S.I.L NO.

PW100-098R5
SERVICE INFORMATION LETTER
This Service Information Letter is valid until superseded or cancelled by revision
EXPORT CONTROL CLASSICATION: P-ECCN / ECCN: 9E991
ISSUED: May 7, 2010 Page 1 of 7
REVISED: Nov 27, 2013
PRATT & WHITNEY CANADA CORP.
MARIE-VICTORIN, LONGUEUIL
QUEBEC, CANADA J4G 1A1
PRINTED IN CANADA
Subject: Fuel Nozzle Flexible Manifold Installation
Applicability: All PW100 Engines Equipped with Flexible Fuel Nozzle Manifolds
Reason for revision: Introduction of new or modified fuel nozzle adapters and conical
gaskets.
This Service Information Letter (SIL) is revised to advise the release of Service Bulletin (SB) 21841
and 21848 to the field. SB21841 introduces new or modified fuel nozzle adapters with a larger
internal diameter while SB21848 introduces a new conical gasket between the metal to metal
sealing surfaces.
Background:
Fuel leakage incidents have been reported following the installation of the fuel nozzle flexible
manifold. In all cases, the fuel nozzles had recently been replaced and the fuel leaks were the
result of improperly torqued B-Nut fittings at the fuel manifold / fuel nozzle adapter connections,
leading to fretting wear of the packing. In order to permit detection of an improperly torqued
manifold by maintenance personnel following replacement of fuel nozzles, Pratt & Whitney Canada
Corp. (P&WC) introduced SB21803. This SB removes the preformed packing. With the preformed
METAL CONICAL
GASKET
LARGER INTERNAL
DIAMETER
PRATT & WHITNEY CANADA
SERVICE INFORMATION LETTER
S.I.L NO. PW100-098R5
This Service Information Letter is valid until superseded or cancelled by revision
EXPORT CONTROL CLASSICATION: P-ECCN / ECCN: 9E991
ISSUED: May 7, 2010 Page 2 of 7
REVISED: Nov 27, 2013
PRATT & WHITNEY CANADA CORP.
MARIE-VICTORIN, LONGUEUIL
QUEBEC, CANADA J4G 1A1
PRINTED IN CANADA
packing removed, fuel leaks caused by improper torquing of the B-Nuts will be detected during wet
motoring or ground running of the engine immediately following installation by maintenance
personnel.
Field experience on post-SB21803 configuration (removal of the o-ring) has shown that it is
sometimes difficult to achieve a seepage-free assembly at the fuel nozzle/manifold interface and
this will affect fuel nozzle system maintenance time. To compensate for imperfections between the
fuel nozzle adapter / fuel manifold interface, P&WC has published SB21848, which introduces new
metal gaskets of a softer material, that will comply with surface variations. The fuel nozzle
adapters have been modified per SB21841 to provide a larger inner diameter to accommodate the
new metal gasket.
Because of the serious implication of fuel leaks and seepage, P&WC invites operators to review
their Line Maintenance practices and if not already implemented, to consider the following Fuel
Nozzle Flexible Manifold Installation Best Practices:
1.0 Tooling
1.1 With the introduction of the conical gasket, 2 new tools,
PWC45140 and PT454379, are introduced to facilitate the
installation and removal of the gaskets from the fuel manifold
respectively.
PWC45140 and PT454379
1.2 Wrench kit number PWC45206 is recommended in the Engine
Maintenance Manual (EMM) for post-SB21841 fuel nozzle
manifold removal and installation. Field experience has
demonstrated this tool kit provides more accessibility and
flexibility for component installation and final torque
application. With the introduction of the new fuel nozzle
adapters and conical gaskets, PWC56601 torque wrench will
need to be re-calibrated to 250-270 lb. in. and re-identified to
PWC45200. TSB PW100-744 addresses this conversion.
