 15 Apr 92 wP/SwP Number 001 00 002 00 003 00 004 00 005 00 ‘Total Number of Pages in this manual is 104 LIST OF EFFECTIVE FRONT MATTER PAGES Page ‘Change No. No. Title 3 Bp siess 3 NOTE: This change wae produced through the Automated Technical Order System (ATOS). Backup pages produced In ATOS are shown as belng changed, although no changes have been effected. Thove pages will not Contain change symbols. The list of effective pages shows all tho pages inthis publication and the latest ‘change leued to each page. Insort latest changed pages; dextroy wuperseded pages. NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES. NOTE Only those work packages assigned to this manual are listed in this index. Insert changed pages in front matter, and in applicable work packages. Text affected in a changed or revised WP is indicated by change bars or change symbol R in outer margin of each column of text. Changes to illustrations are indicated by pointing hands or change bars. Changes to wiring diagrams are indicated by shaded areas. *Change mt Number Alphabetical Index... 1 Introduction... 3 neeea st 1 Oil Cooler Assembly Part No. 152050-4 and Oil... 1 ‘Temperature Regulator Assembly Part No. 87520-3 .. Oil Pump Assembly Part No. 371976-14/-18/-24.. 3 Nonrecoverable Components nnn 1 *Zero in this column indicates an original WP/SWP a7.0. 2G-GTCP85-43.12 WP 003 00 WORK PACKAGE TECHNICAL PROCEDURES LUBRICATION COMPONENTS MAINTENANCE OIL COOLER ASSEMBLY PART NO. 152050-4 OIL TEMPERATURE REGULATOR ASSEMBLY PART NO. 875203 EFFECTIVITY: ENGINE MODELS GTCPS5-180 GTCPS5-180L, GTCP85-180(C) LIST OF EFFECTIVE WP PAGES RECORD OF CHANGES ‘Total Number of Pages in this WP is 38 PAGE CHANGE NO. ‘NO. Change 1 17.0. 2G-GTCP85-43-12 WP 003 00 1, APPLICABLE SUPPORT EQUIPMENT. Tool No. Nomenclature 253057 Holder, Oil Temperature Control Valve (Holder) 253426 Puller, Tube (Puller) 259752 Holder, Tube (Holder) 2587541 Puller, ‘Tube (Puller) 258755 Handle, Tube (Handle) 253756-8/-9/-10/- Tip, Bumping Tube (Tip) 11/-28/-29 256066, Roller, Burring Tube (Roller) 256068, Roller, Tube Expander (Expander) 256070 Tip, Pulling Tube (Tip) 256071 Loosening Tool, Tube (Loosening Tool) 256116-1 ‘Swaging Assembly, Machine-Tube and Header, (Swaging Assembly) 256121-18/-20/-21 Bit, Swaging Machine (Bit) 257990 Stand, Test, Oil Temperature (Test Stand) 258834 Adapter, Leakage Test (Adapter) 258834-2 ‘Adapter, Leakage Test (Adapter) 262730 Cutter, Valve Seat (Cutter) 2, APPLICABLE TCTO'S. None. 8, REFERENCE MATERIAL REQUIRED. Corrosion Prevention and Control for Aerospace 7.0. 1412 Equipment General Information, Depot Maintenance Manual 1.0. 2G-GTCP85-43-1, WP 003 00 Non-Destructive Inspection Methods 7.0. 33B-11 2 Change 1 Item/Figure No. wT 2/TL 3/TI 4/71 5/TL 6/TL TL 8/TL 9/TL 10/T1 nT 12/71 13/TL 4/TL 15/T1m a 7.0, 2G-GTCP85-43-12 WP 003 00 ‘WARNING Corrosion preventive compounds are flammable and may affect skin, eyes and respiratory tract. Use in a well-ventilated area. Chemical goggles, neo- prene gloves, rubber apron and coveralls shail be worn, Keep away from sparks and flames. Respira- tor shall be worn unless waived by the Bioenviron- mental Engineers, Block off 011 passage of ofl cooler and immerse with test panel in corrosion preventive compound (43-30). Shake or vibrate immersed parts to remove air bubbles. Remove oi] cooler and test panel from solution and allow to drain, Direct air on close parts to remove excess solution, Allow 15 minutes to air “dry prior to handling, Check coated surfaces for high specular gloss, uncoated surface is distin- guishable. Wrinkled areas of coating are not cause for rejection, however un- cured pockets of coating are not acceptable. Using back edge of knife blade, scratch test panel coating. There shall be no evidence of chipping or flaking. Should flaking occur, discard and replace Corrosion preventive compound (43-30), WARNING Acetone is flammable and may affect skin, eyes and respiratory tract. Use in a well-ventilated area, Avoid prolonged breathing of vapors. Avoid eye and Tepeated skin contact. Keep away from sparks and ames. Stripping solution may affect skin, eyes and respiratory