Professional Documents
Culture Documents
MAINTENANCE MANUAL
MANUAL PART NO. 3045542
CHAPTER
SECTION
LEP
Contents
72-01-00
Introduction
72-01-10
Removal/
Installation
PAGE
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22 blank
1
2 blank
401
402
403
404
405
406
407
408
DATE
Jan
Jan
Jan
Jan
Jan
Jan
CHAPTER
SECTION
24/2006
24/2006
24/2006
24/2006
24/2006
24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
DATE
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
72-01-10
Inspection
Check
601
602
603
604
605
606
607
608
609
610 blank
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
72-01-10
Cleaning/
Painting
701
702
703
704
May 02/2003
May 02/2003
May 02/2003
May 02/2003
Sep 03/99
Sep 03/99
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
PAGE
72-01 LEP
Page 1
Jan 24/2006
CHAPTER
SECTION
PAGE
DATE
72-01-10
Approved
Repairs
801
802
803
804 blank
May 02/2003
Sep 03/99
Sep 03/99
Sep 03/99
72-01-20
Removal/
Installation
401
402
403
404
405
406
407
408
408 A
408 B blank
409
410
411
412 blank
Mar 09/2001
Oct 18/2002
Mar 09/2001
Mar 09/2001
Oct 18/2002
Oct 18/2002
Mar 09/2001
Mar 09/2001
Oct 18/2002
Oct 18/2002
Mar 09/2001
Mar 09/2001
Mar 09/2001
Mar 09/2001
72-01-20
Adjustment/
Test
501
502
Nov 09/2001
Nov 09/2001
72-01-20
Inspection
Check
601
602
603
604
605
606 blank
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
701
702
Sep 03/99
Sep 03/99
72-01-20
Cleaning/
Painting
72-01-20
Approved
Repairs
801
802
803
804
Sep 03/99
Sep 03/99
Sep 03/99
Sep 03/99
CHAPTER
SECTION
PAGE
DATE
72-01-30
Removal/
Installation
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
Aug 13/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
Jan 16/2004
72-01-30
Adjustment/
Test
501
502
503
504 blank
Jul 07/2000
Jul 07/2000
Jul 07/2000
Jul 07/2000
72-01-30
Inspection
Check
601
602
Jan 16/2004
Jan 16/2004
72-01-30
Cleaning/
Painting
701
702
Jan 16/2004
Jan 16/2004
72-01 LEP
Page 2
Jan 24/2006
CHAPTER
SECTION
PAGE
DATE
72-01-30
Approved
Repairs
801
802
Sep 03/99
Sep 03/99
72-01-40
Servicing
301
302
303
304
305
306
307
308 blank
Mar 03/2000
Mar 03/2000
Mar 03/2000
Mar 03/2000
Mar 03/2000
Mar 03/2000
Mar 03/2000
Mar 03/2000
72-01-40
Removal/
Installation
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
CHAPTER
SECTION
PAGE
DATE
429
430
431
432
433
434
435
436
437
438
439
440
441
442 blank
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
Nov 04/2005
72-01-40
Adjustment/
Test
501
502 blank
Sep 03/99
Sep 03/99
72-01-40
Inspection
Check
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618 blank
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
72-01-40
Cleaning/
Painting
701
702
703
Mar 11/2005
Mar 11/2005
Mar 11/2005
72-01 LEP
Page 3
Jan 24/2006
CHAPTER
SECTION
PAGE
DATE
704
705
706
707
708
709
710
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
72-01-40
Approved
Repairs
801
802
803
804
805
806
807
808
809
810
811
812
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
72-01-50
Servicing
301
302
303
304
305
306 blank
Mar 03/2000
Jul 13/2001
Mar 03/2000
Mar 03/2000
Mar 03/2000
Mar 03/2000
72-01-50
Removal/
Installation
401
402
403
404
405
406
407
408
409
410
411
412
413
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
CHAPTER
SECTION
PAGE
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
72-01 LEP
DATE
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Aug 13/2004
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Aug 13/2004
Nov 09/2001
Aug 13/2004
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Aug 13/2004
Nov 09/2001
Aug 13/2004
Nov 09/2001
Page 4
Jan 24/2006
CHAPTER
SECTION
PAGE
DATE
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
Nov 09/2001
72-01-50
Adjustment/
Test
501
502 blank
Oct 20/2000
Oct 20/2000
72-01-50
Inspection
Check
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
CHAPTER
SECTION
PAGE
DATE
619
620
621
622
623
624
625
626 blank
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
Jan 24/2006
72-01-50
Cleaning/
Painting
701
702
703
704
705
706
707
708
Oct 20/2000
Nov 09/2001
Oct 20/2000
Oct 20/2000
Oct 20/2000
Oct 20/2000
Oct 20/2000
Oct 20/2000
72-01-50
Approved
Repairs
801
802
803
804
805
806
807
808
809
810 blank
Mar 11/2005
Sep 03/99
Mar 11/2005
Sep 03/99
Sep 03/99
Sep 03/99
Sep 03/99
Sep 03/99
Sep 03/99
Sep 03/99
72-01-60
Removal/
Installation
401
402
403
404
405
406
407
408
409
410
411
412
Mar 11/2005
Mar 11/2005
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Mar 11/2005
Mar 11/2005
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
72-01 LEP
Page 5
Jan 24/2006
CHAPTER
SECTION
PAGE
DATE
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436 blank
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Mar 11/2005
Mar 11/2005
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
Oct 18/2002
72-01-60
Inspection
Check
601
602
603
604
605
606
607
608
609
610
611
612
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
Mar 11/2005
72-01-60
Cleaning/
Painting
701
702
Sep 03/99
Sep 03/99
CHAPTER
SECTION
72-01-60
Approved
Repairs
PAGE
801
802
803
804
805
806 blank
72-01 LEP
DATE
Sep 03/99
Sep 03/99
Sep 03/99
Sep 03/99
Sep 03/99
Sep 03/99
Page 6
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
General
72-01-00
1
72-01-10
1.
General
401
2.
Consumable Materials
401
3.
Special Tools
402
4.
402
5.
402
A.
Removal
402
B.
Installation
407
6.
7.
8.
9.
409
A.
Removal
409
B.
Installation
416
417
A.
Removal
417
B.
Installation
422
424
A.
Removal
424
B.
Installation
424
429
A.
Removal
429
B.
Installation
429
72-01-10
1.
General
601
2.
Consumable Materials
601
3.
Special Tools
601
72-01 CONTENTS
Page 1
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-10
4.
601
5.
Inspection
601
A.
601
6.
General
Check
601
A.
601
B.
601
C.
606
72-01-10
1.
General
701
2.
Consumable Materials
701
3.
Special Tools
701
4.
701
5.
Cleaning
702
A.
General
702
B.
702
C.
Wiring Harness
702
D.
703
72-01-10
1.
General
801
2.
Consumable Materials
801
3.
Special Tools
801
4.
801
5.
Repair
801
A.
801
72-01 CONTENTS
Page 2
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-20
1.
General
401
2.
Consumable Materials
401
3.
Special Tools
401
4.
401
5.
Igniters
402
A.
Removal
402
B.
Installation
402
Ignition Cables
403
A.
Removal
403
B.
Installation
403
6.
7.
8.
Ignition Exciter(s)
405
A.
Removal
405
B.
Installation
408A
409
A.
Removal
409
B.
Installation
409
72-01-20
1.
General
501
2.
Consumable Materials
501
3.
Special Tools
501
4.
501
5.
Adjustment/Test
501
A.
501
General
72-01-20
601
72-01 CONTENTS
Page 3
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-20
2.
Consumable Materials
601
3.
Special Tools
601
4.
601
5.
Inspection
601
A.
General
601
B.
Igniter
601
C.
Ignition Exciter
602
602
A.
602
B.
602
C.
Visual Check
602
6.
72-01-20
1.
General
701
2.
Consumable Materials
701
3.
Special Tools
701
4.
701
5.
Cleaning
701
A.
Ignition Exciter
701
B.
Igniter
701
C.
Ignition Cable
702
6.
Painting
702
A.
702
Procedure
72-01-20
1.
General
801
2.
Consumable Materials
801
72-01 CONTENTS
Page 4
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-20
3.
Special Tools
801
4.
801
5.
Ignition Exciter
801
A.
801
6.
7.
Procedure
802
A.
802
Procedure
802
A.
802
Procedure
72-01-30
1.
General
401
2.
Consumable Materials
401
3.
Special Tools
401
4.
402
5.
402
A.
Removal
402
B.
Installation
402
6.
7.
8.
403
A.
Removal
403
B.
Installation
403
405
A.
Removal
405
B.
Installation
405
407
A.
Removal
407
B.
Installation
407
72-01 CONTENTS
Page 5
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
10.
11.
12.
13.
14.
15.
16.
72-01-30
407
A.
Removal
407
B.
Installation
407
409
A.
Removal
409
B.
Installation
409
411
A.
Removal
411
B.
Installation
411
411
A.
Removal
411
B.
Installation
413
413
A.
Removal
413
B.
Installation
413
415
A.
Removal
415
B.
Installation
415
417
A.
Removal
417
B.
Installation
417
417
A.
Removal
417
B.
Installation
419
72-01 CONTENTS
Page 6
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-30
1.
General
501
2.
Consumable Materials
501
3.
Special Tools
501
4.
501
5.
Adjustment/Test
501
A.
501
B.
501
72-01-30
1.
General
601
2.
Consumable Materials
601
3.
Special Tools
601
4.
601
5.
Inspection
601
A.
General
601
B.
601
C.
601
6.
Check
602
A.
602
72-01-30
1.
General
701
2.
Consumable Materials
701
3.
Special Tools
701
4.
701
5.
Cleaning
701
A.
701
General
72-01 CONTENTS
Page 7
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-30
B.
702
C.
702
D.
702
72-01-30
1.
General
801
2.
Consumable Materials
801
3.
Special Tools
801
4.
801
5.
Approved Repairs
801
A.
Tubes
801
B.
Housings
802
72-01-40
1.
General
301
2.
Consumable Materials
301
3.
Special Tools
301
4.
301
5.
301
A.
Removal
303
B.
Installation
303
6.
7.
304
A.
Removal
304
B.
Installation
304
304
A.
Removal
304
B.
Installation
304
72-01 CONTENTS
Page 8
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-40
1.
General
401
2.
Consumable Materials
401
3.
Special Tools
402
4.
402
5.
403
A.
Removal
403
B.
Disassembly
403
C.
Assembly
405
D.
Installation
407
6.
7.
8.
9.
10.
11.
411
A.
411
Rigging
413
A.
413
B.
413
416
A.
Removal
416
B.
Installation
416
417
A.
Removal
417
B.
Installation
419
422
A.
Removal
422
B.
Installation (Post-SB21705)
428
430
A.
430
Removal
72-01 CONTENTS
Page 9
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
13.
Installation
72-01-40
431
Fuel Heater
431
A.
Removal
431
B.
Installation
433
Fuel Waste Tubes, Motive Flow Pressure Fuel Tube Assembly and
MFCU and Fuel Pump Drain Tubes and Fuel Waste Ejector
Assembly
436
A.
Fuel Waste Ejector Tube and Motive Fuel Flow Ejector Tube
436
B.
437
C.
437
72-01-40
1.
General
501
2.
Consumable Materials
501
3.
Special Tools
501
4.
501
5.
Leak Test
501
A.
501
72-01-40
1.
General
601
2.
Consumable Materials
601
3.
Special Tools
601
4.
601
5.
Inspection/Check
602
A.
General
602
B.
602
72-01 CONTENTS
Page 10
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-40
C.
605
D.
605
E.
605
F.
Drain Valve
606
606
H.
Transfer Tubes
606
I.
606
J.
607
K.
612
L.
612
72-01-40
1.
General
701
2.
Consumable Materials
701
3.
Special Tools
701
4.
701
5.
Cleaning
702
A.
General
702
B.
Fuel Filters
702
C.
706
D.
707
6.
707
A.
General
707
B.
Equipment Required
709
C.
709
72-01 CONTENTS
Page 11
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-40
Painting
710
A.
710
72-01-40
1.
General
801
2.
Consumable Materials
801
3.
Special Tools
801
4.
801
5.
Approved Repairs
802
A.
Tubes
802
B.
802
C.
802
D.
Housings
803
E.
805
F.
807
72-01-50
1.
General
301
2.
Consumable Materials
301
3.
Special Tools
301
4.
301
5.
301
A.
Removal
301
B.
Installation
303
6.
303
A.
Removal
303
B.
Installation
305
72-01 CONTENTS
Page 12
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-50
1.
General
401
2.
Consumable Materials
401
3.
Special Tools
402
4.
402
5.
402
A.
Removal
402
B.
Installation
403
6.
7.
8.
9.
10.
405
A.
Removal
405
B.
Installation
407
408
A.
Removal
408
B.
Installation
408
408
A.
Removal
408
B.
Disassembly
409
C.
Assembly
409
D.
Installation
411
413
A.
Removal
413
B.
Installation
417
419
A.
Removal
419
B.
Installation
419
72-01 CONTENTS
Page 13
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
12.
13.
14.
15.
16.
72-01-50
421
A.
Removal
421
B.
Installation
421
421
A.
421
B.
426
C.
427
D.
428
E.
429
F.
431
431
435
A.
435
B.
437
C.
439
441
A.
441
B.
443
445
A.
Removal
445
B.
Installation
447
449
A.
Removal
449
B.
Installation
449
72-01 CONTENTS
Page 14
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
18.
19.
20.
21.
22.
23.
72-01-50
451
A.
Removal
451
B.
Installation
453
454
A.
Removal
454
B.
Installation
454
454
A.
Removal
454
B.
Disassembly
455
C.
Assembly
455
D.
Installation
455
457
A.
Removal
457
B.
Disassembly
457
C.
Assembly
457
D.
Installation
459
459
A.
Removal
459
B.
Installation
461
463
A.
Removal
463
B.
Installation
463
465
A.
Removal
465
B.
Installation
465
72-01 CONTENTS
Page 15
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-50
1.
General
501
2.
Consumable Materials
501
3.
Special Tools
501
4.
501
5.
Adjustment/Test
501
A.
501
B.
501
72-01-50
1.
General
601
2.
Consumable Materials
601
3.
Special Tools
601
4.
601
5.
Inspection
602
A.
General
602
B.
602
C.
Transfer Tube
605
D.
605
E.
605
F.
Spur Gears
605
607
H.
607
I.
609
J.
611
K.
612
72-01 CONTENTS
Page 16
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
6.
72-01-50
616
619
N.
622
Check
623
A.
Chip Detector
623
B.
Spring Compression
624
C.
624
D.
625
E.
Drain Valve
625
72-01-50
1.
General
701
2.
Consumable Materials
701
3.
Special Tools
701
4.
701
5.
Cleaning
702
A.
General
702
B.
702
C.
706
D.
Carbon Removal
707
E.
707
6.
Painting
708
A.
708
Procedure
72-01-50
1.
General
801
2.
Consumable Materials
801
72-01 CONTENTS
Page 17
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-50
3.
Special Tools
801
4.
801
5.
Approved Repairs
802
A.
Tubes
802
B.
802
802
D.
802
E.
Valves
803
F.
803
C.
72-01-60
1.
General
401
2.
Consumable Materials
401
3.
Special Tools
401
4.
402
5.
402
A.
Removal
402
B.
Installation
402
T6 Thermocouples
406
A.
Removal
406
B.
Installation
407
6.
7.
409
A.
Removal
409
B.
Installation
409
72-01 CONTENTS
Page 18
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
9.
10.
11.
12.
13.
14.
15.
72-01-60
409
A.
Removal
409
B.
Installation
411
413
A.
Removal
413
B.
Installation
414
414
A.
Removal
414
B.
Installation
414
415
A.
Removal
415
B.
Installation
415
419
A.
Removal
419
B.
Installation
419
T1.8 Sensor
423
A.
Removal
423
B.
Installation
423
425
A.
Removal
425
B.
Installation
427
428
A.
Removal
428
B.
Installation
428
72-01 CONTENTS
Page 19
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
17.
72-01-60
428
A.
Removal
428
B.
Installation
429
431
A.
Removal
431
B.
Installation
431
72-01-60
1.
General
601
2.
Consumable Materials
601
3.
Special Tools
601
4.
601
5.
Inspection
601
A.
601
6.
Procedure
Check
601
A.
601
B.
609
C.
Torque Sensors
609
D.
T1.8 Sensor
609
E.
610
F.
611
611
H.
612
General
72-01-60
701
72-01 CONTENTS
Page 20
Jan 24/2006
TABLE OF CONTENTS
SUBJECT
PAGE
72-01-60
2.
Consumable Materials
701
3.
Special Tools
701
4.
701
5.
Cleaning
701
A.
General
701
B.
701
C.
T6 Thermocouple
702
72-01-60
1.
General
801
2.
Consumable Materials
801
3.
Special Tools
801
4.
801
5.
801
A.
801
6.
7.
Procedure
803
A.
803
Procedure
T1.8 Sensor
803
A.
803
Procedure
72-01 CONTENTS
Page 21/22
Jan 24/2006
General
Chapters 72-01-10 through 72-01-60 contain maintenance instructions for the engine
external accessories:
72-01-10 Electrical System
72-01-20 Ignition System
72-01-30 Air System
72-01-40 Fuel System
72-01-50 Oil System
72-01-60 Performance Indicating System
72-01-00
EXTERNALS AND ACCESSORIES - INTRODUCTION
Page 1/2
Sep 03/99
General
A.
B.
C.
D.
WARNING:
WARNING:
When installing wiring harness, make sure connectors and receptacles are dry;
use heat gun as necessary.
MAKE SURE YOU SELECT PROPER CLAMP CLASS WHEN INSTALLING
WIRING HARNESS TO ENSURE HARNESS IS NOT LOOSE IN CLAMP.