Wrench Kit PWC45206
1.3 P&WC has also introduced a new tool kit number PWC45215 which includes a complete set
of all aforementioned tools for the post-SB21841/SB21848 fuel nozzle configuration. Of
particular interest for new operators who do not have any of these tools yet, the complete kit
or the components of the tool kit can be procured under their respective tool number:
PRATT & WHITNEY CANADA
SERVICE INFORMATION LETTER
S.I.L NO. PW100-098R5
This Service Information Letter is valid until superseded or cancelled by revision
EXPORT CONTROL CLASSICATION: P-ECCN / ECCN: 9E991
ISSUED: May 7, 2010 Page 3 of 7
REVISED: Nov 27, 2013
PRATT & WHITNEY CANADA CORP.
MARIE-VICTORIN, LONGUEUIL
QUEBEC, CANADA J4G 1A1
PRINTED IN CANADA
PWC45206 Wrench kit
PWC45200 Pre-set torque wrench (7.5 inches long) for flexible manifold final torque.
This tool calibrated to the EMMs recommended final torque limit
features two crowfoot extensions made at different angles to improve
accessibility
PWC56504-1 Wrench (4 inches long) for fuel manifold removal
PWC56504-2 Wrench (2.5 inches long) to run down fuel manifold connector fitting
(hex nut).
PWC56612 Special crowfoot adapter to be used to avoid No. 5 bearing vent tube
removal.
Removal and Installation Tool
PWC45150 Drift
PT454379 Plastic Pick
1.4 Following the introduction of SB21803, the use of Seating
Gauge PWC56962 is no longer required (a revision to the
EMM had been made to that effect).
Seating Gauge PWC56962
2.0 Handling, Removal & Installation
2.1 P&WC reminds operators that it is important to ensure that all fuel manifold / fuel nozzle
adapter connections are properly engaged and the fuel manifold hose connector fittings are
torqued as per EMM recommendations.
2.2 Installation procedures for the fuel nozzle adapters and flexible manifolds can be found in
SB21848. Operators are reminded to refer to the EMM Chapter 72-01-40 for the detailed
instructions.
2.2.1 Lubrication requirements for the fuel nozzle adapter and manifold locations have been
added to the instructions. By applying anti-galling compound to the fuel nozzle
threads, the possibility of thread damage is minimized. Furthermore, the lubrication
requirements serve to minimize assembly friction and optimize the amount of torque
that is converted to assembly preload. The following pictures illustrate these changes:
P
W
C
4
5
2
1
5
PRATT & WHITNEY CANADA
SERVICE INFORMATION LETTER
S.I.L NO. PW100-098R5
This Service Information Letter is valid until superseded or cancelled by revision
EXPORT CONTROL CLASSICATION: P-ECCN / ECCN: 9E991
ISSUED: May 7, 2010 Page 4 of 7
REVISED: Nov 27, 2013
PRATT & WHITNEY CANADA CORP.
MARIE-VICTORIN, LONGUEUIL
QUEBEC, CANADA J4G 1A1
PRINTED IN CANADA
Fuel Nozzle Adapter Threads
B-Nut Thrust Wire Lock Ring Fingers
2.2.2 Torque wrench PWC45200 must be correctly held to avoid applying insufficient torque
to connections.
Incorrect Hand Grip Correct Hand Grip
2.2.3 A three-step torque, un-torque to zero and final torque procedure is necessary to
ensure proper seating of the conical gaskets.
2.3 P&WC wishes to stress the importance of compliance with the following maintenance criteria
and cautionary notes as detailed in the EMM:
2.3.1 Inspection of the fuel manifold hose for damage (Ref. EMM, Chapter 72-01-40, Fuel
System Inspection).
Application of anti-seize
compound to the threads
only. Avoid applying to
conical section.
Application of
engine oil on
thrust wire &
Moeller fingers
prior to applying
torque.