tract. Use in a well-ventilated area. Industrial goggles/face shield and neoprene gloves shall be worn, Keep away from sparks and flames, Respirator shall be worn unless waived by the Bio- environmental Engineers, When test panel indicates defective coating, remove uncured coating by vapor degreasing using acetone (43-5), If ofl cooler has been baked, remove by im- mersing in paint remover (43-62). Repeat steps a through 1. iT.0, 2G-GTCP85-43-12 we 003 00 WARNING Handling hot items presents a serious burn poten- tial. Non-asbestos heat resistant gloves shall be worn, 0. Cure coating by placing of] cooler and test panel in oven at 275 to 300°F (130 to 148°C) 1 1/2 to 2 1/2 hours. Acetone is flammable and may affect skin, eyes and respiratory tract. Use in a well-ventilated area. Avoid prolonged breathing of vapors. Avoid eye and Tepeated skin contact. Keep away fron sparks and james. p. Check test panel for adequacy of curing process by swabbing with a cloth soaked in acetone (43-5). The coating shall be unaffected. WARNING Handling hot items presents a serious burn poten- tial, Non-asbestos heat resistant gloves shall be worn. q. Steam clean outside of oil cooler. WARNING Primer may affect skin, eyes and respiratory tract. Use in a well-ventilated area. Avoid prolonged breathing of vapors. Avoid eyes and repeated skin contact. Keep away from sparks and flames. Handling hot items presents a serious burn poten- tial, Non-asbestos heat resistant gloves shall be worn. r. Apply one coat of primer coating (43-68). Air-dry for 2 hours or bake at ap- proximately 150°F (66°C) for 1/2 hour. 36T.0. 2G-GTCP85-43-12 TECHNICAL MANUAL DEPOT MAINTENANCE MANUAL (PARTIALLY VERIFIED) LUBRICATION COMPONENTS MAINTENANCE PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE MODELS GTCP85-180 GTCP85-180L GTCP85-180(C) ‘GARRETT Nooo1s-80-0.0802 TBs puoton incorporates Special Handing APLC Form 252, Project Number SOFSALDPGOSAOR, dated 24 November 1982; which will be removed from active TB pubs oe of htogn manual covering Depot Malnenane. They are numbered .0, 260TCP8S. ‘44-1 and T.0. 20.0TCPB5-43-4 through 7.0. 200TCPSI DISTRIBUTION STATEMENT - Distibution authorized to the Department of Defense and U.S. DoD contractors ‘only for Administrative and Operational Use. Other requests for this document shall be referred to San Antonlo ‘ALG/T1, 485 Quontin Roceevlt Ra, Koly APB TX 7a242-6425, ‘Warning - This document contains technical data whove export ls restricted by the Arms Export Control Act (Title 22, U.S.C, Sec 2764 ot. seq) or the Export Adminstration Act of 1978, as amended (Title 60, U.S.C. ‘App. 2403 ot. q.). Violations of those export laws ate subject to severe criminal penalties. unaing and Dostraction Notice = For uncles, itd documents, destoy by any method that wil prevent dleclovure of the contents oF reconstruction of the Publlahed under authority ofthe Secretary ofthe Alr Force 14 MAY 1986 CHANGE 4 - 15 MARCH 19937.0, 26GTCP85-43-12 RECORD OF CHANGES Original . 14 May 86 30 Sep 88 CIES Apr 89 Change Benne dB Apr 92 Change 15 Mar 93 ‘wr/swP Number 001 00 002 00 003 00 004 00 005 00 ‘Total Number of Pages in thie manual is 104 ust OF EFFECTIVE FRONT MATTER jaar NOTE: This change was produced through the Automated Technical Order Syatem (ATOS). Backup pages Droduced In ATOS are shown as being changed, although no changes have been effected. Those pages will ot contain change symbols. The lst of effective pages shows al the pagss in tis publication and the latest ‘change lasued to each page. Insert latest changed pages; destroy superseded pages. NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES NOTE Only those work packages assigned to this manual are listed in this index. Insert changed pages in front matter, and in applicable work packages. Text affected in a changed or revised WP is indicated by change bars or change symbol R in outer margin of each column of text. Changes to illustrations are indicated by pointing hands or change bars. Changes to wiring diagrams are indicated by shaded areas. “Change Tite Number i oe 1 Oil Cooler Assembly Part No. 152050-4 and Oi... iMesh 4 ‘Temperature Regulator Assembly Part No. 87520-3 - Oil Pump Assembly Part No. 371976-14/-18/-24. a 3 Nonrecoverable Components .. 