Refer to Inspection/Check for schematic diagram of wiring harness.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC05-089
PWC05-105
PWC05-256
PWC05-273
PWC05-295
PWC06-007
Oil, Engine
Lockwire
Tape, Insulating
Enhancer, Electrical Contact
Sleeve, Shrink, Self-adhesive
Lockwire (May be used instead of PW05-089)
Coating, Film Lubricant
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 401
Nov 04/2005
3.
Item No.
Name
PWC11-014
Alcohol, Isopropyl
Special Tools
Special tools are identified in procedural text by part number in parentheses.
4.
Tool No.
Name
PWC58104
Wrench
5.
Removal
WARNING:
(1)
(2)
(3)
(4)
Remove bolts (1) at bracket (23), washers (2) and wiring harness connector.
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 402
Nov 04/2005
TO
P33
16 17
16
17
8
P5
3
6
4
P8
16 17
5
19
31
TO
P10
10
5
31
15
3
20
MASTER
KEYWAY
LOCATION
19
29
25 27
TO
P14
P4
15
3
20
19
J11
5
30
P1
28
21
5
3
TO
P7
3
TO
P9
13
14
3
23
21
26 24
13
21
5
P2
22
C62642B
Electrical Wiring Harness - Removal/Installation
Figure 401 (Sheet 1 of 3)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 403
Nov 04/2005
Bolt (MS9527-04)
Washer (MS9549-07)
Nut
Bolt (MS9208-05)
Bolt (MS9208-06)
Bolt (MS9208-07)
Bolt (MS9208-13)
Bolt (MS9208-17)
Bolt (MS9208-08)
Spacer (3105512-06)
Spacer (3111826-01)
Washer (MS9549-09)
Spacer (3108991-01)
Tie Wrap
Clamp Assembly (ST1478-04 or -05)
Clamp (3030367)
Grommet (ST3023-04)
Grommet (ST3023-03)
Clamp Assembly (ST1478-05, -06, -07)
Clamp Assembly (ST1478-09, -10, -11)
Clamp Assembly (ST1478-11, -12, -13)
Electrical Wiring Harness Assembly
Bracket (3049877)
Bolt (MS9556-08)
Bolt (MS9556-06)
IDG Support Bracket (3055035-01)
Nut
Bolt (MS9556-12)
Plate
IDG Support Block
Clamp Assembly (ST1478-05, or -06)
Bracket (MS9592-054)
Bolt (MS9556-17)
Bolt (MS9208-17) (Post-SB21687)
Bracket (MS9592-374) (Post-SB21687)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 404
Nov 04/2005
18
3
TO
P5
35
3
16
P10
FW
18
16
10
16 18
32
P10
10
5
34
16
10
10
16 18
16 18
16 18
VIEW A
(POST SB21687)
3
5
16 18
16 18
4
15
P4
16
18
P14
33
TO
P24
FW
31
10
12
C62644B
Electrical Wiring Harness - Removal/Installation
Figure 401 (Sheet 2)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 405
Nov 04/2005
P7
3
15
12
11
15
8
15
4
4
P9
VIEW
15
15
15
3
15
15
4
15
TO P7
C63979
Electrical Wiring Harness - Removal/Installation
Figure 401 (Sheet 3)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 406
Nov 04/2005
B.
(5)
Remove nuts (3, 27), bolts (4, 5, 6, 7, 8, 24, 25, 33) and (34) (Post-SB21687),
bracket assembly (26), bracket (32) and (35) (Post-SB21687), spacers (9, 10,
11, 13), washers (12), tie wrap (14) and wiring harness assembly (22).
(6)
Remove clamp assemblies (15, 19, 20, 21, 31), clamps (16) and grommets (17, 18)
from wiring harness assembly (22).
(7)
If required, remove nuts (27), bolts (28), plate (29) and IDG support block (30).
Installation
(2)
(3)
(4)
Install wiring harness assembly (22), secure to bracket (23) with bolts (1) and
washers (2). Torque bolts 10 to 12 lb.in. (1.13-1.36 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
NOTE:
(5)
Let the liquid flow downward on each pin to make a thin film.
Install grommets (17, 18), clamps (16) and clamp assemblies (15, 19, 20, 21, 31)
on wiring harness assembly (22).
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 407
Nov 04/2005
(6)
Install bracket (32) and (35) (Post-SB21687), bolts (4, 5, 6, 7, 8, 25, 33) and (34)
(Post-SB21687), spacers (9, 10, 11, 13), washers (12), nuts (3, 27) and tie wrap
(14). Torque 36 to 40 lb.in. (4.07-4.57 Nm).
NOTE:
WARNING:
Install connector P7 at torque sensor No. 2, rotating it by hand 1/4 turn clockwise
until a click is heard which indicates the connector is in the locked position. Do not
use a torque wrench or pliers to apply torque.
WARNING:
Install connectors P4, P14, P5, P8, P10, and P9 at T1.8 sensor, NH No. 1 sensor,
NH No. 2 sensor, MFCU, IBV servo valve and NP speed sensor respectively.
Tighten each connector nut by hand until witness band(s) on mating receptacle is/are
covered. It is recommended to further torque connector coupling nuts, using one
of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 408
Nov 04/2005
(9)
6.
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
(10)
Use of insulating tape (PWC05-105) (Post-SB21004) (to wrap the connector joints)
is optional (Ref. Fig. 402).
(11)
(12)
(13)
Removal
WARNING:
(1)
(2)
Remove nuts (21) and disconnect harness leads (22) from terminal block (23).
(3)
Remove clamps (13, 15, 16, 17, 19) and grommets (14, 18, 20).
(4)
Remove nuts (5), washer (11), spacers (12), bolts (6, 7, 8, 9, 10) and (25)
(Post-SB21687), bracket (24) (Post-SB21687) and harness (1).
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 409
Nov 04/2005
TAPE / SLEEVE
COVERAGE ZONE
0.500 IN.
MIN.
(12.7 mm)
0.250 IN.
MIN.
(6.35 mm)
TAPE / SLEEVE
COVERAGE ZONE
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 410
Nov 04/2005
0.500 IN.
(12.7 mm)
MIN.
TAPE / SLEEVE
COVERAGE ZONE
C62304A
Protective Tape/Heat Shrink - Installation Zone
Figure 402 (Sheet 2)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 411
Nov 04/2005
P20
12
10
13 14
8
13 14
16
13 14
P21
8
A
5
TO P24
8
8
13 17
13 17
8
9
24
13 17
25
18 19
13 17
7
1
P25
P27
L.H. SIDE
VIEW A
(POSTSB21687)
C62643C
Electrical Wiring Harness (Instrument Services) - Removal/Installation
Figure 403 (Sheet 1 of 3)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 412
Nov 04/2005
Harness
Nut
Nut
DELETED
Nut
DELETED
Bolt (MS9556-06)
Bolt (MS9208-06)
Bolt (MS9208-07)
Bolt (MS9556-17)
Washer (MS9549-09)
Spacer (3105512-06)
Clamp (3030367)
Grommet (ST3023-03)
Clamp (ST1478-04, ST1478-05)
Clamp (ST1478-06)
Clamp (ST1478-05, ST1478-06)
Grommet (ST3023-04)
Clamp (MS9391-05)
Grommet (MS9393-03)
Nut
Harness Lead
Terminal Block
Bracket (MS9592-374) (Post-SB21687)
Bolt (MS9208-07) (Post-SB21687)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 413
Nov 04/2005
TO P20
H
G
TO P25
TO T6
TERMINAL
BLOCK
TO P24
P24 1
P24 2
D
P4 & P14
7
19
12
TEMPERATURE
INDICATING
SYSTEM CABLE
10
5
15
11
DETAIL
DETAIL
B
8
P33
P5
8
DETAIL
P5
5
8
15
DETAIL
DETAIL
10
15
15
P5
P10
E
5
DETAIL
12
13
13
14
14
DETAIL
16
DETAIL
DETAIL
J
C63499A
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 414
Nov 04/2005
T6 THERMOCOUPLE TRIM
ELECTRICAL CABLE
SEE 720160
E
C
TO P20
D
TO P24
B
A
22
21
TO
P33
23
13 14
13 14
13 14
DETAIL A
DETAIL B
13 14
DETAIL C
13 14
13 14
DETAIL D
DETAIL E
DETAIL F
C79822
Electrical Wiring Harness (Instrument Services) - Removal/Installation
Figure 403 (Sheet 3)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 415
Nov 04/2005
B.
Installation
Install grommets (14, 18, 20) and clamps (13, 15, 16, 17, 19) on harness (1).
(2)
(3)
Install bolts (6, 7, 8, 9, 10) and (25) (Post-SB21687), bracket (24) (Post-SB21687),
washer (11), spacers (12), nuts (21) and nuts (5). Torque nuts (21) to 24 to
40 lbf.in. (2.71 - 4.52 Nm). Torque all bolts and nuts (5) to 36 to 40 lbf-in. (4.07 4.52 Nm).
NOTE:
(4)
(5)
(6)
Let the liquid flow downward on each pin to make a thin film.
Connect chromel and alumel leads to T6 terminal block with nuts (2, 3), respectively.
Torque nut (2) 20 to 25 lb.in. (2.26-2.83 Nm) and nut (3) 25 to 30 lb.in.
(2.82-3.39 Nm).
NOTE:
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 416
Nov 04/2005
WARNING:
Install connectors P24, P25 and P20 at ignition exciters, low oil pressure switch and
firewall connector, respectively. Tighten connector coupling nut by hand until
witness band(s) on mating receptacle is/are covered. It is recommended connector
coupling nuts are further torqued using one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
7.
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
(8)
Post-SB21004: use of insulating tape (PWC05-105) (to wrap the connector joints) is
optional (Ref. Fig. 402).
(9)
Post-SB21269: use heat gun to heat-shrink harness sleeves over plugs. Connector
joints to be covered as shown on Figure 402.
Removal
WARNING:
(1)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 417
Nov 04/2005
P36
A SEE
1
5
P21
SH. 2
5
9 10
TO P20
11
3
TO P33
P37
3
5
P35
12
11
9 12
3
5
P32
4
9 10
6
13 14
15
13 14
15
P25
P27
1
C63502B
Electrical Wiring Harness (Instrument Services A) - Removal/Installation
Figure 404 (Sheet 1 of 3)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 418
Nov 04/2005
Harness
Tie Wrap
Nut
Bolt (MS9556-05)
Bolt (MS9208-06)
Bolt (MS9208-07)
Bolt (MS9208-17)
Spacer (3105512-06)
Clamp (3030367)
Grommet (ST3023-03)
Clamp (ST1478-05, ST1478-06)
Grommet (ST3023-05)
Clamp (MS9391-05)
Grommet (MS9393-03)
Bolt (MS9556-06)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 419
Nov 04/2005
10
9
10
TO P5
TO P24
3
VIEW
C79647
Electrical Wiring Harness (Instrument Services A) - Removal/Installation
Figure 404 (Sheet 2)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 420
Nov 04/2005
T6 HARNESS
P24
DETAIL
10
DETAIL
10
10
DIM. AB
E
FWD
P33
SECTION
AC
DETAIL
ACAC
3
10
9
AC
DETAIL
9
DETAIL
10
B
6
9
10
5
9
10
10
3
DETAIL
DETAIL
DETAIL
C
C63503A
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 421
Nov 04/2005
B.
(2)
Remove nuts (3), spacer (8), bolts (4, 5, 6, 7, 15) and harness (1).
(3)
Remove clamps (9, 11, 13) and grommets (10, 12, 14) from harness.
Installation
WARNING:
(2)
Let the liquid flow downward on each pin to make a thin film.
(3)
(4)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 422
Nov 04/2005
(5)
Install grommets (10, 12, 14) and clamps (9, 11, 13) on harness
(6)
Install bolts (4, 5, 6, 7, 15), spacer (8) and nuts (3). Torque bolts.
NOTE: 1. Clamps of the adjacent wiring harnesses must also be secured.
NOTE: 2. Ensure dimension AB is between 5.900 and 6.100 in. (149.86-154.94 mm).
(7)
Tighten each connector coupling nut by hand until witness band(s) on mating
receptacle is/are covered. It is recommended connector coupling nuts are further
torqued using one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
(8)
Post-SB21004: use of insulating tape (PWC05-105) (to wrap the connector joints) is
optional (Ref. Fig. 402).
(9)
Post-SB21269: use heat gun to heat-shrink harness sleeves over plugs. Connector
joints to be covered as shown on Fig. 402.
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 423
Nov 04/2005
8.
Removal
CAUTION: AIRFRAME ELECTRICAL POWER MUST BE OFF WHEN
DISCONNECTING RECEPTACLES AND PLUGS.
B.
(1)
(2)
(3)
(4)
Disconnect airframe ambient air pressure sensing tube from elbow (11) (Ref. AMM).
(5)
Remove bolts (2, 3, 4), clamp (13), grommet (14), terminal lead (5) and EEC (1).
(6)
Place EEC on bench and remove bolt (4), terminal lead (5), elbows (6, 11), nuts (7,
10). Discard packings (9) and backup rings (8).
(7)
If required, remove bolt (19), spacer (20), nut (21) and characterization plug
assembly (15) and lead (18). Remove clamp (13) and grommet (14).
Installation
(1)
Install nuts (10, 7), backup rings (8), packings (9) and elbows (11, 6) (Ref.
72-00-00, MAINTENANCE PRACTICES), angle of elbows as shown.
(2)
Torque nut (10) 38 to 42 lb.in. (4.29-4.75 Nm) and nut (7) 70 to 80 lb.in.
(7.91-9.04 Nm). Secure nuts with lockwire (PWC05-089) or (PWC05-295).
NOTE:
Install characterization plug (15). Torque fingertight until fully coupled (Ref.
72-00-00, MAINTENANCE PRACTICES).
NOTE:
(4)
(5)
Install EEC (1), bolts (2, 3), grommet (14), clamp (13) and terminal lead (5). Torque
bolts 25 to 28 lb.in. (2.83-3.16 Nm).
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 424
Nov 04/2005
11
2
7
16
9
10
3
8
20
12
1
14
13 14
13
18
19
21
17
15
C17522
Electronic Engine Control (EEC) - Removal/Installation
Figure 405 (Sheet 1 of 2)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 425
Nov 04/2005
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 426
Nov 04/2005
0 DEG. 1 DEG.
IN RELATION TO
EEC VERTICAL AXIS
10 REF.
14
20
13
59 DEG. 1 DEG.
IN RELATION TO
EEC HORIZONTAL
AXIS
19
VIEW
VIEW
C17644
Electronic Engine Control (EEC) - Removal/Installation
Figure 405 (Sheet 2)
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 427
Nov 04/2005
(6)
Install free end of terminal lead (5) and bolt (4). Torque bolt 36 to 40 lb.in.
(4.07-4.52 Nm).
(7)
Install tube (12) at elbow (6). Torque tube nut 90 to 100 lb.in. (10.17-11.30 Nm).
Secure with lockwire (PWC05-089) or (PWC05-295).
Install tube at elbow (11). Torque tube nut 270 to 300 lb.in. (30.51-33.90 Nm).
Secure with lockwire (PWC05-089) or (PWC05-295).
WARNING:
(9)
(10)
Let the liquid flow downward on each pin to make a thin film.
Install connectors P1 (16) and P2 (17) at EEC top and EEC bottom, respectively.
Tighten each connector nut by hand until witness band(s) on mating receptacle
is/are covered. It is recommended to further torque connector coupling nuts, using
one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 428
Nov 04/2005
(12)
Use of insulating tape (PWC05-105) (to wrap the connector joints) is optional (Ref.
Fig. 402).
(13)
If sleeves (PWC05-273) are installed, use heat gun to heat-shrink them over the
plugs. Connector joints to be covered as shown on Figure 402.
(14)
(b) Secure characterization plug assembly (18) lanyard at Flange A with nut (21).
Torque nut 150 to 170 lb.in. (17.0-19.2 Nm).
9.
Removal
(1)
AFU
CAUTION: AIRFRAME ELECTRICAL POWER MUST BE OFF BEFORE
DISCONNECTING RECEPTACLES AND PLUGS.
(a) Disconnect electrical connector at bottom of AFU (1) (Ref. AMM).
(b) Disconnect characterization plug (2).
(c) If required, remove nuts (3,18), bolt (17) and spacer (16) to free lanyard (4)
and remove characterization plug (2).
(d) Remove clamp (14) and grommet (15).
(e) Remove bolt (5) to free terminal lead (6).
(f)
(2)
Remove bolts (7), washers (8), terminal lead (6) and AFU (1).
Bracket
(a) Remove AFU (Ref. step (1)).
(b) Remove EEC (Ref. Para. A.).
(c) Remove nuts (9), bolts (10), washers (11) and brackets (12, 13).
B.
Installation
(1)
Brackets
(a) Install brackets (12, 13). bolts (10), washers (11) and nuts (9). Torque nuts 85
to 95 lb.in. (9.61-10.74 Nm).
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 429
Nov 04/2005
14
15
A
4
VIEW A
18
17
12
11
16
12
10
2
1
13
8
7
8
13
10
9
6
11
C17698B
Autofeather Control Unit (AFU) and Brackets - Removal/Installation
Figure 406
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 430
Nov 04/2005
AFU
(a) Install terminal lead (6) and bolt (5). Torque bolt 36 to 40 lb.in. (4.07-4.52 Nm).
(b) Lubricate bolts (7) with coating (PWC06-007).
NOTE:
(c) Install autofeather control unit (1), washers (8), free end of terminal lead (6)
and bolts (7). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
(d) Install airframe harness connector at bottom of AFU (1).
CAUTION: ENSURE CONNECTORS AND RECEPTACLES ARE FREE FROM
MOISTURE. IF NECESSARY, DRY USING HEAT GUN.
CAUTION: CHARACTERIZATION PLUG IS MATCHED TO RGB COUPLING
SHAFT. ENSURE PLUG OF SAME CLASS AS INDICATED ON
ENGINE DATA PLATE IS INSTALLED.
(e) Install characterization plug (2). Torque fingertight until fully coupled (Ref.
72-00-00, MAINTENANCE PRACTICES).
