Hamilton Sundstrand APU T-20G-10C3A MM

MAINTENANCE MANUAL
DOCUMENT
1068-1
GEMINI GAS TURBINE

AUXILIARY POWER UNIT
MODEL NUMBER
T-20G-10C3A
PART NUMBER
4503135 SERIES
© 1999, 2000, 2004, 2006 Hamilton Sundstrand Corporation

NOTICE
THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION (HSC). RECIPIENT
AGREES TO HOLD ALL SUCH INFORMATION IN CONFIDENCE AND AGREES IT SHALL BE USED ONLY FOR RECIPIENT’S INTERNAL PURPOSES TO
MAINTAIN RECIPIENT’S EQUIPMENT OR AS MAY OTHERWISE BE PERMITTED IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND HSC. THIS
DOCUMENT AND THE INFORMATION CONTAINED HEREIN SHALL NOT BE USED FOR ANY OTHER PURPOSE, INCLUDING THE CREATION,
MANUFACTURE, DEVELOPMENT, OR DERIVATION OF ANY REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGN, OR CONFIGURATION CHANGES, OR
TO OBTAIN FAA OR ANY OTHER GOVERNMENT OR REGULATORY APPROVAL FOR SAME. RECIPIENT AGREES NOT TO DISCLOSE SUCH
INFORMATION TO ANY THIRD PARTY, EXCEPT AS MAY OTHERWISE BE PROVIDED FOR IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND
HSC. COPYING OR DISCLOSURE OF THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN BY ANYONE WITHOUT HSC’S PRIOR WRITTEN
PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY.
INFORMATION SUBJECT TO EXPORT CONTROL LAWS

THIS DOCUMENT CONTAINS INFORMATION SUBJECT TO THE INTERNATIONAL TRAFFIC IN ARMS REGULATION (ITAR) AND/OR EXPORT
ADMINISTRATION REGULATION (EAR) WHICH MAY NOT BE EXPORTED, RELEASED, OR DISCLOSED TO FOREIGN NATIONALS INSIDE OR OUTSIDE
THE UNITED STATES WITHOUT FIRST OBTAINING REQUIRED U.S. GOVERNMENT APPROVAL OR A VALIDATED EXPORT LICENSE. A VIOLATION OF
THE ITAR OR EAR MAY BE SUBJECT TO A PENALTY OF UP TO 10 YEARS IMPRISONMENT AND A FINE OF $100,000 UNDER 22 U.S.C. 2778 OR
SECTION 2410 OF THE EXPORT ADMINISTRATION ACT. INCLUDE THIS NOTICE WITH ANY REPRODUCED PORTION OF THIS DOCUMENT.
NOTICE
THE DATA IN THIS DOCUMENT WERE DEVELOPED ONLY TO MAINTAIN SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON
SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. THE DATA MAY NOT BE APPLICABLE TO ANY OTHER SYSTEMS AND/OR PARTS,
REGARDLESS OF THEIR APPARENT SIMILARITY TO SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR
APPROVED BY HAMILTON SUNDSTRAND. DO NOT RELY IN ANY WAY ON DATA IN THIS DOCUMENT TO MAINTAIN OR OTHERWISE SUPPORT
SYSTEMS AND/OR PARTS THAT WERE NOT MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND
WITHOUT EVIDENCE THAT THE FEDERAL AVIATION ADMINISTRATION OR OTHER REGULATORY AGENCY HAS DETERMINED THAT THE DATA IN
THIS DOCUMENT IS VALID FOR SUCH USE.
TITLE PAGE, 1
ORIGINAL ISSUE JAN 15/99
REVISION 3 (REISSUE) APR 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
PART NUMBER 4503135 SERIES
THIS PAGE INTENTIONALLY LEFT BLANK
TITLE PAGE
Page 2
Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
TO: Holders of Document 1068, for Hamilton Sundstrand Gemini Gas Turbine Auxiliary Power
Unit (APU), Part Number 4503135 Series, Model T-20G-103CA.
Revision 3, dated April 15, 2006
HIGHLIGHTS
The Hamilton Sundstrand Engine Manual (formerly Document 1068) and Illustrated Parts Catalog
(Document 1068-3), have been divided into three separate and independent manuals. These are
Maintenance Manual (Document 1068-1), Repair Manual (Document 1068-2), and Illustrated Parts
Catalog (Document 1068-3). These manuals, following a revision in technical content and in
format, have been re-issued for your convenience. Replace your old Hamilton Sundstrand Bulletin
1068 with this new Maintenance Manual, Document 1068-1 in its entirety. Shown below are
highlights of the significant changes and the affected pages contained in this manual.
If you have any questions about this revision, please contact Technical Publications by telephoning
(912) 965-4125, FAX: (912) 965-3520, or write to Gulfstream Aerospace Corporation, P.O. Box
2206, Mail Stop C20, Savannah, GA 31402-2206.
Page Number Description of Change

NOTE: References to the Standard Practices Manual have been changed to HSPS 490001.
Title Page,
Page 1 Revised to show Revision 3.
Safety Advisory,
Pages 1 to 7 Replaced entire section with new Safety Advisory section.
Record of Revisions,
Service Bulletin List,

Page 1, Changed serial no. effectivities for three Service Bulletins and added
part numbers for one Service Bulletin.
List of Effective Pages,

Pages 1 and 2 Revised to show Revision 3.
Table of Contents,
Introduction,
Page 1 Revised associated manuals paragraph.
Cleaning,
Page 403 Revised metric conversion.
MM Repair-02
Pages 804 and 806 Changed warning for paint enamel. Revised metric conversion.
HIGHLIGHTS
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
HIGHLIGHTS
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Apr 15/06
49-00-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
SAFETY ADVISORY
1. Scope
A. This publication describes processes that may require the use of chemicals, solvents,
paints, or other materials that can affect a person’s health or safety. It may also cover
high energy procedures that can affect a person’s health or safety. Warnings are placed
just ahead of these procedures to bring attention to the existence of a procedure or
material that can be dangerous.
2. Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS
WARNING: BEFORE USING ANY OF THE MATERIALS SPECIFIED IN HAMILTON

SUNDSTRAND MAINTENANCE PUBLICATIONS, 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
PERSONAL INJURY OR DISEASE.
THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL

SAFETY DATA SHEETS [OCCUPATIONAL SAFETY AND HEALTH ACT
(OSHA) FORM 20 OR EQUIVALENT] FROM THE MANUFACTURERS OR
SUPPLIERS OF MATERIALS TO BE USED. THE USER MUST BECOME
COMPLETELY FAMILIAR WITH THE MANUFACTURER OR SUPPLIER
INFORMATION AND ADHERE TO THE PROCEDURES,
RECOMMENDATIONS, WARNINGS, AND CAUTIONS OF THE
MANUFACTURER OR SUPPLIER FOR THE SAFE USE, HANDLING,
STORAGE, AND DISPOSAL OF THESE MATERIALS.
A. Refer to the materials list at the beginning of each section of this manual for materials
used to repair and maintain the covered equipment.
B. If you do not have a copy of the manufacturer’s MSDS for the materials covered in the
materials list, contact the manufacturer and request that a MSDS be supplied before you
use the material.
3. Purpose
A. The warnings bring your attention to the existence of a procedure that can affect a
person’s health or safety.
B. Short warnings are provided in this maintenance publication to alert operating and
maintenance personnel of potential hazards that could result in personal injury or health
hazards. The warnings do not replace the manufacturer’s recommendations. When there
is a reference to the Warnings Registry 341-006, that publication will provide more
information about the dangers of the material. The information contained in the Warnings
Registry is a summary of the manufacturer’s MSDS. The full-length warnings provide
three principle parts of safety: (1) a listing of the known dangers, (2) what is needed to do
to protect you from the dangers, and (3) what to do if the dangers occur.
SAFETY ADVISORY
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
C. The detailed warnings in Warnings Registry 341-006 are a summary of the

manufacturer’s MSDS and are not intended to replace the material on the sheet, but are
intended to supplement them.
D. Cautions are provided in the maintenance publication or service bulletin to alert operating
and maintenance personnel to conditions that could result in equipment damage.
4. Definitions Applying to Warnings
A. Flammable: A material that can catch fire easily and can be explosive. These materials
are labeled according to the flash point of the material.
B. Flash Point: The lowest temperature at which a flammable liquid gives off fumes that can
burn.
C. Ignition Source: Includes flames, sparks, or heat.
(1) Flames: Materials that are burning such as lit matches, propane torches, or pilot
lights.
(2) Sparks: Materials such as lighted cigarettes, electrical motors, or static electricity.
(3) Heat: Any source of energy that will raise the temperature of a flammable material
to its flash point and could include hot parts, heated tools, or direct sunlight.
D. Corrosive: Acidic or alkaline material that will remove human tissue or create chemical
reactions with other materials.
E. Toxic: Material that is poisonous.
F. Reactive: Material that will make fumes, burn, or can be explosive when mixed with
certain other materials.
G. Shock (Electrical): The result of any source of electricity more than 50 volts that causes
current to flow through a person and can result in dangerous burns to human tissues or
death.
H. Exposure: Contact with the material or physical process without protection. Contact may
be by the eyes, breathing, touch, skin absorption, or swallowing.
I. Irritation: Any sense of pain, soreness, rash, or general discomfort.
5. Reporting Materials or Processes Not Covered
A. Please contact Technical Publications at (912) 965-4125, FAX: (912) 965-3520, or write
to Gulfstream Aerospace Corporation, P.O. Box 2206, Mail Stop C20, Savannah, GA
31402-2206.
SAFETY ADVISORY
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
6. List of Warnings Covered in This Publication
A. The following is a list of all the warnings covered in this maintenance document:
WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR

AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED. REMOVE
METALLIC RULERS, PENS, PENCILS, WATCHES, RINGS, AND OTHER
ITEMS HAVING EXPOSED CONDUCTING MATERIAL WHEN WORKING ON
ELECTRICAL EQUIPMENT TO PREVENT INJURY FROM ELECTRICAL
SHOCK. PERSONNEL WORKING WITH ELECTRICITY SHALL HAVE
ANOTHER PERSON SKILLED IN MODERN METHODS OF FIRST AID AND
RESUSCITATION NEARBY.
WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING EXHAUST

DEPOSITS INTO OPEN WOUNDS.
WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAT 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT
PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD
TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO
PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE
INJURY, GET MEDICAL ATTENTION.
WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROYPL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON
CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY
DATA SHEET LIMIT.
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS
TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A
PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR
GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD
CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU
REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH
SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO
YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE
THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE
LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES
THE LOCKWIRE.
SAFETY ADVISORY
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
WARNING: USE AQUEOUS (WATER) BASED CLEANER, TURCO 6783-10, ALSO

KNOWN AS MIL-PRF-85704, TYPE II TURBINE ENGINE GAS PATH
CLEANING COMPOUND, CORRECTLY. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE CLEANER, GET THE
MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0238SSE, IN THE WARNING REGISTRY 341-006.
PUT ON CHEMICAL-SPLASH GOGGLES AND NEOPRENE OR NITRILE
GLOVES BEFORE YOU USE THE CLEANER. MAKE SURE YOU HAVE
SUFFICIENT AIRFLOW TO KEEP FUMES BELOW THE MATERIAL SAFETY
DATA SHEET LIMIT.
WARNING: USE POLYSULFIDE SEALANT, PR-1826 B-1/2, A TWO PART COMPOUND,

CORRECTLY. THE COMPOUND IS ALSO KNOWN AS MIL-S-29574, TYPE I,
GRADE B, POLYHIOETHER SEALING COMPOUND. THE SEALANT IS
FLAMMABLE AND REACTIVE (STRONG OXIDIZER). IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE SEALANT,
GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER
OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0242SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES OR
CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MIL-C-

5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING)
LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE,
POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD EFFECT
ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET
THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
BEFORE YOU USE THE COATING, PUT ON A CHEMICAL FACE SHIELD,
SOLVENT-RESISTANT GLOVES (BUTYL, NEOPRENE, NITRILE, OR PVC),
APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW
TO KEEP THE COATING POWDER OR FUMES BELOW THE MATERIAL
SAFETY DATA SHEET LIMIT.
WARNING: SODIUM OXIDE SOLUTION IS CORROSIVE TO HUMAN TISSUE. DO NOT

BREATHE VAPORS. USE IN WELL-VENTILATED AREA. PUT ON CHEMICAL-
RESISTANT CLOTHING, GLOVES, SPLASH GOGGLES, AND FACE SHIELD.
IN CASE OF EYE OR SKIN CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION.
SAFETY ADVISORY
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
WARNING: SODIUM PYROPHOSPHATE IS TOXIC AND FLAMMABLE. DO NOT

BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM
SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES,
SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE
OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP
AND WATER.
WARNING: USE CHROMIC ACID (ALSO KNOWN AS CRO4, CHROMIUM TRIOXIDE, OR

CHROMIUM VI OXIDE) CORRECTLY. THE ACID IS REACTIVE, CORROSIVE,
AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACID, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL
AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0003SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ACID, PUT ON
RUBBER GLOVES, CHEMICAL APRON, CHEMICAL-SPLASH GOGGLES,
AND A FACE SHIELD. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW
TO KEEP THE ACID FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT. DO NOT ADD WATER TO ACID. VERY SLOWLY ADD ACID TO WARM
WATER. KEEP THE ACID-CONTAINER TIGHTLY SEALED EXCEPT WHEN
POURING THE ACID. AVOID SPILLS.
WARNING: CHROMATE METAL CONVERTER AND PRIMER 5251 IS CORROSIVE TO

HUMAN TISSUE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED
AREA. PUT ON CHEMICAL-RESISTANT CLOTHING, GLOVES, SPLASH
GOGGLES, AND FACE SHIELD. IN CASE OF EYE OR SKIN CONTACT,
FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION.
WARNING: PAINT, ENAMEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.

USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT
SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES,
AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH
WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE
OF SKIN CONTACT, WASH WITH SOAP AND WATER.
WARNING: PACKING LUBRICANT CAN CAUSE IRRITATION OF YOUR SKIN OR EYES.

BEFORE YOU USE THE LUBRICANT, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL
AND READ IT CAREFULLY. PUT ON SAFETY GLASSES OR SPLASH
GOGGLES. IF THE LUBRICANT GETS IN YOUR EYES, IMMEDIATELY
FLUSH THEM WITH WATER FOR A MINIMUM OF 15 MINUTES WHILE YOU
HOLD THE EYELIDS OPEN. IF THE ASSEMBLY FLUID GETS ON YOUR
SKIN, WASH THE SKIN WITH SOAP AND WATER. IF THE EYE OR SKIN
IRRITATION CONTINUES, GET MEDICAL AID.
SAFETY ADVISORY
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN
WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT
SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES,
AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH
WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE
OF SKIN CONTACT, WASH WITH SOAP AND WATER.
WARNING: USE SYNTHETIC TURBINE OIL CORRECTLY. IT IS FLAMMABLE AT HIGH
TEMPERATURES AND IS MILDLY POISONOUS. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE OIL, GET
THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
BEFORE YOU USE THE OIL, PUT ON CHEMICAL-SPLASH GOGGLES AND
OIL-RESISTANT GLOVES.
WARNING: USE ANAEROBIC THREADLOCKING COMPOUND (THREAD SEAL 592)

CORRECTLY. THE COMPOUND IS COMBUSTIBLE. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE
REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY
GLASSES OR GOGGLES AND NEOPRENE, RUBBER, OR BUTYL RUBBER
GLOVES.
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH

TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE BAD
EFFECT ON YOUR HEALTH OF SAFETY. BEFORE YOU USE THE ANTI-
SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE
REGISTRY 341-006. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, PUT
ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE
COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: USE LOCQUIC PRIMER GRADE N OR T, CORRECTLY. THE PRIMER IS

FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE PRIMER, GET THE
BEFORE YOU USE THE PRIMER, PUT ON CHEMICAL-SPLASH GOGGLES
AND SOLVENT RESISTANT GLOVES (BUTYL RUBBER). MAKE SURE THAT
YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE PRIMER FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.
SAFETY ADVISORY
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
WARNING: PUT ON THERMALLY-INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
WARNING: MAKE ELECTRICAL CONNECTIONS BEFORE ENERGIZING ANY

ELECTRICAL COMPONENT TO AVOID SPARKS IN AREAS WHERE FUEL
VAPOR MAY BE PRESENT. USE A SUITABLE SWITCH WITH THE 28 VDC
SOURCE.
WARNING: FAILURE TO DISCONNECT FUEL VALVE ELECTRICAL INPUT, AS

DESCRIBED ABOVE, WILL PERMIT FUEL TO ENTER COMBUSTION
CHAMBER AND CREATE A FIRE HAZARD.
SAFETY ADVISORY
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HAMILTON SUNDSTRAND
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SAFETY ADVISORY
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HAMILTON SUNDSTRAND
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RECORD OF REVISIONS
REV ISSUE DATE REV ISSUE DATE REV ISSUE DATE

NO. DATE INSERTED BY NO. DATE INSERTED BY NO. DATE INSERTED BY
1 Aug 15/00 Aug 15/00 HS
2 Aug 1/04 Aug 1/04 HS
3 Apr 15/06 Apr 15/06 G
RECORD OF REVISIONS
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RECORD OF REVISIONS
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RECORD OF TEMPORARY REVISIONS
TEMPORARY PAGE ISSUE DATE

REV NO. NUMBER DATE BY REMOVED BY
49-1 1-3 Apr 1/03 HS Aug 1/04 HS
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SERVICE BULLETIN LIST
PARTS ADDED
MOD SERIAL NO.
SERVICE BULLETIN DESCRIPTION OR CHANGED
SYMBOL EFFECTIVITY
NUMBER
T-20G-49-5 ESU Software 160935-203B 0001 through 0107
Upgraded to
Improve APU Start
Reliability
T-20G-49-6 (R1) Improved Cold 163415-100A MOD dot 3 All fielded units
Start Reliability 163416-100B through SP-E00327
4502863A
4503711
T-20G-49-8 Introduction of Fuel 4504283 MOD dot 4 All fielded units

Atomizer Assembly 4505684 through
and Interconnect SP-E022377
Harness Assembly
T-20G-49-10 Introduction of 161627-2 MOD dot 6 All fielded units

Mechanical Fuel
Pump with
Increased
Clearance
T-62T-49-76 (Rev. 13) Replacement of 164253-3 All fielded units

APU Life-Limited 160915-3
Components 160915-4
(Turbine Wheel and
Compressor
Wheel)
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LIST OF EFFECTIVE PAGES
Subject Page Date Subject Page Date

Title Page 1 Apr 15/06 6 Apr 15/06
2 Apr 15/06 7 Apr 15/06
8 Apr 15/06
Highlights 1 Apr 15/06 9 Apr 15/06
2 Apr 15/06 10 Apr 15/06
11 Apr 15/06
Safety Advisory 1 Apr 15/06 12 Apr 15/06
2 Apr 15/06 13 Apr 15/06
3 Apr 15/06 14 Apr 15/06
4 Apr 15/06 15 Apr 15/06
5 Apr 15/06 16 Apr 15/06
6 Apr 15/06 17 Apr 15/06
7 Apr 15/06 18 Apr 15/06
8 Apr 15/06 19 Apr 15/06
20 Apr 15/06
Record of Revisions 1 Apr 15/06 21 Apr 15/06
2 Apr 15/06 22 Apr 15/06
Record of Temporary 1 Apr 15/06 Fault Isolation 101 Apr 15/06

Revisions 2 Apr 15/06 102 Apr 15/06
103 Apr 15/06
Service Bulletin List 1 Apr 15/06 104 Apr 15/06
2 Apr 15/06 105 Apr 15/06
106 Apr 15/06
List of Effective Pages 1 Apr 15/06 107 Apr 15/06
2 Apr 15/06 108 Apr 15/06
109 Apr 15/06
Table of Contents 1 Apr 15/06 110 Apr 15/06
2 Apr 15/06 111 Apr 15/06
112 Apr 15/06
Introduction 1 Apr 15/06 113 Apr 15/06
2 Apr 15/06 114 Apr 15/06
3 Apr 15/06 115 Apr 15/06
4 Apr 15/06 116 Apr 15/06
117 Apr 15/06
49-20-00 118 Apr 15/06
APU Maintenance 119 Apr 15/06
Manual 120 Apr 15/06
121 Apr 15/06
Title Page 1 Apr 15/06 122 Apr 15/06
2 Apr 15/06 123 Apr 15/06
124 Apr 15/06
Description and 1 Apr 15/06 125 Apr 15/06
Operation 2 Apr 15/06 126 Apr 15/06
3 Apr 15/06 127 Apr 15/06
4 Apr 15/06 128 Apr 15/06
5 Apr 15/06 129 Apr 15/06
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Subject Page Date Subject Page Date