1 *Zero in this column indicates an original WP/SWP ‘A Change 47.0, 2G-6TCP85.43-12 WP 003 00 WORK PACKAGE TECHNICAL PROCEDURES LUBRICATION COMPONENTS MAINTENANCE OIL COOLER ASSEMBLY PART NO. 152050-4 OIL TEMPERATURE REGULATOR ASSEMBLY PART NO. 87520-3 EFFECTIVITY: ENGINE MODELS GTOP85-180 GTCP85-180L, GTCP85-180(C) LIST OF EFFECTIVE WP PAGES ‘Total Number of Pages in this WP is 38. Page Change Page Change No. No. No. No. 35 - 86... 87 Deleted. 4 38 Blank Deleted... 4 4 Change 4 41.0. 2G-.4TcP85.43-42 WP'603 00 1. APPLICABLE SUPPORT EQUIPMENT. Nomenclature Item/Figure No. Holder, Oil Temperature Control uri Valve (Holder) Puller, Tube (Puller) 201 ‘Holder, Tube (Holder) aT Puller, Tube (Puller) ari 258755 Handle, Tube (Handle) STL 253756-8/-9/-10/- ‘ip, Bumping Tube (Tip) 6rL 1281-29 256066 Roller, Burring Tube (Roller) un 256068 Roller, Tube Expander (Expander) art 256070 ‘ip, Pulling Tube (Tip) ott 256071 Loosening Tool, Tube (Loosening Tool) 20/71 256116-1 Swaging Aseembly, Machine-Tube and wT Header, (Swaging Assembly) (256121-18/-20/-21 Bit, Swaging Machine (Bit) 1271 257990 Stand, Test, Oil Temperature (Test Stand) 13/71 258884 Adapter, Leakage Test (Adapter) wr 258834-2 ‘Adapter, Leakage Test (Adapter) 262730 Cutter, Valve Seat (Cutter) 15/71 . APPLICABLE TCTO'S. None. 3, REFERENCE MATERIAL REQUIRED. Corrosion Preventive and Control for Aerospace Tu. 112 Equipment General Information, Depot Maintenance Manual 7.0. 2G-GTCP85-43-1, ‘WP 003 00 Non-Destructive Inspection Methods 7.0. 38B-1-1 © Chen’.T.0. 2G-GTCP85~43-12 WP 003 00 4. CONSUMABLE MATERIALS. NOTE Index numbers are for reference to master consum- able list T.0. 2G-GTCP85-43-1. All references to consumables in text will be preceded by 43, (Example: 011 (43-58)) Index_No. Nomenclature 1 Abrasive Cloth (600 Grit) (P-C-451) 5 Acetone (0-A-51) 19 Brush, Bristled (Non-Metallic) (H-T-560) 26 Chromic Acid Solution (MIL-N-3171, Type I) 30 Compound, Corrosion Preventive (MIL-C-6529, Type III) 58 O47 (MIL-L-7808 or MIL-L~23699) 59 O17 (MIL~C-8188) 61 Paint, Gloss Black Baking (Type II, Class A) 62 Paint Remover (MIL-R-6892) 68 Primer: Coating (Epoxy) (MIL-P-23377) 82 Soap, Aviation (WIL-S-36421) 86 Solvent, Dry Cleaning (P-D-680, Type II) 102 Wetting Agent (MIL-W-81244) 5. INTRODUCTION. This work package provides procedures for disassembly, cleaning, inspection, repair, assembly and testing of the 0i1 Cooler Assembly Part. No. 152050-4 and the 011 Temperature Regulator Assembly Part No. 87520-3. All special tools and torque values are called out in text,7.0, 2G-GTCP85~43~12 WP 003 00 6. ILLUSTRATED SUPPORT EQUIPMENT. N\ K-19A-1586 Figure Tl. Support Equipment (Sheet 1 of 3)T.0, 2G-GTCP85-43-12 c. Cleaning of Non-Contaminated 0i1 Cooler. WARNING Use approved personal protective equipment (goggles/tace shield) when using dry cleaning solvent. Use dry cleaning solvent in a well-ventilated area. Avoid excessive skin contact or prolonged inhala- tion of vapor, Do not use near open flame or in area where high temperatures prevail. WP 003 00 (1) Pump dry cleaning solvent (43-86) through of] cooler at a flow rate of 20 gpm for 30 minutes (10 minutes reverse flow, 10 minutes normal flow, 10 minutes reverse flow). Repeat flushing procedures three times. (2) Check for metal particles or chips in inlet and outlet connecting ports, which may have been dislodged during flushing. If none, proceed to step (3). If particles or chips are present, refer to step d. (3) Drain of1 cooler. WARNING Handling hot items presents a serious burn poten- tial, Non-asbestos heat resistant gloves shall be worn, (4) Dry oi1 cooler in oven at 250°F (121°C) for 2 1/2 to 3 hours. (5) Corrosion treat 017 cooler in accordance with T.0, 1-1-2, d. Cleaning of Contaminated 011 Cooler. (1) Remove one-third of tubes in accordance with paragraph 11. (2) Visually inspect tubes for corrosion. Replace corroded tubes with paragraph 11, in accordance 11T.0. 