(f)
If required, secure lanyard (4) on RGB Flange A with nut (3). Torque nut 36 to
40 lb.in. (4.07-4.52 Nm).
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 431
Nov 04/2005
(g) Install grommet (15), clamp (14), spacer (16), bolt (17) and nut (18). Torque nut
36 to 40 lb.in. (4.07-4.52 Nm).
72-01-10
ELECTRICAL SYSTEM - REMOVAL/INSTALLATION
Page 432
Nov 04/2005
General
A.
These instructions provide the information necessary to inspect and functionally check
the electrical system components.
Consumable Materials
Not Applicable
3.
Special Tools
Not Applicable
4.
5.
Inspection
A.
6.
General
(1)
(2)
Check
A.
(2)
B.
Check continuity between pins C-A, C-D and C-E using ohmmeter.
72-01-10
ELECTRICAL SYSTEM - INSPECTION/CHECK
Page 601
Nov 09/2001
P7
H
U j X n k F a c b G
G F S T H A B C P R J L N M
72-01-10
186
187
184
185
136
DISCRETE RTN
129
B n R
3 4 1 2 5
139
140
136
137
138
135
133
134
132
131
130
u t w
IGNITION
NH SIGNAL HI
NH SIGNAL RTN
UPTRIM LAMP
121
122
123
124
125
126
127
128
118
119
120
117
LL j
COIL 2
P8
EE u c
NH SIGNAL HI
NH SIGNAL RTN
i W
g F v
7288
A C B
p x X HH
AA
COIL 1
K J
X Y MM r
3645
A B G E F D C
m a Z M S HH g F
AB 5278
PC/RC 76114
r q L p e R P
174
175
176
177
178
179
180
181
182
183
BB h C
EEC POWER RTN
EEC POWER RTN
EEC POWER 28VDC
EEC POWER 28VDC
ECS FAULT RTN
PW127H ENGINE TRIM DISC
SPARE
LRU SELECTOR
172
173
G w
FG/SG/TG/HG
115155
BLEED VALVE TM HI
BLEED VALVE TM RTN
114
115
116
f CC DD
NM 3255
P14
133166
3 4 1 2 5
COIL 2
Z E
COIL 1
P T S GG z k m AA V r U q A y W CC
DISCRETE RTN
GROUND TEST RTN
112
113
y NN FF
612664
P4
RATING LOGIC BIT 2 DISC
SPARE
RATING LOGIC BIT 1 DISC
103
104
105
106
107
108
109
110
111
KK x
108.0 NOM.
3 2 1 4 5
165
166
167
168
169
170
171
K J d
TORQUE 2 SENSOR HI
TORQUE 2 SENSOR RTN
TOR. SEN. TEMP HI
TOR. SEN. TEMP RTN
TOR. SEN. TEMP LO
TORQUE 1 SENSOR RTN
TORQUE 1 SENSOR HI
163
164
SPARE
FROM AC DATA BUS ARINC (RTN)
FROM AC DATA BUS ARINC (SIG)
TEST SERIAL INPUT UART (SIG)
TEST SERIAL INPUT UART (RTN)
TEST SERIAL OUTPUT UART (SIG)
TEST SERIAL OUTPUT UART (RTN)
TO AC DATA BUS ARINC (SIG)
TO AC DATA BUS ARINC (RTN)
t z h E e d c G H
557589
NH SIGNAL HI
NH SIGNAL RTN
160
161
162
P2
COIL 1
T1.8 SENSOR HI
T1.8 SENSOR LO
T1.8 SENSOR RTN
100
101
102
b U c
3645
108.0 NOM.
TORQUE SIGNAL HI
TORQUE SIGNAL RTN
TORQUE SIGNAL REF.
J11
C D V W
L K
E s a D L M N
EEC (LOCAL)
D Y C
P1
P10
P5
C68079A_1
Page 602
Nov 09/2001
COIL 1
c U b
S
T
H J K L
A B G F E C D H J K
E F
A P a B N
FEATHER SOL HI
157
158
159
A P a B N
156
E F
151
152
153
154
155
149
150
148
147
146
145
UPTRIM OUTPUT
A/F RELAY HI
612664
COIL 2
1 2 3 4 5
V
188
189
190
191
102
101
100
TORQUE 2 SENSOR HI
TORQUE 2 SENSOR RTN
TOR. SEN. TEMP HI
TOR. SEN. TEMP LO
141
142
143
144
108.0 NOM.
COIL 1
NP SIGNAL HI
NP SIGNAL RTN
NP SIGNAL HI
NP SIGNAL RTN
U T EE q
557589
3050
P9
6595
COIL 2
P16
AFU (LOCAL)
P5
J16
P16
C A B E F
PVM
(LOCAL)
P6
C68079A_2
72-01-10
Page 603
Nov 09/2001
IGNITER PLUGS
192
193
B
A
194
195
F
G
196
197
198
M
D
R
199
200
V
K
U
THERMOCOUPLE
TRIM CIRCUIT
T6 THERMOCOUPLES
C68209A_1
Electrical Wiring Harness - Schematic Diagram
Figure 601 (Sheet 3)
72-01-10
ELECTRICAL SYSTEM - INSPECTION/CHECK
Page 604
Nov 09/2001
201
202
G
F
A
B
203
204
B
P
205
206
V
C
A
B
207
208
M
A
209
210
211
212
H
J
L
K
N
U
P33 NL SENSOR
1
2
NL SIGNAL HI
NL SIGNAL RTN
213
214
R
E
D
S
C68209A_2
Electrical Wiring Harness - Schematic Diagram
Figure 601 (Sheet 4)
72-01-10
ELECTRICAL SYSTEM - INSPECTION/CHECK
Page 605
Nov 09/2001
(2)
(3)
Check that insulation resistance to ground using test set is not less than 2
megohms minimum at 45 volts DC or AC.
(4)
Check resistance between pins C-A (resistor R1), C-D (resistor R3) and C-E
(resistor R4) using ohmmeter (Ref. RGB identification plate).
NOTE: 1. Q2G on RGB identification plate corresponds to resistor R4, and Q2B to
resistor R3.
NOTE: 2. Values (in ohms) on characterization plug decal R3xxxx and R4xxxx
must be identical to those on RGB identification plate Q2Bxxxx and
Q2Gxxxx, respectively.
NOTE: 3. If resistance 1% is not as indicated on RGB identification plate, or if
values on decal are not identical to those on RGB identification plate,
reject plug and replace with new one of correct values.
(5)
C.
Replace defective plugs with similar ones having the same class (Ref. Approved
Repairs for replacement of resistors).
Determine which circuits are used in relation to the plug class and check continuity
1% using ohmmeter.
NOTE: 1. The characterization plug classes are recorded on the reduction gearbox
reference data plate (offset value is first two digits; gain, last two digits).
NOTE: 2. The characterization plug classes may also be recorded (by vibropeen)
on the characterization plug (offset value is first two digits; gain, last two
digits).
(2)
If characterization plug classes are recorded (by vibropeen) on the plug itself,
ensure values are identical to those on the RGB reference data plate.
(3)
(4)
Check that insulation to ground resistance is not less than 2 megohms at 45 volts
DC or AC. Use test set.
(5)
A defective plug must be replaced with one having the same class.
72-01-10
ELECTRICAL SYSTEM - INSPECTION/CHECK
Page 606
Nov 09/2001
NOT USED
A
R1
R4
R3
R3
R4
X X
C
SCHEMATIC
DECAL
PLUG
NOT USED
MASTER
KEYWAY
F
E
G
R4
D
R3
A
C
TURBOPROP ENGINE
REDUCTION GEARBOX MODULE
B
NOT USED
ENGINE MODEL
MODULE SERIAL NO.
EEC TRIM
CONTACT PINS
VIEW ON
NOT USED
Q2G X X X X
Q2B X X X X
AFU TRIM
C
R3
R4
R1
A
D
RESISTOR SIDE
C30182D
Characterization Plug (EEC) Resistor Installation - Circuit Diagram
Figure 602
72-01-10
ELECTRICAL SYSTEM - INSPECTION/CHECK
Page 607
Nov 09/2001
C15238A
Characterization Plug (AFU) - Jumper Circuits (OFFSET)
Figure 603
72-01-10
ELECTRICAL SYSTEM - INSPECTION/CHECK
Page 608
Nov 09/2001
GAIN
GAIN
CLASS
% TRIM
CONNECTIONS
CLASS
% TRIM
01
+ 15.0
SGH, UJK
32
0.5
PL
02
+ 14.5
SGH, UJL
33
1.0
PK
03
+ 14.0
SGH, UJ
34
1.5
PK, TL
04
+ 13.5
SGH, UJ, PL
35
2.0
PJ
05
+ 13.0
SGH, UK
36
2.5
PJ, TL
06
+ 12.5
SGH, UL
37
3.0
PJ, TK
07
+ 12.0
SG, UH
38
3.5
PH, SL
08
+ 11.5
SG, UH, PL
39
4.0
PH
09
+ 11.0
SG, UH, PK
40
4.5
PH, TL
10
+ 10.5
41
5.0
PH, TK
11
+ 10.0
SG, UJ
42
5.5
PH, TJ, SL
12
+ 9.5
SG, UJ, PL
43
6.0
PH, TJ
13
+ 9.0
SG, UK
44
6.5
PG, SK, UL
14
+ 8.5
SG, UL
45
7.0
PG, SK
15
+ 8.0
SG
46
7.5
PG, SL
16
+ 7.5
SG, PL
47
8.0
PG
17
+ 7.0
SG, PK
48
8.5
PG, TL
18
+ 6.5
SG, PK, UL
49
9.0
PG, TK
19
+ 6.0
SH, UJ
50
9.5
PG, TJ, SL
20
+ 5.5
SH, UJ, PL
51
10.0
PG, TJ
21
+ 5.0
SH, UK
52
10.5
22
+ 4.5
SH, UL
53
11.0
PG, TH, SK
23
+ 4.0
SH
54
11.5
PG, TH, SL
24
+ 3.5
SH, PL
55
12.0
PG, TH
25
+ 3.0
SJ, UK
56
12.5
PGH, TL
26
+ 2.5
SJ, UL
57
13.0
PGH, TK
27
+ 2.0
SJ
58
13.5
PGH, TJ, SL
28
+ 1.5
SK, UL
59
14.0
PGH, TJ
29
+ 1.0
SK
60
14.5
PGH, TJL
30
+ 0.5
SL
61
15.0
PGH, TJK
31
0.0
NONE
CONNECTIONS
C15250A
Characterization Plug (AFU) - Jumper Circuits (GAIN)
Figure 604
72-01-10
ELECTRICAL SYSTEM - INSPECTION/CHECK
Page 609/610
Nov 09/2001
General
A.
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-256
PWC11-012
PWC11-022
PWC11-023
PWC11-027
PWC11-031
PWC11-035
PWC11-036
PWC11-036A
Special Tools
Not Applicable
4.
72-01-10
ELECTRICAL SYSTEM - CLEANING/PAINTING
Page 701
May 02/2003
5.
Cleaning
WARNING:
WARNING:
A.
General
(1)
Unless otherwise specified, clean all parts with petroleum solvent (PWC11-027) or
cleaner (PWC11-031).
NOTE:
B.
Clean external parts, using non-metallic bristle brush and MEK (PWC11-022) or
solvent (PWC11-023).
WARNING:
(2)
C.
Wiring Harness
WARNING:
Wipe harness using clean, lint-free, unsized cloth moistened with one of the
following:
v Acetone (PWC11-012).
v Methyl-ethyl-ketone (PWC11-022).
v Solvent cleaner (PWC11-023).
(2)
Air-dry harness.
72-01-10
ELECTRICAL SYSTEM - CLEANING/PAINTING
Page 702
May 02/2003
D.
WARNING:
WARNING:
(1)
(2)
WARNING:
(3)
Shake or swab connector to remove all liquid. Dry connector using clean compressed
air, regulated to 29 psig (200 Kpa) maximum.
(4)
WARNING:
(5)
(6)
(7)
72-01-10
ELECTRICAL SYSTEM - CLEANING/PAINTING
Page 703
May 02/2003
(8)
Dry connector using clean compressed air, regulated to 29 psig (200 Kpa)
maximum or let the solvent completely evaporate.
NOTE:
(9)
Hold the connector in a vertical position, apply a small amount of the electrical
contact enhancer (PWC05-256) into the contact socket as follows:
(a) Use the kit supplied lint-free applicator and wet the contact socket surface face
with the contact enhancer solution (PWC05-256).
NOTE:
If the ambient temperature is too cold for the solution to flow into the
sockets, the solution can be diluted. Use 4 parts isopropyl alcohol
(PWC11-014) and one part contact enhancer (PWC05-256).
(b) To make sure the solution goes into the contacts, remove the cotton tip
material from the kit supplied applicator. Carefully insert the plastic tip into the
socket to push the solution into the socket.
(c) If the contact enhancer solution was diluted, let the part air dry at room
temperature for one hour minimum.
72-01-10
ELECTRICAL SYSTEM - CLEANING/PAINTING
Page 704
May 02/2003
2.
General
A.
B.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-027
PWC05-089
PWC05-295
PWC07-011
PWC09-011
PWC11-014A
Marker, Ink
Lockwire
Lockwire (may be used instead of PWC05-089)
Varnish (air-dry)
Sealant, RTV
Alcohol, Isopropyl
Special Tools
Not Applicable
4.
5.
Repair
A.
72-01-10
ELECTRICAL SYSTEM - APPROVED REPAIRS
Page 801
May 02/2003
CAUTION: MAKE SURE THE INTERNAL THREADS AND /OR CIRCUIT BOARD
ARE NOT DAMAGED WHEN THE RTV SEALANT (PWC09-011) IS
REMOVED.
(b) Remove sealant (PWC09-011) using a hard plastic pick.
(c) Clean the plug (Ref. Cleaning/Painting).
WARNING:
Install resistor into appropriate holes of circuit board. Ensure full contact and no
tension or stress.
(3)
72-01-10
ELECTRICAL SYSTEM - APPROVED REPAIRS
Page 802
Sep 03/99
NOT USED
MASTER
KEYWAY
F
0.195 IN. (4.95 mm)
0.175 IN. (4.45 mm)
R4
R3
0.500 IN.
(12.7 mm)
R1
A
B
NOT
USED
RESISTOR
CONNECTOR PINS
A
RTV SEALANT
WITHIN ENCLOSED AREA
A
SECTION
AA
MASTER
KEYWAY
T/M TRIM VALUES
TURBO/RGB MODULE S/N
R3
R1
R2
R4
DECAL
NOTE: PLACE DECAL IN RELATION
TO MASTER KEYWAY AS SHOWN
C30183F
EEC Characterization Plug - Resistor Installation
Figure 801
72-01-10
ELECTRICAL SYSTEM - APPROVED REPAIRS
Page 803/804
Sep 03/99
General
A.
These instructions provide the information necessary for the replacement of components
of the engine ignition system.
WARNING:
WARNING:
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-089
PWC05-295
PWC06-005
PWC06-007
PWC06-023
Lockwire
Lockwire (may be used instead of PWC05-089)
Lubricant, Dry Spray, (Fluorocarbon)
Compound, Film Lubricant
Compound, Antiseize (Silver Goop)
Special Tools
Not Applicable
4.
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 401
Mar 09/2001
5.
Removal
(1)
Remove igniters (1) (Pre-SB21649) or (3) (Post-SB21649) and gaskets (2). Discard
gaskets.
Installation
WARNING:
(2)
Install new gaskets (2) on igniters (1) or (3) (Post-SB21649) and install igniters.
Torque igniters 300 to 360 lb.in. (33.90-40.68 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
NOTE:
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 402
Oct 18/2002
Removal
WARNING:
WARNING:
B.
(1)
(2)
(3)
(4)
(5)
Open clamps (9, 10, 11) and remove ignition cables (1, 2).
(6)
Installation
NOTE:
Mask central conductors at both ends of ignition cables, using suitable sleeve
protectors, and apply fluorocarbon dry spray (PWC06-005) to seal band.
Install cable (1) to rear exciter (13) and cable (2) to front exciter (14). Torque
coupling nuts fingertight plus 45 degrees. Secure with lockwire (PWC05-089) or
(PWC05-295).
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 403
Mar 09/2001
2
1
2
1
C38665
Igniter - Removal/Installation
Figure 401
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 404
Mar 09/2001
Install cable (1) at igniter on RH side of engine and cable (2) at igniter on LH
side of engine. Torque coupling nuts fingertight.
(4)
Secure cable sealing plates at mounting brackets with bolts (4) and nuts (3). Torque
nuts.
(5)
(6)
(7)
(8)
Secure clamps (7) with bolts (6) and nuts (5). Torque bolts.
NOTE:
(9)
7.
Igniter (Pre-SB21649)
Gasket
Igniter (Post-SB21649) (not illustrated)
Position clamps to ensure a clearance exists between the cables and fuel
tubes.
Torque coupling nuts 200 to 270 lb.in. (22.60-30.51 Nm). Secure with lockwire
(PWC05-089) or (PWC05-295).
Removal
WARNING:
WARNING:
(1)
(3)
Remove bolts (3), one end of ground terminals (4), spacers (16) and ignition
exciters (5) from mounting plate assembly (13).
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 405
Oct 18/2002
14
13
12
6
6
1
12
12
12
VIEW A
(POST SB21687)
10
5
4
9
12
9
3
3
4
C63360A
Ignition Cables - Removal/Installation
Figure 402 (Sheet 1 of 2)
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 406
Oct 18/2002
Ignition Cable
Ignition Cable
Nut
Bolt
Nut
Bolt
Clamp
Grommet
Clamp
Clamp
Clamp
Grommet
Ignition Exciter (Rear)
Ignition Exciter (Front)
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 407
Mar 09/2001
9
11
11
11
11
11
12
12
1
12
FW
12
12
2
VIEW
12
A
C63412
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 408
Mar 09/2001
B.