130 Apr 15/06 Inspection/Check 501 Apr 15/06
131 Apr 15/06 502 Apr 15/06
132 Apr 15/06 503 Apr 15/06
504 Apr 15/06
Operational Check 201 Apr 15/06 505 Apr 15/06
202 Apr 15/06 506 Apr 15/06
203 Apr 15/06 507 Apr 15/06
204 Apr 15/06 508 Apr 15/06
509 Apr 15/06
Removal/Installation 301 Apr 15/06 510 Apr 15/06
302 Apr 15/06 511 Apr 15/06
303 Apr 15/06 512 Apr 15/06
304 Apr 15/06
305 Apr 15/06 Servicing 601 Apr 15/06
306 Apr 15/06 602 Apr 15/06
307 Apr 15/06 603 Apr 15/06
308 Apr 15/06 604 Apr 15/06
309 Apr 15/06 605 Apr 15/06
310 Apr 15/06 606 Apr 15/06
311 Apr 15/06
312 Apr 15/06 Storage 701 Apr 15/06
313 Apr 15/06 702 Apr 15/06
314 Apr 15/06 703 Apr 15/06
315 Apr 15/06 704 Apr 15/06
316 Apr 15/06 705 Apr 15/06
317 Apr 15/06 706 Apr 15/06
318 Apr 15/06
319 Apr 15/06 MM Repair 801 Apr 15/06
320 Apr 15/06 802 Apr 15/06
321 Apr 15/06
322 Apr 15/06 MM Repair-01 801 Apr 15/06
323 Apr 15/06 802 Apr 15/06
324 Apr 15/06
325 Apr 15/06 MM Repair-02 801 Apr 15/06
326 Apr 15/06 802 Apr 15/06
327 Apr 15/06 803 Apr 15/06
328 Apr 15/06 804 Apr 15/06
329 Apr 15/06 805 Apr 15/06
330 Apr 15/06 806 Apr 15/06
331 Apr 15/06
332 Apr 15/06 MM Repair-03 801 Apr 15/06
802 Apr 15/06
Cleaning 401 Apr 15/06
402 Apr 15/06 Special Tools, 901 Apr 15/06
403 Apr 15/06 Fixtures, and 902 Apr 15/06
404 Apr 15/06 Equipment
405 Apr 15/06
406 Apr 15/06
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TABLE OF CONTENTS
Chapter
Section
Subject Unit Page
GEMINI GAS TURBINE - 49-00-00

Front Matter
Title Page 1
Safety Advisory 1
Record of Revisions 1
Record of Temporary Revisions 1
Service Bulletin List 1
List of Effective Pages 1
Table of Contents 1
Introduction 1
GEMINI GAS TURBINE - 49-20-00

MAINTENANCE MANUAL
Description and Operation 1
Fault Isolation 101
Operational Check 201
Removal/Installation 301
Cleaning 401
Inspection/Check 501
Servicing 601
Storage 701
Repair 801
Special Tools, Fixtures and Equipment 901
TABLE OF CONTENTS
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TABLE OF CONTENTS
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INTRODUCTION
1. General
This manual provides instructions for maintenance and repair for the Gemini gas turbine
auxiliary power unit (APU), part number 4503135 series, Model T-20G-10C3A. The APU is
manufactured by Hamilton Sundstrand Power Systems, a division of United Technologies
Corporation (UTC), 4400 Ruffin Road, P.O. Box 85757, San Diego, CA 92138-5757.
2. Standard Practices
A. Standard Practices Manual, HSPS 490001, contains information on the types and use of
technical publications and provides practices and philosophies related to maintenance.
3. Statement of Verification
Section Method Date
Testing and Fault Isolation Analysis Oct 1/98

Disassembly Analysis Oct 1/98
Assembly Analysis Oct 1/98
4. Associated Manuals (Manual Effectivity)

A. All facilities that perform both maintenance and repair of the APU will require the
following manuals:
Maintenance Manual 49-20-00 (Document 1068-1)

Repair Manual 49-20-10 (Document 1068-2)
Illustrated Parts Catalog 49-00-00 (Document 1068-3)
Cleaning, Inspection, and Repair (Document APS500C/I/R)
5. Application
A. Equipment covered in this manual applies to the following applications:
Model Number Application
T-20G-10C3A Lear 60
Water Bombers CL215T
Water Bombers CL415
INTRODUCTION
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6. Materials, Equipment, Compounds, and Special Tools
A. Materials, equipment, compounds, and special tools are listed in appropriate sections as
required. Consult these lists so that the materials, compounds, and special tools may be
gathered prior to starting maintenance or repair.
7. Repair Cycle
A. The APU shall be returned to Hamilton Sundstrand Power Systems, or one of its licensed
agencies, when the repair or test procedure required is beyond the capability of the user
or upon reaching the limits of the life cycle limited components listed below. The APU
should be maintained on an ON-CONDITION program as described below.
(1) On-Condition Maintenance
(a) The APU is maintained on an “On-Condition” basis, subject to the

maintenance intervals and periodic inspections contained in this manual, and
the terms of the purchase agreement. The maintenance intervals and
inspections may vary according to individual operator application and duty
cycle. Life limited part replacement requirements listed below supersede the
established on-condition maintenance intervals.
CAUTION: TO PREVENT EXCEEDING COMPONENT REPLACEMENT SCHEDULES,

TURBINE AND COMPRESSOR WHEELS SHALL BE TRACKED BY PART
NUMBER, SERIAL NUMBER, AND APU MODEL IDENTIFICATION
NUMBER.
(2) Life Limited Components
(a) The APU life limited components are listed below, and must be replaced at the
cycle limit shown. The APU shall be returned to Hamilton Sundstrand Power
Systems, or one of its licensed agencies upon reaching established limit, for
replacement of the required components and assemblies.
NOTE: Refer to service bulletin T-62T-49-76 for the latest APU component
replacement schedule.
Life Limited Component Replacement

Cycles
Description Part Number Replace
Turbine Wheel 164253-1 2000

164253-3 3500
Compressor Wheel 160915-3 7000

160915-4 7000
INTRODUCTION
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8. List of Abbreviations
A. The following abbreviations/symbols are used in this manual:
Abbreviation Definition Abbreviation Definition
APU Auxiliary Power l/hr liters per hour

Unit lb pound
BITE Built-in Test m Meter
Equipment lb/hr Pounds per hour
C Celsius Max Maximum
cc Cubic min Minute
centimeters ml Milliliter
cm Centimeter mm Millimeter
Corp. Corporation N·m Newton-meter
CPU Central O.D. Outside diametet
Processing Unit oz-in Ounce inch
EGT Exhaust Gas % Percentage
Temperature Pcd Pressure
ESU Electronic (Compressor
Sequence Unit Discharge)
F Fahrenheit pph Pounds per hour
Ft foot psi Pounds per
FOD Foreign Object square inch
Damage psid Pounds per
> Greater than square inch
hr Hour differential
Hz Hertz psig Pounds per
in Inch square inch
in. H2O Inches of water gauge
in. Hg Inches of ROM Read-Only
Mercury Memory
I.D. Inside diameter rpm Revolutions per
I/O Input/Output minute
IPC Illustrated Parts RTL Ready-to-Load
Catalog SB Service Bulletin
kg Kilogram sec Second
kg/hr Kilogram per shp Shaft
hour horsepower
kHz Kilohertz
kPa Kilopascal T/C Thermocouple
kPag Kilopascal Vdc Volts direct
gauge current
kW Kilowatt < Less than
l Liter
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INTRODUCTION
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DOCUMENT 1068-1

MAINTENANCE MANUAL
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DESCRIPTION AND OPERATION
1. Introduction
A. The Gemini auxiliary power unit (APU) provides shaft horse power used to drive the
reduction drive unit. Rated performance of the APU at sea level, standard day 59°F (15°C)
uninstalled conditions are shown in Figure 1.
B. The APU reduction drive unit is used to drive the fuel pump/acceleration control assembly.
The APU direction of rotation is clockwise, when viewed from the aft end.
2. Leading Particulars
A. The physical and operational characteristics of the APU are listed in Figure 1.
Item Characteristics*
OPERATING CHARACTERISTICS
Rated Engine Speed 93,882 rpm (100% rated speed)
Maximum Allowable Engine Speed 99,515 rpm (106% rated speed)
Weight (Dry) (Approximately) 66 lb (29.5 kg)
Standard Operating Conditions Sea Level to 20,000 feet altitude
Rated Output Power (Sea Level, 59°F 26.8 shp

(15°C) zero inlet and exhaust duct
losses)
Maximum Rated Exhaust Gas 1300°F (704°C)

Temperature (EGT)
Fuel consumption at Rated Power 28 lb/hr (12.7 kg/hr) at 28 shp, sea level, 59°F
(Max) (15°C) engine inlet temperature
REDUCTION GEAR ACCESSORIES
APU Rotor Speed (Rated) 93,882 rpm
Axial Pad Speed (Rated) 12,000 rpm
Leading Particulars
Figure 1 (Sheet 1 of 5)
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Accessory Pad Speeds
Fuel Pump 15,346 rpm
FUEL AND LUBRICANT
Fuel ASTM D-1655, Type A [minimum fuel

temperature -30°F (-34°C)]
ASTM D-1655, Type A-1 [minimum fuel
ASTM D-1655, Type B [minimum fuel
MIL-DTL-5624, Type JP-4 [minimum fuel
Lubricating Oil MIL-PRF-7808, or commercial equivalents

[minimum oil temperature -65°F (-54°C)]
MIL-PRF-23699F C/I, or commercial
equivalents [minimum oil temperature -40°F (-
40°C)]
NOTE: Information obtained from the oil manufacturers indicates the following brand names
meet approved specifications to the extent noted. Additional brand names of oils which meet this
specification may be obtained from oil manufacturers. Because Hamilton Sundstrand Power
Systems has no control of specifications applying to brand name products or control of
compliance to those specifications, it must be the user's responsibility to ensure that the oils
used in Sundstrand engines meet Sundstrand specifications, regardless of brand name. None
of the oils shall be mixed with each other in any proportion for use in the APU.
AEROSHELL Turbine Oil 500 ESSO Turbine Oil 35

AEROSHELL Turbine Oil 750 ESSO Extra Turbo Oil 274
ENCO Extra Turbo Oil 274 CALTEX SATO 35
ENCO Turbo Oil 35 MOBIL 254
SINCLAIR Turbo Oil 35 AEROSHELL Turbine Oil 560
TEXACO SATO 35 B.P. AERO Turbine Oil 35
MOBIL Jet Oil 2 EXXON Turbo Oil 500
REGENT SATO 35 EXXON Turbo Oil 560
MOBIL Jet Oil 254 ROYCO Turbine Oil 500
CASTROL 5000 (1C) ROYCO Turbine Oil 560
CASTROL 98 (1C)
Leading Particulars
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Oil Consumption Rate (max) 0.01 lb/hr [0.17 U.S. fluid ounces (5 ml)]
Oil Pump Pressure at Rated Speed 15 to 40 psig (103 to 276 kPag)
Oil Sump Capacity (max) 2 U.S. quarts (1890 cc). APU must be level
and oil hot when checking oil level
COMPONENTS AND SYSTEMS
Compressor Single-stage, centrifugal-flow
Turbine Single-stage, radial-inflow
Combustor Can-type
ELECTRICAL SYSTEM
Electronic Sequence Unit (ESU) (P/N Solid-state device, controls engine operating
160935-203 and -203A) and Built-In sequence and provides built-in-test, fault
Test Equipment (BITE) box (P/N isolation and automatic malfunction
161212-100) shutdowns
Power Requirements 14 to 30 Vdc (optimum 28 Vdc)
Ignition Exciter Capacitor discharge-type
Igniter Plug Shunted-surface gap-type
Thermocouple Chromel/Alumel (single element)
Magnetic Pickup Generates pulsed voltage signal to provide

ESU with speed data (3600 Hz = 100%)
FUEL SYSTEM
Fuel Cup Motor Rotates 18,500 to 21,500 rpm at 12 Vdc
Leading Particulars
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Fuel Filter (Inlet) 10 microns absolute
Fuel Pump Gear-type
Fuel Control Flyweight-droop type (hydromechanical)
Inlet Fuel Pressure 5 psi (34 kPa) above true vapor pressure of
fuel to maximum of 10 psig (68 kPag)
LUBRICATION SYSTEM
Oil Pump Gear-type
Oil Pressure Switch Opens to shut down APU on decreasing

pressure of 6 ±1 psig (41 ±7 kPag)
Bypass Relief Valve Spring-loaded ball valve, 50 psi (345 kPa)
Oil Filter Impregnated cellulose, 10 microns absolute

(disposable)
Oil Cooler External air-cooled
Pressure Relief Valve Spring-loaded ball valve, 15 to 40 psi (103 to

276 kPa)
ESU BITE FAULT INDICATIONS
RAM test failure Processor Failure
Fail to accelerate (5 sec) Overspeed
No start signal time out Underspeed
Overtemperature No Speed Data
Oil pressure switch failed Temperature Probe Open
Temperature probe shorted Low Oil Pressure
Leading Particulars
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Main fuel valve failed High Oil Temperature
Fail to accelerate > 65% to 98% No Temperature Data
Sequence failed Loss of Interlock
Flameout deceleration - low/high Low Fuel Cup Motor Voltage
Fail to accelerate < 65% Data Circuit Test Failure
INSTRUMENTATION
Hourmeter Accumulated engine operating hours
Start Counter Recorder of total engine start events
SETTINGS AND READINGS
Main Fuel Valve and Ignition Exciter 5% rated speed

Energized
Starter and Ignition Exciter 65% rated speed

Deenergized
Maximum Fuel Valve Energized 98% rated speed + 10 seconds
Ready for Service 98% rated speed + 20 seconds
Overspeed 106% rated speed
Low Oil Pressure Switch Closes at 6 ±1 psig (41 ±7 kPag) increasing

Opens at 6 ±1 psig (41 ±7 kPag) decreasing
High Oil Temperature Switch Opens on rising temperature above 275 ±5°F
(135 ±3°C)
Overtemperature Shutdown 1300°F (704°C) at rated speed
*Nominal unless specified.

Leading Particulars
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3. Description (Figure 2)
A. Auxiliary Power Unit
The APU consists of three main assemblies and three subassemblies. The main
assemblies include the turbine, combustor, and reduction drive assemblies. The
subassemblies include the fuel, lubrication, and electrical systems. The above
assemblies, along with the associated plumbing, wiring, attaching hardware, and
mounting provisions, comprise the complete APU and are described in detail in latter
chapters of this manual.
The APU includes an integral lubrication system, with the oil supply contained in an
oil sump at the bottom of the reduction drive unit. A 24 Vdc power supply provides
electrical power to the electronic sequence unit (ESU), for ignition, and operating the
electrical components. The fuel supply connected to the APU must have the flow
and pressure characteristics listed in Figure 1. All fuel system components
necessary for operation of the APU are installed on the unit.
Various components can be located by the terms aft, left, and right. These
directions, established by facing the exhaust end of the APU, are used throughout
this manual.
B. Gas Turbine Assembly
The gas turbine assembly consists of an air inlet housing, rotor assembly diffuser,
turbine nozzle assembly, and bearing adapter housing. The air inlet housing is a
contoured, cylindrical casting with forward and aft end openings. The flanged
forward end of the bearing adapter housing is bolted to aft end of the reduction drive
assembly. The aft end of the air inlet housing is externally flanged to allow
attachment of the combustor assembly.
C. Combustor Assembly
The can-type combustor assembly consists of a combustor housing and a

combustor liner. An external flange at the forward end of the combustor housing
mates with an external flange on the aft end of the turbine assembly. The combustor
assembly is secured to the turbine assembly by a V-type clamp that fits over the
flanges. The outer wall of the combustor liner fits precisely onto the outside diameter
of the turbine nozzle assembly. The combustor can outer wall mates with the inner
diameter of the combustor housing scroll to form a guided route of air flow through
the turbine nozzle assembly, turbine wheel, and exhaust as it leaves the turbine
assembly section of the APU.
A high energy igniter plug is mounted in a boss at the aft, right-hand side of the
combustor housing and a thermocouple is installed in a boss at the aft top side.
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Legend for Figure 2:
1. Exciter Bracket Assembly 19. Oil Dipstick

(Inboard)
20. Engine Harness
2. Exciter Bracket
(Outboard) 21. Fuel Filter
3. Fuel Solenoid Bracket 22. Oil Fill Tube
4. Combustor Drain 23. Output Pad
5. Fuel Pump Drain 24. High Oil Temperature

Switch
6. Ignition Cable
25. Combustion Chamber and
7. Hourmeter/Start Counter Cover Assembly
8. Solenoid Valve 26. Fuel Atomizer Assembly
9. Combustor Housing 27. Igniter
10. Fuel Control and Pump Assembly
11. Oil Level Sight Gage
12. Reduction Drive Assembly
13. Engine Mount
14. Oil Cooler Assembly
15. Turbine Assembly
16. V-Band Clamp
17. V-Band Clamp
18. Ignition Exciter
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Gas Turbine Auxiliary Power Unit

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D. Reduction Drive Assembly
The reduction drive assembly reduces the output rotational speed of the turbine
assembly rotor to the speeds necessary to drive the APU accessories and driven
equipment.
The reduction drive housing is machined from a magnesium casting. The integral
reduction drive lubricating system of the APU, consists of an oil pump, oil filter, pressure
relief valve, filter bypass relief valve, oil jets, oil sump, oil sight gage, oil pressure switch,
oil temperature switch, oil ejector pump, and connecting passages contained in the
reduction drive housing.
E. Fuel System
The fuel system consists of components that function automatically, to provide proper
engine acceleration and maintain a near constant operating speed under all operating
conditions. Fuel system components are the inlet fuel filter, fuel control, fuel pump, main
and maximum fuel solenoid valves, and fuel atomizing assembly. Fuel is supplied to the
APU from an external fuel source with the flow and pressure characteristics listed in
Figure 1.
Fuel input is supplied to the 10-micron filter through rigid fuel lines to the fuel pump and
from the fuel pump internally to the fuel control, from the fuel control to the solenoid
valves, and then from the solenoid valves to the fuel motor cup.
The fuel pump is a positive-displacement, gear-type pump with a through-drive. The

through-drive shaft has splines on both ends. The lube pump and fuel control drives
also have male splines on the drive shafts. Torque is transmitted through two female
spline couplings engaging the male splines. Two shaft seals are contained in the fuel
pump with an overboard drain port between them. One seals the fuel pump and the
other seals the lube pump.
The main and maximum fuel valves are 2-way, normally closed solenoid valves. These
valves are operated by an electrical input of 18 to 32 Vdc, received from the ESU.
Stainless steel tubing connects each valve to the fuel control.
The fuel atomizer assembly consists of a fuel injector, fuel atomizer cup drive motor and
fuel atomizer cup.
F. Lubrication System
The lubrication system is a fully pressurized, wet sump, entirely self-contained system.
The system provides lubrication to the high-speed input pinion, reduction and accessory
gears, and bearings. The lubrication system consists of an oil pump, oil filter, pressure
relief valve, filter bypass relief valve, low oil pressure switch, high oil temperature
switch, oil cooler, oil passages, oil ejector pump, and oil sump.
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The oil pump consists of two gears pinned on shafts, mounted inside a two-piece
housing, which is secured in the reduction drive housing. One oil pump gear (driver
gear) is pinned to the oil pump drive shaft. The other gear (driven gear) is pinned to
the oil-pump-driven shaft. A third gear, the oil pump drive gear, is pinned and
secured with a nut to the end of the pump drive shaft, just outside the oil pump
housing, and is driven by the input pinion. The oil ejector is located inside the
reduction gear assembly and operates by means of suction to remove excess oil
from the bearing support housing. The pump is a static pump and has no moving
parts. The oil filter consists of a filter housing in the reduction drive assembly, a 10-
micron disposable filter element, a bypass relief valve, oil filter adapter, and an oil
filter plug. The oil filter plug serves as the top housing of the bypass relief valve and
also as the cap for the filter element. The low oil pressure switch incorporates
normally open contacts that actuate at 6 ±1 psig (41 ±7 kPag) oil pressure.
The pressure relief valve is a spring-loaded ball-type relief valve internally mounted
in the main oil gallery. The valve regulates the system oil pressure at 15 to 40 psig
(103 to 276 kPag) by bypassing excess oil to the oil sump.
The high oil temperature switch is located on the lower forward end of the oil sump.
It has normally closed contacts that actuate on rising oil temperature of 275° ±5°F
(135° ±3°C) to shut down the engine. The oil cooler, attached to the right side of the
APU, is an external, full flow unit. Air is used as the cooling medium.
G. Electrical System
The APU engine-mounted components of the electrical system consist of a

thermocouple, ignition exciter, ignition cable, igniter, magnetic pickup, time totalizing
meter (hourmeter), start counter, fuel cup motor, high oil temperature switch, low oil
pressure switch, and fuel solenoid valves. Other electrical system components
include the ESU, toggle switches, indicating lights, RPM meter and EGT meter. All
except the ESU are normally mounted on the aircraft control panels. Electrical power
at 14 to 30 Vdc is required during starting to operate the electrical components
mounted on the APU and components mounted on the aircraft control panel (s).
A capacitor discharge-type ignition exciter is bolted to the reduction drive housing.