2G-GTCP85-43-12 WP 003 00 12 (3) (4) (5) (6) (7) (8) (9) (10) (1) (12) (13) (4) WARNING Use approved personal protective equipment (goggles/face shield) when using dry cleaning solvent. Use dry cleaning solvent in a well-ventilated area. Avoid excessive skin contact or prolonged inhala- tion of vapor. Do not use near open flame or in area where high temperatures prevail. With tubes removed, completely submerge of] cooler in dry cleaning solvent (43-86) for 4 hours, Pump (flush) dry cleaning solvent (43-86) through oi] cooler in reverse flow for 20 minutes. Flush of] cooler in normal flow for 20 minutes. Repeat step (4). Drain oi! cooler. Flush of1 cooler using clean water for 20 minutes. Flush of1 cooler in each direction for 10 minutes until water is clean. Connect oi! cooler to solvent flush equipment. Install 70 mesh screen in return line. WARNING Use approved personal protective equipment (goggles/face shield) when using dry cleaning solvent. Use dry cleaning solvent in a well-ventilated area. Avoid excessive skin contact or prolonged inhala- tion of vapor. Do not use near open flame or in area where high temperatures prevail. Using dry cleaning solvent (43-86), normal flow flush oi) cooler for 30 minutes. Reverse flush oi] cooler for 15 minutes. Normal flow flush oi] cooler for 15 minutes. Drain and thoroughly dry oil cooler.PROCEDURE 4. 7.0, 2G-GTCP85-43-12 WP 003 MALFUNCTIONING BYPASS VALVE Fe CHECK FOR PROPER OPENING AND CLOSING WITHIN SPECIFIED TEMPERATURE RANGE. 00 OK-CHECK FOR FAULTY B} SPRING. IF YPASS VALVE NOT OK-REPLACE VALVE KIT. IF- NOT OK-REPLACE VALVE. TEMPERATURE CONTROL NOT OK-REPLACE VALVE KIT. 337.0, 2G-GTCP85~43-12 WP 003 00 15, CORROSION PREVENTIVE AFTER TUBE REPLACEMENT. 34 a WARNING Acetone is flammable and may affect skin, eyes and respiratory tract. Use in a well-ventilated area. Avoid prolonged breathing of vapors. Avoid eye and repeated skin contact. Keep away from sparks and flames. Using acetone (43-5), degrease of] cooler. WARNING Alkaline cleaning solution can cause burns. Chemi- cal goggles, rubber boots, apron and industrial rubber gloves shall be worn. Use in a well- ventilated area. Respirator shall be worn unless waived by the Bioenvironmental Engineers. Handling hot items presents a serious burn poten- tial. Non-asbestos heat resistant gloves shall be worn, Wash oi] cooler for 30 minutes in solution of 5 to 6 ounces aviation soap (43-82) to a gallon of water maintained at 160 to 180°F (71 to 82°C). Repeat until Soap drains clean. Power flush internal and external surfaces with an air-water mixture for 10 to 15 minutes to remove soap solution. WARNING Handling hot items presents a serious burn poten- tial. Non-asbestos heat resistant gloves shall be worn. Ory with air blast and bake in oven at 250°F (121°C) for 2 1/2 to 3 hours. Ensure surfaces are free from grease, oil, dirt or any foreign matter. Prepare test panel of aluminum chemically treated in accordance with T.0. 1-1-2 to check adhesion of solution to oi] cooler.7.0, 2-GTCP85.43-12 ‘WP 004 00 ‘WORK PACKAGE TECHNICAL PROCEDURES LUBRICATION COMPONENTS MAINTENANCE OIL PUMP ASSEMBLY PART NO. 371976-14/-18/-24 EFFECTIVITY: ENGINE MODELS GTCP85-180 GTCP85-180L GTCP85-180(C) LIST OF EFFECTIVE WP PAGES Total Number of Pages In this WP Is 46 Page Chant Page Change Page Change No. No. No. No, No. No. 1-2... 3 5-14 ... 0 VD =4B csesneineee 0 a-4 1 15-16 ... 2 46 Blank... 07.0, 26-GTCP85-43-.12 WP 004 00 1, APPLICABLE SUPPORT EQUIPMENT. ‘Tool No. ‘Nomenclature Item/Figure No, PE-C-9037-U-2 Seal Mold (Naval Air Rework. Facility, Marine Corps Air Station, Cherry Point, NC 28583) ‘T2RIB10 ‘Test Block (Crissar Inc, 38905 - 10th St, E Palmdale, CA 93550 or equivalent) 25-241 Dial Indicator = 284584-1-1 Cover, Filter vg. 296937-1 Puller, Mechanical, Seal (Puller) an V-Block 2. APPLICABLE TCTO'S. None. 3, REFERENCE MATERIAL REQUIRED. Aircraft and Missile Repair, Structural Hardware TO. 114-8 ‘Anodic Coatings for Aluminum and Aluminum Alloys MIL-A-8625 Chemical Conversion Coatings on Aluminum and MIL-C-5541 ‘Aluminum Alloys General Information, Depot Maintenance Manual 7.0. 2G-GTCP85-43-1, ‘WP 003 00 General Maintenance Instructions for Support 7.0. 1-14-15, Equipment ‘Methods of Preservation-Packaging MIL-P-116 ‘Non-Destructive Inspection Methods 7.0. 