Installation
(1)
Install spacers (16) and ignition exciters (5) on mounting plate assembly (13),
ensuring input electrical connectors are at top.
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 408A/408B
Oct 18/2002
(2)
Install bolts (3) and free end of ground terminals (4) Torque bolts 36 to 40 lb.in.
(4.07-4.52 Nm).
WARNING:
(4)
8.
B.
Removal
(1)
(2)
(3)
(4)
Remove bolts (6), ground terminals (4), brackets (7, 8), washers (9, 11, 15),
vibration mounts (12), sleeves (14) and mounting plate (13).
Installation
(1)
Install vibration mounts (12) and sleeves (14) on mounting plate (13).
(2)
Install mounting plate, washers (9, 11, 15), brackets (7, 8), ground terminals (4) and
bolts (10, 15). Torque bolts 14 to 16 lb.in. (1.58-1.81 Nm).
NOTE: 1. Lubricate with coating (PWC06-007), bolts which fasten ground
terminals.
NOTE: 2. Include oil-cooler bracket (10) under washer (9).
(3)
(4)
(5)
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 409
Mar 09/2001
12
11
4
15
A
INSTALLATION AT
A
13
11
P24
12
6
15
14
P24
4
A
10
11
12
16
9
3
14
4
4
6
15
12
6
11
7
3
2
C38604A
Ignition Exciters and Mounting Plate - Removal/Installation
Figure 403
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 410
Mar 09/2001
Connector
Cable
Bolt
Ground Terminal
Exciter
Bolt
Bracket
Bracket
Washer
Oil-cooler Bracket
Washer
Vibration Mount
Mounting Plate
Sleeve
Washer
Spacer
72-01-20
IGNITION SYSTEM - REMOVAL/INSTALLATION
Page 411/412
Mar 09/2001
General
A.
Consumable Materials
Not Applicable
3.
Special Tools
Not Applicable
4.
5.
Adjustment/Test
A.
(2)
(3)
(4)
WARNING:
WARNING:
(6)
Advance condition lever 5 degrees and switch on ignition (Ref. AMM) for 30
seconds maximum.
(a) If igniter does not spark, proceed as follows:
72-01-20
IGNITION SYSTEM - ADJUSTMENT/TEST
Page 501
Nov 09/2001
WARNING:
Ignition exciter.
Ignition cable.
Re-check system.
72-01-20
IGNITION SYSTEM - ADJUSTMENT/TEST
Page 502
Nov 09/2001
General
A.
Consumable Materials
Not Applicable
3.
Special Tools
Not Applicable
4.
5.
Inspection
A.
B.
General
(1)
(2)
Igniter
CAUTION: ALWAYS REPLACE AN IGNITER THAT HAS BEEN DROPPED. INTERNAL
DAMAGE MAY NOT BE EVIDENT AT TESTING.
(1)
Fretting depth at firing end exceeds 0.025 in. (0.635 mm) or fretting
extends more than one half its circumference.
72-01-20
IGNITION SYSTEM - INSPECTION/CHECK
Page 601
Oct 18/2002
Ignition Exciter
(1)
6.
B.
Check, using test set, that continuity resistance is not more than 0.05 ohm at
45 volts AC or DC.
C.
Check, using test set, that insulation resistance to ground is not less than 2
megohms at 45 volts DC or AC.
Visual Check
(1)
(2)
(3)
The outside shield (braided stainless steel) for condition. Repair if required (Ref.
Approved Repairs).
(4)
Connection nuts for condition. Threads must be free from dirt and not defective.
72-01-20
IGNITION SYSTEM - INSPECTION/CHECK
Page 602
Oct 18/2002
72-01-20
IGNITION SYSTEM - INSPECTION/CHECK
Page 603
Oct 18/2002
0.240 IN.
DIA.
6.096 mm
NEW IGNITER
180 MAX.
NOTE :
EROSION IN ANY
OTHER AXIS IN
EXCESS OF 0.350 IN.
(8.89 mm) IS ACCEPTABLE
SECTION BB
FRETTING LIMIT
VIEW
EROSION LIMIT
C30186E
(PRE-SB21649)
Igniter - Erosion Limit
Figure 601 (Sheet 1 of 2)
72-01-20
IGNITION SYSTEM - INSPECTION/CHECK
Page 604
Oct 18/2002
0.168 IN.
DIA.
4.267 mm
NEW IGNITER
180 MAX.
NOTE :
EROSION IN ANY
OTHER AXIS IN
EXCESS OF 0.300 IN.
(7.62 mm) IS ACCEPTABLE
SECTION BB
FRETTING LIMIT
VIEW
EROSION LIMIT
C86670
(POST-SB21649)
Igniter - Erosion Limit
Figure 601 (Sheet 2)
72-01-20
IGNITION SYSTEM - INSPECTION/CHECK
Page 605/606
Oct 18/2002
General
A.
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS
Item No.
Name
PWC06-005
PWC11-010
PWC11-022
PWC11-027
PWC11-031
Special Tools
Not Applicable
4.
5.
Cleaning
WARNING:
NOTE:
A.
Ignition Exciter
(1)
B.
Igniter
CAUTION: ALWAYS REPLACE AN IGNITER THAT HAS BEEN DROPPED. INTERNAL
DAMAGE MAY NOT BE EVIDENT AT TESTING.
(1)
72-01-20
IGNITION SYSTEM - CLEANING/PAINTING
Page 701
Sep 03/99
(2)
WARNING:
(3)
C.
Ignition Cable
WARNING:
(1)
6.
The nose of igniter should never be cleaned. Do not remove carbon from
electrodes or annular gap areas. Carbon deposits in the gap area are an
aid to igniter operation.
Painting
CAUTION: DO NOT ALLOW ANY LUBRICANT TO COME IN CONTACT WITH CENTRAL
CONDUCTORS OF EXCITER CONNECTORS. CONTACT WITH
CONDUCTORS MAY RESULT IN A HIGH-RESISTANCE PATH, WHICH
COULD GENERATE HEAT AND OXIDATION.
A.
Procedure
(1)
72-01-20
IGNITION SYSTEM - CLEANING/PAINTING
Page 702
Sep 03/99
2.
General
A.
These instructions provide the information necessary to achieve the approved repairs of
components of the engine ignition system.
B.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-029
PWC05-058
PWC05-066
PWC05-089
PWC05-101
PWC05-295
PWC06-005
PWC11-002
PWC11-022
PWC11-032
Flux
Solder, 50/50
Tape, Insulating
Lockwire
Cloth, Abrasive (320 grit)
Lockwire (may be used instead of PWC05-089)
Lubricant, Dry Spray (Fluorocarbon)
Trichloroethane 1-1-1 (Inhibited)
Methyl-Ethyl-Ketone
Solvent, Degreasing
Special Tools
Not Applicable
4.
5.
Ignition Exciter
A.
Procedure
(1)
72-01-20
IGNITION SYSTEM - APPROVED REPAIRS
Page 801
Sep 03/99
WARNING:
(2)
Procedure
(1)
7.
Procedure
(1)
Areas not exceeding 0.375 in. (9.52 mm) in length and 0.5 in. (12.70 mm) from
connector or flange with no damage to underlying insulation, may be repaired as
follows:
WARNING:
(a)
(b) Solder (PWC05-058 and PWC05-029) damaged area overlapping by 0.125 in.
(3.18 mm).
(c) Clean area using trichloroethane (PWC11-002) or degreasing solvent
(PWC11-032).
NOTE:
72-01-20
IGNITION SYSTEM - APPROVED REPAIRS
Page 802
Sep 03/99
(d) Blend area with abrasive cloth (PWC05-101). Repeat steps (b) and (c), as
required.
(e) Check continuity and insulation (Ref. Inspection/Check).
(2)
Areas exceeding a length of 0.375 in. (9.52 mm) but not exceeding a length of
1.0 in. (25.4 mm) may be repaired providing the finished repair will be at least
0.5 in. (12.70 mm) from nearest connector, flange or existing repair, as follows:
(a) Cut off all loose strands of braiding around damaged area.
(b) Wrap insulating tape (PWC05-066) around harness covering all of the
damaged area as shown (Ref. Fig. 801).
(c) Wrap repaired area with lockwire (PWC05-089) or (PWC05-295) as shown.
Hold wrapping wire snugly along length of harness braid beginning from the
left. Starting at opposite end, wrap wire tightly and uniformly over harness braid
and repaired area.
NOTE:
Ensure that wire overlaps tape and contacts harness braid at each
end of repair.
72-01-20
IGNITION SYSTEM - APPROVED REPAIRS
Page 803
Sep 03/99
INSULATING TAPE
X
1/3 X
C4960C
Harness Braid Repair
Figure 801
72-01-20
IGNITION SYSTEM - APPROVED REPAIRS
Page 804
Sep 03/99
General
A.
WARNING:
WARNING:
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC05-089
PWC05-295
PWC09-010
Oil, Engine
Lockwire
Lockwire (may be used instead of PWC05-089)
Sealant, Silicone Rubber
Special Tools
Not Applicable
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 401
Aug 13/2004
4.
5.
B.
Removal
(1)
(2)
(3)
Remove nuts (2), bolts (3, 4) and clamp assemblies (8, 9).
(4)
Remove bolts (5), tube assembly (6) and gasket (7). Discard gasket.
Installation
CAUTION: LUBRICATE P3 TUBE ASSEMBLY FERRULE AND TUBE NUT THREADS,
USING A MINIMAL AMOUNT OF OIL (PWC03-001). THIS WILL REDUCE
STRESS ON THE P3 TUBE ASSEMBLY. EXCESSIVE STRESS CAN
OCCUR WHEN THE FERRULE AND TUBE NUT THREADS ARE NOT
LUBRICATED.
(1)
Install gasket (7), tube assembly (6) and bolts (5). Torque bolts 27 to
30 lb.in. (3.05-3.39 Nm).
Install clamp assemblies (8, 9), bolts (3, 4) and nuts (2). Torque nuts 36 to
40 lb.in. (4.07-4.52 Nm).
NOTE:
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 402
Jan 16/2004
6.
Removal
(1)
B.
Remove bolts (2) and tube assembly (1). Discard packing (3).
Installation
CAUTION: LUBRICATE TUBE ASSEMBLY FERRULES AND TUBE NUT THREADS,
USING A MINIMAL AMOUNT OF OIL (PWC03-001). THIS WILL REDUCE
STRESS ON THE TUBE ASSEMBLY. EXCESSIVE STRESS CAN
OCCUR WHEN THE FERRULE AND TUBE NUT THREADS ARE NOT
LUBRICATED.
(1)
Lubricate packing (3) with engine oil (PWC03-001) and install on tube assembly (1).
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 403
Jan 16/2004
5
10
2
7
4
9
6
8
C39134A
P3 and Overspeed Governor Pressure Sensing Tube Assemblies - Removal/Installation
Figure 401
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 404
Jan 16/2004
Tube Assembly
Nut
Bolt
Bolt
Bolt
Tube Assembly
Gasket
Clamp Assembly
Clamp Assembly
Tube Assembly
7.
(2)
Lubricate ferrule and tube nut threads using a minimal amount of oil (PWC03-001),
and install tube assembly (1) and bolts (2). Torque bolts 36 to 40 lb.in.
(4.06-4.52 Nm).
(3)
Torque tube nuts 90 to 100 lb.in. (10.17-11.30 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
No. 3 and 4 Bearing Cavity Pressure Sensing Tube (Ref. Fig. 403)
A.
B.
Removal
(1)
Remove nuts (2), bolts (1), clamps (3) and grommets (4).
(2)
Remove bolts (5) and tube assembly (6) and packing (7). Discard packing.
Installation
(1)
Lubricate tube assembly ferrule and tube nut thread, using a minimal amount of oil
(PWC03-001), and install tube assembly and bolts (5). Torque bolts 36 to 40 lb.in.
(4.07-4.52 Nm) and tube nut 90 to 100 lb.in. (10.17-11.30 Nm). Secure tube nut with
lockwire (PWC05-089) or (PWC05-295).
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 405
Jan 16/2004
C26647
Inlet Air Pressure Sensing Tube - Removal/Installation
Figure 402
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 406
Jan 16/2004
Install grommets (4), clamps (3), bolts (1) and nuts (2). Torque nuts 36 to 40 lb.in.
(4.07-4.52 Nm).
NOTE:
8.
Include clamp and grommet of the electrical wiring harness and clamp
assembly of No. 3, 4 and 5 bearing oil pressure tube.
B.
9.
Tube
Bolt
Packing
Removal
(1)
(2)
(3)
Installation
(1)
(2)
Install clamp (1) and secure with lockwire (PWC05-089) or (PWC05-295) as shown.
Switching Valve-to-rear Inlet Case Sealing Air Tube (Ref. Fig. 405)
A.
B.
Removal
(1)
Remove nuts (7, 10), bolts (6, 9) and clamp assembly (8).
(2)
(3)
(4)
Installation
(1)
Install gaskets (3, 5), tube (1) and bolts (2, 4). Torque bolts (4) 62 to 72 lb.in.
(7.01-8.14 Nm) and bolts (2) 36 to 40 lb.in. (4.07-4.52 Nm).
(2)
Install clamp assembly (8), bolt (6) and nuts (7). Torque nuts 36 to 40 lb.in.
(4.07-4.52 Nm).
(3)
Install bolts (9) and nuts (10). Torque nuts 36 to 40 lb.in. (4.07-4.52 Nm).
NOTE:
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 407
Jan 16/2004
4
6
7
2
CHECK VALVE
TUBE
1
3
4
2
3
No. 3, 4 & 5
OIL PRESSURE
TUBE
1
C63454
No. 3 and 4 Bearing Cavity Pressure Sensing Tube - Removal/Installation
Figure 403
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 408
Jan 16/2004
Bolt
Nut
Clamp
Grommet (ST3023-04)
Bolt
Tube Assembly
Packing
B.
Removal
(1)
(2)
Remove nuts (2, 7) and bolts (3, 6), clamp (4) and grommet (5).
(3)
Disconnect tube nuts at both ends of tube and remove tube assembly (1).
(4)
If required, remove elbow (8), nut (9), backup ring (10) and packing (11). Discard
backup ring and packing.
Installation
(1)
If removed, install elbow (8), nut (9), backup ring (10) and packing (11) according to
standard procedure (Ref. 72-00-00, MAINTENANCE PRACTICES).
Lubricate tube assembly ferrule and tube nut thread, using a minimal amount of oil
(PWC03-001), and install tube assembly (1). Torque tube nuts 90 to 100 lb.in.
(10.17-11.30 Nm) and secure with lockwire (PWC05-089) or (PWC05-295).
(3)
Torque nut (9) 65 to 75 lb.in. (7.35-8.48 Nm) and secure with lockwire (PWC05-089)
or (PWC05-295).
NOTE:
Metal-to-metal contact between nut (9) and boss must be obtained without
exceeding recommended torque, and there must be no extrusion of
packing or backup ring.
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 409
Jan 16/2004
VIEW A
LOCKWIRE ARRANGEMENT
LOOKING REARWARD
C63239
P3 Bleed Air Boss Insulation - Removal/Installation
Figure 404
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 410
Jan 16/2004
Clamp
Insulation Blanket
Insulation Blanket
Install clamp (4), grommet (5), bolts (3, 6) and nuts (2, 7). Torque nut 36 to
40 lb.in. (4.07-4.52 Nm).
NOTE: 1. Include clamp of motive fuel flow ejector tube at bolt (3).
NOTE: 2. Include clamps of electrical wiring harness at bolts (6).
11.
B.
Removal
(1)
(2)
(3)
(4)
Installation
CAUTION: LUBRICATE TUBE ASSEMBLY FERRULE AND TUBE NUT THREADS,
USING A MINIMAL AMOUNT OF OIL (PWC03-001). THIS WILL REDUCE
STRESS ON THE TUBE ASSEMBLY. EXCESSIVE STRESS CAN
OCCUR WHEN FERRULE AND TUBE NUT THREADS ARE NOT
LUBRICATED.
12.
(1)
Lubricate ferrules and tube nuts using a minimal amount of oil (PWC03-001) and
install tube assembly (1).
(2)
Tighten tube nuts 90 to 100 lb.in. (10.17-11.29 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
(3)
(4)
Install nut (1) and bolt (2). Torque nut 36 to 40 lb.in. (4.07-4.52 Nm).
Removal
(1)
(2)
(3)
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 411
Jan 16/2004
10
10
10
9
3
10
6
8
10
7
C26649
Switching Valve-to-Rear Inlet Case Air Sealing Tube - Removal/Installation
Figure 405
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 412
Jan 16/2004
B.
13.
Tube Assembly
Bolt
Gasket
Bolt
Gasket
Bolt
Nut
Clamp Assembly
Bolt
Nut
(4)
(5)
Installation
(1)
Install gasket (6), IBV assembly (5), washers (4) and bolts (3),. Torque bolts 36 to
40 lb.in. (4.07-4.52 Nm).
(2)
(3)
(4)
Removal
(1)
Remove nuts (1), washers (2), bolts (3), servo valve (4) and packing (5). Discard
packing.
(2)
Remove metering plug (6) using a standard screwdriver. Record class number.
NOTE:
(3)
B.
Installation
(1)
(2)
Install packing (5), servo valve (4), washers (2), bolts (3) and nuts (1). Torque nuts
36 to 40 lb.in. (4.07-4.52 Nm).
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 413
Jan 16/2004
8
9
1
10
TO P10
11
7
6
2
5
C30272B
Oil Check Valve Air Tube - Removal/Installation
Figure 406
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 414
Jan 16/2004
Lubricate packing (9) with a light film of engine oil (PWC03-001) and install on reducer
(7).
(4)
(5)
Lubricate classified metering plug (10) and install in reducer. Torque 10 to 15 lb.in.
(1.13-1.69 Nm).
NOTE:
(6)
14.
Tube Assembly
Nut
Bolt
Clamp
Grommet
Bolt
Nut
Elbow
Nut
Backup Ring
Packing
Intercompressor Bleed Valve (IBV) Servo Valve Screen (Ref. Fig. 410)
A.