The ignition cable connects the ignition exciter to the igniter. The ignition cable is
shielded to minimize electromagnetic interference. The igniter is a 10-millimeter,
surface, discharge-type igniter. The igniter is threaded into a boss in the upper right
side of the cannular portion of the combustor.
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A single element, chromel/alumel thermocouple extends into the exhaust stream and
sense engine exhaust-gas temperature. The extension wires from the thermocouple
to the ESU are shielded and sheathed and must be to a specified resistance for the
installation.
A magnetic pickup, which provides APU speed data, is installed in the accessory
drive housing assembly. An hourmeter (time totalizing meter) is installed in a
mounting bracket on the top middle section of the reduction drive. A start counter is
installed on the exciter and hourmeter mounting bracket. It is located on the top
middle section of the reduction drive.
An ESU is provided, to sequence the functions during unit starting. Safety circuits
are provided within the ESU to shutdown the APU in the event of failure to
sequence, overspeed, or overtemperature.
4. Operation
A. Auxiliary Power Unit
The APU is a continuous cycle gas-turbine engine that uses a single-stage

centrifugal compressor and a single-stage radial in-flow turbine.
The cranking cycle is initiated when the starter motor is energized. During cranking,
air is drawn into the compressor portion of the turbine, where it is compressed and
then directed through the diffuser into the combustor. Fuel from the fuel atomizer
assembly is atomized by a rotating cup, mixed with compressor air in the combustion
chamber assembly and ignited by the igniter plug. This ignition results in a hot gas
mass flow. The combustion gases flow through the turbine nozzle and impinge on
the blades of the turbine wheel. Rotation of the turbine rotor shaft provides the power
to drive the compressor and output shaft of the APU. The compressor rotor (wheel)
continues to draw air into the compressor. Ignition and starter are cut-off at a
predetermined point and combustion is self-sustaining. A continuous cycle of intake,
compression, combustion, and exhaust is maintained within the engine.
B. Gas Turbine Assembly
During operation, air is drawn through the air intake screen to the center of the
compressor. Rotary action of the compressor and the change of cross section of the
housing directs the air through the housing, increasing the pressure and reducing
velocity. The air passes into the combustor assembly where fuel is added and it is
ignited and heated. The hot gasses flow through the turbine nozzle to strike the
blades of the turbine wheel. The resulting rotation of the turbine wheel provides the
power to drive the compressor and the input pinion of the gas turbine engine. The
combustion gases then flow through the combustor housing assembly, out the aft
end, into the atmosphere.
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C. Combustor Assembly
Compressor discharge air enters the combustor section and flows between the inner
surfaces of the combustor housing and the outer surfaces of the liner assembly. This
airflow cools the surfaces of the outer housing and liner assembly.
Air enters the combustion area through radial holes in the outside wall of the liner,
and at the dome through a hole which the fuel atomizer cup protrudes. Air flowing
through the radial holes serves to cool the inside surface of the liner inner wall. This
same air flow also cools the rear facing surfaces of the turbine nozzle assembly.
The igniter plug ignites the fuel supplied by the rotating fuel atomizer cup during
starting. Fuel to the combustor is supplied through the rotating cup which protrudes
into the combustor liner dome. The rotating cup provides atomized fuel into the
internal chamber of the combustor liner for burning. A port in the lowest point of the
combustor housing provides a drain for the fuel that might accumulate in the
combustor during false engine starts or shutdowns. The thermocouple, which is
mounted in a boss at the aft end of the combustor housing, senses exhaust gas
temperature.
D. Reduction Drive Assembly
The reduction drive assembly reduces the output rotational speed of the turbine
assembly rotor to the speeds necessary to drive the engine accessories and engine-
driven equipment.
The turbine assembly input pinion mates inside of the bearing capsule. The bearing
capsule is an integral part of the reduction drive assembly and incorporates a
preloaded bearing spring with a helical gearshaft supported by ball bearings. The
gearshaft drives two internal gears; the output gear and the lubrication gear. The
output gear is internally splined to mate with driven-equipment. The lube gear, which
is attached to the lube-pump-shaft drives the lube-pump which, in turn, drives the
fuel-pump.
To prevent foaming, a deflector shield is installed between the sump and lube gear.
This minimizes direct contact of the lubricating oil and the rotating gear. Lubrication
of the gears and bearing is accomplished by oil jet stream and oil splash.
The reduction drive has an axial output pad and accessory drive pads. The axial pad
normally drives equipment such as a starter-generator or alternator. One accessory
pad drives the externally mounted fuel control/pump assembly. The other accessory
pad is available for mounting an optional starter motor.
The reduction drive assembly also incorporates an oil sump. The oil pump draws oil
directly from the sump and passes the oil through a full flow filter prior to being
directed to several jets lubricating the bearings and gears.
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An oil ejector pump, operating statically on a suction principle, is provided to prevent

flooding of the bearings, by removing excess oil from the bearing support housing.
E. Fuel System (Figure 3)
Fuel for the APU is supplied through the fuel inlet filter assembly, which is plumbed
into the fuel pump inlet port. The fuel control assembly incorporates the function of
acceleration control and speed governing. The fuel from the fuel-pump is routed
through internal passages to the fuel control, where its pressure is controlled
proportional to the compressor discharge pressure (Pcd). This is accomplished via
the double diaphragm assembly, which positions the bypass valve. The excess fuel
flows back to the pump inlet through this valve.
The pressure differential across the acceleration orifice, established by the Pcd
proportional fuel pressure, determines the rate of fuel flow to the engine. This flow is
restricted slightly during acceleration to avoid the surge region of the compressor.
For this reason, enrichment is required prior to applying load to the engine. This is
accomplished by opening the maximum fuel solenoid valve and bypassing the
acceleration orifice.
Speed governing takes place as the flyweights cause the flapper to throttle fuel flow
at the governing nozzle. A minimum-flow orifice parallels the flapper nozzle, and
prevents a flameout on a sudden loss of load.
The main fuel solenoid is energized to the open position, upon ESU command, at
5% rated speed to supply fuel to the fuel atomizing cup. The maximum solenoid
valve is energized at 98% speed + 10 seconds, also supplying fuel to the fuel
atomizing cup. This allows maximum fuel flow for governing at rated speeds and
loading conditions. Engine shutdown (normal or emergency) is obtained by
deenergizing both solenoid valves.
Fuel and air (plumbed to the fuel atomizer assembly) travels through the injector’s
internal passages. Fuel is fed onto the internal surface or the fuel rotating cup
through a tube running down the center of the hollow motor-shaft. Atomization takes
place in the air stream as fuel is swirled from the periphery of the cup.
The 12 Vdc fuel cup drive motor rotates the fuel atomizing cup at 18,000 to 20,000
rpm.
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Fuel System Schematic

Figure 3
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F. Lubrication System (Figure 4)
The pump draws oil out of the sump and into the pump housing. The oil from the
pump is then divided into two circuits; one to the oil cooler and the other to the
ejector-pump. After passing through the ejector-pump, the oil (along with the
scavenged oil) flows back to the reduction drive sump. The balance of the oil from
the pump flows through the oil cooler and then to the oil filter. Oil enters the filter
housing, passes through the element (from outside to inside), and flows to several
jets lubricating the bearing and gears.
A bypass relief valve (in the filter element cap) unseats at 50 psid (345 kPad)
pressure and allows oil to flow from the outside element through a passage in the
element cap to the filter outlet passage. If the filter element becomes clogged, oil will
bypass the element.
The main filtered flow (or filtered bypass flow) enters drilled passages in the gear
assembly for distribution to lubrication points and cooling surfaces.
The system relief valve regulates the system oil pressure at 15 to 40 psig (103 to
276 kPag) by bypassing a portion of the pump output directly into the reduction drive
assembly. Bypassed oil then returns to the sump by gravity flow.
The normally open contacts of the low oil pressure switch close on increasing oil
pressure at 6 ±1 psig (41 ±7 kPag). At rated engine operating speed, decreasing oil
pressure below 6 ±1 psig (41 ±7 kPag), opens the low-oil pressure contacts, which is
sensed by the ESU as a malfunction. The ESU in turn commands the two fuel
solenoid valves to close and shutdown the engine.
G. Electrical System (Figure 5)
The APU uses 24 Vdc (nominal) for starting, control, and operation.
The exciter converts a direct current input to a high-energy alternating current, which
is supplied to the igniter for start fuel ignition. The high-energy pulse from the exciter
to the igniter is supplied through the ignition cable. The ignition cable is shielded to
minimize electromagnetic interference.
The 10 millimeter, shunted-surface, gap-type, igniter plug provides the spark

necessary for initial ignition of the fuel during the starting phase of the APU
operation.
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Lubrication System Schematic

Figure 4
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APU Harness Assembly

Figure 5
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The single element, chromel/alumel thermocouple senses engine exhaust gas

temperature (EGT). The element is used for controlling shutdown.
The magnetic pickup, installed in the accessory drive housing assembly, generates a
pulsed-frequency voltage output as the output drive gear passes through the
magnetic field surrounding the pole piece at the sensing end of the pickup. The
frequency voltage output is transmitted to the ESU. An engine shutdown will occur if
an underspeed or overspeed condition is detected by the ESU.
The hourmeter (time totalizing meter) indicates total accumulated hours of APU
operation. The hourmeter operates from 24 to 30 Vdc. The start counter records
total engine starts and operates at 12 to 30 Vdc.
The RPM meter (optional) indicates engine speed that is expressed in percent rpm
from 0 to 120. The meter is a long-scale instrument, having minor graduation of 2%.
At rated load, the pointer indicates 100%. The signal from the magnetic pickup is
transmitted to the ESU, which produces an analog output speed signal.
The EGT meter (optional), graduated from 0 to 1500°F (-17.8 to 816°C), operates
from analog input. An analog temperature signal is available from the ESU. This
signal is transmitted to the EGT meter, avoiding the need for long special leads from
the thermocouple to the meter.
H. Electronic Sequence Unit
The microprocessor within the ESU is programmed to control and initiate a

sequence of events necessary for satisfactory operation of the APU. Control is
achieved by the continuous monitoring of the APU speeds and EGT.
Before the microprocessor instructs the ESU to initiate a required event, the
microprocessor compares input data just received against programmed data
representing limiting conditions for the required event. As a result of this comparison
and program logic, the ESU initiates the next event or a malfunction shutdown.
Functions controlled by this logic, are engine start and start sequence to operation,
malfunction indication and shutdown during the start sequence and during engine
operation. The logic sequences itself to restart condition on replication of power to
the system after a shutdown. In addition to sequencing and protecting the engine,
the ESU provides engine condition monitoring for fault isolation.
The microprocessor complemented with Input/Output (I/O) ports and Read-Only-

Memory (ROM) forms the primary functional unit for the ESU. The ROM contains the
tables and program, and the Central Processing Unit (CPU) controls the operations,
as directed by the ROM. The I/O ports allow transfer of data and instructions
between these components and the APU. Input and output to the ESU takes place
through two electrical receptacles on the ESU.
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In addition, five BITE indicators are remotely mounted on a separate housing. These
are binary coded, magnetic latching devices, which show white or black depending
on position. These devices indicate engine conditions (refer to FAULT ISOLATION,
Figure 103). The BITE indicators provide a visual indication of the malfunction that
occurred at the time of unscheduled shutdown. A listing of the events that may
appear at the time of an unscheduled shutdown is provided in FAULT ISOLATION,
Figure 103.
An event indication is retained only until the next event or malfunction occurs. In
case of a malfunction, the malfunction indication is retained at shutdown and
remains after the electrical power is turned off. It is reset when the power to the ESU
is applied.
The ESU also contains a checkable overspeed safety device circuit that allows
manual shutdown of the APU. This is accomplished by a toggle switch which may be
installed in some aircraft cockpits. If installed, when the switch is activated, a signal
is applied to the overspeed circuit in the ESU that simulates an overspeed condition
and causes the APU to shut down.
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FAULT ISOLATION
1. Introduction
A. This section lists faults that may occur in the Gemini auxiliary power unit (APU) or
electronic sequence unit (ESU) and the corrective actions to be taken. All corrective
actions listed in the fault isolation charts can be performed with the APU in the aircraft,
where interference from aircraft structures or components does not occur. When
interference occurs, refer to the aircraft manual for appropriate corrective action. As each
corrective action is performed, it is assumed that a restart will be attempted before
proceeding to the next action, unless otherwise specified.
B. Faults resulting in an APU shutdown are analyzed by noting APU action and built-in test
equipment (BITE) indications displayed on the BITE annunciator box. Five magnetic,
latching indicators, controlled by solid-state driver circuits, are provided in the BITE
annunciator box. The indicators normally show black and change to white indicating
events as they occur in the event of a malfunction. The BITE indicators operate in two
modes, start sequence mode and operation mode.
2. Equipment and Materials
A. Equipment and materials required for fault isolation procedures are listed in Figure 101.
NOTE: Equivalent substitutes may be used for items listed.
Equipment/Material Manufacturer (Vendor Code)
Heater probe assembly (P/N 22217-40) Howell Instruments

(98869)
Multimeter (as required) Commercially Available
Pressure gauge [0 to 50 psig (483 kPa)] Commercially Available
Jet Cal EGT controller (P/N 239-4) Howell Instruments

(98869)
Fault Isolation Equipment and Materials
Figure 101
3. Fault Isolation
A. The APU harness schematic in Figure 102 is provided as an aid in fault isolation.
B. Preliminary Fault Isolation Procedures
(1) Set APU MASTER switch to ON. BITE indicators should show all black. This means
that the ESU has reset and is ready for a start sequence.
(2) If BITE indicators do not show all black, the fault may be in the aircraft electrical
system. Perform aircraft diagnostic procedures before attempting to troubleshoot
the APU.
FAULT ISOLATION
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(3) If the APU begins to rotate when the APU CONTROL switch is set to START, but a
fault exists, refer to Figure 103, and then proceed to the applicable fault isolation
procedure in Figure 104 and associated fault isolation notes in Figure 105. Note the
APU speed and Exhaust Gas Temperature (EGT) at the time of malfunction.
(4) If the APU does not rotate when the APU CONTROL switch is set to START,
proceed to Fault A.
(5) If the malfunction lights on the APU control panel flicker, remove power to the ESU
immediately and check the aircraft electrical system. If the aircraft electrical system
is not malfunctioning, replace the ESU.
FAULT ISOLATION
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APU Harness Schematic

FAULT ISOLATION
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APU Harness Schematic

FAULT ISOLATION
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BITE Information
Figure 103
FAULT ISOLATION
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FAULT A
Fault Isolation
FAULT ISOLATION
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FAULT B
Fault Isolation
FAULT ISOLATION
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FAULT D
Fault Isolation
FAULT ISOLATION
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FAULT E
Fault Isolation
FAULT ISOLATION
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FAULT G
Fault Isolation
FAULT ISOLATION
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FAULT H
Fault Isolation
FAULT ISOLATION
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FAULT K
Fault Isolation
FAULT ISOLATION
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FAULT N
Fault Isolation
FAULT ISOLATION
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FAULT O
Fault Isolation
FAULT ISOLATION
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FAULT Q
Fault Isolation
FAULT ISOLATION
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FAULT S
Fault Isolation
FAULT ISOLATION
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FAULT U
Fault Isolation
FAULT ISOLATION
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FAULT W
Fault Isolation
FAULT ISOLATION
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FAULT Y
Fault Isolation
FAULT ISOLATION
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FAULT NOTE NUMBER, COMPONENT, CHECKOUT PROCEDURES,

DISPOSITION OR CORRECTIVE ACTION
Electronic Sequence Unit (ESU) input and output checks.

1
The ESU input and output checks must be made with P2 and P3 plugs in the
respective ESU J2 and J3 jacks. Therefore a harness “TEE” must be provided or
harness connectors disassembled in order to provide probe access. Inputs and
outputs necessary for proper ESU operation are indicated below:
INPUTS
Input Pin Jack Signal APU Condition
Power (Start) A J3 15 - 30V Start initiation
Power (Run) E J3 24 - 30V Arm, crank, running
Overspeed Test D J3 24 - 30V Overspeed shutdown

0V Running
Interlock B J3 24 - 30V Loss of interlock

0V Running
Speed Signal M-N J2 3600 - 3816 Hz APU speed between

100% and 106%
Oil Pressure H J2 24 - 30V APU armed and running
Oil Pressure G J2 24 - 30V Oil pressure greater

than 6 psi (41 kPa)
Oil Temperature H J2 24 - 30V Arm, crank, running
Oil Temperature Y J2 24 - 30V Oil temperature is less

than or equal to 270°F
(132°C)
Fault Isolation Notes
FAULT ISOLATION
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INPUTS (Continued)
Input Pin Jack Signal APU Condition
Oil Temperature Y J2 0V Oil temperature is

greater than or equal
to 270°F (132°C)
Thermocouple R and S J2 See Note 12
OUTPUTS
Output Pin Jack Signal APU Condition
DS1 (Malfunction) C J3 24 - 30V Malfunction shutdown
DS2 (Ready-to-Load) L J3 24 - 30V APU ready-to-load
Start Command P J3 24 - 30V APU speed is greater

than 0 but less than
65%
Speed (M) T and V J3 163 - 171 Ma 100% APU speed
Temperature (M) U and V J3 156 - 164 Ma 1200°F (649°C) EGT
Exciter C and D J2 15 - 30V APU speed is greater

than 0 but less than
65%
Maximum Fuel Valve A J2 15 - 30V APU speed greater than

98%
Main Fuel Valve E J2 15 - 30V APU speed greater than

5%

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OUTPUTS (Continued)
Output Pin Jack Signal APU Condition
Hourmeter and Event X J2 15 - 30V EGT is greater

Meter than 600°F (316°C)
Fuel Cup Motor* J and K J2 12 - 13.0V Arm, crank, running
* Fuel cup motor must rotate in correct direction, clockwise looking into cup.
NOTE: If any of the ESU outputs are grounded (except output to BITE indicator
pin R and S of J2) during fault isolation or component failure the ESU
must be replaced.
Ignition Exciter
2

ELECTRICAL COMPONENT TO AVOID SPARKS IN AREAS
WHERE FUEL VAPOR MAY BE PRESENT. USE A SUITABLE
SWITCH WITH THE 28 VDC SOURCE.
Ignition Exciter Specifications
Spark Rate: 2.7 sparks (minimum) per second at 14 Vdc.
Duty Cycle: 1 minute on, 5 minutes off.
Voltage: 14 to 30 Vdc.
Current: 1 ampere maximum.
NOTE: Input resistance checks of the ignition exciter is not a valid or

recommended test. The exciter is a capacitor discharge type which has a
capacitor in the input circuitry. Resistance reading across a capacitor has
no significance.

FAULT ISOLATION
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Ignition Exciter Specifications (Continued)
(1) Disconnect plug P1 from J1 at APU harness connector and apply 28 Vdc
(nominal) to J1-C (+) and J1-D (-).
- If exciter actuates (loud ignition discharge noise will be heard coming

from APU combustor), replace ESU. If no ignition noise is heard, proceed
to next step.
(2) Apply 28 Vdc (nominal) to exciter receptacle pins J301B (-) and J301A (+). If
exciter actuates (loud ignition discharge noise), replace or repair harness. If
harness is shorted, replace harness. If ignition discharge sound is not heard,
proceed to next step.
(3) Disconnect ignition cable from exciter and igniter. Check resistance of
ignition cable center conductor. Resistance should be essentially zero. Check
for a short circuit between conductor and external wire braid. An open circuit
condition should exist. Replace ignition cable if either fault is detected.
(4) Retest exciter per step (2). If ignition discharge sound is not heard,
de-energize exciter, disconnect ignition cable from igniter, replace igniter,
reconnect and repeat test per step (2). If ignition sound is not heard, replace
exciter.
(5) Reconnect P1 to J1 at APU harness connector and P301 to ignition exciter at

conclusion of fault isolation.
Ignition Cable. Check ignition cable (high tension lead) and

3 ignition system in accordance with note 2.
Igniter Plug. Check ignition system in accordance with note 2.