33B-1-1 General Installation of 7.0. 44H1-1-117 ‘Heli-Coil Inserts4, CONSUMABLE MATERIALS. Index No. 3 9A 10A, 19 40 51 58 58 65 67a, 6B 68 86 89, 908. 90B 108 1.0, 26-GTCP85-43-12 WP 004 00 NOTE Index numbers are for reference to master consumable list T.0. 2G-GTCP85-43-1. All references to consumables in text will be preceded by 43. (Example: Oil (43-58)) ‘Nomenclature Abrasive Paper (400 and 600 Grit) (P-P-101) ‘Adhesive (Curing Catalyst Silicone 1-24) Adhesive (RTV90) (MIL-A-46106, Type 1) Brush, Bristled (Non-Metallic) (H-1-560) Grease (Hi Vacuum Silicone) Lockwire (MS20995C32) Lubricant, Dry Film (MIL-L-8987) Oil (MIL-1-7808 or MIL-1-23699) Paper, Kraft Wrapping (UU-P-268) Primer, (Dow Corning No. 1200) imer (Release Agent MS-12) Primer Coating (Epoxy (MIL-P-28377) Solvent, Dry Cleaning (P-D-680, Type II) Solvent (1,1,1-Trichloroethane) (MiL-T-81533) Solvent, Cieaning (Freon 113) (MIL-C-81802) Solvent, Cleaning (Seotchbrite) ‘Wool, Steel Grade 0000 5. INTRODUCTION. This work package provides the procedures for disassembly, cleaning, inspection, repair, assembly and testing of the oil pump assembly. All special tools and torque valves are called out in text. All lockwiring shall be in accordance with (@TCP85-180/-180(C)) T.0. 1-1A-15 and (GTCP85-180L) 0. LIAS. Change 1 37.0. 2G-GTCP85.43-12 WP 004 00 6. ILLUSTRATED SUPPORT EQUIPMENT, K19A 184 Figure TI, Support Equipment 7. GENERAL DESCRIPTION. The oil pump assembly consists of a gearshaft, oil filter element, filter bypass valve, pressure and seavenge pumping elements and a pressure relief valve contained within or ‘mounted to body assemblies. & DISASSEMBLY. a. Removal of Pressure and Scavenge Pumps. a) @) @) @ ©) 6) @ @) Remove ring (1, figure 1, sheet 1). ‘Using 296937-1 puller, remove and discard shaft seal (2). Remove packing (8), ring (4) and precision washer (6). Discard packing (3). Remove serew (6), washer (7) and packing with retainer (8). Discard packing with retainer (8). Remove serew (9) and washer (10). Remove bolt (11) and washer (12). Remove serew (18) and washer (14). Remove nut (16), washer (16) and screw (17). 4 Change 19 Packing Spring T.0. 2G-GTCPS5-43-12 WP 004 00 + Guide 7. 8. Filter 9. Seat 10. Poppet 11. Adapter Figure 2. Pressure Relief Valve Assembly - DisassemblyT.0. 2G-GTCP85-43-12 WP 004 00 (4) Remove assembled filter (8, figure 2 continued), seat (9) and poppet (10). (5) Remove filter (8) from seat (9). 9. CLEANING. WARNING Use approved personal protective equipment (goggles/face shield) when using dry cleaning solvent. Use dry cleaning solvent in a well-ventilated area. Avoid excessive skin contact or prolonged inhala- ‘tion of vapor. Do not use near open flame or in area where high temperatures prevail. a. Using dry cleaning solvent (43-86), dip or spray all parts until oil and grease have been removed. b. Using a bristled brush (43-19), remove caked grease or carbon deposits. ¢. Drain cleaned parts. Use 1,1,1-trichloroethane in a well-ventilated area, Avoid excessive skin contact or prolonged inhalation of vapors. Do not use near open flame or in area where high temperatures prevail. The vapor degreaser should be surveyed annually by Medical Service Bioenvironmental Engineers. Follow their recommendations. d, Vapor degrease using solvent (43-89). Flush thoroughly with clean water. Use approved personal protective equipment (goggles/face shield) when using compressed air. Provide protection from flying particles. Do not direct airstream towards self or other personnel. Air pressure is restricted to 30 psig. e. Dry parts thoroughly using clean, filtered, compressed air regulated at 15 to 30 psig. 10(2) (3) (4) (5) (6) (7) (8) (9) T.0. 