Removal
CAUTION: ENSURE PACKING GROOVE IS NOT DAMAGED WHEN REMOVING
SCREEN.
(1)
B.
Using minimum amount of force necessary, press a 0.125 in. (3.175 mm) diameter
plastic (or equivalent soft material) rod against the center of screen (1) sufficient to
deform and allow the screen to come out of its seat in housing (2).
Installation
(1)
Position screen (1) with fine mesh showing, opposite servo valve housing (2) seat.
(2)
(3)
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 415
Jan 16/2004
2
4
C63241
Bleed Valve Air Supply Tube Assembly - Removal/Installation
Figure 407
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 416
Jan 16/2004
B.
16.
Nut
Bolt
Tube Assembly
Clamp
Removal
(1)
Disconnect the airframe duct from the P2.5 check valve assembly (1) (Ref. AMM).
(2)
(3)
(4)
Remove the P2.5 check valve assembly (1) from the P2.5 adapter (4). Discard
gasket (3).
(5)
Remove bolts (5), P2.5 adapter (4) and gasket (6). Discard gasket.
Installation
(1)
Install gasket (6), P2.5 adapter (4) and bolts (5). Torque bolts 36 to 40 lb.in.
(4.07-4.52 Nm).
(2)
(3)
Position P2.5 check valve assembly (1) on P2.5 adapter with gasket centered in
face recess and engage coupling assembly (2).
(4)
(5)
Removal
(1)
Remove the intercompressor bleed air valve assembly (Ref. Para. 12. A.).
(2)
Remove the P2.5 check valve assembly (Ref. Para. 15. A.).
(3)
Remove the transfer tube from the intercompressor case and discard packings.
(4)
Clean the transfer tube cavity in the intercompressor case with petrolium solvent
(PWC11-027)
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 417
Jan 16/2004
3
4
C63272
Intercompressor Bleed Valve Assembly - Removal/Installation
Figure 408
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 418
Jan 16/2004
Installation
CAUTION: MAKE SURE THE TRANSFER TUBE AND THE HOUSING CAVITY ARE FREE
OF OLD CURED SILICONE. REMOVE OLD COMPOUND AND CLEAN TUBE
AND INTERCOMPRESSOR CAVITY WITH PETROLIUM SOLVENT.
(1)
Apply a thin layer of (PWC09-010) to the inside lower fillet of the housing.
(2)
Lubricate the new packings with engine oil, (PWC03-001) and install on the transfer
tube.
(3)
Install the transfer tube in the intercompressor case cavity. Inspect mating surfaces
for excess sealant.
NOTE:
Remove all excess sealant visible with a clean rag when inspecting the
mating surface between the tube and the housing
(4)
Install the P2.5 check valve assembly (Ref. Para. 15. B.).
(5)
Install the intercompressor bleed air valve assembly (Ref. Para. 12. B.).
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 419
Jan 16/2004
C63274
Intercompressor Bleed Valve Assembly Servo Valve - Removal/Installation
Figure 409
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 420
Jan 16/2004
Nut
Washer
Bolt
Servo Valve
Packing
Metering Plug
Reducer
Packing
Intercompressor Bleed Valve Assembly
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 421
Jan 16/2004
COARSE SCREEN
FINE SCREEN
2
1
C21126
IBV Servo Valve Screen - Removal/Installation
Figure 410
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 422
Jan 16/2004
Screen
Housing
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 423
Jan 16/2004
1
2
A
4
FWD
VIEW A
COUPLING INSTALLATION
C63280
P2.5 Check Valve and Bleed Air Adapter - Removal/Installation
Figure 411
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 424
Jan 16/2004
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 425
Jan 16/2004
1 (REF.)
3
4
C93622
Intercompressor Case Transfer Tube - Removal/Installaion (Typical)
Figure 412 (Sheet 1 of 2)
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 426
Jan 16/2004
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 427
Jan 16/2004
TRANSFER TUBE
ENSURE NO SEALANT
CONTAMINATES THIS
AREA
PACKING
HOUSING
SEALANT
(PWC09010)
SEALANT
(PWC09010)
C93709
Intercompressor Case Transfer Tube - Removal/Installaion (Typical)
Figure 412 (Sheet 2)
72-01-30
AIR SYSTEM - REMOVAL/INSTALLATION
Page 428
Jan 16/2004
General
A.
2.
These instructions provide the information necessary for the adjustment/test of engine
air system components.
Consumable Materials
Not Applicable
3.
Special Tools
Not Applicable
4.
5.
Adjustment/Test
A.
After installation or at ground test, check servo valve torque motor as follows:
NOTE:
Checking the torque motor requires two persons: one in the cockpit
and one beside the engine.
72-01-30
AIR SYSTEM - ADJUSTMENT/TEST
Page 501
Jul 07/2000
(b) Select EEC to Manual, then slowly accelerate (taking not less than 30
seconds) to a required NH, equivalent to a normalized NH of 84%. Allow engine
to stabilize and record NL.
NOTE: 1. Required NH is NH modified to compensate for effect of outside air
temperature (OAT) (Kelvin or Rankine scale) and is obtained using
Table 501.
NOTE: 2. On some cold days, Flight Idle (FI) will result in an actual NH greater
than required NH. In this case, set FI, do not retard the Power Lever
(PL) since the IBV is commanded to close just below FI.
(c) Set engine to a required NH, equivalent to a normalized NH of 91.5%. Allow
engine to stabilize and record the NL.
CAUTION: IF THE EMERG. EEC IS PULLED FIRST, THE 28V SIGNAL GOING
TO THE EEC IS LOST RESULTING IN AN UPTRIM OF THE
ENGINE.
(d) Set engine to flight idle and switch off the EEC by pulling out EEC circuit
breaker (Ref. AMM).
NOTE: 1. Selecting preferred mode does not close the intercompressor bleed
valve. Power must be removed from the EEC to close the valve.
NOTE: 2. NORMAL EEC circuit breaker to be pulled first followed by
EMERG. EEC circuit breaker (Ref. AMM).
(e) Set engine to a required NH, equivalent to a normalized NH of 84%. Allow
engine to stabilize. Record the NL.
NOTE:
(f)
The difference in NL recorded with the EEC on (Ref. step (b)) and
EEC off must be between 3 and 6%.
The difference in NL recorded with the EEC on (Ref. step (c)) and the
EEC off must be less than 0.5%.
72-01-30
AIR SYSTEM - ADJUSTMENT/TEST
Page 502
Jul 07/2000
(i)
Required NH Equivalent
to NH of 84%
Normalized
-58
-50
74
80.2
-49
-45
75
81.5
-40
-40
76
82.3
-31
-35
76
83.0
-22
-30
77
84.1
-13
-25
78
84.8
-4
-20
79
85.5
-15
80
86.3
14
-10
81
87.2
23
-5
82
88.0
32
82
88.7
41
82
89.9
50
10
83
90.7
59
15
84
91.5
68
20
85
92.0
77
25
85
93.0
86
30
86
93.8
95
35
87
94.3
104
40
87
95.0
113
45
88
95.9
122
50
89
96.9
OAT
(2)
If replacement of the metering plug does not bring the intercompressor bleed valve
within limits check:
(a) The tube connecting the LP diffuser exit duct to the bleed valve for air leaks. If
necessary, rectify the air leak and retest the valve.
(b) The valve cover gasket for extrusion. If the gasket is extruded, an air leak
occurs and the valve must be returned to an approved overhaul facility for
gasket replacement.
NOTE:
The valve will remain open at a higher NH or not close if an air leak
occurs (Ref. steps (a) and (b)).
72-01-30
AIR SYSTEM - ADJUSTMENT/TEST
Page 503/504
Jul 07/2000
General
A.
Consumable Materials
Not Applicable
3.
Special Tools
Not Applicable
4.
5.
Inspection
A.
General
(1)
In addition to the details specifically mentioned, inspect for obvious damage, cracks
and defective threads.
(2)
(3)
B.
C.
Inspect intercompressor bleed valve metering plug for obstructed orifice (Ref.
Cleaning/Painting).
Inspect the intercompressor case transfer tube for surface damage as follows:
72-01-30
AIR SYSTEM - INSPECTION/CHECK
Page 601
Jan 16/2004
(a) Remove local surface damage from 0.005 to 0.010 in. (0.12 to 0.25 mm) deep
maximum.
NOTE:
Chamfers and radii must be the same as they were before the
damage.
(b) Measure the lenght of the transfer tube. Replace the transfer tube if its less
then 1.854 in. (47.09 mm).
(c) Measure the depth of the packing grooves. Replace the transfer the tube if the
grooves are less then 0.050 in. (1.27 mm) deep.
6.
Check
A.
(2)
72-01-30
AIR SYSTEM - INSPECTION/CHECK
Page 602
Jan 16/2004
General
A.
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC11-027
PWC11-031
Solvent, Petroleum
Cleaner, Engine Parts
Special Tools
Not Applicable
4.
5.
Cleaning
A.
General
WARNING:
WARNING:
(1)
With the exception of the items specifically mentioned, clean all parts using
petroleum solvent (PWC11-027) or cleaner (PWC11-031) and blow dry with clean
compressed air at 29 psig (200 kPa) maximum.
NOTE:
72-01-30
AIR SYSTEM - CLEANING/PAINTING
Page 701
Jan 16/2004
B.
(2)
D.
Clean the metering plug orifice with a standard wooden pick . Remove any debris
with clean compressed air at 29 psig (200 kPa) maximum.
Clean the ICC cavity and the transfer tube with petroleum solvent(PWC11-027) or
equivalent.
NOTE:
You can use a plastic or wooden scraper to remove cured silicone on the
ICC cavity and the transfer tube.
72-01-30
AIR SYSTEM - CLEANING/PAINTING
Page 702
Jan 16/2004
2.
General
A.
These instructions provide the information necessary to carry out the approved repairs
of components of the engine air system.
B.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-019
PWC05-061
PWC05-101
Compound, Lapping
Cloth, Abrasive, Coated, Crocus
Cloth, Abrasive (320 grit)
Special Tools
Not Applicable
4.
5.
Approved Repairs
A.
Tubes
(1)
Blend out nicks, scratches, pits and corrosion not exceeding 0.005 in. (0.127 mm)
deep, provided blended areas do not exceed one-half square inch (322.6 sq. mm)
and are separated by one-half inch (12.70 mm) minimum undamaged surface.
(2)
(3)
72-01-30
AIR SYSTEM - APPROVED REPAIRS
Page 801
Sep 03/99
B.
Housings
(1)
Blend out nicks, scratches, burrs and corrosion using abrasive cloth (PWC05-101)
followed by polishing with crocus cloth (PWC05-061).
(2)
(3)
(4)
(5)
Dress mating surfaces using lapping plate and lapping compound (PWC05-019).
72-01-30
AIR SYSTEM - APPROVED REPAIRS
Page 802
Sep 03/99
General
A.
These instructions provide information necessary for servicing components of the engine
fuel system.
B.
WARNING:
WARNING:
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC05-089
PWC05-090
PWC05-295
Oil, Engine
Lockwire
Lockwire
Lockwire (may be used instead of PWC05-089)
Special Tools
Special tools are identified in procedural text by part number in parentheses.
4.
Tool No.
Name
PWC32396
PWC54639
Jackscrew
Socket
5.
72-01-40
FUEL SYSTEM - SERVICING
Page 301
Mar 03/2000
CENTERING TABS
CENTERING TABS
5
3
2
C27055A
Fuel Heater Inlet Filter - Removal/Installation
Figure 301
72-01-40
FUEL SYSTEM - SERVICING
Page 302
Mar 03/2000
Removal
(1)
(2)
Remove nuts (7), cover (4) and filter (5) from fuel heater assembly (1). Discard
packing (6).
Installation
(1)
Lubricate packing (6) with engine oil (PWC03-001) and install on cover (4).
(2)
(3)
Lubricate packing (3) with engine oil (PWC03-001) and install on drain plug (2).
Torque plug 65 to 75 lb.in. (7.34-8.47 Nm) and secure with lockwire (PWC05-089)
or (PWC05-295).
(4)
72-01-40
FUEL SYSTEM - SERVICING
Page 303
Mar 03/2000
6.
Removal
WARNING:
(1)
(2)
Remove nuts (3) and cover (4) using jackscrews (PWC32396). Discard packings
(5).
(3)
B.
Installation
(1)
Lubricate packings (7, 8) with engine oil (PWC03-001) and install in filter (6).
(2)
Install filter.
(3)
Lubricate packings (5) with engine oil (PWC03-001) and install on cover (4).
(4)
Install cover and nuts (3). Torque nuts 65 to 75 lb.in. (7.35-8.48 Nm).
NOTE:
WARNING:
7.
(5)
(6)
Removal
(1)
B.
Remove screen (1) using socket (PWC54639)and packing (2). Discard packing.
Installation
(1)
Lubricate packing (2) with engine oil (PWC03-001) and install on screen (1).
(2)
Install screen. Torque 100 to 150 lb.in. (11.30-16.95 Nm) and secure with lockwire
(PWC05-090).
(3)
72-01-40
FUEL SYSTEM - SERVICING
Page 304
Mar 03/2000
72-01-40
FUEL SYSTEM - SERVICING
Page 305
Mar 03/2000
45
45
MASTER
KEYWAY
10
7
6
9
8
2
1
C63303
Fuel Pump Filter and Screen - Removal/Installation
Figure 302
72-01-40
FUEL SYSTEM - SERVICING
Page 306
Mar 03/2000
Inlet Screen
Packing
Nut
Cover
Packing
Outlet Filter
Packing
Packing
Retaining Ring (Ref.)
Pressure Differential Switch (Ref.)
Packing (Ref.)
72-01-40
FUEL SYSTEM - SERVICING
Page 307/308
Mar 03/2000
General
A.
B.
WARNING:
WARNING:
WARNING:
WARNING:
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC04-006
Oil, Engine
Grease, Corrosion Preventative
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 401
Nov 04/2005
3.
Item No.
Name
PWC05-048
PWC05-089
PWC05-295
Marker, Pen
Lockwire
Lockwire (may be used instead of PWC05-089)
Special Tools
Special tools are identified in procedural text by part number in parentheses.
4.
Tool No.
Name
PWC32396
PWC37303
PWC37442
PWC38163
PWC54021
PWC56489
PWC56504
PWC58145
Jackscrews
Pusher
Locator
Rigging Pins
Template
Stand
Wrench
Wrench
Remarks
See NOTE
See NOTE
The shipping base (P/N 3243907) and the bracket (P/N 3243908) are vendor supplied
and can be purchased at the following address:
Air Parts and Supply Company,
12840 SW 84th Avenue Rd.,
Miami, FL 33156
USA
TEL: (305) 235 5401
FAX: (305) 235 8185
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 402
Nov 04/2005
5.
It is recommended that the MFC and fuel pump be removed as one assembly,
then separated on the bench.
WARNING:
(2)
(4)
Remove fuel tubes (Ref. Para. 7.) and drain tube (Ref. Para. 13.) from MFC.
(5)
(6)
Push transfer tube (4) into fuel pump (6) as far as possible.
(7)
Loosen coupling assembly (7) nut and remove MFC/fuel pump assembly (8).
Discard packings (9, 10).
(8)
(9)
Install the MFC/fuel pump assembly (8) on the stand (PWC56489) (11) and secure
with the coupling assembly (7).
(10)
B.
Disassembly
(1)
(c) Install the MFC (3) on the shipping base (P/N 3243907) and the bracket (P/N
3243908).
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 403
Nov 04/2005
7
9
10
8
6
ADAPTER
(REF.)
12
5
4
5
3
2
1
11
C84026
MFC/Fuel Pump Assembly - Removal/Installation
Figure 401
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 404
Nov 04/2005
Bolt
Bracket
Plate
Transfer Tube
Packing
Fuel Pump
Coupling Assembly
MFC/Fuel Pump Assembly
Packing
Packing
Stand (PWC56489)
Bolt
(2)
(3)
C.
Assembly
NOTE:
(1)
All elbow nuts may be torqued after installation of the tube assemblies (Ref.
Sub Para. D.).
(2)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 405
Nov 04/2005
1
MFC LEVERS
(REF.)
STAND
(REF.)
C83999
MFC/Fuel Pump Assembly - Removal/Installation
Figure 402
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 406
Nov 04/2005
Nut
Washer
Mechanical Fuel Control (MFC)
Fuel Pump
Coupling
Packing
(a) Lubricate packing (8) with engine oil (PWC03-001) and install on adapter (7).
Install adapter and torque 65 to 75 lb.in. (7.35-8.48 Nm).
(b) Install elbow (4), nut (3), backup ring (5) and packing (6) (Ref. 72-00-00,
MAINTENANCE PRACTICES). Angle of elbow as shown.
(c) Torque nut 38 to 42 lb.in. (4.29-4.75 Nm). Secure with lockwire (PWC05-089)
or (PWC05-295).
NOTE:
(d) Lubricate packings (2) with engine oil (PWC03-001) and install on nipples (2).
Install nipples and torque 110 to 120 lb.in. (12.43-13.56 Nm).
(3)
D.
Loosen coupling assembly (7) nut and remove MFC/fuel pump assembly (8) from
the stand (PWC56489) (11).
(2)
Lubricate packings (9, 10) with engine oil (PWC03-001) and install on fuel pump
(6).
(3)
Lubricate mating face, adjacent outer diameter and clamp mating surface of
adapter using grease (PWC04-006).
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 407
Nov 04/2005
VIEW
A
4
1
7
C83178A
MFC and Fuel Pump - Disassembly/Assembly
Figure 403 (Sheet 1 of 2)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 408
Nov 04/2005
Nipple
Packing
Nut
Elbow
Backup Ring
Packing
Adapter
Packing
Nipple
Packing
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 409
Nov 04/2005
10
9
VIEW B
FUEL PUMP
(REF.)
STAND
(REF.)