4
Fuel Solenoid Valves. The following steps apply to the two, normally closed, two-
5 way fuel valves. Select the appropriate pin numbers for the specific valve in
question.

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ELECTRICAL COMPONENT TO AVOID SPARKS IN AREAS
WHERE FUEL VAPOR MAY BE PRESENT. USE A SUITABLE
SWITCH WITH THE 28 VDC SOURCE.
CAUTION: BEFORE TESTING FUEL VALVES, DISCONNECT P301 FROM

IGNITION EXCITER TO PREVENT IGNITION OF FUEL VAPOR.
Fuel Solenoid Valves Function Check
(1) Disconnect plug P1 from J1 at APU harness connector and apply 28 Vdc
(nominal) to:
(a) Main Fuel Solenoid Valve J1-E (+) and J1-F (-).
(b) Maximum Fuel Solenoid Valve J1-A (+) and J1-F (-).
- Valve must open (can be felt by placing hand on valve electrical

connector). Valve must close when 28 Vdc signal is removed.
(2) Remove 28 Vdc source and at J1, check resistance through harness and
valve solenoid at pins noted above. Nominal resistance value to be expected
is 80 ohms at 75°F (24°C) (ambient).
- If essentially zero resistance is measured (i.e., short circuit), proceed to

next step. If open circuit is indicated, proceed to step (4).

FAULT ISOLATION
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Fuel Solenoid Valves Function Check (Continued)
(3) To isolate short (i.e., solenoid or the harness) disconnect wiring harness plug
from solenoid valve in question (TB301-3 and TB301-2) and repeat step (2).
- If short was found in harness, repair or replace harness. Functionally

check or replace ESU.
- If short was not found in harness, replace solenoid valve. Functionally

check or replace ESU.
(4) To isolate an open condition (i.e., solenoid or harness) repeat step (3) except
apply 28 Vdc (nominal) to valve terminal board in question.
- If the valve opens (can be felt by placing hand on valve electrical

connector), repair or replace wiring harness.
- If valve does not open, replace valve.
(5) Reconnect P1 to J1 at APU harness connector after conclusion of fault

isolation.
Fuel Solenoid Valves (fail to deenergize). The following steps apply to all fuel
valves. Select the appropriate pin numbers for the specific valve in question. The
6 ESU must be energized (armed APU not running) during these checks.
(1) Disconnect plug P1 from J1 at APU harness connector and check for
presence of 28 Vdc (nominal) at interconnect receptacle.
a. Main Fuel Solenoid Valve P1-E (+) and P1-F (-).
b. Maximum Fuel Solenoid Valve P1-A (+) and P1-F (-).
- If voltage is detected replace ESU.
(2) Reconnect P1 to J1 at APU harness connector. Then disconnect one of

following plugs for specific valve in question. Check for presence of 28 Vdc
(nominal) at valve terminal board points:

FAULT ISOLATION
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Fuel Solenoid Valves Function Check (Continued)
(a) Main Fuel Solenoid Valve TB301-2 (+) and TB301-4 (-).
(b) Max Fuel Solenoid Valve TB301-3 (+) and TB301-4 (-).
- If voltage is detected, repair or replace the APU harness.
(3) Reconnect all plugs at completion of fault isolation.
Fuel Solenoid Valves Leakage Test. Disconnect wires at TB301-2 and TB301-3
7 from fuel valves and P301 from ignition exciter. Motor the APU with starter for each
of the following tests.
WARNING: FAILURE TO DISCONNECT FUEL VALVE ELECTRICAL INPUT, AS

DESCRIBED ABOVE, WILL PERMIT FUEL TO ENTER
COMBUSTION CHAMBER AND CREATE A FIRE HAZARD.
(1) Check for main and maximum fuel solenoid valves leakage by disconnecting
fuel line at input to fuel cup motor. Position suitable container to collect fuel
that may come from open line. Motor APU with starter and check for fuel flow
from open line.
- If fuel flow is detected, replace main or maximum fuel valve.
(2) Reconnect fuel line and all electrical wires.
Low Oil Pressure Switch. Perform the following steps to determine if the oil
pressure measuring circuit or the pressure system has malfunctioned. The oil
8 pressure switch (S1) is normally open and closed at 6 psig (41 kPa) on increasing
oil pressure.

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Continuity Check
(1) Disconnect plug P1 from J1 at APU harness connector and wire P6B20 and
ground wire P5A20 at oil pressure switch. Check wiring for continuity from
jack J1-H to wire P6B20 and from jack J1-G to wire P5A20 and for shorts to
ground in both wires.
- If wiring discontinuity or shorts to ground are detected, repair or replace

wiring harness. Also, if a short to ground is detected, replace ESU.
Replace plug P1 at APU connector and wires at switch.
NOTE: A short to ground can also be caused by defective high oil

temperature switch (S2).
Switch Operation Check
(1) Check switch circuit at terminal lugs with wires removed.
- If a short circuit (essentially zero resistance) is detected between the

lugs, replace low oil pressure switch.
- If a short circuit is detected between the switch lugs at S1 and ground

replace oil pressure switch and ESU.
(2) Remove oil pressure switch and install a pressure gage [0 to 50 psi (0 to 345
kPa)]. Disconnect wires P6B20 and P5A20 and leave open. Start APU, then
after 90% speed is obtained perform the following:
- If gage reading of 6 psig (41 kPa) or less is observed immediately shut

down APU. Reinstall original oil pressure switch and replace APU.
- If gage reading of 6 psig (41 kPa) or greater is observed, replace oil

pressure switch.
- With switch wires open APU will shutdown at 90% speed.
- If APU does not crank, replace ESU.

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High Oil Temperature Switch. Perform the following steps to determine if the oil
temperature measuring circuit, or the temperature system has malfunctioned.
9 Switch (S2) is normally closed and opens on rising oil temperature above 275°F
±5°F (135°C ±3°C).
Wiring Circuit Continuity
(1) Disconnect plug P1 from J1 at APU harness connector and plug P305 at oil
temperature switch. Check wiring for continuity from plug J1-Y to plug
P305-B and from plug J1-H to plug P305-A and for shorts to ground in both
wires.

wiring harness. Replace plug P1 at the APU and plug P305 at the high oil
temperature switch.
NOTE: Short to ground also can be caused by a defective low oil pressure switch
(S1) which is connected in parallel.
Switch Operation
(1) Check switch S2 circuit at switch with connector P305 disconnected. Check
must be made with oil at 250°F (121°C) or less.
- If an open circuit (high resistance) is detected between S2-A and S2-B,

replace high oil temperature switch.
- If a short circuit (essentially zero resistance) is detected between S2-A

and S2-B and ground, replace high oil temperature switch.
(2) Functional field testing of the high oil temperature switch is not recommended
due to dangers of heating oil. Replace the switch if in doubt.

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Fuel Cup Motor.

10
Continuity Check
(1) Disconnect J303 and check wiring continuity from plug J1-J to jack J303-A
and from plug J1-K to jack J303-B. Check both wires for possible shorts.

wiring harness. Also, if a short to ground is detected, replace ESU.
- Replace plug P1 at APU harness connector and jack J303 at fuel cup
motor connector.
(2) Fuel cup motor testing. Disconnect plug P303 and remove fuel cup motor
assembly from combustor. Mount cup motor in vertical position (shaft down)
and apply 12 Vdc to P303-A (+) and P303-B (-). Measure current flow, if
greater than 1.5 amperes replace cup motor.
Magnetic Pickup. Disconnect plug P1 from J1 at APU connector and P302 from
11 magnetic pickup.
Magnetic Pickup Check
(1) Check magnetic pickup continuity between G1-A and G1-B.
- If open circuit is detected, replace magnetic pickup. If resistance is

correct (1190 to 1450 ohms), proceed to next step. If resistance is outside
these limits, replace the magnetic pickup.
(2) Check magnetic pickup continuity between G1-A and G1-B and ground.
- If a resistance reading of less than 100 megohms is detected, replace

magnetic pickup.
(3) Connect P1 to J1 at APU harness connector and connect P302 to magnetic

pickup.

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Magnetic Pickup Circuit Check
(1) Check for continuity between J1-M and P302-A and between J1-N and
P302-B.
- If an open circuit is detected (high resistance), repair or replace APU

harness.
(2) Check for short circuit (essentially zero resistance) between J1-M to J1-N,
J1-M to J1-P and J1-N to J1-P.
- If short is detected, repair or replace APU harness.
(3) Reconnect P1 to J1 at APU connector and reconnect P302 to magnetic

pickup.
Thermocouple Circuit Check.

12
(1) Disconnect plug P1 from J1 at APU connector. Check thermocouple (TC1)

resistance from chromel/alumel wires to shield. Check J1-R and J1-S to J1-T.
- If resistance is less than 10 megohms, replace thermocouple.
(2) Check thermocouple resistance from chromel/alumel wire to thermocouple

body, J1-R, J1-S to thermocouple body.
- If resistance is less than 30 kilohms, replace thermocouple.
(3) Check thermocouple resistance from shield to thermocouple body, J1-T to

thermocouple body.
- If resistance is less than 10 megohms, replace thermocouple.


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Thermocouple Circuit Check (Continued)
(4) Functional Test: Remove thermocouple from the combustor. Using Jet Cal
EGT Controller, P/N 239-4 and a specially designed heater probe assembly,
insert the thermocouple into the heater probe. Set the heater at 1200°F
(649°C) and stabilize the temperature.
- If the thermocouple output is not at 1200°F ±10°F (649°C ±6°C), replace

thermocouple.

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OPERATIONAL CHECK
1. Introduction
A. This section contains the procedures necessary to perform an operational check of the
Gemini gas turbine auxiliary power unit (APU). Included in this section are prestarting
procedures, starting procedures, operating limitations, protective shutdowns, and normal
shutdown procedures.
B. The APU is cranked by a starter generator until self-sustaining speed is attained. Beyond
this point, the APU accelerates to rated speed.
C. During operation, the APU will shut down automatically if operating limits are either
exceeded or not attained within specified periods outlined in paragraph 2.D.
2. Operational Check of APU
CAUTION: DO NOT OPERATE THE APU ABOVE 20,000 FEET ALTITUDE. FAILURE TO
COMPLY COULD RESULT IN SERIOUS DAMAGE TO EQUIPMENT.
A. Prestarting Procedures
(1) Verify that MASTER switch is set to OFF and load circuit breaker is closed.
(2) Check for adequate fuel supply. Make sure fuel supply to APU has flow and
pressure characteristics as shown in DESCRIPTION AND OPERATION.
CAUTION: NEVER ALLOW THE OIL LEVEL TO BE ABOVE THE “FULL” MARK ON
SIGHT GAUGE. AN OVERFILLED SUMP WILL RESULT IN OIL FOAMING,
LOW OIL PRESSURE, HIGH OIL TEMPERATURE, AND ABNORMAL
GEAR AND BEARING WEAR.
(3) When the APU cools down, check the oil level on the sight gauge glass with the
APU in the level position. It is essential that the oil level does not exceed FULL.
NOTE: It is acceptable for the oil level to rise above the FULL indication when the
oil is hot, providing the oil returns to the correct level when cool.
(4) If necessary, replenish oil level with lubricating oil specified in SERVICING.
(5) Check plumbing and electrical wiring for security.
CAUTION: BE SURE AREA AROUND APU IS CLEAN AND FREE OF FOREIGN
OBJECTS. THE GREATEST HAZARDS TO A TURBINE ENGINE ARE
LEAKING FUEL CONNECTIONS AND ENTRY OF FOREIGN MATERIAL
INTO THE COMPRESSOR.
(6) Remove any loose objects or material from around APU, especially objects that may
be ingested into the APU during operation.
(7) Purge fuel system per SERVICING if:
(a) The fuel system was opened for replacement of components and APU fails to
start after three attempts.
OPERATIONAL CHECK
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DOCUMENT 1068-1
(b) The fuel system was allowed to become empty and APU fails to start after
three attempts.
B. Starting Procedures
NOTE: During an APU fail-to-start condition on a start attempt, every effort should be
made to determine the reason for fail-to-start before another start is made. It is
recommended that a period of at least 5 minutes be allowed between
consecutive start attempts to allow fuel to drain from combustor. If after three
consecutive start attempts a fail-to-start condition still occurs, a visual inspection
of the APU compartment must be made to inspect for excessive fuel around the
tailpipe area, and a cold crank of the APU made to purge fuel from the engine.
To accomplish a cold crank, disconnect electrical connector P301 from ignition
exciter. Disconnect main and maximum fuel solenoid valve wire terminal lugs at
studs 2, 3, and 4 on terminal board TB301. Motor the APU approximately 15
seconds with starter.
(1) Perform cockpit malfunction light test (when used) by moving LIGHT TEST switch to
LIGHT TEST position. All malfunction lights should illuminate, then extinguish when
switch is released.
(2) Replace malfunction light that did not illuminate. Repeat step (1). If all lights did not
illuminate, refer to aircraft troubleshooting procedures to correct the problem before
proceeding.
(3) Set the OFF-RUN-START switch to RUN. Wait until APU ON (when used) indicator
light illuminates. The fuel boost pump and fuel cup motor will start at this time.
CAUTION: IT IS POSSIBLE FOR A START TO PRODUCE A ROAR WITH FLAME IN

THE EXHAUST. THE CAUSE IS PROBABLY AN ACCUMULATION OF
UNBURNED FUEL IN COMBUSTOR FROM PREVIOUS OPERATION. THE
APU MUST BE SHUT DOWN AND THE CAUSE INVESTIGATED. WAIT
FOR ALL FUEL TO DRAIN FROM COMBUSTOR BEFORE ATTEMPTING
ANOTHER START. DURING A START, IF IT APPEARS THAT EXHAUST
GAS TEMPERATURE EXCEEDED LIMITS IN FIGURE 201 AND APU DID
NOT SHUT DOWN, THIS INDICATES A PROBLEM WITH
INSTRUMENTATION. REFER T0 FAULT ISOLATION PROCEDURES.
(4) Set the OFF-RUN-START switch to START and release. Allow engine to reach
rated speed. If installed, observe RPM and Exhaust Gas Temperature (EGT) meters
during APU acceleration. During normal start, RPM meter indicates constantly
increasing speed until approximately 102% is reached and EGT meter shows
steady temperature rise
OPERATIONAL CHECK
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DOCUMENT 1068-1
C. Operating Limitations
(1) During APU operation, make sure that the operating limitations in Figure 201 are
not exceeded.
Item Limitations
Rated Engine Speed 93,882 rpm (106% rated speed)
NOTE: The RPM logic circuit is set to shut down the APU at 110% rated speed. The normal no-
load speed is approximately 102%.
Reduction Drive Axial Pad Speed (Rated) 12,000 rpm
Accessory Drive Pad Speed
Fuel Pump 15,346 rpm
Overtemperature Shutdown 1300°F (704°C) at rated speed
NOTE: The ESU continuously monitors EGT via thermocouples located in the APU exhaust
outlet. EGT temperature exceeding above limits cause the ESU to automatically shut
down the APU for an overtemperature condition. If an automatic shutdown does not
occur within five seconds of an observed overtemperature condition, the APU must be
shut down manually.
Oil Pump Pressure at Rated Speed 15 to 40 psig (103 to 276 kPag)

NOTE: An oil pressure indicator is not provided on the unit, although, provisions for an oil
pressure sensor are provided. Automatic shutdown occurs if APU has passed 90% rated
speed and oil pressure drops below 6 ±1 psig (41.3 ± 6.8 kPag).
Operating Limitations
Figure 201
D. Protective Shutdowns
CAUTION: DO NOT ATTEMPT TO OPERATE THE APU BY WIRING AROUND OR

DISABLING CIRCUITS TO THE SHUTDOWN OR WARNING DEVICES. A
CONDITION THAT PRODUCES AUTOMATIC SHUTDOWN OR WARNING
DESERVES ATTENTION. THESE DEVICES ARE INCORPORATED TO
PREVENT DAMAGE TO THE APU.
(1) Protective devices in the electrical circuit monitors lubricating oil pressure, turbine
exhaust temperature, APU overspeed, APU underspeed, and sequence failure. The
operation of these circuits are described as follows:
(a) Low oil pressure APU shutdown occurs whenever oil pressure is
less than 6 ±1 psig (41.3 ±6.8 kPag) after the APU
has attained 90% rated speed.
OPERATIONAL CHECK
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DOCUMENT 1068-1
(b) High exhaust gas APU shutdown occurs when EGT

temperature exceeds 1300°F (704°C) for 0.5 second at
any time during normal operation.
(c) High oil APU shutdown occurs whenever oil temperature

temperature exceeds 275 ±5°F (135 ±3°C).
(d) APU overspeed APU shutdown occurs when speed reaches 106%.
(e) APU underspeed APU shutdown occurs if speed decreases below

90% after 90%.
(f) Start-up failure APU shutdown occurs when APU fails to receive
Ready-to-Load (RTL) signal within 30 ±7 seconds
after starter is engaged.
(2) The electronic sequence unit (ESU) incorporates built-in test equipment (BITE)
features to provide visual indications if any of the safe operating parameters have
been exceeded, as well as indications of other malfunctions. All BITE indications
are shown in Figure 103 of FAULT ISOLATION.
(3) If a protective (malfunction) shutdown occurs:
(a) Set the OFF-RUN-START switch to OFF.
(b) Note BITE indication and go to FAULT ISOLATION to determine malfunction
before attempting restart.
E. Normal Shutdown Procedures
NOTE: No cool down of the APU is required. The APU should be shutdown while under
load or immediately after the load is removed.
(1) Allow 30 seconds to elapse after APU rotor has stopped before setting OFF-RUN-
START switch to OFF.
OPERATIONAL CHECK
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DOCUMENT 1068-1
REMOVAL/INSTALLATION
1. General
A. This section has the procedures for removal and installation of components on the
Gemini gas turbine auxiliary power unit (APU). Item numbers in the procedures are the
same as those in the ILLUSTRATED PARTS CATALOG (IPC), 49-20-00 (Document
1068-3). Refer to Standard Practices Manual, HSPS 490001, for general information.
NOTE: Alpha-variant items can replace an item when permitted by the effectivity code for
that item. For example, procedures that apply to item (10) also apply to alpha-
variant items (-10A, -10B, and -10C).
B. Access to the APU may prevent performance of some procedures while the APU is
installed on the aircraft or APU enclosure. Refer to the Aircraft Maintenance Manual for
access.
C. A post-maintenance operational check should be performed after required maintenance

tasks to verify repair. Refer to OPERATIONAL CHECK.
D. Exercise extreme care to prevent entrance of dirt, dust, and foreign objects into the APU.
If a foreign object is dropped into the APU, stop maintenance procedure until the object is
located and removed.
E. Cover large openings with protective covers. Cap or plug open tube assemblies, fittings,
and ports. Do not cover tube ends with tape.
NOTE: Refer to Standards Practice Manual, HSPS 490001, for a listing of all
protective covers used on the APU for shipment and/or storage.
F. When installing gaskets, packings, or mating flange faces, coat the surfaces with
assembly fluid.
NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or
holding other small components in place for ease of assembly and prevention of
galling. If necessary, assembly fluid may be diluted with MIL-PRF-7808 or
MIL-PRF-23699F C/I.
G. All parts attached with lockwire or safety cable prior to removal must be attached with
lockwire or safety cable after installation. Safety cable is preferred.
H. When the fuel system has been disturbed for replacement or repair of components, the
APU must be operated and checked for fuel leakage. If the APU fails to start after three
attempts, purge fuel system of air according to APU maintenance instructions (refer to
SERVICING).
I. All seals, gaskets, packings, tab washers, lockpins, and lockwires are to be discarded
when removed and replaced with new like items.
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DOCUMENT 1068-1

A. Equipment and materials required for removal and installation are listed in Figure 301.
B. Tools required for removal and installation are listed in Figure 302.
NOTE: Equivalent substitutes may be used for listed items.
Material Source (Vendor Code)

Anti-Seize compound, 51102 Fel-Pro, Inc. (73165)
Assembly Fluid (4950515) Hamilton Sundstrand (55820)
Connector Pliers, Soft-Jawed TG69 Glenair, Inc.
Heat Gun Commercially Available
Engine Oil (MIL-PRF-7808 or MIL-PRF-23699F Commercially Available
C/I)
Ferrule Cartridge (5909035-2B) Hamilton Sundstrand (99167)
Heat Shrink M23053 Commercially Available
Tubing MS23053/5-107-0
Isopropyl Alcohol ASTM D770 Commercially Available
Lockwire MS20995C32 Commercially Available
Primer, Grade N or T MIL-S-22473 Commercially Available
Safety Cable (5909034-5B) Hamilton Sundstrand (99167)
Sealant 5902435 Hamilton Sundstrand (55820)
Sealing Compound PST 592 Loctite Corp. (0A083)
Solder SN3WRMAP2 or SN63WRMAP3 or Commercially Available
SN63BS
Torque Wrench 0 to 30 pound inches Commercially Available
(0 to 3.4 N.m)
(0 to 17 N.m)
Removal/Installation Equipment and Materials

Figure 301
Tool Number Description

ST71076 Combustor Installation/Removal Tool
ST93470 Wrench
Removal/Installation Tools
Figure 302
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DOCUMENT 1068-1
3. Removal and Installation Procedures
NOTE: The minimum clearance between tubes, and between tubes and adjacent
components must be 0.080 inch (2.032 mm).
A. Removal and Installation of Tube Assemblies

CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.
REMOVE METALLIC RULERS, PENS, PENCILS, WATCHES, RINGS,
AND OTHER ITEMS HAVING EXPOSED CONDUCTING MATERIAL
WHEN WORKING ON ELECTRICAL EQUIPMENT TO PREVENT INJURY
FROM ELECTRICAL SHOCK. PERSONNEL WORKING WITH
ELECTRICITY SHALL HAVE ANOTHER PERSON SKILLED IN MODERN
METHODS OF FIRST AID AND RESUSCITATION NEARBY.
WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.

USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
(1) Position container or drip pan under APU to catch spilled fuel.
NOTE: Be sure caps and plugs are installed on all open lines, fittings, and ports.
(2) Remove clamps (140 and 150, IPC Figure 1, 49-20-00), bolt (160), washer (170)
and nut (180) from tube assemblies (10 and 130).
(3) Disconnect tube assembly (10) from elbow (120, IPC Figure 3, 49-20-00) and tee
(40, IPC Figure 1, 49-20-00).
(4) Disconnect tube assembly (90) from union (100) and elbow (150, IPC Figure 3, 49-
20-00).
(5) Disconnect tube assembly (110, IPC Figure 1, 49-20-00) from union (100) and
union (170, IPC Figure 3, 49-20-00).
(6) Disconnect tube assembly (120, IPC Figure 1, 49-20-00) from fuel atomizer
assembly (10, IPC Figure 1, 49-20-01).
(7) Disconnect tube assembly (130, IPC Figure 1, 49-20-00) from tee (20) and fuel
atomizer assembly (10, IPC Figure 1, 49-20-01).
(8) Disconnect tube assembly (190, IPC Figure 1, 49-20-00) from tee (20) and
union (100).
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DOCUMENT 1068-1
(9) Disconnect tube assembly (200) from elbow (220) on reduction drive assembly
(760) and elbow (230) on oil cooler.
(760) and at oil cooler (640).
(11) Disconnect fuel pump drain assembly (240) from the base of fuel pump (110,
IPC Figure 3, 49-20-00) at tee (20).
(12) Disconnect combustor drain tube assembly (250, IPC Figure 1, 49-20-00) from
reducer (270) and at combustor (730).
(13) Disconnect combustor drain tube assembly (260) from reducer (270).
(14) Disconnect gearbox oil tube assembly (280) from reducer (290) at reduction drive
assembly (760).
(15) Disconnect gearbox vent tube assembly (300) from starter pad cover (290, IPC
Figure 1, 49-23-00).
NOTE: Be sure caps and plugs are removed from all open lines, fittings, and ports.
(16) Install gearbox vent tube assembly (300, IPC Figure 1, 49-20-00) to starter pad
cover (290, IPC Figure 1, 49-23-00) and torque to 135 to 150 pound inches
(15 to 17 N•m).
(17) Connect gearbox oil tube assembly (280, IPC Figure 1, 49-20-00) to reducer (290).
(18) Connect combustor drain tube assembly (260) to reducer (270).
(19) Connect combustor drain tube assembly (250) to reducer (270) and at combustor
(730).
(20) Connect fuel pump drain assembly (240) to the base of fuel pump (110, IPC Figure
3, 49-20-00) at tee (20) and torque to 55 to 65 pound inches (6.2 to 7.3 N•m).
(21) Install tube assembly (210, IPC Figure 1, 49-20-00) to elbow (220) on reduction
drive assembly (760) and at oil cooler (640). Torque elbow to 40 to 55 pound inches
(4.5 to 6.2 N•m). Torque tube assembly B-nuts to 135 to 150 pound inches
(15 to 17 N•m).
(22) Install tube assembly (200) to elbow (220) on reduction drive assembly (760) and
elbow (230) on oil cooler (640). Torque tube assembly B-nuts to 135 to 150 pound
inches (15 to 17 N•m).
(23) Install tube assembly (190) to tee (20) and union (100). Torque tube assembly
B-nuts to 55 to 65 pound inches (6.2 to 7.3 N•m).
(24) Install tube assembly (130) to fuel atomizer assembly (10, IPC Figure 1, 49-20-01)
and tee (20, IPC Figure 1, 49-20-00). Torque tube assembly B-nuts to 55 to 65
pound inches (6.2 to 7.3 N•m).
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DOCUMENT 1068-1
(25) Install tube assembly (120) to fuel atomizer assembly (10, IPC Figure 1, 49-20-01).
Torque tube assembly B-nuts to 135 to 150 pound inches (15 to 17 N•m).
(26) Install tube assembly (110) to union (100) and union (170, IPC Figure 3, 49-20-00).
Torque tube assembly B-nuts to 55 to 65 pound inches (6.2 to 7.3 N•m).
(27) Install tube assembly (90, IPC Figure 1, 49-20-00) to union (100) and elbow (150,
IPC Figure 3, 49-20-00). Torque tube assembly B-nuts to 55 to 65 pound inches
(6.2 to 7.3 N•m).
(28) Install tube assembly (10, IPC Figure 1, 49-20-00) to elbow (120, IPC Figure 3,
49-20-00) and tee (40, IPC Figure 1, 49-20-00). Torque tube assembly B-nuts to 50
to 70 pound inches (5.6 to 7.9 N•m).
(29) Secure tube assembly (130) to tube assembly (10) with clamps (140 and 150), bolt
(160), washer (170), and nut (180).
B. Removal and Installation of High Oil Temperature Switch

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY

WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(1) Remove lockwire and disconnect electrical connector P305 (230, IPC Figure 2, 49-
20-00) from high oil temperature switch (310, IPC Figure 1, 49-20-00).
(2) Place container under reduction drive assembly (760) to catch spilled oil.
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DOCUMENT 1068-1
WARNING: USE SYNTHETIC TURBINE OIL CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND IS MILDLY POISONOUS. IT CAN HAVE A
BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
OIL, GET THE MATERIAL SAFETY DATA SHEET FROM THE
CAREFULLY. READ THE DETAILED WARNING, W0126SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE OIL, PUT ON
CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES.
(3) Unscrew and remove high oil temperature switch (310) and packing (320). Discard
packing.

WARNING: PACKING LUBRICANT CAN CAUSE IRRITATION OF YOUR SKIN OR

EYES. BEFORE YOU USE THE LUBRICANT, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. PUT ON SAFETY SAFETY
GLASSES OR SPLASH GOGGLES. IF THE LUBRICANT GETS IN YOUR
EYES, IMMEDIATELY FLUSH THEM WITH WATER FOR A MINIMUM OF
15 MINUTES WHILE YOU HOLD THE EYELIDS OPEN. IF THE
ASSEMBLY FLUID GETS ON YOUR SKIN, WASH THE SKIN WITH SOAP
AND WATER. IF THE EYE OR SKIN IRRITATION CONTINUES, GET
MEDICAL AID.
(4) Install high oil temperature switch (310) and packing (320) in reduction drive
assembly (760). Torque to 55 to 75 pound inches (6.2 to 8.4 N•m). Safety wire high
oil temperature switch using lockwire.
(5) Connect electrical connector P305 (230, IPC Figure 2, 49-20-00) to high oil
temperature switch (310, IPC Figure 1, 49-20-00). Safety wire electrical connector
P305 using lockwire.
NOTE: When possible, connectors should be tightened with a pair of soft-jawed

connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(6) Service APU with lubricating oil. Refer to SERVICING.
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DOCUMENT 1068-1
C. Removal and Installation of Ignition Cable


(1) Disconnect ignition cable (330) from ignition exciter (340) and igniter plug
(100, IPC Figure 1, 49-20-01).
(2) Remove ignition cable (330) from APU.
(3) Connect ignition cable (330, IPC Figure 1, 49-20-00) to ignition exciter (340) and
igniter plug (100, IPC Figure 1, 49-20-01). Torque B-nuts to 95 to 125 pound inches
(10.7 to 14.1 N•m).
(4) Safety wire ignition cable B-nuts using lockwire.
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DOCUMENT 1068-1
D. Removal and Installation of Ignition Exciter


(1) Disconnect electrical connector P301 (130, IPC Figure 2, 49-20-00) from ignition
exciter (340, IPC Figure 1, 49-20-00).
(2) Disconnect ignition cable (330) from ignition exciter (340).
(3) Remove bolt (380), bolt (390), and washers (360) securing ignition exciter to
outboard bracket (540).
(4) Slide out and remove ignition exciter (340) from inboard bracket (530) and outboard
bracket (540).
(5) Slide in ignition exciter (340) into inboard bracket (530) and over outboard bracket
(540). Secure with bolt (380), bolt (390), and washers (360) to outboard bracket
(540). Torque bolts to 18 to 20 pound inches (2.0 to 2.2 N•m).
(6) Connect electrical connector P301 (130, IPC Figure 2, 49-20-00) to ignition exciter
(340, IPC Figure 1, 49-20-00).

(7) Connect ignition cable (330) to ignition exciter (340). Torque B-nut to 95 to 125
pound inches (10.7 to 14.1 N·m).
(8) Safety wire electrical connector P301 (130, IPC Figure 2, 49-20-00) and ignition
cable B-nut using lockwire.
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DOCUMENT 1068-1
E. Removal and Installation of Electrical Harness


NOTE: Tag all electrical wires prior to removal as an aid when reconnecting electrical
wires to their related components.
(1) Disconnect electrical connector P302 (200) from magnetic pickup (200, IPC Figure
1, 49-23-00).
(3) Remove shrink tubing and disconnect harness (400) leads P6B20 and P5A20 from
low oil pressure switch (20, IPC Figure 1, 49-23-00).
(4) Disconnect electrical connector P305 (230, IPC Figure 2, 49-20-00) from high oil
temperature switch (310, IPC Figure 1, 49-20-00).
(5) Disconnect fuel atomizer assembly electrical connector P303 from electrical
connector J303 (150, IPC Figure 2, 49-20-00).
(6) Remove thermocouple (120) from combustor housing assembly (110, IPC Figure 1,
49-20-01).
(7) Remove nuts (460, IPC Figure 1, 49-20-00), screws (450), and washers (470).
Remove harness terminal board assembly (430) from terminal block strip (440) and
remove terminal block strip from exciter bracket (520).
(8) Remove harness ground wire P4C12N from middle stud on reduction drive
assembly (760).
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DOCUMENT 1068-1
(9) Remove bolt (510) and clamps (490 and 500) securing harness and cup motor
wires.
(10) Remove screws (410) and nut ring (420) securing electrical connector J303 (150,
IPC Figure 2, 49-20-00) to bracket (590, IPC Figure 1, 49-20-00). Remove electrical
connector J303.
WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(10A) Clean all harness and component connectors using a soft-bristled brush and
cotton wipes moistened with isopropyl alcohol to remove oil, grease, and
contamination from the pins and inside of the electrical connectors. Allow
connectors to air dry.
(11) Install electrical connector J303 (150, IPC Figure 2, 49-20-00) to bracket (590, IPC
Figure 1, 49-20-00) and secure with nut ring (420, IPC Figure 1, 49-20-00) and
screws (410).
(12) Secure harness and cup motor wires with clamps (490 and 500) and bolt (510).
(13) Install harness ground wire P4C12N to middle stud on reduction drive assembly
(760). Torque to 55 to 70 pound inches (6.2 to 7.9 N•m) above prevailing torque.
(14) Install terminal block strip (440) on exciter bracket (520). Install harness terminal
block buss on strip and secure with screws (450), washers (470), and nuts (460).

(15) Install thermocouple (120, IPC Figure 2, 49-20-00) into APU exhaust outlet. Safety
wire thermocouple with lockwire.
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DOCUMENT 1068-1
(16) Connect fuel atomizer assembly electrical connector P303 to electrical connector
J303 (150).

(17) Connect electrical connector P305 (230) to high oil temperature switch (310, IPC
Figure 1, 49-20-00). Safety wire electrical connector P305 with lockwire.

(18) Install heat shrink tubing around low oil pressure switch (20, IPC Figure 1,
49-23-00) leads.
(19) Connect harness (400, IPC Figure 1, 49-20-00) leads P6B20 and P5A20 to low oil
pressure switch (20, IPC Figure 1, 49-23-00).
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

(20) Use heat gun to form tubing around lead ends, covering exposed contacts.
(340, IPC Figure 1, 49-20-00). Safety wire electrical connector P301 with lockwire.
(22) Connect electrical connector P302 (200, IPC Figure 2, 49-20-00) to magnetic pickup
(200, IPC Figure 1, 49-23-00). Safety wire electrical connector P302 with lockwire.
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DOCUMENT 1068-1
F. Removal and Installation of Fuel Solenoid Valves


SOAP AND WATER.
NOTE: Prior to removal of the main and maximum fuel solenoid valves, tag each valve
and its respective electrical harness connector in order to facilitate valve
installation.
(2) Disconnect tube assembly (10, IPC Figure 1, 49-20-00) from elbow (120, IPC Figure
3, 49-20-00) and tee (40, IPC Figure 1, 49-20-00).
(3) Disconnect tube assembly (90) from union (100) and elbow (150, IPC Figure 3,
49-20-00).
(4) Disconnect tube assembly (110, IPC Figure 1, 49-20-00) from union (100).
(5) Remove tee (20) from reducer (80). Remove reducer (80), packing (60), and washer
(50) from union (30).
(6) Remove unions (100) and union (30) from fuel solenoid valves (550).
(7) Disconnect fuel solenoid valve wire terminal lugs from terminal board TB301 (430).
(8) Remove screws (560) and washers (570) securing fuel solenoid valves (550) to
bracket (580). Remove fuel solenoid valves.
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DOCUMENT 1068-1
(9) Install fuel solenoid valves (550) on bracket (580).
(10) Install screws (560) and washers (570) and secure fuel solenoid valves (550) to
bracket (580).
(11) Connect fuel solenoid valve wire terminal lugs to terminal board TB301 (430).

CORRECTLY. THE COMPOUND IS COMBUSTIBLE. IT CAN HAVE A
WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND,
PUT ON SAFETY GLASSES OR GOGGLES AND NEOPRENE, RUBBER,
OR BUTYL RUBBER GLOVES.
(12) Apply sealant to union threads. Install unions (100) and union (30) to fuel solenoid
valves (550). Torque unions (100) to 25 to 35 pound inches (2.8 to 3.9 N•m) and
union (30) to 40 to 55 pound inches (4.5 to 6.2 N•m).
CAUTION: ENSURE THAT WASHER AND REDUCER ARE CENTERED OR A FUEL

LEAK MAY OCCUR.
(13) Install washer (50), packing (60), and reducer (80) onto union (30). Install tee (20) to
reducer. Torque to 55 to 65 pound inches (6.2 to 7.3 N•m).
(14) Connect tube assembly (110) to union (100). Torque tube assembly B-nuts to
55 to 65 pound inches (6.2 to 7.3 N•m).
(15) Connect tube assembly (90) to union (100) and elbow (150, IPC Figure 3,
49-20-00). Torque tube assembly B-nuts to 55 to 65 pound inches
(6.2 to 7.3 N•m).
(16) Connect tube assembly (10, IPC Figure 1, 49-20-00) to elbow (120, IPC Figure 3,
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G. Removal and Installation of Fuel Atomizer and Combustion Chamber Assembly

(1) Disconnect tube assembly (120) from fuel atomizer assembly (10, IPC Figure 1, 49-
20-01).
(3) Disconnect tube assembly (190, IPC Figure 1, 49-20-00) from tee (20) and union
(100).
(4) Disconnect electrical connector P303 from electrical connector J303 (150, IPC
Figure 2, 49-20-00).
(5) Disconnect ignition cable (330, IPC Figure 1, 49-20-00) and remove igniter
(100, IPC Figure 1, 49-20-01) from boss in combustor housing (110).
(6) Loosen nut of V-band clamp (80) and remove V-band clamp securing combustion
chamber assembly (70) and fuel atomizer assembly (10) to combustor housing
(110).
(7) Lift combustion chamber (70) and fuel atomizer assembly (10) out of combustor
housing (110). Discard packing (90).
(8) Unscrew fuel atomizer assembly (10) from combustion chamber assembly (70).
Discard packing (20).
(9) Remove screws (40) and washers (50) to separate combustor cover (60) from
combustion chamber assembly (70).
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NOTE: To prevent leakage of compressor gases, be sure to apply sealant as

specified.
(10) Apply a thin coating of sealant to threads on screws (40) and bottom surface of
combustor cover (60)
(11) Install combustor cover (60) on combustion chamber assembly (70) and secure with
screws (40) and washers (50). Torque screws to 10 to 13 pound inches
(1.1 to 1.5 N·m).

MEDICAL AID.
(12) Install packing (20) onto fuel atomizer assembly (10). Use wrench ST93470 and
screw fuel atomizer assembly into combustion chamber assembly (70).
(13) Install packing (90) on combustor cover (60).
(14) Install combustion chamber and fuel atomizer assembly into combustor housing
(110).
(15) Install V-band clamp (80) and secure combustion chamber and fuel atomizer
assembly to combustor housing (110). Torque nut to 50 to 60 pound inches
(5.6 to 6.7 N•m) above prevailing torque.
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(16) Install igniter plug (100) to boss in combustor housing (110) and torque to 30 to 40
pound inches (3.4 to 4.5 N•m). Connect ignition cable (330, IPC Figure 1,
49-20-00) to igniter plug. Safety wire ignition cable B-nut using lockwire.
(17) Connect electrical connector P303 to electrical connector J303 (150, IPC Figure 2,
49-20-00).

(18) Connect tube assembly (190, IPC Figure 1, 49-20-00) to tee (20) and union (100).
NOTE: In steps (19) and (20), if the fuel atomizer tee does not align with the tube
assemblies, remove the two screws and reorient the tee. Then, reinstall the
screws and torque them to 2 to 3 pound inches (0.2 to 0.3 N·m).
(19) Connect tube assembly (130) to tee (20) and fuel atomizer assembly (10, IPC
Figure 1, 49-20-01). Torque tube assembly B-nuts to 55 to 65 pound inches
(6.2 to 7.3 N•m).
(20) Connect tube assembly (120, IPC Figure 1, 49-20-00) to fuel atomizer assembly
(10, IPC Figure 1, 49-20-01). Torque tube assembly B-nuts to 135 to 150 pound
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H. Removal and Installation of Fuel Control and Pump Assembly


SOAP AND WATER.
(2) Disconnect tube assembly (10, IPC Figure 1, 49-20-00) from elbow (120, IPC Figure
3, 49-20-00) and tee (40, IPC Figure 1, 49-20-00).
(3) Disconnect tube assembly (90) from union (100) and elbow (150, IPC Figure 3,
49-20-00).
(4) Disconnect tube assembly (110, IPC Figure 1, 49-20-00) from union (100) and
union (170, IPC Figure 3, 49-20-00).
(5) Loosen nut and remove elbow (120) and packing (130) from fuel control (30).
Discard packing.
(6) Remove elbow (150) and packing (160) from fuel control (30). Discard packing.
(7) Remove union (170) and packing (160) from fuel control (30). Discard packing.
(8) Remove elbow (120), packing (130), and safety screen (140) from fuel pump (110).
(9) Remove nuts (690, IPC Figure 1, 49-20-00) and washers (700) securing fuel control
and pump assembly (680) to reduction drive assembly (760). Remove gasket (710)
and shaft coupling (720). Discard gasket.
(10) Disconnect fuel drain tube assembly (100, IPC Figure 3, 49-20-00) from elbow (150)
and tee (20).
(11) Loosen nut and remove elbow (150) and packing (160) from fuel control (30).
Discard packing.
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(12) Loosen seal nut (10) and remove tee (20).
(13) Remove bolts (40), nuts (50), and washers (60). Remove fuel pump (110) from fuel
control (30).
(14) Remove shaft coupling (70) and packings (90 and 80). Discard packings.