2G-GTCP85-43-12 WP 004 00 WARNING Cleaning solvent (freon) is an asphyxiant and toxic to skin and eyes. Skin and eye protection required. Use only in a well-ventilated area. Cleaning solvent (Scotchbrite) is flammable and toxic to eyes, skin and respiratory tract. Skin/eye protection required. Avoid repeated/ prolonged contact. Good general ventilation is normally adequate. Clean gasket grooves with cleaning solvent (43-908), then degrease with cleaning solvent (43-908). WARNING Paints, primers, lacquers and varnishes must be handled carefully and used only in well-ventilated approved areas. Avoid prolonged breathing of vapors. Avoid eye and repeated skin contact. Keep away from sparks and flames. Apply primer (43-67A) to the sealing surfaces and allow to dry for 2 hours at room temperature. WARNING Perform all adhesive operations in a well- ventilated area. Avoid prolonged breathing of vapors. Avoid repeated skin contact. keep adhe- sives away from sparks and flames. Chemical gog- gles shall be worn. Mix adhesive (43-9A) with 1.0 percent adhesive (43-10A) ensuring that adhe- sive (43-10A) is thoroughly dispersed throughout the paste and that a mini- mum amount of air is entrapped. Apply the mixture to the grooves within 2 hours after mixing. Select PE-C-9037-1 or PE-C-9037-2 seal mold as applicable and coat with primer (43-678). Instal] seal mold on oi] pump plate (21, figure 1, sheet 1 continued). Cure at room temperature for 48 hours. Remove PE-C-9037-1 or PE-C-9037-2 seal mold and the flash material from oil pump plate (21). 23T.0, 2G-GTCPB5-43-12 WP 004 00 (10) Inspect sealing surface of of1 pump plate (21, figure 1, sheet 1 continued) for defects. A smooth continuous surface is required. f. Spur Gearshaft Dry Film Lubricant Application. (1) Remove remaining dry film lubricant from indicated dry film part of spur gearshaft, figure 10. (2) Apply dry film lubricant (43-53) at 0.0001 to 0.0003 inch thick to spur gearshaft. (3) Allow to dry. (4) Lightly polish lubricated part of spur gearshaft using steel wool (43-103). 9. Shaft Bushing (29, figure 1, sheet 1) Replacenent. WARNING Machining operations create metal particles which could enter the eye. Safety goggles shall be worn. (1) Using a No. 52 (0.0635 inch diameter) drill, drill through axis of pin (28) to dimension F and angle E, figure 11. (2) sing an arbor press, press shaft bushing (29, figure 1, sheet 1) from body 36). NOTE Do not remove pin (31) unless inspection requires removal. (3) Remove body plate (30) and pin (31) and oil screen assembly (32) from body (36). (4) Collapse and remove remaining drilled pin (28) from body (36). (5) Clean and inspect disassembled oil screen assembly (32), body plate (30) and bore of body (36) in accordance with paragraphs 7 and 8. 247.0. 2G-GTCP85-43-12 WP 005 00 WORK PACKAGE ‘TECHNICAL PROCEDURES LUBRICATION COMPONENTS MAINTENANCE NONRECOVERABLE COMPONENTS EFFECTIVITY: ENGINE MODELS GTCP85-180 GTCP86-180L, GTCP85-180(C) LIST OF EFFECTIVE WP PAGES RECORD OF CHANGES Original ... 0... 14 May 86 Change 1... 80 Sep 88 ‘Total Number of Pages in this WP is 10 PAGE CHANGE NO. NO. 1-2, 1 3-9. 0 10 Blank. 0 Change 1 11.0.) 2G-GTCPB5-43-12 WP 005 00 (c) (4) PN a7a205-4 Ps 692525 F-19747 Figure 1. Oi] Pressure Switch Assemblies Visually inspect electrical connector for damaged pins, burns and corrosion. No damage or corrosion allowed. Replace low oil pressure switch if inspection requirements are not met. (3) Testing. (a) (b) (c) (d) (e) (f) Install low oil pressure switch in a test setup similar to that shown in figure 2. Supply air pressure at 100 +10 psig to test setup. Provide an obmneter or continuity light to check actuation and reset Points of switch and continuity of circuits. (See figure 3.) Open shutoff valve (2, figure 2) and adjust regulator valve (1), until pressure of 100 =10 psig (switch inlet port pressure) is indicated on gage (3). Using regulator valve (1), reduce pressure until 60 psig is indicated on gage (3), Maintain 60 psig for 2 minutes, there shall be no leakage through low oi1 pressure switch (4). Reduce pressure to zero.T.0. 