C84027B
MFC and Fuel Pump - Disassembly/Assembly
Figure 403 (Sheet 2)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 410
Nov 04/2005
(5)
Align splines of pump drive with engine gearshaft, dowel pin with corresponding
hole in pump flange and install MFC/fuel pump assembly (8).
(6)
(7)
Using a teflon drift and a soft hammer, tap coupling (7) as far as possible around
the circumference to ensure it is seated correctly. Retorque coupling nut 50 to
65 lb.in. (5.65-7.35 Nm).
(8)
Lubricate packings (5) with engine oil (PWC03-001) and install on transfer tube (4).
(9)
(10)
(11)
Install plate (3), bracket (2) and bolts (1). Torque bolts 85 to 95 lb.in. (9.61-10.74 Nm).
(12)
(13)
(14)
WARNING:
6.
(15)
(16)
Secure harness branch at bracket (2) with bolts (12). Torque bolts 36 to 40 lb.in.
(4.07-4.52 Nm).
(17)
If required, carry out a wet motoring run to flush out any preservation fluid (Ref.
AMM).
(18)
Power Fuel Control and Condition Fuel Control Arms (Ref. Fig. 404)
A.
Rigging
(1)
DELETED
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 411
Nov 04/2005
DELETED
C00000
Power Fuel Control and Condition Fuel Control Arms - Rigging
Figure 404
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 412
Nov 04/2005
7.
Removal
CAUTION: HOLD ADJACENT FITTINGS SECURELY IN POSITION WHEN
REMOVING TUBE NUTS.
(a) Unscrew tube nuts and remove tube assemblies (1, 3).
(b) Remove nut (4), clamp assembly (5) and bolt (6).
(c) Unscrew tube nut and remove tube assembly (7).
(2)
Installation
CAUTION: HOLD ADJACENT FITTING SECURELY IN POSITION WHEN
TORQUING TUBE NUTS.
CAUTION: LUBRICATE TUBE ASSEMBLY FERRULES AND TUBE NUT
THREADS, USING A MINIMAL AMOUNT OF ENGINE OIL
(PWC03-001). THIS WILL REDUCE STRESS ON THE TUBE
ASSEMBLY. EXCESSIVE STRESS CAN OCCUR WHEN THE
FERRULE AND TUBE THREADS ARE NOT LUBRICATED.
(a) Lubricate ferrules and tube nut threads of tubes (1, 3, 7), using a minimum
amount of engine oil (PWC03-001).
(b) Install tubes (1, 3, 7). Torque tube nuts 270 to 300 lb.in. (30.51-33.90 Nm).
Secure with lockwire (PWC05-089) or (PWC05-295).
(c) Install clamp assembly (5), bolt (6) and nut (4). Torque nut 36 to 40 lb.in.
(4.07-4.52 Nm).
(d) Carry out a leak check (Ref. Adjustment/Test).
B.
Removal
(a) Remove nuts (10, 15), bolts (11, 16, 17), spacer (18) and clamp assemblies
(12, 19).
CAUTION: HOLD ADJACENT FITTING SECURELY IN POSITION WHEN
REMOVING TUBE NUT.
CAUTION: DO NOT REMOVE LOCKWIRE SECURING THRUST PIN (23) TO
TUBE NUT.
(b) Unscrew tube nuts and remove tubes assemblies (13, 21).
(c) Remove transfer tube (23) and packings (24). Discard packings.
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 413
Nov 04/2005
OUTER END OF
THRUST PIN
25
C
A
DETAIL
VIEW
21
24
3
22
15
19
20
23
11
15
16
16
5
14
8
12
15
9
4
15
18
20
7
10
10
11
15
16
13
12
17
21
16
20
20
16
C63309
Fuel Tube Assemblies - Removal/Installation
Figure 405
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 414
Nov 04/2005
Tube Assembly
MFCU (Ref.)
Tube Assembly
Nut
Clamp Assembly
Bolt
Tube Assembly
Oil Cooler (Ref.)
Exciter Mounting Plate (Ref.)
Nut
Bolt
Clamp Assembly
Tube Assembly
Oil Filter Cover (Ref.)
Nut
Bolt
Bolt
Spacer
Clamp Assembly
Ignition Cables (Ref.)
Tube Assembly
Dump Valve
Transfer Tube
Packing
Thrust Pin
Installation
(a) Lubricate packings (24) with engine oil (PWC03-001) and install on transfer
tube (23).
(b) Install transfer tube in flow divider and dump valve (22).
CAUTION: LUBRICATE TUBE ASSEMBLY FERRULES AND TUBE NUT
THREADS, USING A MINIMAL AMOUNT OF ENGINE OIL
(PWC03-001). THIS WILL REDUCE STRESS ON THE TUBE
ASSEMBLY. EXCESSIVE STRESS CAN OCCUR WHEN THE
FERRULE AND TUBE THREADS ARE NOT LUBRICATED.
(c) Lubricate ferrules and tube nut threads, using a minimum amount of engine oil
(PWC03-001), and install tube assemblies (13, 21). Torque tube nuts
fingertight.
NOTE:
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 415
Nov 04/2005
(d) Install clamp assemblies (12, 19), bolts (11, 16, 17), ignition cable (20) clamps,
spacer (18) and nuts (10, 15). Torque nuts 36 to 40 lb.in. (4.07-4.52 Nm).
CAUTION: HOLD ADJACENT FITTING SECURELY IN POSITION WHEN
TORQUING TUBE NUTS.
CAUTION: ENSURE LOCKWIRE SECURES THRUST PIN (23) TO THE
COUPLING NUT.
(e) Torque tube nut at flow divider and dump valve (20) 320 to 350 lb.in.
(36.16-39.55 Nm). Secure tube nut with lockwire (PWC05-089) or (PWC05-295)
to two of the bolts securing the flow divider to the gas generator case.
(f)
Torque remaining tube nuts 270 to 300 lb.in. (30.51-33.90 Nm). Secure with
lockwire (PWC05-089) or (PWC05-295).
B.
Removal
(1)
(2)
Holding associated fittings securely, loosen tube nuts and remove tube (1).
(3)
Holding associated fittings securely, loosen tube (2) nuts and remove tube.
(4)
Loosen nut (4) and remove elbow (3). Discard gasket (5).
(5)
Loosen nut (7) and remove drain valve assembly (6) and cover (9). Discard gaskets
(8).
(6)
Remove retaining ring (10), valve (11) and spring (12) from adapter (13).
(7)
(8)
Remove retaining ring (16), valve (17) and spring (18) from adapter (19).
Installation
(1)
Install spring (18), valve (17) (flat surface away from spring) and retaining ring (16)
in adapter (19).
(2)
Install valve assembly (14) and gasket (15). Torque 450 to 550 lb.in.
(50.85-62.15 Nm).
(3)
Install spring (12), valve (11) (flat surface away from spring) and retaining ring (10)
in adapter (13).
(4)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 416
Nov 04/2005
(5)
Install gaskets (8), cover (9), and valve assembly (6). Torque nut (7) 450 to
550 lb.in. (50.85-62.15 Nm).
(6)
Lubricate ferrules and tube nuts using a minimal amount of oil (PWC03-001) and
install tube assembly (2). Torque both ends fingertight, then 270 to 300 lb.in.
(30.51-33.90 Nm) at valve assembly (6).
(8)
Install nut (4), gasket (5) and elbow (3). Torque nut fingertight.
(9)
Lubricate ferrules and tube nuts using a minimal amount of oil (PWC03-001) and
install tube assembly (1).
(10)
9.
(11)
Torque tube nuts at both ends of tube assembly (1) and at front end of tube
assembly (2) 90 to 100 lb.in. (10.17-11.30 Nm).
(12)
Secure nut (4), valve assembly (14) and tube assembly (1, 2) nuts with lockwire
(PWC05-089) or (PWC05-295).
Removal
(1)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 417
Nov 04/2005
9
15
8
16
5
4
17
14
10
18
11
19
12
2
13
C38630
Fuel Drain Valves - Removal/Installation
Figure 406
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 418
Nov 04/2005
Tube Assembly
Tube Assembly
Elbow
Nut
Gasket
Drain Valve Assembly
Nut
Gasket
Cover
Retaining Ring
Valve
Spring
Adapter
Drain Valve Assembly
Gasket
Retaining Ring
Valve
Spring
Adapter
B.
(3)
Remove bolts (2) and valve (3) . Discard packings (4, 5).
(4)
Remove nipple (6) and packing (7). Discard packing and backup ring.
(5)
Installation
(1)
Lubricate packings (9) with engine oil (PWC03-001) and install on transfer tube (8).
(2)
(3)
Lubricate packings (4, 5) with engine oil (PWC03-001) and install on valve (3).
(4)
Install valve (3) and bolts (2). Torque bolts 27 to 30 lb.in. (3.05-3.39 Nm). Secure
with lockwire after tube assembly (1) tube nut is torqued.
NOTE:
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 419
Nov 04/2005
FW
10
1
5
4
8
6
OUTER END OF
THRUST PIN
VIEW B
C65800
Flow Divider and Dump Valve - Removal/Installation
Figure 407
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 420
Nov 04/2005
Connect fuel tube assembly (1). Torque tube nut 320 to 350 lb.in. (36.16-39.55 Nm).
NOTE:
CAUTION: ENSURE LOCKWIRE SECURES THRUST PIN (10) TO THE TUBE NUT.
(6)
Secure tube nut and dump valve bolts using lockwire (PWC05-089) or (PWC05-295).
Tube nut to be lockwired to adjacent bolts on dump valve.
(7)
Torque nipple 65 to 75 lb.in. (7.35-8.48 Nm) and secure with lockwire (PWC05-089)
or (PWC05-295).
(9)
(10)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 421
Nov 04/2005
10.
Removal
Disconnect the accessory gearbox breather tube and the No. 5 bearing vent tube
assembly at both ends (Ref. 72-01-50 Oil System- Removal/Installation).
NOTE: 1. Step (1) is optional if using (PWC56612) crowfoot.
NOTE: 2. Do not remove the tubes, but move the tubes as required to get access
to the fuel manifold adapters bolts and coupling nuts.
(2)
Post-SB21674: remove nut (12), bolt (11) and clamp (10) from bracket (13).
Remove the clamp from the primary hose.
(3)
(4)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 422
Nov 04/2005
FUEL
ADAPTER
FITTING
FUEL MANIFOLD
HOSE FITTING
BORE
FUEL
MANIFOLD
HOSE
FUEL
MANIFOLD
NOZZLE
BORE
PACKING GROOVE
MANIFOLD
TUBE
SECTION
AA
C76544A
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 423
Nov 04/2005
13
11
0.0500 in. MIN.
(1.27 mm)
10
12
C
5
1
4
VIEW B
ASSEMBLED COMPONENTS
4
5
8
SECONDARY FLOW
ADAPTER
LOCATING PIN
9
4
PRIMARY AND
SECONDARY
FLOW ADAPTER
LOCATING PIN
FW
6
4
2
FW
5
VIEW
A
C38467C
Fuel Manifold - Removal/Installation
Figure 409 (Sheet 1 of 3)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 424
Nov 04/2005
Hose, Primary
Hose, Secondary
Hose, Secondary
Packing (AS3209-008)
Bolt
Inlet Adapter
Adapter (Secondary-flow)
Adapter (Primary- and Secondary-flow)
Gasket
Clamp (Post-SB21674)
Bolt (Post-SB21674)
Nut (Post-SB21674)
Bracket (Post-SB21674)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 425
Nov 04/2005
14
1
2
13
8
8
3
12
7
11
4
8
10
5
8
9
6
8
6
VIEW LOOKING FORWARD
C38468
Fuel Manifold - Removal/Installation
Figure 409 (Sheet 2)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 426
Nov 04/2005
FW
LOCATING HOLES
TYPICAL
PARKERHANNIFIN
NOZZLE
FW
TYPICAL
DELAVAN
NOZZLE
FW
LOCATING HOLES
LOCATING HOLES
C72511
Fuel Manifold - Removal/Installation
Figure 409 (Sheet 3)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 427
Nov 04/2005
Remove bolts (5), adapters (6, 7, 8) and gaskets (9) at four equally spaced
intervals. Install four outer combustion chamber locators (PWC37442)at these
locations. Remove the remaining bolts (5), adapters (6, 7, 8) and gaskets (9). Discard
gaskets.
NOTE:
B.
(6)
Remove and discard packings (4) from primary and secondary hose connections.
(7)
Installation (Post-SB21705)
Lubricate new packings (4) (AS3209-008) using a minimal amount of engine oil
(PWC03-001) and install on primary and secondary hoses (1, 2, 3) connectors.
NOTE: 1. Inspect the preformed packings for damage after installation on the
manifolds. Replace packings if damaged.
NOTE: 2. Make sure the correct fuel manifold adapter type is installed at each
correct location (Ref. Fig. 409, Sheet 2).
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 428
Nov 04/2005
CAUTION: MAKE SURE THE ARROW ON ALL THE FUEL NOZZLES, POINTS
FORWARD WHEN INSTALLED.
NOTE: THE DIRECTIONAL ARROW IS NOT PRESENT ON POST-SB21705
PRODUCTION FUEL NOZZLES. ONLY THE NOZZLES IN SERVICE
THAT HAVE BEEN MODIFIED BY SB21705 WILL STILL CARRY THE
DIRECTIONAL ARROW.
CAUTION: MAKE SURE THE TORQUE IS BETWEEN THE RECOMMENDED VALUE.
(2)
Use new gaskets (9), install adapters (6, 7, 8) with the locating pin and fuel
nozzle tip facing toward the rear of the engine. Install bolts (5) and torque bolts Fig.
409), 27 to 30 lb.in. (3.05-3.39 Nm).
NOTE: 1. Adapters of primary and secondary flow incorporate dowel pins which
locate in a mating hole in the gas generator case.
NOTE: 2. Adapters of secondary flow have a hole which mates with dowel pins
fitted to gas generator case.
NOTE: 3. Do not lubricate bolts.
Lubricate primary and secondary hose connector threads using a minimal amount
of engine oil (PWC03-001).
Lubricate fuel nozzle elbow threads and locking fingers using a minimal amount of
engine oil (PWC03-001).
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 429
Nov 04/2005
CAUTION: MAKE SURE YOU APPLY THE FINAL TORQUE TO ALL MANIFOLD
CONNECTORS. IF FINAL TORQUE IS NOT DONE, IT IS POSSIBLE THE
FITTINGS CAN COME LOOSE AND SUBSEQUENTLY RESULT TO A
FUEL LEAKAGE OF THE CONICAL SEALING FACES
CAUTION: HOLD THE TEE FITTINGS SECURELY WHEN YOU TORQUE THE NUT
ASSEMBLY.
(6)
Hold the tee fittings (part of 1, 2, 3) and use torque wrench (PWC56601) to apply
the final torque of 160 to 180 lb.in. (18.08 to 20.34 Nm).
NOTE: 1. Final torque of the secondary manifold of the fuel nozzle no. 14 maybe
applied using a standard crowfoot 11/16 with a standard torque wrench
having an extension.
NOTE: 2. Final torque of secondary manifold of fuel nozzle no. 6 can be applied
using special crowfoot PWC56612. If access is too restricted refer to
step (1) of removal instruction where instruction are given for the removal
of no. 5 bearing vent tube assembly.
NOTE: 3. Two crowfoot extensions are available for pre-setted torque wrench
PWC56601 to get more flexibility in restricted area access. Appropriate
selection of crowfoot extensions should be made to ease the final torque
application.
(7)
Post-SB21674: Install the clamp on the primary hose at location shown. Align clamp
with bracket (13) and secure with nut (12), bolt (11). Torque the nut 36 to 40 lb.in.
(4.07-4.52 Nm).
(8)
Connect the accessory gearbox breather tube and the No. 5 bearing vent tube
assembly at both ends (Ref. 72-01-50, OIL SYSTEM- REMOVAL/INSTALLATION).
(9)
Removal
WARNING:
(1)
(2)
(3)
Remove nuts (3) and cover (4), using jackscrews (PWC32396) and packings (5).
Discard packings.
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 430
Nov 04/2005
B.
(4)
Remove retaining ring (9), pressure differential switch (10) and packing (11) from
cover. Discard packing.
(5)
Installation
(1)
Lubricate packings (11, 7) with engine oil (PWC03-001) and install on pressure
differential switch (10) and in filter (6), respectively.
(3)
Install switch in cover (4), aligning flange hole with locating pin in cover and
ensuring switch electrical connection master keyway is within 45 degrees of TDC
mark.
(4)
(5)
Lubricate packings (5) with engine oil (PWC03-001) and install on cover (4).
(6)
Align TDC marks, install cover and nuts (3). Torque nuts 65 to 75 lb.in.
(7.35-8.48 Nm).
NOTE:
WARNING:
12.
(7)
(8)
Removal
(1)
Disconnect aircraft fuel supply tube and remove associated nipple (Ref. AMM).
WARNING:
(2)
Disconnect impending bypass switches electrical harness connectors P35 and P36.
(3)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 431
Nov 04/2005
45
45
MASTER
KEYWAY
10
7
6
9
8
2
1
C63303
Fuel Pump Pressure Differential Switch - Removal/Installation
Figure 410
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 432
Nov 04/2005
B.
(4)
Remove electrical wiring harness and associated parts at brackets (11, 12) (Ref.
72-01-10, REMOVAL/INSTALLATION).
(5)
(6)
Remove fuel heater-to-fuel cooled oil cooler oil pressure tube (18) (Ref. 72-01-50).
(7)
(8)
Slide transfer tube (5) into fuel pump (7) clear of fuel heater.
(9)
Slide transfer tube (14) into fuel heater using pusher (PWC37303).
(10)
Remove bolts (8), washers (9), spacers (10), brackets (11, 12) and fuel heater (13).
(11)
Remove transfer tube (14) and packings (15) from heater. Discard packings.
(12)
Remove transfer tube (5) and packings (6) from fuel pump. Discard packings.
(13)
(14)
Installation
CAUTION: IF FUEL HEATER HAS BEEN STORED, FLUSH FUEL CIRCUIT WITH
CLEAN FUEL AND OIL CIRCUIT WITH CLEAN OIL (PWC03-001).