MEDICAL AID.
(15) Install shaft coupling (70) and packings (80 and 90) on fuel pump (110).
(16) Assemble fuel pump (110) and fuel control (30) and install bolts (40), washers (60),
and nuts (50).
NOTE: Maintain squareness of mating flanges until at least one bolt is tight.
(17) Install tee (20) and seal nut (10). Tighten seal nut.
(18) Install packing (160) and elbow (150) in fuel control (30). Tighten nut.
(19) Connect fuel drain tube assembly (100) to elbow (150) and tee (20).
(20) Install shaft coupling (720, IPC Figure 1, 49-20-00) and gasket (710) on reduction
drive assembly (760).
(21) Install fuel control and pump assembly (680) on reduction drive assembly (760) and
secure with washers (700) and nuts (690). Torque nuts to 20 to 22 pound inches
(2.3 to 2.5 N•m).
(22) Install safety screen (140, IPC Figure 3, 49-20-00), packing (130), and elbow (120)
in fuel pump (110).
(23) Install packing (160) and union (170) in fuel control (30).
(26) Connect tube assembly (110, IPC Figure 1, 49-20-00) to union (100) and union
inches (6.2 to 7.3 N•m).
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(27) Connect tube assembly (90, IPC Figure 1, 49-20-00) to union (100) and elbow (150,
(6.2 to 7.3 N•m).
I. Removal and Installation of Oil Cooler Assembly

(1) Position container or drip pan under APU to catch spilled oil.
(760) and elbow (230) at oil cooler assembly (630).
(760) and at oil cooler assembly (630).
(4) Remove bolts (660) and nuts (670) securing oil cooler assembly (630) to air outlet
duct (650).
(5) Remove oil cooler assembly (630).
(6) Install oil cooler assembly (630) on air outlet duct (650) and secure with bolts (660)
and nuts (670).
(7) Connect tube assembly (210) to elbow (220) on reduction drive assembly (760) and
at oil cooler assembly (630). Torque elbow to 40 to 55 pound inches (4.5 to 6.2
N•m). Torque tube assembly B-nuts to 135 to 150 pound inches (15 to 17 N•m).
(8) Connect tube assembly (200) to elbow (220) on reduction drive assembly (760) and
elbow (230) at oil cooler assembly (630). Torque tube assembly B-nuts to 135 to
150 pound inches (15 to 17 N•m).
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J. Removal and Installation of Fuel Filter


SOAP AND WATER.
(2) Remove screw (30, IPC Figure 1, 49-23-00) securing clamp (750, IPC Figure 1,
49-20-00), fuel filter (740), and oil fill tube (50, IPC Figure 1, 49-23-00) to reduction
drive assembly (760, IPC Figure 1, 49-20-00).
(3) Remove clamp (750) from fuel filter (740).
(4) Install clamp (750) on fuel filter (740).
(5) Install screw (30, IPC Figure 1, 49-23-00) and secure fuel filter (740, IPC Figure 1,
49-20-00) and oil fill tube (50, IPC Figure 1, 49-23-00) with clamp (750, IPC Figure
1, 49-20-00) to reduction drive assembly (760).
K. Removal and Installation of Oil Fill Tube
(1) Remove screw (30, IPC Figure 1, 49-23-00) and clamp (750, IPC Figure 1,
49-20-00) securing fuel filter (740) and oil fill tube (50, IPC Figure 1, 49-23-00) to
reduction drive assembly (760, IPC Figure 1, 49-20-00).
(2) Remove oil fill tube (50, IPC Figure 1, 49-23-00) and packing (60). Discard packing.
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MEDICAL AID.
(3) Install packing (60) and oil fill tube (50) in reduction drive assembly (760, IPC Figure
1,49-20-00).
(4) Install screw (30, IPC Figure 1, 49-23-00) and clamp (750, IPC Figure 1, 49-20-00),
and secure oil fill tube (50, IPC Figure 1, 49-23-00) and fuel filter (740, IPC Figure 1,
49-20-00) to reduction drive assembly (760).
L. Removal and Installation of Oil Overfill Tube Assembly
(1) Remove nut (110, IPC Figure 1, 49-23-00) and washer (120) securing oil overfill
tube assembly (100) to reduction drive assembly (760, IPC Figure 1, 49-20-00).
(2) Remove oil overfill tube assembly (100, IPC Figure 1, 49-23-00) and gasket (130).
Discard gasket.
(3) Install oil overfill tube assembly (100) and gasket (130) on reduction drive assembly
(760, IPC Figure 1, 49-20-00).
(4) Install nut (110, IPC Figure 1, 49-23-00) and washer (120) and secure oil overfill
tube assembly (100) to reduction drive assembly (760, IPC Figure 1, 49-20-00).
M. Removal and Installation of Oil Filter Element

(1) Position container or drip pan under APU to catch spilled oil.
(2) Remove oil filter plug (140, IPC Figure 1, 49-23-00) and packing (150) from
reduction drive assembly (760, IPC Figure 1, 49-20-00). Discard packing.
(3) Remove oil relief spring (160, IPC Figure 1, 49-23-00) and oil filter adapter (170).
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(4) Pull filter element (180) and packing (190) from reduction drive assembly (760, IPC
Figure 1, 49-20-00) housing. Discard packing and filter element as required.
NOTE: Refer to Periodic Inspections (Figure 501) and aircraft log book to
determine replacement time of filter element. Filter element may be reused
if not damaged or contaminated, and life limited time is not exceeded.

MEDICAL AID.
(5) Install packing (190, IPC Figure 1, 49-23-00) in filter element (180) groove, as
required.
(6) Install filter element (180) in reduction drive assembly housing (760, IPC Figure 1,
49-20-00).
(7) Install filter adapter (170, IPC Figure 1, 49-23-00) and oil relief spring (160).
(8) Install packing (150) and secure filter adapter (170) with oil filter plug (140) to
reduction drive assembly (760, IPC Figure 1, 49-20-00).
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N. Removal and Installation of Combustor Housing


SOAP AND WATER.
WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING

EXHAUST DEPOSITS INTO OPEN WOUNDS.
(2) Remove clamps (140 and 150), bolt (160), washer (170), and nut (180) from tube
assemblies (10 and 130).
(3) Disconnect tube assembly (10) from elbow (120, IPC Figure 3, 49-20-00) and tee
(40, IPC Figure 1, 49-20-00).
(4) Disconnect tube assembly (120) from fuel atomizer assembly (10, IPC Figure 1, 49-
20-01).
(5) Remove tee (40, IPC Figure 1, 49-20-00), nut (70), and packing (60) from
combustor housing (110, IPC Figure 1, 49-20-01). Discard packing.
(100).
(8) Disconnect electrical connector P303 from electrical connector J303 (150, IPC
Figure 2, 49-20-00).
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(9) Remove thermocouple (120) from APU combustor housing (110, IPC Figure 1,
49-20-01).
(10) Disconnect ignition cable (330, IPC Figure 1, 49-20-00) from igniter plug (100, IPC
Figure 1, 49-20-01. Remove igniter plug.
(11) Loosen nut of V-band clamp (80) and remove V-band clamp securing fuel atomizer
assembly (10) and combustion chamber assembly (70) to combustor housing (110).
(12) Loosen nut (120) of V-band clamp (130) and remove V-band clamp securing
combustor housing (110) to gas turbine assembly (790, IPC Figure 1, 49-20-00).
(13) Use combustor removal tool ST71076 and remove combustor housing (110, IPC
Figure 1, 49-20-01) from gas turbine assembly (790, IPC Figure 1, 49-20-00).
(14) Remove and discard packing (150, IPC Figure 1, 49-20-01).

MEDICAL AID.
(15) Install packing (150) in gas turbine assembly (790, IPC Figure 1, 49-20-00)
mounting flange groove.
(16) Use combustor installation tool ST71076 and install combustor housing (110, IPC
Figure 1, 49-20-01) on gas turbine assembly (790, IPC Figure 1, 49-20-00).
(17) Secure combustor housing (110, IPC Figure 1, 49-20-01) with V-band clamp (130).
Torque nut (120) to 30 to 40 pound inches (3.4 to 4.5 N•m).
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(18) Install fuel atomizer assembly (10) and combustion chamber assembly (70) into
combustor housing (110) and secure with V-band clamp (80). Torque nut to
50 to 60 pound inches (5.6 to 6.7 N•m).
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT

HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
CAUTION: ANTISEIZE COMPOUNDS CONTAINING LEAD ARE HARMFUL TO THE

COMBUSTOR LINER AND HOUSING ASSEMBLIES. DO NOT APPLY
ANTISEIZE COMPOUNDS CONTAINING LEAD TO THOSE
COMPONENTS.
CAUTION: ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO TIP OF

IGNITER OR DAMAGE TO THE PLUG WILL OCCUR.
(18A) Apply a thin coat of anti-seize compound to threads of igniter plug (100).

(19) Install igniter plug (100) to boss in combustor housing (110) and torque to 30 to 40
pound inches (3.4 to 4.5 N•m). Connect ignition cable (330, IPC Figure 1,
49-20-00) to igniter plug. Safety wire ignition cable B-nut using lockwire.
(20) Install thermocouple (120, IPC Figure 2, 49-20-00) into combustor housing (110,
IPC Figure 1, 49-20-01). Safety wire thermocouple using lockwire.
(21) Connect electrical connector P303 to electrical connector J303 (150, IPC Figure 2,
49-20-00).

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DOCUMENT 1068-1
(22) Connect tube assembly (130) to tee (20) and fuel atomizer assembly (10, IPC
Figure 1, 49-20-01). Torque tube assembly B-nuts to 55 to 65 pound inches (6.2 to
7.3 N•m).
(24) Install nut (70) and packing (60) on tee (40). Install tee in combustor housing (110,
IPC Figure 1, 49-20-01).
(25) Connect tube assembly (120, IPC Figure 1, 49-20-00) to fuel atomizer assembly
(160), washer (170), and nut (180).
O. Removal and Installation of Turbine Assembly


SOAP AND WATER.

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DOCUMENT 1068-1
(1) Position container or drip pan under APU to catch spilled fuel or oil.
(2) Remove clamps (140 and 150), bolt (160), washer (170), and nut (180) from tube
assemblies (130 and 10).
(3) Disconnect tube assembly (10) from elbow (120, IPC Figure 3,
49-20-00) and tee (40, IPC Figure 1, 49-20-00).
(4) Disconnect tube assembly (130) from tee (20) and fuel atomizer assembly (10, IPC
Figure 1, 49-20-01).
(100).
(6) Disconnect fuel atomizer electrical connector P303 from electrical connector J303
(150, IPC Figure 2, 49-20-00)
(7) Remove thermocouple (120) from combustor housing (110, IPC Figure 1,
49-20-01).

(8) Remove lockwire and disconnect ignition cable (330, IPC Figure 1, 49-20-00) from
igniter plug (100, IPC Figure 1, 49-20-01).
(9) Loosen nut (140) and remove V-band clamp (130) securing combustor housing
(110) to gas turbine assembly (790, IPC Figure 1, 49-20-00).
(10) Remove and discard packing (150, IPC Figure 1, 49-20-01).
(11) Remove nuts (800, IPC Figure 1, 49-20-00) and washers (810) securing gas turbine
assembly (790) to reduction drive assembly (760). Remove gas turbine assembly.
(12) Remove and discard packings (830 and 820), and packings (150, IPC Figure 1, 49-
22-00).
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DOCUMENT 1068-1
MEDICAL AID.
(13) Install packings (830 and 820, IPC Figure 1, 49-20-00) in grooves on forward flange
of gas turbine assembly (790).
(14) Install packings (150, IPC Figure 1, 49-22-00) in grooves around air inlet housing
(20).
(15) Install gas turbine assembly (790, IPC Figure 1, 49-20-00) on reduction drive
assembly (760) and secure with nuts (800) and washers (810). Torque nuts to 97 to
107 pound inches (10.9 to 12.0 N•m) above prevailing torque.

MEDICAL AID.
(16) Install packing (150, IPC Figure 1, 49-20-01) in groove on aft flange of gas turbine
assembly (790, IPC Figure 1, 49-20-00)
(17) Use combustor installation tool ST71076 and install combustor housing assembly
(110, IPC Figure 1, 49-20-01) to gas turbine assembly (790, IPC Figure 1,
49-20-00) and secure with V-band clamp (130, IPC Figure 1, 49-20-01). Torque nut
(140) to 30 to 40 pound inches (3.4 to 4.5 N•m) above prevailing torque.
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DOCUMENT 1068-1
(18) Connect ignition cable (330, IPC Figure 1, 49-20-00) to igniter plug (100, IPC Figure
1, 49-20-01). Safety wire ignition cable B-nut using lockwire.
(19) Install thermocouple (120, IPC Figure 2, 49-20-00) into combustor housing (110,
IPC Figure 1, 49-20-01). Safety wire thermocouple using lockwire.
(20) Connect fuel atomizer electrical connector P303 to electrical connector J303
(150, IPC Figure 2, 49-20-00).

(22) Connect tube assembly (130) to fuel atomizer assembly (10, IPC Figure 1,
(23) Connect tube assembly (10) to elbow (120, IPC Figure 3, 49-20-00) and tee (40,
(5.6 to 7.9 N•m).
(160), washer (170), and nut (180).
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P. Removal and Installation of Magnetic Pickup


20-00) from magnetic pickup (200, IPC Figure 1, 49-23-00).
(2) Loosen jamnut (210) and remove magnetic pickup (200).
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WARNING: USE LOCQUIC PRIMER GRADE N OR T, CORRECTLY. THE PRIMER IS
FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE PRIMER, GET
THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER
OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ
THE DETAILED WARNING, W0135SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE PRIMER, PUT ON CHEMICAL-
SPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES (BUTYL
RUBBER). MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO
KEEP THE PRIMER FUMES BELOW THE MATERIAL SAFETY DATA
SHEET LIMIT.

(3) Apply a light coat of primer Grade N and pipe sealer Loctite 532 to threads of
magnetic pickup (200). Install magnetic pickup, then back off one turn. Verify
clearance in accordance with Figure 303, and tighten jamnut (210). Torque to 25 to
35 pound inches (2.6 to 3.7 N•m).
NOTE: Clearance in Figure 303 shall be obtained with output gear loaded toward
magnetic pickup and with magnetic pickup indexed between gear web and
speed sensing holes.
Magnetic Pickup Clearance

Figure 303
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DOCUMENT 1068-1
(4) Connect electrical connector P302 (200, IPC Figure 2, 49-20-00) to magnetic pickup
(200, IPC Figure 1, 49-23-00). Safety wire electrical connector with lockwire.
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DOCUMENT 1068-1
CLEANING
1. Introduction
A. This section has the procedures for cleaning the Gemini gas turbine auxiliary power unit
(APU) components. Item numbers in the procedure are the same as those in the
ILLUSTRATED PARTS CATALOG (IPC), 49-20-00 (Document 1068-3). Refer to
Standard Practices Manual, HSPS 490001, for general information.
2. Cleaning Materials
A. Cleaning materials are listed in Figure 401.
Material Source
Goggles Commercially Available
Lint-free cloth Commercially Available
Spray gun, 1 quart (1 liter) capacity Commercially Available
Lubricating oil MIL-PRF-6081, Grade 1010 Commercially Available
Cleaning Solution MIL-PRF-85704 Type II or Commercially Available

Type II RTU
Commercially Available
Isopropyl Alcohol, ASTM D770
Razor knife Commercially Available
Stiff-bristle brush Commercially Available
Q-tips Commercially Available
Ultrasonic cleaning tank Commercially Available
Simple Green or equivalent alkaline solution Commercially Available
with 8 - 9 pH
Solvent-resistant gloves Commercially Available
Toothpick (round) Commercially Available
Cleaning Materials
Figure 401
CLEANING
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DOCUMENT 1068-1
3. Cleaning Procedures
A. General
(1) When considerable time has elapsed between cleaning and inspection or
reassembly, apply a light coat of lubricating oil to components and mating surfaces.
Place cleaned parts in clean plastic bags to prevent contamination.
B. Cleaning
(1) Cleaning requirements are listed in Figure 402.
Component Cleaning Method

Fuel filter (910, IPC Figure 1, 49-20-00) Wash and flush. Clean by ultrasonic method
using Simple Green.
Fuel pump (110, IPC Figure 3, 49-20-00) Wipe with clean, lint-free cloth soaked in
Simple Green.
Fuel control (30, IPC Figure 3, 49-20-00) Wipe with clean, lint-free cloth soaked in
Simple Green.
Fuel cup Wipe with clean, lint-free cloth soaked in
Simple Green.
Combustor drain (250 and 260, IPC Figure 1, Wash and flush with Simple Green.
49-20-00)
Low oil pressure switch (20, IPC Figure 1, Wipe with clean lint-free, dry cloth.
49-23-00)
Cleaning Requirements
CLEANING
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Component Cleaning Method
Thermocouple (120, IPC Figure 2, 49-20-00) Wipe with clean lint-free, dry cloth.
Ignition exciter (340, IPC Figure 1, 49-20-00) Wipe clean with lint-free, dry cloth.
NOTE: Cap electrical receptacles or connections as required before cleaning.
Hourmeter/Event Counter (480, IPC Figure 1, Wipe clean with lint-free, dry cloth.
49-20-00)
High oil temperature switch (310, IPC Figure 1, Wipe clean with lint-free, dry cloth.
49-20-00)
Solenoid valves (550, IPC Figure 1, 49-20-00) Wipe clean with lint-free, dry cloth.
CAUTION: DO NOT USE CONVENTIONAL ABRASIVE OR IGNITER PLUG
CLEANER. DAMAGE TO IGNITER PLUG CAN OCCUR.
Igniter plug (100, IPC Figure 1, 49-20-01) Use a dry, stiff-bristle brush and wipe with
clean, lint-free, dry cloth.
WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL

IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL,
GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES.
MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE SURE
THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER SQUARE INCH
(207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR
LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR
EYES. THIS WILL HELP PREVENT INJURIES TO PERSONNEL OR DAMAGE
TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET MEDICAL
ATTENTION.
Fuel lines Force-flush thoroughly with isopropyl alcohol

and dry with compressed air.
NOTE: Install protective caps or plugs on fuel lines after cleaning.
Magnetic pickup (200, IPC Figure 1, 49-23-00) Wipe clean with lint-free, dry cloth.
Cleaning Requirements
CLEANING
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DOCUMENT 1068-1
4. Cleaning of Assembled Turbine Rotor
CAUTION: THE COMPRESSOR WHEEL IS OF TITANIUM CONSTRUCTION. DO NOT USE

WATER SOLUBLE CLEANERS CONTAINING CHLORINATED
HYDROCARBONS. CHLORINATED HYDROCARBONS ARE DETRIMENTAL TO
TITANIUM.
A. Prepare to Clean
(1) Remove components as necessary to gain access to air inlet screen (200, IPC
Figure 1, 49-22-00). Do not remove screen.


20-00) from ignition exciter (340, IPC Figure 1, 49-20-00).
(3) Disconnect PCD (air) line (10) from fitting (40) and tee (50). Install protective caps
on all disturbed fittings and tubing.
(4) Ensure that the APU drain collecting tank (EPA tank) is completely empty.
CLEANING
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DOCUMENT 1068-1
B. Clean Turbine Rotor Assembly
WARNING: USE AQUEOUS (WATER) BASED CLEANER, TURCO 6783-10, ALSO

KNOWN AS MIL-PRF-85704, TYPE II TURBINE ENGINE GAS PATH
CLEANING COMPOUND, CORRECTLY. IT CAN HAVE A BAD EFFECT
ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE CLEANER,
GET THE MATERIAL SAFETY DATA SHEET FROM THE
WARNING REGISTRY 341-006. PUT ON CHEMICAL-SPLASH GOGGLES
AND NEOPRENE OR NITRILE GLOVES BEFORE YOU USE THE
CLEANER. MAKE SURE YOU HAVE SUFFICIENT AIRFLOW TO KEEP
(1) Fill a suitable spray gun with one quart (1 liter) of cleaning fluid.
(2) Position one technician at the APU control panel and one on the APU.
(3) At the control panel, turn the master switch on and press “System Test”.
CAUTION: DO NOT EXCEED THE STARTER DUTY CYCLE LIMITS, REFER TO THE
AIRCRAFT MAINTENANCE MANUAL. EXCEEDING THE STARTER DUTY
LIMITS WILL RESULT IN DAMAGE TO THE STARTER.
(4) Before 30 seconds elapsed time, press the start switch and release.
(5) At the APU air inlet, spray cleaning fluid into the bottom of the air inlet muff with the
spray pointing upward while the APU is cranking.
NOTE: Cleaning fluid that is ingested during slow rotation of the turbine will be
most effective for cleaning operation.
(6) Repeat steps (3) through (5) until all of the cleaning fluid has been ingested.
(7) Allow engine to stand for approximately 15 minutes to allow deposits to be

dissolved.
(8) Fill a suitable spray gun with one quart (1 liter) of distilled or demineralized water.
(9) Repeat steps (3) through (5) and spray water into air inlet while engine is rotating.
(10) Repeat steps (3) through (5) until all water has been ingested.
(11) Repeat steps (1) through (10) as required until water running from the exhaust is
clear.
C. Reassembly
(1) Clean exterior surfaces of dirt and grease. Dry the APU.
NOTE: Remove caps and plugs from all open lines, fittings, and ports.
CLEANING
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DOCUMENT 1068-1
NOTE: The minimum clearance between tubes, and between tubes and adjacent
components must be 0.080 inch (2.032 mm).
(2) Inspect combustor drain tube assemblies (250 and 260) and clean as necessary.
Reconnect combustor drain tube assemblies (250 and 260). Torque tube assembly
B-nuts to 135 to 150 pound inches (15 to 17 N·m).