26-GTCP85~43-12 We 005 00 , | aw surety - 1194-1711 1, Regulator valve 3. Gage (0 to 300 psig) 2, Shutoff valve 4. Low ofl pressure switch Figure 2. Low Oil Pressure Switch Part No. 373205-4 Test Setup (g) Open shutoff valve (2, figure 2 continued), gradually adjust regulator valve (1) and monitor gage (3) until low oi] pressure switch (4) actuates. Actuation shall occur before 26 psig is obtained. (h) After low oil pressure switch (4) actuates, check circuits. Circuit between switch receptacle pins B and C shall be closed. Circuit between switch receptacle pins A and B shall be open. (See figure 3.) (i) Using regulator valve (1, figure 2), slowly bleed off pressure until switch deactuates. Deactuation shall occur at 17 to 23 psig minimum. (J) After low oil pressure switch (4) deactuates, check circuits. Circuit between switch receptacle pins A and C shall be open. Circuit between switch receptacle pins A and B shall be closed. (See figure 3.) (k) Remove low oil pressure switch from test setup. (1) Reject low of] pressure switch if test requirements are not met. (m) Place low oi] pressure switch in a dust and waterproof bag.1.0, 26-GTCPE5~43-12 WP 005 00 PRESSURE note PINS A AND BNORMALLY CLOSED PINS B AND C NORMALLY OPEN, Wo19a-1685 Figure 3. Low Oi] Pressure Switch Part No. 373205-4 wiring Diagram b. Oi Pressure Switch Assembly Part No. 692525 (1) Cleaning, WARNING Use approved personal protective equipment (goggles/face shield) when using dry cleaning solvent. Use dry cleaning solvent in a well-ventilated area. Avoid excessive skin contact or prolonged inhala~ tion of vapor. Do not use near open flame or in area where high temperatures prevail. (a) Clean a11 external surfaces of of! pressure switch assenbly (figure 1) with cleaning cloth (43-27) dipped in dry cleaning solvent (43-86). WARNING Ethy! alcohol is flammable and may affect eyes, skin and respiratory tract. Use in a well- ventilated area. Avoid prolonged breathing of vapors. Avoid eye and repeated skin contact, Keep away from sparks and flames, (b) Clean electrical connector with a cotton swab dipped in alcohol (43-14). (c) Clean corrosion from electrical connector in accordance with T.0. 1-1-1.T.0. 2G-GTCP85-43-12 TECHNICAL MANUAL DEPOT MAINTENANCE MANUAL (PARTIALLY VERIFIED) LUBRICATION COMPONENTS MAINTENANCE PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE MODELS GTCP85.180 GTCP85-180L GTCP85-180(C) arReTt Nooo19806-0602 ‘This publication ls one of thirtoen manuals covering Depot Malntenance. They are numbered T.0. 26-6TCPES- ‘444 and 7.0, 26-GTCP85-43-4 through 7.0, 2G4TCPSS-49-42, Propared By: SA-ALC Automated Technical Order System (ATOS). DISCLOSURE NOTICE - This information is furnished upon the condition that it wll nat be released to another nation without the spectic authority ofthe Departmont of the Alr Force of the United States, that it wil bo {sod for military purposes only, that Indlvidual or corporate rights originating Inthe information, whether patonted or not, wll be respected, that tho rociplont wil report prompty to the United States, any known or Suspected compromise, and that the Information wil bs provided substantially the same dogree of securty ‘afforded It by the Department of Defense of the United States. Also, regardless of any other markings on tho ‘document, I wll not be downgraded or declassified without witton approval of te orilnating United Statos agency. DISTRIBUTION STATEMENT - Distribution authorised to U.S. Goverment agoncles only fr Administrative and ‘Operational Use (EFFECTIVE DATE IS DATE OF PUBLICATION), Other requests for tia document shal be feferred to San Antonio ALC/TILD, 485 Quentin Roosevelt Rd, Ste 2, Kelly AFB TX 78243-6424. WARNING - This document contains technleal data whose export Is restricted by the Arms Export Control Act {Title 22, U.S.C, See 2753, ot soa.) oF the Export Adminstration Act of 1979, as amended, Title 60, U.C., [App. 2464 et seq. Violations of these export law are subject to severe criminal penatles. Disseminate In ‘accordance with provisions of DoD Directive 5230. HANDLING AND DESTRUCTION NOTICE - Handle in compliance withthe distribution statement and destroy by ‘Sey mothod that will prevent diclosure ofthe contents of reconstruction ofthe document. Publlshod under authority ofthe Secretary ofthe Ar Foree 14 MAY 1986 CHANGE 5 - 15 DECEMBER 19957.0. 