(1)
(2)
(3)
Lubricate packings (15) with oil (PWC03-001) and install on transfer tube (14).
Install transfer tube in fuel heater (13).
(4)
Install fuel heater, spacers (10), brackets (11, 12), washers (9) and bolts (8). Torque
bolts (8) 62 to 72 lb.in. (7.01-8.13).
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 433
Nov 04/2005
11
10
12
10
13
P37
8
16
17
19
P35
10
P36
8
15
10
14
9
15
18
7
6
5
6
4
3
2
C79712
Fuel Heater - Removal/Installation
Figure 411
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 434
Nov 04/2005
(5)
(6)
Install retaining plate (4), bracket (3) and bolts (2). Torque bolts 85 to 95 lb.in.
(9.61-10.74 Nm).
(7)
Lubricate packing (17) with engine oil (PWC03-001) and install on nipple (16).
(8)
(9)
(10)
(11)
Install nipple and associated aircraft fuel supply line (Ref. AMM).
(12)
Install electrical wiring harness and associated parts at brackets (11, 12) (Ref.
72-01-10, REMOVAL/INSTALLATION).
WARNING:
(13)
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 435
Nov 04/2005
13.
(14)
Install harness electrical connectors P35, P36, and P37 (Ref. 72-00-00,
MAINTENANCE PRACTICES and 72-01-10, ELECTRICAL SYSTEM
REMOVAL/INSTALLATION).
(15)
Fuel Waste Tubes, Motive Flow Pressure Fuel Tube Assembly and MFCU and Fuel Pump
Drain Tubes and Fuel Waste Ejector Assembly
A.
Fuel Waste Ejector Tube and Motive Fuel Flow Ejector Tube (Ref. Fig. 412)
(1)
Removal
(a) Remove nuts (10, 14, 19), bolts (9, 13, 18, 28), brackets (29, 30, 31, spacers
(15, 20), clamps (7, 11, 16, 26) and grommets (8, 12, 17, 27).
(b) Disconnect tube assembly (1, 21) at both ends and remove.
(c) Remove nipple (2) or elbow (4) as follows:
1
(d) If required, remove nut (24), washer (23) and elbow (22).
(2)
Installation
(a) Install nipple (2) or elbow (4) as follows:
1
Lubricate packing (3) with engine oil (PWC03-001) and install on nipple (2).
Install nipple, torque 65 to 75 lb.in. (7.35-8.48 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
Install elbow (4) (angle as shown), washer (5) and nut (6). Torque nut 38 to
42 lb.in. (4.29-4.75 Nm).
(b) If required, install elbow (22) (angle as shown), washer (23) and nut (24).
Torque nut 58 to 62 lb.in. (6.55-7.01 Nm).
(c) Install tube assembly (1). Torque tube nut at elbow (4) 90 to 100 lb.in.
(10.17-11.30 Nm). Secure with lockwire (PWC05-089) or (PWC05-295).
(d) Install tube assembly (21). Torque tube nut at elbow (22) 135 to 150 lb.in.
(15.26-16.95 Nm). Secure with lockwire (PWC05-089) or (PWC05-295).
(e) Torque tube nuts at cover (25) 270 to 300 lb.in. (30.51-33.90 Nm) and secure
with lockwire (PWC05-089) or (PWC05-295).
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 436
Nov 04/2005
(f)
Install grommets (12, 17), clamps (11, 16), spacers (15, 20), bracket (31), bolts
(13, 18) and nuts (14, 19). Torque nuts 36 to 40 lb.in. (4.07-4.52 Nm).
NOTE:
(g) Install grommets (8, 27), clamps (7, 26), bolts (9, 28), brackets (29, 30) and
nuts (10). Torque nuts 36 to 40 lb.in. (4.07-4.52 Nm).
NOTE:
B.
Include clamp of check valve air pressure tube at bolt (28) and wiring
harness clamps at brackets (29) and (30).
Removal
(a) Disconnect tube (1) at both ends and remove.
(b) Remove cap assembly (2), nut (3), and washer (4).
(c) Remove Tee (5).
(2)
Installation
(a) Install tee (5), washer (4), and nut (3). Torque nut 70 to 80 lbf.in. (8.0-9.0 Nm)
and secure with lockwire (PWC05-089) or (PWC05-295).
CAUTION: LUBRICATE TUBE ASSEMBLY FERRULE AND NUT THREAD,
USING A MINIMAL AMOUNT OF OIL (PWC03-001). THIS WILL
REDUCE STRESS ON THE TUBE ASSEMBLY. EXCESSIVE STRESS
CAN OCCUR WHEN THE FERRULE AND TUBE NUT THREADS
ARE NOT LUBRICATED.
CAUTION: HOLD ASSOCIATED FITTINGS FIRMLY IN POSITION WHEN
TORQUING TUBE NUTS.
(b) Lubricate ferrules and tube nuts using a minimal amount of oil (PWC03-001)
and install tube (1). Torque both ends 270 to 300 lb.in. (30.51-33.90 Nm).
Secure with lockwire (PWC05-089) or (PWC05-295).
(c) Install cap assembly (2). Torque cap assembly to 270 to 300 lbf.in.
(30.6-33.8 Nm). Secure with lockwire (PWC05-089) or (PWC05-295).
C.
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 437
Nov 04/2005
MUST BE WITHIN
11 DEG. 40 MIN. 1 DEG.
OF ENGINE AXIS
P5
P10
18
21
12
13
VIEW AT
11
31
MUST BE WITHIN
32 DEG. 35 MIN. 1 DEG.
OF ENGINE AXIS
12
1
15
11
20
25
17
16
27
26
3
19
9
27
14
10
10
21
26
26
27
P35
P36
P37
27
30
26
10
28
26
10
29
27
10
24
P33
9
A
VIEW FROM LEFT SIDE OF ENGINE
23
22
C63314A
Fuel Waste Ejector Tube and Motive Flow Ejector Tube Assemblies - Removal/Installation
Figure 412
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 438
Nov 04/2005
Tube Assembly
Nipple
Packing
Elbow
Washer
Nut
Clamp
Grommet
Bolt
Nut
Clamp
Grommet
Bolt
Nut
Spacer
Clamp
Grommet
Bolt
Nut
Spacer
Tube Assembly
Elbow
Washer
Nut
Cover
Clamp
Grommet
Bolt
Bracket
Bracket
Bracket
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 439
Nov 04/2005
2
3
4
C79488A
Motive Flow Pressure Fuel Tube Assembly - Removal/Installation
Figure 413
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 440
Nov 04/2005
Tube Assembly
Cap Assembly, Tube
Nut
Washer
Tee
72-01-40
FUEL SYSTEM - REMOVAL/INSTALLATION
Page 441/442
Nov 04/2005
General
A.
2.
These instructions provide the information necessary for the adjustment/test of engine
fuel system components.
Consumable Materials
Not Applicable
3.
Special Tools
Not Applicable
4.
5.
Leak Test
A.
Mechanical Fuel Control Unit, Fuel Pump, Oil to Fuel Heater, Flow Divider and Dump
Valve, Fuel Lines and Fuel Manifold..
(1)
Start engine, run for two minutes at 80% torque. Shut down engine (Ref. AMM).
(2)
(3)
72-01-40
FUEL SYSTEM - ADJUSTMENT/TEST
Page 501/502
Sep 03/99
General
A.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC11-002
PWC11-027
PWC11-031
PWC11-032
Special Tools
Special tools are identified in procedural text by part number in parentheses.
4.
Tool No.
Name
PWC54030
Tester
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 601
Mar 11/2005
Name
Spring compressor tester
Transparent tank (1.5 gal.) (5.7 liter)
5.
Inspection/Check
A.
General
(1)
(2)
(3)
(4)
B.
(2)
The bubble point test is not a cleaning procedure. The test is carried out
to ensure the filter body is undamaged and the element not punctured.
(a) Carry out a bubble point test as follows (Ref. Fig. 601):
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 602
Mar 11/2005
PRESSURE
GAGE
AIR
PRESSURE
INLET
AIR
REGULATOR
BLEED
VALVE
NEEDLE
VALVE
AIR
FILTER
MANOMETER
ELEMENT
ADAPTER
P1
P2
SOLVENT
TRANSPARENT
TANK
FILTER
ELEMENT
PLUG
VACUUM
SCALE
h = MANOMETER READING
P1= PRESSURIZED AIR
P2= ATMOSPHERIC AIR
P1
MANOMETER
FLUID
ALTERNATE TYPES
OF MANOMETERS
C32394
Fuel Heater Inlet and Pump Outlet Filter Element - Bubble Point Test
Figure 601
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 603
Mar 11/2005
WARNING:
Install element in fluid tank using a suitable plug to seal open end of core.
Maintain approximately 12 in. (12.70 mm) between fluid surface and filter
top during test.
Open air regulator until pressure gage reads 5 to 6 psig (34.47-41.37 kPa).
Open needle valve and gradually increase air pressure until manometer
reading is equivalent to 4.5 in. (114.3 mm) of water for the fuel pump
outlet filter, or 2.5 in. (63.5 mm) for the fuel heater inlet filter. No bubbles
must escape from filter mesh before these values are exceeded.
NOTE:
Check bore seals if bubbles escape from locations other than the
filter mesh before the 4.5 in. (114.3 mm) and 2.5 in. (63.5 mm)
values, as applicable, are exceeded.
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 604
Mar 11/2005
10
C.
D.
Rotate element slowly and watch for air bubbles. If no bubble stream
appears, increase pressure by opening needle valve. When a stream
of bubbles appears, reduce pressure until bubbles stop, then slowly increase
pressure until bubble stream begins again. The manometer reading is the
difference between lower and upper level of fluid, or twice the distance from
fill line to fluid line after pressurization. The reading when the stream
begins must be 4.5 in. (114.3 mm) (fuel pump outlet filter) or 2.5 in.
(63.5 mm) (fuel heater inlet filter) of water, minimum. Replace filter element
if these requirements are not met.
(1)
(2)
Switch
(a) Check continuity using ohmmeter; resistance between pins B and C (open
circuit), minimum 2 megohms at 45 volts DC or AC.
(b) Check insulation using test set; resistance between pins and backshell,
minimum 2 megohms at 45 volts DC or AC.
(2)
Housing
(a) Visually inspect for cracks in metal surfaces, paying particular attention to
mounting lugs. Replace heater if any cracks are found.
(b) Visually inspect for cracks in flame-retardant coating (where applicable). Cracks
are acceptable providing:
NOTE:
E.
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 605
Mar 11/2005
(a) Resistance between pins A and B (open circuit): minimum 2 megohms (infinite)
at 45 volts AC or DC.
(2)
F.
Drain Valve
(1)
(2)
Transfer Tubes
(1)
I.
Inspect for fretting. Fretting on tubes is allowed on the shoulder, but the maximum
allowable on the tube itself is 0.008 in. (0.203 mm). Replace tubes if fretting limit is
exceeded.
(3)
(4)
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 606
Mar 11/2005
(5)
(6)
J.
General
NOTE:
The following values from the Component Maintenance Manual (CMM) for
zero time fuel nozzles are provided here strictly for reference purposes.
(a) The acceptance limits and test setup for fuel nozzles are outlined in the Fuel
Nozzle CMM.
(b) The flow requirements for the ten Hybrid Fuel Nozzles are:
1
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 607
Mar 11/2005
(c) The flow requirements for the three Secondary and one Inlet Fuel Nozzles are:
1
(d) The above values from the CMM for zero time nozzles are for reference only
and must not be used for sampling purposes.
(3)
Primary Jets: For each nozzle, flow test as per CMM instructions and record
fuel flow number.
Secondary Jets: For each nozzle, flow test as per CMM instructions and
record fuel flow number.
For each nozzle, flow test as per CMM instructions and record fuel flow
number.
(5)
(6)
Primary Jets: For each nozzle, spray quality test for streaking as per CMM
instructions and record results
Primary Jets: Eight of the ten recorded flows must be within 1.5
pph of the set average on the hybrid primary jets.
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 608
Mar 11/2005
50 o MIN.
MINIMUM
CONE ANGLE
C24920A
Fuel Nozzles - Spray Inspection Criteria
Figure 602
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 609
Mar 11/2005
All the pure secondary and inlet nozzles recorded flows must be within
2.0 pph of the set average on the secondary and inlet nozzle jets.
(7)
Primary spray cone: Eight of the ten nozzles must have a minimum cone
angle of 50 degrees.
Secondary spray cone: All fourteen secondary spray cones (on all ten
hybrids, three secondary and one inlet nozzles) must have a minimum cone
angle of 50 degrees.
(b) The maintenance interval is considered optimized if 80% of the fleet samples
meet the sampling criteria.
(c) An operator is recommended to adjust the maintenance interval in increments
not greater than 250 flight hours following a fleet sample.
TABLE 601, Example of Successful Nozzle Sampling
Primary
Flow
Primary
Spray
Quality
Primary
Cone Angle
Secondary
Flow
Secondary
Cone Angle
n/a
36.0
70
6.70
No heavy streaks
84
32.0
70
Blocked
No heavy streaks
32.5
65
n/a
37.0
60
7.64
No heavy streaks
102
32.1
90
7.76
No heavy streaks
95
31.0
72
8.21
No heavy streaks
88
30.0
77
Fuel Nozzle
Position No.
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 610
Mar 11/2005
Primary
Spray
Quality
Primary
Cone Angle
Secondary
Flow
Secondary
Cone Angle
n/a
38.0
59
7.21
No heavy streaks
97
31.0
60
10
7.78
No heavy streaks
80
31.5
64
11
7.46
No heavy streaks
88
30.0
72
12
n/a
37.5
78
13
5.56
No heavy streaks
76
30.5
80
14
6.92
No heavy streaks
91
30.4
90
Fuel Nozzle
Position No.
8 (Inlet)
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 611
Mar 11/2005
Primary
Flow
Secondary Spray
Cones:
K.
L.
Primary
Spray
Quality
Primary
Cone Angle
Secondary
Flow
Secondary
Cone Angle
Examine lip and associated face (Ref. View B) for erosion and burnt material.
Replace adapter if damage on lip exceeds 0.005 in. (0.127 mm) and on face
0.020 in. (0.508 mm).
(2)
Visually check sheath for erosion and burnt material (Ref. Area L) (indication of
spray pattern distortion). Replace adapter if parent material loss is evident.
(3)
Visually check primary and secondary air and fuel passages for carbon deposits.
Replace adapter if carbon deposits are found.
(4)
Inspect for fretting on sheath - acceptable to 0.020 in. (0.508 mm) deep.
(5)
Inspect transfer tube bores for fretting. Replace adapter if fretting exceeds 0.005 in.
(0.127 mm) deep.
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 612
Mar 11/2005
A
SECTION
A-A
C32600
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 613
Mar 11/2005
AREA
L
0.020 IN.
(0.508 mm)
MAX.
NO PITTING IN
THIS AREA
ALLOWED
LIGHT PITTING
UP TO 0.010 IN.
(0.254 mm)
ACCEPTED
PARENT
MATERIAL
LOSS
AIR CAP
C21390
Fuel Manifold Adapters (Delavan) - Dimensional/Visual Checks
Figure 603 (Sheet 2)
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 614
Mar 11/2005
DETAIL
0.006 IN.
(0.152 MM)
MAX.
C21391
Fuel Manifold Adapters (Delavan) - Dimensional/Visual Checks
Figure 603 (Sheet 3)
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 615
Mar 11/2005
(g) Inspect for exposed, broken or protruding wire overbraid material. If the wire
overbraid material is exposed, broken or protruding, reject the flexible fuel
manifold.
(2)
In Zone A, when hose material loss, nicks, cuts or scratches are less than 0.750 in.
(19.05 mm) in length, the fuel manifold hose can be repaired (Ref. Approved
Repairs).
(3)
In Zone B, when hose material loss, nicks, cuts or scratches are less than 0.750 in.
(19.05 mm) in length, and the wire overbraid is not exposed, the fuel manifold hose
can be repaired (Ref. Approved Repairs).
NOTE:
(4)
Do not attempt to repair a fuel manifold hose that has the wire overbraid
material exposed.
Rejected fuel manifolds that are outside of the repair limits above, can be returned
to the address below for evaluation and possible proprietary repair:
Pratt & Whitney Canada
333 Rue dAuvergne (Area 2K)
Longueuil, Quebec
Canada J4H 3Y3
TEL: (450) 442-6837
FAX: (450) 442-6810
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 616
Mar 11/2005
FUEL MANIFOLD
FITTING (REF.)
ZONE A
ZONE B
C97100A
Flexible Fuel Manifold Hose - Inspection/Check
Figure 604
72-01-40
FUEL SYSTEM - INSPECTION/CHECK
Page 617/618
Mar 11/2005
General
A.
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-050
PWC07-008
PWC11-002
PWC11-003
PWC11-010
PWC11-024
PWC11-027
PWC11-031
PWC11-032
PWC11-033
PWC11-054
PWC11-055
Nitrogen
Paint, Thermal Insulating Coating
Trichloroethane 1-1-1 (Inhibited)
Cleaning Agents (Biodegradable)
Methanol
Solvent, Methylene Chloride
Solvent, Petroleum
Cleaner, Engine Parts
Solvent, Degreasing
Cleaner, Aqueous
Cleaner, Aqueous (Low Foam)
Degreasing, Aqueous (Wax Remover)
Special Tools
Special tools are identified in procedural text by part number in parentheses.
4.
Tool No.
Name
PWC32677-300
Remarks
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 701
Mar 11/2005
Name
Remarks
Ultrasonic cleaner
Back-flushing fixture
5.
Cleaning
A.
General
WARNING:
WARNING:
(1)
With the exception of items specifically mentioned, clean all parts with petroleum
solvent (PWC11-027) or cleaner (PWC11-031) or solvent (PWC11-032) and blow
dry with clean, low pressure compressed air.
NOTE:
B.