(330, IPC Figure 1, 49-20-00) and secure with lockwire.

(4) Connect PCD (air) line (10) to fitting (40) and tee (50). Torque tube assembly
B-nuts to 135 to 150 pound inches (15 to 17 N·m).
(5) Install components removed to gain access to the air inlet screen (200, IPC Figure
1, 49-23-00).
D. Operational Check
(1) Operationally check the APU (refer to 49-20-00, OPERATIONAL CHECK).
5. Clean Fuel Nozzle Components
(1) Clean fuel nozzle components in an ultrasonic parts cleaner serviced with Simple
Green or equivalent alkaline solution with 8 - 9 pH for 20 minutes at 104°F (40°C).
Rinse with hot water for 5 minutes. If necessary, wipe parts dry with a clean lint-free
cloth.
NOTE: A Q-tip and round tooth pick may be used to remove any remaining
contaminants from the fuel nozzle body. If necessary, use a razor knife to
remove contaminants from the slots in the face of the distributor.
6. Clean Filter Element
A. Clean filter element (180, IPC Figure 1, 49-23-00) using the ultrasonic cleaning method.
NOTE: The filter element should remain in ultrasonic cleaning tank for about 5 minutes.
CLEANING
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DOCUMENT 1068-1
INSPECTION/CHECK
1. General
A. This section provides procedures to determine serviceability of the Gemini gas turbine
auxiliary power unit (APU). Item numbers in the procedure are the same as those in the
ILLUSTRATED PARTS CATALOG (IPC), 49-20-00 (Document 1068-3).
2. Inspection/Check
3. Periodic Inspection/Check
A. Refer to Figure 501 for periodic inspections.
Task
Nomenclature Inspection/Check Periodicity
Exhaust Gas Temperature Observe maximum EGT during At APU startup

(EGT) and Engine Speed starting, no-load, and steady-state
(RPM)* operation. Observe governed no-load
and full-load speed. Listen for
unusual noise and vibration during
start, operation, and shutdown.
APU Oil Sight Gage 220, Check oil level at sight gage for Monthly
IPC Figure 1, 49-23-00) proper quantity. Replenish as
necessary.
* Some installations may not have EGT/RPM meters.
Periodic Inspection/Check
Figure 501
INSPECTION/CHECK
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DOCUMENT 1068-1
4. Periodic Maintenance
A. Refer to Figure 502 for periodic maintenance.
Task
Nomenclature Maintenance Inspection Periodicity
Auxiliary Power Unit (APU) Check complete APU externally for 500 hours
fuel and oil leakage. Check for
obstructions in the air inlet duct,
exhaust, and drains.
Check attaching bolts and screws for 500 hours
condition and security. Tighten bolts
and screws as required.
Engine Harness (400, IPC Visually check for loose or frayed 500 hours
Figure 1, 49-20-00) wires, rubbing or chafing. Replace oil
or fuel soaked wiring and wiring that
appears to have deteriorated from
heat. Check attaching points for
security. Check for early signs of
corrosion and plugs and terminals for
tightness.
Igniter Plug (100, IPC Check for cracked or eroded insulator 500 hours
Figure 1, 49-20-01) or electrode. Replace as required.
Combustor fuel drain line Check for cleanliness and 500 hours
(250 and 260, IPC Figure obstructions. Remove and clean as
1, 49-20-00) required.
Oil Overfill Tube Assembly Visually check for cleanliness and 500 hours
(100, IPC Figure 1, obstruction.
49-23-00
Periodic Maintenance
INSPECTION/CHECK
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
Task
Maintenance Inspection Periodicity
Nomenclature
Housings, covers, and Visually check for cracks, dents, 500 hours
brackets deformation, or other damage that
may affect strength or performance.
Lubricating oil sump and oil Drain oil sump and replenish with 2 500 hours or
filter U.S. quarts (1890 cc) of lubricating oil biennial (whichever
to correct oil level. Replace oil filter. occurs first)
Fuel Inlet Filter (740, IPC Replace fuel inlet filter. 500 hours or
Figure 1, 49-20-00)** biennial (whichever
occurs first)***
NOTE: The above maintenance actions are the minimum recommended. Operators may
add to the maintenance task or increase the frequency of the maintenance
intervals based on APU operational experience and conditions, such as
degradation in APU performance or unreliable starts. If, due to circumstances, a
need arises to extend the maintenance interval, permission must be obtained
from the local aviation regulatory agency. This is providing that there are no prior
limitations which would prohibit the extension.
** The fuel inlet filter may be installed on the aircraft or the APU, depending on the
aircraft type. If the fuel filter is supplied by the airframe manufacturer, follow the
airframe manufacturer inspection recommendation.
*** For aircraft that have exceeded the biennial but not the 500-hour requirement,
replace the fuel inlet filter at the next scheduled airframe inspection but not to
exceed 500 APU hour requirement.
Periodic Maintenance
B. Overtemperature Inspection
(1) The measured continuous EGT shall not exceed 1300°F (704°C). In the event the
temperature exceeds these limits, an overtemperature shutdown should occur. If
the APU does not shutdown automatically, it must be manually shutdown
immediately. A notation of the temperature reached and the duration of operating
time in an overtemperature condition should be entered in the log book. The
following checks shall be performed if the corrective actions suggested by FAULT
ISOLATION procedures do not correct the condition:
INSPECTION/CHECK
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DOCUMENT 1068-1
(a) Remove and disassemble combustor. Refer to combustor assembly, removal,
and disassembly.
(b) Check combustor housing and liner for cracks, warpage, or hot spots
(49-20-00 and 49-20-01).
(c) Check clearance between turbine wheel vane tips and turbine nozzle with a
feelers wire. If clearance is 0.016 inch (0.406 mm) or less, remove APU for
repair.
(d) If inspection revealed satisfactory condition of combustor housing and liner,

reassemble and install combustor.
(e) Disconnect electrical connector P301 (130, IPC Figure 2, 49-20-00) from
ignition exciter (340, IPC Figure 1, 49-20-00).
(f) Crank APU to maximum cranking speed and allow to coast down. Carefully
listen for unusual noises or vibration during run-up and coast-down.
(g) Connect electrical connector P301 (130, IPC Figure 2, 49-20-00) to ignition
(h) Start APU and accelerate to 50% rated speed and shutdown APU. Carefully
listen for unusual noises or vibration during run-up and coast-down.
(i) If all conditions appear normal, start APU and accelerate to rated speed. If
APU operation is normal, apply partial load. At each change of load, allow EGT
to stabilize to determine if APU operation is normal before applying additional
load.
(j) If all conditions appear normal at rated speed and load, the APU can be
returned to service. However, if overtemperature continues, remove APU for
repair.
C. Oil Contamination Inspection
(1) If particles are found in the reduction drive oil, refer to Figure 503 for contamination
criteria.
D. APU Inspection
(1) Refer to Figure 504 for the APU inspection limits.
E. Borescope Inspection
(1) Insert the probe of a borescope through the following openings in the APU to gain
access to the internal components of the turbine assembly. Refer to Figure 504 for
inspection limits.
(a) Igniter plug. Provides access to the combustor liner.
INSPECTION/CHECK
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
(b) Air inlet screen (200, IPC Figure 1, 49-22-00). Provides access to the
compressor wheel.
(c) Exhaust end of the combustor housing (110, IPC Figure 1, 49-20-01). Provides
access to the turbine wheel and turbine nozzle.
Metal Type Particle Form Disposition

(Note 1)
Magnetic Fuzz Change oil and filter (refer to
SERVICING). Run APU and recheck
magnetic plug and oil filter (Note 2).
Splinter or granular Remove APU.
Flakes smaller than 0.060 square Change oil and filter (Refer to
inch (0.387 square cm) SERVICING). Run APU and recheck
magnetic plug and oil filter (Note 2).
Flakes larger than 0.060 square Remove APU.
inch (0.387 square cm)
Nonmagnetic Splinter or granular Remove APU.

Flakes smaller than 0.060 square Change oil and filter (refer to
inch (0.387 square cm) SERVICING). Run APU and recheck
oil filter (Note 2).
Flakes larger than 0.060 square Remove APU.
inch (0.387 square cm)
NOTE 1: Definition of particle forms:
Flake: thin flat piece or layer
Fuzz: light particles or fibers
Granular: consisting of or appearing to consist of grains
Splinter: thin pieces or sliver split off lengthwise
NOTE 2: If particles are found after test, remove APU.
Contamination Criteria
Figure 503
INSPECTION/CHECK
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DOCUMENT 1068-1
Nomenclature Inspection Limits Corrective Action

Support Clamps Check for crack, distortion, Replace damaged clamps.
and deterioration of cushions.
Exciter Bracket (520, IPC Check for condition, security, Replace bracket.
Figure 1, 49-20-00) and cracks.
Tube Assemblies Check for chafing, cracks, or Reposition support clamps to
leakage, condition, and prevent chaffing. Replace
security. Minimum clearance is cracked or leaking tube
0.080 inch (2.032 mm). assemblies.
Air Inlet Screen (200, IPC Check for cracked, broken, or Remove blockage. Remove
Figure 1, 49-22-00) blockage of screen mesh. screen to check for possible
foreign object damage (FOD).
If FOD is suspected, remove
turbine assembly for further
investigation.
Check screen for condition of Replace screen if damaged.
lacing hooks.
Check for missing or damaged Repair edge sealer
edge sealer. Bare spots up to (MM REPAIR-01).
1 inch (2.54 cm) long are
acceptable providing there is
sealant of at least 1 inch (2.54
cm) between bare spots and
there is no more than 7 inches
(17.8 cm) of bare spots total
per edge.
APU Inspection Limits

INSPECTION/CHECK
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DOCUMENT 1068-1
Turbine Assembly Check for nicks, burrs, or scratches. Blend out minor nicks,
(790, IPC Figure 1, burrs, or scratches (MM
49-20-00) REPAIR-02).
Check for corrosion. Remove corrosion
(MM REPAIR-02).
Check for loose attaching hardware. Tighten loose attaching
hardware.
Check for cracks. If cracks are Replace turbine assembly.
suspected, perform flourescent penetrant
inspection.
Rotate turbine wheel by hand. Pay Replace turbine assembly.
particular attention to unusual noise,
rubbing sounds, and ease of rotation.
Turbine wheel should rotate easily. No
rubbing or unusual noises permitted.
Engine Harness Check for damage, deterioration, and fuel Replace harness.
(1, IPC Figure 2, and oil soaked areas.
49-20-00)
Check heat shrink tubing for deterioration. Replace damaged tubing
(Note 1).
Check for harness chafing. Reposition harness and
clamps as necessary.
Check for continuity or shorts Replace damaged wire.
Splice in replacement wire.
Check connector plugs for damaged Replace harness.
threads, bent or broken pins.
Check terminal lugs for damage. Replace damaged terminal
lugs.
Check terminal board for security of Replace terminal board.
terminal posts and damage to post
threads.
Ignition Cable Check for frayed braiding. Replace ignition cable.
(330, IPC Figure 1,
49-20-00)
Check insulator and terminals for Replace ignition cable.
damage.

INSPECTION/CHECK
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DOCUMENT 1068-1
Ignition Exciter (340, IPC Check housing and mounting Blend out minor nicks, burrs,
Figure 1, 49-20-00) bracket for nicks, burrs, or or scratches
scratches. (MM REPAIR-02).
Check housing for dents, Replace ignition exciter.
distortion, or cracks.
Check mounting bracket for Straighten mounting bracket to
distortion. original contour.
Check mounting bracket for Replace ignition exciter.
cracks.
Check connectors for Remove corrosion
corrosion, damaged threads, (MM REPAIR-02).
bent or broken pins.
Thermocouple (120, IPC Check sheath and shielding for Replace thermocouple.
Figure 2, 49-20-00) damage.
Magnetic Pickup (200, IPC Check for damaged connector Replace magnetic pickup.
Figure 1, 49-23-00) threads, bent or broken pins.
Check body for damage or Replace magnetic pickup.
damage to pole piece.
High Oil Temperature Switch Check for security and Replace high oil temperature
(310, IPC Figure 1, 49-20-00) damage. switch.
Igniter Plug (100, IPC Figure Check for mechanical Replace igniter plug.
1, 49-20-01) damage, impact damage,
connector shell or firing end
insulator cracked or loose, or if
connector pin is bent or
broken.
Check for security and Replace igniter plug.

damage.
Check firing end shell for Replace igniter plug.

chafing or fretting wear.
Maximum allowable is 0.015
inch (0.381 mm). Check if the
wear is more than one-half the
circumference of shell.

INSPECTION/CHECK
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DOCUMENT 1068-1

Check for swollen or distorted Replace igniter plug.
shell body.
Check igniter plug for electrical Replace igniter plug.

erosion (refer to Figure 504)
Perform a functional check Replace igniter plug.

using a known serviceable
ignition exciter. 2.7 sparks per
second minimum with 14 Vdc
input
Low Oil Pressure Switch (20, Check for corrosion. Remove corrosion
IPC Figure 1, 49-23-00) (MM REPAIR-02).
Check for dents, nicks, or Blend out minor dents, nicks,

scratches or scratches
(MM REPAIR-02).
Check condition of threads. Replace low oil pressure
switch.
Solenoid Valves (550, IPC Check connector and valve Remove corrosion (MM
Figure 1, 49-20-00) body for corrosion. REPAIR-02).
Check valve body for nicks, Blend out minor nicks, dents,
burrs, and scratches. or scratches (MM REPAIR-
02).
Check fuel connection threads Repair by chasing or tapping
for damage. threads.
Check connector for bent or Replace solenoid valves.

broken pins, threads for
damage.
Fuel Control and Pump Check for condition, security, Disassemble and replace
Assembly (1, IPC Figure 3, 49- and evidence of fuel leakage. packings.
20-00) and Fuel Control and
Fuel Pump (30 and 110, IPC
Figure 3)

INSPECTION/CHECK
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DOCUMENT 1068-1

Combustor Housing (110, IPC Check for burning or Replace combustor housing if
Figure 1, 49-20-01) discoloration. Heat burnt spots are found.
discoloration due to normal
operating temperatures is
acceptable.
Check for gas leakage around Replace packing seal.
turbine and combustor flange.
Check for cracks, creases or Repair per APS500 C/I/R.
holes in combustor housing.
Check for cracks in blazed Repair per APS500 C/I/R.
joints or separation of blazed
material.
Check for dents as follows: Repair per APS500 C/I/R.
Dents in the external surface
of the housing are allowed up
to an area of 4.000 square
inches (101.6 square mm) and
less than 0.100 inch (2.54 mm)
deep. The total number of
dents is not limited. However,
there must be a minimum of
1.000 inch (25.4 mm)
separation between dents.
Dented areas cannot
encompass any attaching
feature, such as a radial pin
locating boss, start fuel nozzle
boss, main fuel injector boss,
thermocouple boss, or forward
mounting flange.
Check for dents in the exhaust Repair per APS500 C/I/R.
flange.
Terminal Board Assembly Check for condition and Replace cover assembly.
Cover (430, IPC Figure 1, security. No cracks allowed.
49-20-00)

INSPECTION/CHECK
Page 510
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1

Reduction Drive Assembly Check for oil leakage. Tighten connections as
(760, IPC Figure 1, 49-20-00) needed. Replace reduction
drive assembly if leakage is
persistant.
Check housing for cracks. Replace reduction drive
assembly.
Check housing for corrosion Remove corrosion (MM
and damage to protective REPAIR-02).
finish.
Check for leakage around oil Replace oil seal
seal. (MM REPAIR-03).
NOTE 1: Build up heat insulating sleeving, M2305/5-104-0, M2305/5-106-0, and M2305/5-108-0,

1.5 to 2.5 inches (38 to 64 mm) long, to provide a snug fit under each strain relief clamp.
F. Igniter Plug Inspection
(1) Refer to Figure 505 for the igniter plug inspection.
Igniter Plug Inspection

Figure 505
INSPECTION/CHECK
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DOCUMENT 1068
1068-1
INSPECTION/CHECK
Page 512
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
SERVICING
1. General
A. This section has the procedures for replacement of the Gemini gas turbine auxiliary
power unit (APU) lubricating oil, cleaning the air inlet and compressor, and purging the
fuel system. Item numbers in the procedures are the same as those in the
ILLUSTRATED PARTS CATALOG (IPC), 49-20-00 (Document 1068-3). Refer to Standard
Practices Manual, HSPS 490001, for general information.
B. Access to the APU may prevent performance of some procedures while the APU is
installed on the aircraft. Refer to the Aircraft Maintenance Manual for access.
C. Exercise extreme care to prevent entrance of dirt, dust, and foreign objects into the APU.
If a foreign object is dropped into the APU, stop maintenance procedure until the object is
located and removed.
D. Cover large openings with protective covers. Cap or plug open tube assemblies, fittings,
and ports. Do not cover tube ends with tape.
E. All parts attached with lockwire prior to removal must be re-attached with lockwire after
installation.
A. Equipment and materials required for servicing are listed in Figure 601.

Container 1 Gallon (3.8 liters) Commercially Available
Drain Line Commercially Available
Lubricating Oil 1.5 U.S. quarts (1.4 liters) MIL- Commercially Available
PRF-7808 or MIL-PRF-23699F C/I
Assembly Fluid, 4950515 Hamilton Sundstrand
(55820)
Lint-free Cloth Commercially Available
Lockwire MS20995C32 Commercially Available
(8 to 9 N·m)
Servicing Equipment and Materials

Figure 601
SERVICING
Page 601
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
3. Replace APU Lubrication Oil
A. Drain APU Lubrication Oil


(2) Place a container of approximately 3 quarts (3.8 liters) capacity beneath oil sump.

(3) Remove high oil temperature switch (310) from oil sump. Drain oil from oil sump.
(4) Remove packing (320) from high oil temperature switch (310) and discard.
CAUTION: TO PREVENT SERIOUS DAMAGE TO THE ENGINE, DO NOT OPERATE

THE APU IF METALLIC PARTICLES ARE FOUND IN THE DRAIN OIL.
REMOVE THE APU FROM THE AIRCRAFT FOR OVERHAUL.
(5) Check container for metal chips in oil.
SERVICING
Page 602
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
MEDICAL AID.

(6) Install new packing (320) on high oil temperature switch (310), and install switch in
oil sump. Safety wire high oil temperature switch using lockwire.

B. Replenish APU Lubrication Oil

CAUTION: DO NOT ALLOW THE OIL LEVEL TO BE ABOVE THE “FULL” MARK ON
THE SIGHT GLASS. AN OVERFILLED SUMP WILL RESULT IN OIL
FOAMING AND LOW OIL PRESSURE.
(1) Remove oil dipstick (40, IPC Figure 1, 49-23-00) from oil fill tube (50) and fill oil
sump with 1.5 U.S. quarts (1.4 liters) of approved lubrication oil.
SERVICING
Page 603
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
(2) Install oil dipstick (40) back into oil fill tube (50).
(3) Start and run APU to circulate the oil and check for leaks.
(4) Shut down APU. Wait approximately 3 minutes before checking oil through the oil
sight gage (220).
(5) Add oil to full line as necessary.
4. Purge APU Fuel System
A. Purging Procedures


(1) Remove lockwire and disconnect and insulate electrical connector P301 (130, IPC
Figure 2, 49-20-00) from ignition exciter (340, IPC Figure 1, 49-20-00).