26-6TCP85.43.12 Original.. Change Change... beeeno RECORD OF CHANGES 14 May 86 30 Sep 88 16 Apr 89 15 Apr 92 "15 Mar 93 15 Dec 95 ‘Total Number of Pages in this manual is 104 LIST OF EFFECTIVE FRONT MATTER PAGES Page ‘Change No. No. 5 5 NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES NOTE Only those work packages assigned to this manual are listed in this index. Insert changed pages in front matter, and in applicable work packages. Text affected in a changed or revised WP is indicated by change bars or change symbol R in outer margin of each column of text. Changes to illustrations are indicated by pointing hands or change bars. Changes to wiring diagrams are indicated by shaded areas. WwP/SWP- *Change Number Tith ‘Number 001 00 Alphabetical Index. 1 002 00 —_Introduction.. acs 1 003 00 Oil Cooler Assembiy Part No. 152050-4 and Oil, 5 ‘Temperature Regulator Assembly Part No. 875203 004 00 Oil Pump Assembly Part No. 371976-14/-18/-2 5 005 00 —_Nonrecoverable Components ... 5 “Zero in this column indic A Change 5 icates an original WP/SWP7.0, 26-4TCP85.43.12 WP 004 00 WORK PACKAGE TECHNICAL PROCEDURES LUBRICATION COMPONENTS MAINTENANCE OIL PUMP ASSEMBLY PART NO. 371976-14/-18/-24 EFFECTIVITY: ENGINE MODELS GTOP85-180 GTCP85-180L, GTCP85-180(C) LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP Is 46 Page Change Page Change Page Change No. No. No. No. No. No. 1 5 o 0 2 3 5 5 3 5 0 0 4 1 2 0 Change 5 4.1.0. 2G-6TCP85.43.12 WP'004 00 1. APPLICABLE SUPPORT EQUIPMENT. Tool No. ‘Nomenclature Itom/Figure No. PE-C-9037-U-2 Seal Mold (Naval Air Rework Facility, Marine Corps Air Station, Cherry Point, NC 28533) TeR1810 ‘Test Block (Crissar Inc, 38905 10th St, E Palmdale, CA 93550 or equivalent) 25-241 Dial Indicator - 284584. Cover, Filter vt 296937-1 Puller, Mechanical, Sal (Puller) 2T1 Block 2. APPLICABLE TCTO'S. None. 3. REFERENCE MATERIAL REQUIRED, Aircraft and Missile Repair, Structural Hardware TO. 1-148 Anodic Coatings for Aluminum and Aluminum Alloys MIL-A-8625 Chemical Conversion Coatings on Aluminum and MIL-C-5541 Aluminum General Information, Depot Maintenance Manual ‘7.0. 2G-GTCP85-43-1, WP 003 00 General Maintenance Instructions for Support TO. 1-14-15 Equipment Methods of Preservation-Packaging MIL-P-116 Non-Destructive Inspection Methods TO. 88B-1-1 General Installation of TO. 44H1-1-117 Heli-Coil Inserts 2 Change 31.0, 2G-aTcPss.43.42 WP 004 00 4. CONSUMABLE MATERIALS. NOTE Index numbers are for reference to master consumable list 7.0. 2G-GTCP85-43-1. All references to consumables in text, will be preceded by 43. (Example: Oil (43-58) Index No. Nomenclature 3 Abrasive Paper (400 and 600 Grit) (P-P-101) 5 Acetone (O-A-51) 9A Adhesive (Curing Catalyst Silicone L-24) 108, Adhesive (RTV90) (MIL-A-46106, Type 1) 19 Brush, Bristled (Non-Metallic) (H-T-560) 41 Grease (Hi Vacuum Silicone) 51 Lockwire (MS20995C32) 58 Lubricant, Dry Film (MIL-L-8937) 58 il (MIL-L-7808 or MIL-L-23699) 65 Paper, Kraft Wrapping (UU-P-268) 67a, Primer, (Dow Corning No. 1200) e7B Primer (Release Agent MS-12) 68 Primer, Epoxy (MIL-P-23377, Type I, Class C or N) Primer, Water Borne Epoxy (MIL-P-85582, Type I, Class 2) 86 Solvent, Dry Cleaning (P-D-680, Type II or III) 908. Deleted 90B Solvent, Cleaning (Scotchbrite) 108 ‘Wool, Steel Grade 0000 5. INTRODUCTION. This work package provides the procedures for disassembly, cleaning, inspection, repair, assembly and testing of the oil pump assembly. All special tools and torque valves are called out in text. All lockwiring shall be in accordance with (GTCP85-180/-180(C)) T.O, 1-1A-15 and (GTCP85-180L) TO. LIAS,1.0, 26-6TCPBB4242 WP 004 00. 6. ILLUSTRATED SUPPORT EQUIPMENT. Kot9Antbad Figure T1. Support Equipment 7, GENERAL DESCRIPTION; The oil pump assembly consists of a gearshaft, oil filter element, filter bypass valve, pressure and scavenge pumping elements and a pressure relief vaive contained-within or mounted to body assemblies, 8 DISASSEMBLY. a, Removal of Pressure and Scavenge Pumps. (1) Remove ring (1, figure 1, sheet 1). (2) Using 296987-1 puller, remove and discard shaft seal (2). (3) Remove packing (3), ring (4) and precision washer (5). Discard packing (3). (4) Remave screw (6), washer (7) and packing with retainer (8). Discard packing with retainer (8).. (5) Remove.screw (8) and washer (10). (6) Remove bolt (11) and washer (12). (1) Remove screw (13) and washer (14), (8) Remove nut (15), washer (16) and screw (17). 4 Change 1