PRATT & WHITNEY CANADA
SERVICE INFORMATION LETTER
S.I.L NO. PW100-098R5
This Service Information Letter is valid until superseded or cancelled by revision
EXPORT CONTROL CLASSICATION: P-ECCN / ECCN: 9E991
ISSUED: May 7, 2010 Page 5 of 7
REVISED: Nov 27, 2013
PRATT & WHITNEY CANADA CORP.
MARIE-VICTORIN, LONGUEUIL
QUEBEC, CANADA J4G 1A1
PRINTED IN CANADA
2.3.2 Upon Fuel Nozzle replacement, there should be adequate clearance between the
manifolds and adjacent tubing (Ref. EMM, Chapter 72-01-40, Fuel System
Installation).
2.3.3 Make sure that the preformed packings are NOT installed (Ref. SB21803 and AD CF-
2013-29).
2.3.4 Once all Fuel Nozzle Manifold B-Nuts are torqued properly, the locking feature (crown
ring & lock ring) should be as shown in the illustration below.
3.0 Final Torque Witness Check
3.1 To ensure sealing integrity of the flexible manifold / fuel nozzle adapter connections, P&WC
recommends the implementation of a witness check of the final torque and the visual
observation of the lock ring engagement. Appendix 1 shows a sample sign-off sheet for
completion by the Line Maintenance mechanic and the witnessing mechanic/inspector.
4.0 Testing of the Fuel Manifold System for Leaks
4.1 With the removal of the preformed packing, a Leak Check is introduced to flow Nitrogen
through the manifolds via the Flow Divider & Dump Valve in order to help locate B-Nuts that
would not have been torqued properly (Ref. EMM, Chapter 72-01-40, Fuel System
Installation). In addition, leak detection fluid is permissible as an aid during the leak test
(Refer to SB21848).
PRATT & WHITNEY CANADA
SERVICE INFORMATION LETTER
S.I.L NO. PW100-098R5
This Service Information Letter is valid until superseded or cancelled by revision
EXPORT CONTROL CLASSICATION: P-ECCN / ECCN: 9E991
ISSUED: May 7, 2010 Page 6 of 7
REVISED: Nov 27, 2013
PRATT & WHITNEY CANADA CORP.
MARIE-VICTORIN, LONGUEUIL
QUEBEC, CANADA J4G 1A1
PRINTED IN CANADA
5.0 Commercial coverage
5.1 The introduction of the conical seal is supported commercially by P&WC. Refer to CSPN
1007035. Coverage consists of the following:
5.1.1 One set of conical seals at no charge, claimable once per engine S/N.
5.1.2 Subsequent orders of conical seals at the published list price less 75%.
5.1.3 The rework of the fuel nozzle inner diameter to accommodate the conical seal is
provided at no additional cost to the operator. The rework of the fuel nozzle will be
included in the normal price the operator currently pays for refurbishing nozzles. No
claims are required to obtain this coverage.
To conclude, substantiation testing has demonstrated that the fuel manifold connector fitting will not
become loose if properly engaged and the newly introduced metal conical gasket will address any
fuel seepage if the recommended torque is applied and the locking feature properly engaged.
Yours truly,
PRATT & WHITNEY CANADA CORP.
Alfred Lum Alexandre Fortier
Customer Engineer, Customer Engineering Manager, Customer Engineering
PW100/PW150 Engine Programs PW100/PW150 Engine Programs
Customer Service Regional Market Customer Service Regional Market
PRATT & WHITNEY CANADA
SERVICE INFORMATION LETTER
S.I.L NO. PW100-098R5
This Service Information Letter is valid until superseded or cancelled by revision
EXPORT CONTROL CLASSICATION: P-ECCN / ECCN: 9E991
ISSUED: May 7, 2010 Page 7 of 7
REVISED: Nov 27, 2013
PRATT & WHITNEY CANADA CORP.
MARIE-VICTORIN, LONGUEUIL
QUEBEC, CANADA J4G 1A1
PRINTED IN CANADA