SOAP AND WATER.
(2) Disconnect main fuel tube assembly (130) from tee (20) in fuel atomizer assembly
(10, IPC Figure 1, 49-20-01).
(3) Attach a flexible drain line to end of disconnected tube. Place open end of drain line
in a suitable container.
SERVICING
Page 604
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HAMILTON SUNDSTRAND
DOCUMENT 1068-1
(4) Set MASTER switch to ON. Set START switch momentarily to START and release
to run. Check fuel flow from drain tube. Ensure that an air-free flow of fuel is
obtained. After 15 seconds, set START switch to STOP.
NOTE: It may be necessary to repeat this step to obtain an air-free flow of fuel.
(5) Connect main fuel tube assembly (130, IPC Figure 1, 49-20-00) to tee (20) in fuel
atomizer assembly (10, IPC Figure 1, 49-20-01). Torque tube assembly B-nut to 75
to 80 pound inches (8 to 9 N·m).

(340, IPC Figure 1, 49-20-00). Safety wire electrical connector using lockwire.

CAUTION: IF FLAME APPEARS IN THE EXHAUST (HOT START) AND EXCESSIVE
TAILPIPE TEMPERATURE RESULTS, THE CAUSE IS AN
ACCUMULATION OF UNBURNED FUEL IN THE COMBUSTOR. IF
CONDITION PERSISTS, SHUT DOWN THE APU, AND CHECK FOR
POSSIBLE RESTRICTIONS IN THE COMBUSTOR FUEL DRAIN LINE.
AFTER THE RPM METER INDICATES ZERO RPM, WAIT 60 SECONDS
BEFORE RESTARTING. IF, ON A RESTART, THE CONDITION IS NOT
CORRECTED, AND EXCESSIVE TEMPERATURE OCCURS, SHUT DOWN
THE APU IMMEDIATELY AFTER STARTING.
(7) Start and operate APU. Check all fuel line connections for leaks. Shut down APU.
SERVICING
Page 605
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DOCUMENT 1068-1
SERVICING
Page 606
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DOCUMENT 1068-1
STORAGE
1. General
A. This section details the requirements necessary to prepare the Gemini gas turbine
auxiliary power unit (APU) for storage. Item numbers in the procedure are the same as
those in the ILLUSTRATED PARTS CATALOG (IPC), 49-20-00 (Document 1068-3).
Refer to ASTM D-3951-82 for general requirements of industrial packaging.
A. Preservation and storage equipment and materials are listed in Figure 701.
B. Refer to Standard Practices Manual, HSPS 490001, for a list of protective covers.

Barrier bag (165151-1) Hamilton Sundstrand
(55820)
Barrier bag MIL-B-131 Commercially Available
Barrier material MIL-B-131 Commercially Available
Container 1 gallon (3.8 liters) Commercially Available
Desiccant (60) units MIL-D-3464 Commercially Available
Heat seal machine Commercially Available
Label Commercially Available
Lint-free cloth Commercially Available
Lubricating oil MIL-PRF-6081, Grade 1010 Commercially Available
Masking tape PPP-T-42 Commercially Available
Polystyrene foam cushioning Commercially Available
Shipping container P/N 167139-100 Hamilton Sundstrand
(55820)
Cleaning Compound (Simple Green 13002, or Sunshine Makers, Inc. (1Z575)

equivalent alkaline cleaner with 8-9 pH)
Connector Pliers, Soft-Jawed TG69 Glenair
Tags Commercially Available
Vacuum machine Commercially Available
Vacuum tube (used with vacuum machine) Commercially Available
Preservation and Storage Equipment and Materials

Figure 701
STORAGE
Page 701
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
3. Preservation and Storage of APU
A. Preserve APU Fuel System


SOAP AND WATER.
(2) Disconnect fuel supply tube at fuel filter (740).

(3) Connect gravity-feed oil supply to inlet end of fuel filter (740).
(4) Crank APU for 20 seconds until oil flows through fuel control assembly and out of
fuel lines.
(5) Disconnect oil supply from fuel filter (740) and reconnect fuel supply tube assembly
to fuel filter. Do not turn on APU fuel supply.
(340, IPC Figure 1, 49-20-00).

(7) Attach a tag to APU warning that fuel system has been preserved.
STORAGE
Page 702
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
B. General Preservation
(1) Clean all external metal surfaces of APU with a clean lint-free cloth dampened with
Simple Green or equivalent.
(2) Wipe off residual cleaning compound and dry metal surfaces with clean, lint-free
cloth.
(3) Install a suitable cover around air inlet screen (200, IPC Figure 1, 49-22-00).


(5) Place container under reduction drive assembly to catch oil.

(6) Remove high oil temperature switch (310, IPC Figure 1, 49-20-00) and packing
(320) from reduction drive assembly (760) and allow oil to drain into container.
Discard packing.
STORAGE
Page 703
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
(7) Install high oil temperature switch (310) and packing (320) into reduction drive
assembly (760). Torque to 135 to 150 pound inches (15 to 17 N·m). Safety wire
high oil temperature switch using lockwire.

(9) Attach a tag to APU warning that APU oil system has been drained.
C. Preparation for Storage or Shipment
(1) Cover all open connections, ports, and openings, including exhaust outlet with
barrier material and masking tape.
(2) Hoist APU from assembly stand or table.
(3) Wrap APU with barrier bag.
(4) Hoist APU into shipping container body. Be sure APU is seated properly in
polystyrene foam cushioning.
(5) Place 60 units of fresh desiccant in barrier bag.
(6) Align seam edges around barrier bag. Apply staples around edge of barrier bag to
keep seams even.
(7) Seal barrier bag seam around APU, except for one opening small enough to permit
installation of a vacuum tube, using a heat seal machine.
NOTE: When using heat seal machine, use care to prevent wrinkles in barrier bag
seams and fabric pulling which will cause leaks.
(8) Place vacuum tube in small opening of barrier bag and attach air vacuum machine
to tube.
(9) Operate air vacuum machine to remove air from barrier bag until bag clings snugly
to APU.
(10) Remove vacuum machine and tube from barrier bag and immediately seal small
opening.
(11) Apply masking tape around barrier bag.
(12) Attach APU records and applicable documents to barrier bag.
(13) Place top half of polystyrene foam cushioning on APU.
(14) Install shipping container cover and secure.

STORAGE
Page 704
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
(15) Attach applicable records, documents, and markings to exterior of shipping
container.
STORAGE
Page 705
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
STORAGE
Page 706
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
REPAIR
1. General
A. This section has procedures for repair of the Gemini gas turbine auxiliary power unit
(APU) to return the APU to service. Item numbers in the procedures are the same as
those in the ILLUSTRATED PARTS CATALOG (IPC), 49-20-00 (Document 1068-3).
Refer to Standard Practices Manual, HSPS 490001, REPAIR, for general repair information.
2. Repair
A. Repair air inlet screen according to MM REPAIR-01.
B. Repair minor damage and corrosion according to MM REPAIR-02.
C. Replace oil seal according to MM REPAIR-03.
MM REPAIR
Page 801
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
MM REPAIR
Page 802
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
AIR INLET SCREEN EDGE SEALER REPAIR

REPAIR-01
1. Effectivity
IPL
Nomenclature Fig.-Item Part No.
49-22-00
Air Inlet Screen 1-200 162884-100
A. Standard Equipment:
Standard hand tools
B. Special Tools:
None
C. Consumable Materials:
Sealant PR-1826, Class A
D. Expendable Parts:
None
3. Procedure
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

A. Remove existing edge sealant by heating air inlet screen in an oven at 350 to 375°F (177
to 190°C).
MM REPAIR-01
Page 801
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
WARNING: USE POLYSULFIDE SEALANT, PR-1826 B-1/2, A TWO PART COMPOUND,
CORRECTLY. THE COMPOUND IS ALSO KNOWN AS MIL-S-29574, TYPE I,
GRADE B, POLYHIOETHER SEALING COMPOUND. THE SEALANT IS
FLAMMABLE AND REACTIVE (STRONG OXIDIZER). IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE SEALANT,
GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER
OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE
BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES OR
CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT
B. Reapply by dipping edges of air inlet screen in PR-1826, Class A sealant (manufactured
by Courtauld Aerospace).
MM REPAIR-01
Page 802
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
REPAIR OF MINOR DAMAGE AND CORROSION

REPAIR-02
1. Effectivity
IPC
49-20-00
Auxiliary Power Unit 1-1 4503135
Equivalent substitutes may be used for listed items.
Abrasive stone
Fine-tooth file
Nylon wheel (aluminum oxide)
Nylon brush
Thread tap set
B. Special Tools:
None
C. Expendable Parts:
None
Consumable Materials:
P-C-451 Aluminum oxide abrasive cloth, 320-grit

MIL-A-9962, Aluminum oxide abrasive mat
Type I, Grade B
----- Alkaline cleaning solution
----- Anodic coating (Alodine 1200)
TT-E-489, Class A Black enamel
----- Chrome acid pickling solution
----- Cleaning compound (water emulsion)
----- Emery cloth, 320-grit
PPP-T-76 Tape
TT-P-1757 Zinc chromate primer
MM REPAIR-02
Page 801
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
3. Procedure
A. Auxiliary Power Unit Repairs
WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MIL-

C-5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM
COATING) LIQUID OR POWDER FORM CORRECTLY. COATING IS
FLAMMABLE, POISONOUS, CORROSIVE, AND REACTIVE. IT CAN
USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM
WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT
ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES
(BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE
COATING POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA
SHEET LIMIT.
(1) Polish out minor nicks or scratches with aluminum oxide abrasive cloth or mat.
Apply anodic coating (Alodine 1200) to exposed aluminum surface.
(2) Thoroughly rinse treated area with fresh water. Allow surfaces to air dry.
(3) Repair minor thread damage by chasing threads with proper size thread tap. Lightly
coat chased threads with anodic coating (Alodine 1200).
(4) Remove burrs with fine-tooth file. Apply anodic coating (Alodine 1200) to exposed
aluminum surface.
(6) Polish out minor nicks or scratches on flanges and sealing surfaces with fine
abrasive.
(7) Restore protective finish (refer to paragraph D.).
B. Cleaning and Treatment of Aluminum Corrosion
CAUTION: OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN

USING CONSUMABLES. WEAR NECESSARY PROTECTIVE GEAR
DURING HANDLING AND USE. MAKE CERTAIN CONSUMABLE AND ITS
VAPORS ARE KEPT AWAY FROM HEAT, SPARK AND FLAME.
(1) Remove surface corrosion with aluminum oxide abrasive cloth or aluminum oxide
abrasive bonded nylon wheel.
NOTE: Do not remove more than 4% of material thickness during corrosion

removal.
MM REPAIR-02
Page 802
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
(2) Clean required area with aluminum oxide abrasive cloth or mat and water emulsion
cleaning compound.

SHEET LIMIT.
(3) Apply anodic coating (Alodine 1200) to exposed surfaces.
(5) Restore protective finish (refer to paragraph D.).
C. Cleaning and Treatment of Magnesium Corrosion
WARNING: SODIUM OXIDE SOLUTION IS CORROSIVE TO HUMAN TISSUE. DO

NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA. PUT ON
CHEMICALRESISTANT CLOTHING, GLOVES, SPLASH GOGGLES, AND
FACE SHIELD. IN CASE OF EYE OR SKIN CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION.
WARNING: SODIUM PYROPHOSPHATE IS TOXIC AND FLAMMABLE. DO NOT

BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM
SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES,
SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN
CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND
SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.

(1) Prepare an alkaline cleaning solution composed of 2 to 3 ounces (59 to 89 ml) of

sodium hydroxide, 1.3 ounces (38 ml) of sodium phosphate, 0.1 ounce (3 ml) of
soluble soap (such as Ivory Liquid), and 1 gallon (3.8 l) of purified or distilled water.
(2) Scrub contaminated areas with alkaline cleaning solution and nylon brush.
MM REPAIR-02
Page 803
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
(3) Rinse treated areas with cold running water.
NOTE: To prevent recontamination do not touch exposed cleaned surface with

bare hands.
WARNING: USE CHROMIC ACID (ALSO KNOWN AS CRO4, CHROMIUM TRIOXIDE,

OR CHROMIUM VI OXIDE) CORRECTLY. THE ACID IS REACTIVE,
CORROSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ACID, GET THE
BEFORE YOU USE THE ACID, PUT ON RUBBER GLOVES, CHEMICAL
APRON, CHEMICAL-SPLASH GOGGLES AND A FACE SHIELD. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ACID
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. DO NOT
ADD WATER TO ACID. VERY SLOWLY ADD ACID TO WARM WATER.
KEEP THE ACID-CONTAINER TIGHTLY SEALED EXCEPT WHEN
POURING THE ACID. AVOID SPILLS.
(4) Prepare pickling solution composed of 1.3 ounces (38 ml) of chromic acid, 1 ounce
(29 ml) of calcium sulfate, and 1 gallon (3.8 l) of purified of distilled water.
(5) Mix solution vigorously, either mechanically or by air agitation for at least 15
minutes.
(6) Apply pickling solution to treated areas. Keep affected areas wet with solution for 1
to 3 minutes to produce brown film on treated areas.
NOTE: Pickling solution should contact only areas being treated. Avoid getting
solution onto areas not being treated.
(7) Rinse areas with cold running water.
NOTE: In no case should parts be rinsed in hot water. If cold running water is not
available, the rinse cycle may be eliminated without materially altering the
treatments effectiveness.
WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.
(8) Allow components to air dry or use dry compressed air not to exceed 30 psi (207
kPa). Do not wipe component dry, as protective coating will be removed.
(9) Restore protective finish as required (refer to paragraph D.).
MM REPAIR-02
Page 804
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
D. Restore Protective Finish

(1) Mask all ports, machine surfaces, and identification plate.
(2) Remove all loose or flaking paint.
(3) Sand exposed surfaces with 320-grit emery cloth.

SHEET LIMIT.
(4) Apply anodic coating (Alodine 1200) to exposed aluminum surfaces, or pickling
solution to magnesium surfaces.
WARNING: CHROMATE METAL CONVERTER AND PRIMER 5251 IS CORROSIVE

TO HUMAN TISSUE. DO NOT BREATHE VAPORS. USE IN WELL-
VENTILATED AREA. PUT ON CHEMICAL-RESISTANT CLOTHING,
GLOVES, SPLASH GOGGLES, AND FACE SHIELD. IN CASE OF EYE OR
SKIN CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION.
(6) Apply one coat of zinc chromate primer to repaired area. Allow primer to dry for 1
hour.
MM REPAIR-02
Page 805
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
WARNING: PAINT, ENAMEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.
SOAP AND WATER.
(7) Apply two coats of black enamel to repaired area. Allow 4 hours drying time
between coats of paint and 24 hours curing time after painting.
NOTE: Do not paint holes, threads, internal surfaces, or machined surfaces.
MM REPAIR-02
Page 806
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
PART NUMBER 4503135 SERIES ES
REPLACE OIL SEAL

REPAIR-03
1. Effectivity
IPL
49-23-00
Oil Seal 1-10 169013-1
Equivalent substitutes may be used for listed items.
Standard handtools
B. Special Tools:
Seal driver ST93228

Seal puller ST93057
C. Expendable Parts:
None
D. Consumable Materials:
Assembly fluid 4950515
3. Procedure
A. Replace Seal
(1) Drill three equally-spaced 0.125-inch (3.175 mm) diameter holes in seal to match
mounting holes of seal puller ST93057.
(2) Install seal puller ST93057 using no. 10 sheet metal screws.
(3) Use seal puller ST93057 to remove seal. Discard seal.
MM REPAIR-03
Page 801
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
MEDICAL AID.
(4) Apply a light coat of assembly fluid around lip of seal being replaced.
(5) Use seal driver ST93228 and an arbor press to install seal into reduction drive
housing assembly. Ensure that seal is flush with recessed surface of housing
assembly.
MM REPAIR-03
Page 802
Apr 15/06 49-20-00
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

1. Introduction
A. This section lists the special tools, fixtures, and equipment required to perform the
maintenance procedures listed throughout the maintenance manual.
2. Special Tools, Fixtures, and Equipment
A. Special tools, fixtures, and equipment required for maintenance are listed in Figure 901.
Tool Number Description Manufacturer (Vendor Code)

ST71076 Combustor installation/removal tool Hamilton Sundstrand
(55820)
ST93057 Seal puller Hamilton Sundstrand
(55820)
ST93228 Seal driver Hamilton Sundstrand
(55820)
167139-100 Shipping container Hamilton Sundstrand
(55820)
ST93470 Wrench Hamilton Sundstrand
(55820)
Special Tools, Fixtures, and Equipment

Figure 901
3. Test Tools, Fixtures, and Equipment
A. Test tools, fixtures, and equipment required for testing the APU are listed in Figure 902.
Tool Number Description Manufacturer (Vendor Code)

22217-40 Heat probe assembly Hamilton Sundstrand
(55820)
239-4 Jet Cal EGT controller Howell Instruments
(98869)
160935-203 and -203A Electronic Sequence Unit Hamilton Sundstrand
(ESU) (55820)
161212-100 Built-In Test Equipment (BITE) Hamilton Sundstrand
box (55820)
Testing Tools, Fixtures, and Equipment

Figure 902
Page 901
49-20-00 Apr 15/06
HAMILTON SUNDSTRAND
DOCUMENT 1068-1
Page 902
Apr 15/06 49-20-00

Hamilton Sundstrand APU T-20G-10C3A MM

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MAINTENANCE MANUAL

GEMINI GAS TURBINE

© 1999, 2000, 2004, 2006 Hamilton Sundstrand Corporation

INFORMATION SUBJECT TO EXPORT CONTROL LAWS

THIS PAGE INTENTIONALLY LEFT BLANK

Page Number Description of Change

Service Bulletin List,

List of Effective Pages,

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WARNING: BEFORE USING ANY OF THE MATERIALS SPECIFIED IN HAMILTON

THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL

C. The detailed warnings in Warnings Registry 341-006 are a summary of the

4. Definitions Applying to Warnings

C. Ignition Source: Includes flames, sparks, or heat.

E. Toxic: Material that is poisonous.

I. Irritation: Any sense of pain, soreness, rash, or general discomfort.

5. Reporting Materials or Processes Not Covered

6. List of Warnings Covered in This Publication

WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR

WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING EXHAUST

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROYPL

WARNING: USE AQUEOUS (WATER) BASED CLEANER, TURCO 6783-10, ALSO

WARNING: USE POLYSULFIDE SEALANT, PR-1826 B-1/2, A TWO PART COMPOUND,

WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MIL-C-

WARNING: SODIUM OXIDE SOLUTION IS CORROSIVE TO HUMAN TISSUE. DO NOT

WARNING: SODIUM PYROPHOSPHATE IS TOXIC AND FLAMMABLE. DO NOT

WARNING: USE CHROMIC ACID (ALSO KNOWN AS CRO4, CHROMIUM TRIOXIDE, OR

WARNING: CHROMATE METAL CONVERTER AND PRIMER 5251 IS CORROSIVE TO

WARNING: PAINT, ENAMEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.

WARNING: PACKING LUBRICANT CAN CAUSE IRRITATION OF YOUR SKIN OR EYES.

WARNING: USE ANAEROBIC THREADLOCKING COMPOUND (THREAD SEAL 592)

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH

WARNING: USE LOCQUIC PRIMER GRADE N OR T, CORRECTLY. THE PRIMER IS

WARNING: PUT ON THERMALLY-INSULATED GLOVES AND OTHER SUITABLE

WARNING: MAKE ELECTRICAL CONNECTIONS BEFORE ENERGIZING ANY

WARNING: FAILURE TO DISCONNECT FUEL VALVE ELECTRICAL INPUT, AS

THIS PAGE INTENTIONALLY LEFT BLANK

REV ISSUE DATE REV ISSUE DATE REV ISSUE DATE

1 Aug 15/00 Aug 15/00 HS

2 Aug 1/04 Aug 1/04 HS

3 Apr 15/06 Apr 15/06 G

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RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE DATE

RECORD OF TEMPORARY REVISIONS

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RECORD OF TEMPORARY REVISIONS

SERVICE BULLETIN LIST

T-20G-49-8 Introduction of Fuel 4504283 MOD dot 4 All fielded units

T-20G-49-10 Introduction of 161627-2 MOD dot 6 All fielded units

T-62T-49-76 (Rev. 13) Replacement of 164253-3 All fielded units

SERVICE BULLETIN LIST

THIS PAGE INTENTIONALLY LEFT BLANK

SERVICE BULLETIN LIST

LIST OF EFFECTIVE PAGES

Subject Page Date Subject Page Date

Record of Temporary 1 Apr 15/06 Fault Isolation 101 Apr 15/06

Subject Page Date Subject Page Date

LIST OF EFFECTIVE PAGES

GEMINI GAS TURBINE - 49-00-00

GEMINI GAS TURBINE - 49-20-00

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Testing and Fault Isolation Analysis Oct 1/98