Fuel Filters
NOTE: 1. The following instructions apply to cleanable filters only. Filters marked NON
CLEANABLE must not be cleaned.
NOTE: 2. P&WC is unable to supply a specific number of times a filter element can be
cleaned before it is replaced. This number is dependent on the engine
operating conditions. The number of filter element cleanings is based on the
Operators experience, as well as the cleaning and inspection process. It
is possible that an impending by-pass indication may result prior to the next
scheduled filter element removal because of the filter element serviceability.
NOTE: 3. There are three acceptable methods to clean the fuel filters. The first method
is the preferred and most efficient method, with the other two as alternatives:
(1)
Ensure packings, if fitted, are removed from bore of filter element and
discarded.
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 702
Mar 11/2005
WARNING:
Spray flush filters from the outside to the inside with aqueous cleaner
solution (PWC11-054), heated at 57 to 63 C (135-145F) with a maximum
pressure of 30 PSIG.
Remove from bath and carefully remove a plug from one end of the filter.
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 703
Mar 11/2005
Using protective gloves, back-flush the filter (from the inside to the outside)
and rotate filter element 90 degrees after each three minutes of cleaning
operation, while providing 1 to 3 gallons per minute at 30 PSIG Max. for ten
minutes Min.
Remove the back-flush fixture and filter element from tank and with
protective glooves remove the filter.
Using protective gloves, carefully remove all remaining plugs from bore.
WARNING:
(2)
Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(c) Immerse the filter element in cleaner (PWC11-031) for 30 minutes Min.
Maintain temperature at 21C (70F) or heat cleaner to 45C (113F) Max.
WARNING:
(d) Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(e) Spray flush filters with aqueous cleaner (PWC11-033), heated at 21C (70F),
using one part cleaner to three parts water.
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 704
Mar 11/2005
WARNING:
(f)
Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(h) Fill tank to approximately 14 in. (6.350 mm) below edge with degreaser solvent
(PWC11-032).
(i)
(j)
(k) Using protective gloves, immerse the filter element horizontally in the ultrasonic
or electrosonic bath
(l)
Back-flush the filter element using 1 to 3 gallons per minute (3.78-11.35 liters)
at 30 psig (206.9kPa) for ten minutes, rotating filter 180 degrees while
back-flushing.
(m) Using protective gloves, remove element from tank and plugs from bore.
WARNING:
(n) Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(o) Inspect filter element (Ref. Inspection/Check).
(3) METHOD 3: Ultrasonic clean filter using solvent (PWC11-002) (Alternative Method)
NOTE:
(a) Ensure packings, if fitted, are removed from bore of filter element and discarded.
CAUTION: FAILURE TO PLUG CENTER OF THE FILTER ELEMENT CAN
RESULT IN CONTAMINATION OF THE INTERIOR. FUEL FLOW IS
FROM THE OUTSIDE TO THE INSIDE, THE INTERIOR BEING THE
CLEAN SIDE.
(b) Plug the centers of the filter element by inserting a tapered rubber or plastic
plugs of the appropriate size into the bores.
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 705
Mar 11/2005
(d) Fill tank to approximately 14 in. (6.350 mm) below edge with solvent
(PWC11-002).
(e) Operate the cleaner for 10 to 15 minutes. Use protective gloves, rotate the filter
element 90 degrees after every three minutes of cleaning operation.
(f)
Remove the filter element from the tank and install on a back-flush fixture.
C.
(i)
Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(j)
(2)
WARNING:
(3)
Dry screen with clean filtered air at 29 psig (200 kPa) maximum.
(4)
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 706
Mar 11/2005
D.
6.
(1)
Clean the outside surface of the fuel manifold hose per SPOP 209 (wiping method
only).
(2)
Remove all old packing material from the adapter packing groove using petroleum
solvent (PWC11-027) and be careful to not scratch the surfaces. Do not let debris
enter the fuel passages.
(3)
Manually wipe the external surfaces of the fuel manifold to remove all foreign
material using a soft brush or a lint-free cloth.
General
CAUTION: IF YOU DO THIS OPTIONAL CLEANING METHOD, THE CLEANING
MUST START BETWEEN 150 AND 250 HOURS ON NEW OR
OVERHAULED NOZZLES USED IN NORMAL ENVIRONMENTS AND
WITHIN 100 HOURS IF USED IN HOT AND SALT LADEN ENVIRONMENTS.
(1)
(2)
(3)
After the wash, the adapters are rinsed of wash solution, using water or a
water/methanol (PWC11-010) solution, depending on the ambient temperature.
(4)
(5)
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 707
Mar 11/2005
(6)
The wash cart (PWC32677-300) operating schedule is given in Table 703. This
schedule contains all the valve positions necessary for the wash.
TABLE 701, Rinse Solutions
AMBIENT TEMPERATURE
WATER
% BY VOL.
METHANOL
% BY VOL.
+2C up
+36F up
100
Nil
-25 to +2C
-13 to +36F
50
50
Below -25C
Below -13F
40
60
TABLE 702, Biodegradable Wash Solutions (Ardrox 6367 (Turboclean 2), B & B TC100,
R-MCS-G21 and ZOK27)
AMBIENT TEMPERATURE
CLEANING
AGENT
% BY VOL.
METHANOL
% BY VOL.
WATER
% BY VOL.
+2C up
+36F up
20
Nil
80
-25 to +2C
-13 to +36F
20
30
50
Below -25C
Below -13F
20
40
40
NOTE: Ardrox 6368 (Turboclean 2 RTU) is used undiluted at temperatures above +2C (36F).
This product must not be used below this temperature.
TABLE 703, Wash Cart (PWC32677-300) Operating Schedule
VALVE POSITION
OPERATION
AGITATE
AGITATE
OFF
WASH
WASH
ON
OFF
OFF
OFF
WASH
WASH
ON
OFF
OFF
OFF
RINSE
RINSE
ON
OFF
OFF
OFF
(7)
Depending upon the operating environment, the nature and frequency of washing is
recommended to be in accordance with Table 704.
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 708
Mar 11/2005
Initial
Subsequent
Remarks
100 FH
100 FH
Other Normal
Environments
150-250 FH
150-250 FH
B.
Equipment Required
(1)
(2)
C.
Depending upon the ambient temperature, fill rinse-and-wash tanks with appropriate
rinse and wash solutions (Ref. Tables 701 and 702).
(2)
Disconnect tubes at combustion chamber and turbine support case drains (Ref.
AMM).
(3)
Install suitable drain hoses at combustion chamber and turbine support case drains.
(4)
Disconnect drain line from flow divider and dump valve (Ref. AMM).
(5)
Connect wash cart fluid delivery hose to outlet of dump valve, using suitable quick
disconnect fitting set (0.4375-20 UNF).
Before washing, ensure engine temperature is below 65C (150F) by one of the
following methods:
(a) Allow engine time to cool down (40 minutes minimum), or;
CAUTION: ENGINE MUST BE AT REST AT LEAST 40 MINUTES PRIOR TO
WATER INJECTION TO PREVENT THERMAL SHOCK AND
RESULTING DAMAGE.
(b) Carry out a dry motoring run (Ref. AMM) and inject demineralized water
through the wash nozzle.
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 709
Mar 11/2005
(8)
Set reservoir pressure to 60 psig (413 kPa), using reservoir air regulator.
(9)
Set pulse pressure to 70 psig (483 kPa), using pulse air regulator.
(10)
(11)
(12)
Disconnect wash cart fluid delivery hose from outlet of dump valve.
(13)
Connect drain line to flow divider and dump valve (Ref. AMM).
(14)
Remove drain hoses at combustion chamber and turbine support case drains.
(15)
Connect tubes at combustion chamber and turbine support case drains (Ref. AMM).
Carry out an engine run, at 80% torque for one minute minimum, to completely dry
engine(Ref. AMM).
Painting
A.
(1)
(2)
(3)
Inspect treated surface and ensure that damaged area is completely covered.
Recoat as necessary.
(4)
Fuel heaters must be allowed to air dry at room temperature for an additional
12-hour period minimum.
72-01-40
FUEL SYSTEM - CLEANING/PAINTING
Page 710
Mar 11/2005
General
A.
These instructions provide the information necessary to achieve the approved repairs of
components of the engine fuel system.
B.
C.
WARNING:
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC05-019
PWC05-037
PWC05-061
PWC05-089
PWC05-101
PWC05-161
PWC05-295
PWC05-390
PWC08-016
PWC09-017A
PWC11-014
PWC11-019
PWC13-001
Oil, Engine
Compound, Lapping
Enamel, Epoxy
Cloth, Abrasive, Coated, Crocus
Lockwire
Cloth, Abrasive (320 grit)
Solution, Chromel Pickle
Lockwire (may be used instead of PWC05-089)
Tube Wrap
Epoxy, Adhesive Paste
Adhesive/Sealant
Isopropyl Alcohol
Solution, Chromate Conversion
Primer, Epoxy
Special Tools
Not Applicable
4.
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 801
Mar 11/2005
Name
Dies
File
Files, Rotary
Gun, Heating, (temperature range minimum 300F (149C) to maximum 450F (232C))
Plate, Lapping
Swiss Files
Taps
5.
Approved Repairs
A.
Tubes
(1)
B.
C.
(1)
Remove wire (2) from nut (1). Discard nut and wire.
(2)
Do the steps that follow to repair the fuel manifold hose in zones A and/or B (Ref.
Fig. 802):
NOTE:
This repair cannot be done on wing. The flexible fuel manifold must be
removed from the engine.
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 802
Mar 11/2005
(a) Clean the fuel manifold hoses thoroughly before you do the repair (Ref.
Cleaning/Painting).
(b) Cover the repair location with a clean lint free cloth, and let the fuel manifold
hose dry for 20 minutes at room temperature.
(c) Re-inspect the repair location on the fuel manifold hose to make sure that the
damage does not exceeded the specified limits (Ref. Inspection/Check).
NOTE:
(Optional) Do the steps that follow to apply tube wrap (PWC05-390) on the fuel
manifold hose (Ref. Fig. 803):
NOTE:
This repair cannot be done on wing. The flexible fuel manifold must be
removed from the engine.
(a) Clean the fuel manifold hoses (3) thoroughly before you do the repair (Ref.
Cleaning/Painting).
(b) Place the flexible fuel manifold on a clean work bench.
(c) Remove the protective backing from both sides of the tube wrap (2)
(PWC05-390).
(d) Align the tube wrap (2) with the fuel manifold fitting (1) and fuel manifold hose
(3) as shown, and firmly press the short tabs up and around the fuel manifold
hose. Then, firmly press the long tabs down and around the fuel manifold
hose and overlap the short tabs.
(e) Using a heat gun (temperature range 300F (149C) to 450F (232C)), apply
heat to the tube wrap for 3 to 4 minutes until the tube wrap is fully cured.
NOTE:
D.
The tube wrap will change from a glossy orange to a matt orange when
cured.
Housings
(1)
Blend out nicks, burrs, scratches, pits and corrosion using 320 grit abrasive cloth
(PWC05-101) followed by polishing with crocus cloth (PWC05-061).
(2)
(3)
(4)
(5)
Dress mating surfaces using lapping plate and lapping compound (PWC05-019).
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 803
Mar 11/2005
C11214A
Super B Nut Replacement
Figure 801
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 804
Mar 11/2005
Nut
Wire
This will prevent contamination of the engine oil due to fuel migrating from
the aircraft fuel tank.
WARNING:
WARNING:
(2)
Carefully remove the retaining cap assembly (1) from the fuel heater (2).
NOTE:
(3)
As the last threads of the retaining cap disengage from the housing, spring
tension from the thermal valve spring can be felt through the retaining cap.
If this tension is not felt, then the fuel heater must be removed from the
engine (Ref. Removal/Installation) and inspected for free movement of the
thermal element (Ref. Stewart Warner SB10718-73-12 or 10839-73-07
and Component Maintenance Manuals 73-10-06 or 73-10-08).
Remove the thermal element (3) from the retaining cap (4) and packings (5, 6).
Discard the thermal element and packings.
NOTE:
Use Stewart Warner thermal element replacement parts kit P/N G726681.
(4)
Lubricate packing (5) with engine oil (PWC03-001) and install on retaining cap (4).
(5)
Lubricate packing (6) with engine oil (PWC03-001) and install on the thermal
element (3).
(6)
Immerse the thermal element assembly in cold water 2 to 8C (36 to 46F) to fully
retract the piston prior to assembly with the retaining cap.
CAUTION: MAKE SURE WHEN YOU DRY THE THERMAL ELEMENT NOT TO
DAMAGE THE PUSH ROD GUIDE .
(7)
Remove the thermal element from the water and dry with a clean lint free cloth.
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 805
Mar 11/2005
FUEL MANIFOLD
FITTING (REF.)
ZONE A
ZONE B
C97100A
Flexible Fuel Manifold Hose - Sealant Repair
Figure 802
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 806
Mar 11/2005
(8)
Install the thermal element counterclockwise in the retaining cap, until the thermal
element screws through the retaining cap thread and disengages. The thermal
element should then be able to move freely in the retaining cap.
NOTE:
Insert retaining cap assembly into the thermal element valve housing. Make sure
the cap is seated in the push rod guide and engages the hole in the sliding sleeve.
NOTE:
(10)
F.
Torque the retaining cap assembly 75 to 80 lb.in. (8.5-9.0 Nm) and lockwire
(PWC05-089) or (PWC05-295).
(2)
Using a small steel brush and/or file and/or rotary file (regulated at 40 psi), remove
corrosion from:
(a) The crosshatched areas shown on views A, B and Detail D (total area affected
must not exceed 50% of the surface over the arc of 120 degrees).
(b) Face C outside the crosshatched area shown in View A to a maximum depth of
0.050 in. (1.27 mm) (total area affected must not exceed 20% of the surface).
NOTE:
(3)
(4)
Adapters exceeding the limits after removal of the corrosion are unacceptable and
must be rejected.
WARNING:
(5)
(6)
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 807
Mar 11/2005
C100032
Flexible Fuel Manifold Hose - Tube Wrap Repair
Figure 803
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 808
Mar 11/2005
(7)
Dry thoroughly with clean low pressure compressed air at 29 psig (200 kPa).
(8)
WARNING:
(9)
(10)
Apply one coat of primer (PWC13-001) (may be diluted with 10% solvent) to
reworked areas. Allow 8 hours for air drying of primer before application of enamel
paint. Clean low pressure compressed air at 29 psig (200 kPa) may be used to
accelerate drying.
Apply two to three coats of aluminized epoxy enamel (PWC05-037) to primed
surface. Allow surface of enamel to become tacky between each coat. Allow final
coat of paint to dry for 24 hours before re-installing fuel pump adapter.
NOTE:
Drying times of primer and paint can be reduced by heating (use an oven
(temperature 60 to 82C (140-180F) for one hour) or a heat gun at the
low heat setting - see manufacturers instructions).
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 809
Mar 11/2005
2
5
3
4
C36520
Fuel Heater Thermal Element - Removal/Installation of
Figure 804
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 810
Mar 11/2005
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 811
Mar 11/2005
A
0.315 in.
(8.00 mm) MIN.
A
EPOXY FILLING
PERMITTED
60
60
VIEW
FACE
A
SECTION
.135 in REF.
(3.43 mm)
AA
60
EPOXY FILLING
PERMITTED
60
VIEW B
DETAIL
D
C38702A
72-01-40
FUEL SYSTEM - APPROVED REPAIRS
Page 812
Mar 11/2005
General
A.
These instructions provide information necessary for servicing components of the engine
oil system.
B.
Refer to 72-00-00, SERVICING, for draining, filling, flushing and replenishing engine oil.
C.
WARNING:
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC05-089
PWC05-295
Oil, Engine
Lockwire
Lockwire (may be used instead of PWC05-089)
Special Tools
Not Applicable
4.
5.
Removal
(1)
Remove plug (1) and drain oil into a container. Discard packing (2).
(2)
Remove nuts (3), washers (4), bracket (5), cover (6) and packing (7). Discard
packing.
(3)
Remove retaining ring (8) and filter (9) from cover (6). Discard packing (10).
(4)
72-01-50
OIL SYSTEM - SERVICING
Page 301
Mar 03/2000
10
8
9
6
5
12
3
11
2
1
4
3
C37181A
Pressure Oil Filter - Removal/Installation
Figure 301
72-01-50
OIL SYSTEM - SERVICING
Page 302
Jul 13/2001
B.
Plug
Packing
Nut
Washer
Bracket
Cover
Packing
Retaining Ring
Filter
Packing
Retaining Ring
Screen
Installation
(1)
Install screen (12) (concave face outward) and secure with retaining ring (11).
6.
(2)
Lubricate packing (10) with engine oil (PWC03-001) and install in filter (9).
(3)
(4)
(5)
Lubricate packing (7) with engine oil (PWC03-001) and install on cover (6).
(6)
Install cover (6), bracket (5), washers (4) and nuts (3). Torque nuts 75 to 85 lb.in.
(8.48-9.61 Nm).
(7)
Lubricate packing (2) with engine oil (PWC03-001) and install on plug (1). Install
plug, torque 65 to 75 lb.in. (7.35-8.48 Nm) and secure with lockwire (PWC05-089)
or (PWC05-295).
(8)
Removal
(1)
Remove nuts (1), washers (2), bracket (3), cover (4) and packing (5). Discard
packing.
72-01-50
OIL SYSTEM - SERVICING
Page 303
Mar 03/2000
6
9
7
2
1
C63455
RGB Scavenge Oil Filter - Removal/Installation
Figure 302
72-01-50
OIL SYSTEM - SERVICING
Page 304
Mar 03/2000
B.
Nut
Washer
Bracket
Cover
Packing
Retaining Ring
Filter
Spacer Ring
Packing
(2)
Remove retaining ring (6), filter (7) and spacer ring (8) from cover.
(3)
(4)
Installation
(1)
Lubricate packing (9) with engine oil (PWC03-001) and install on filter (7).
(2)
Install spacer ring (8) and filter (7) in cover (4) and secure with retaining ring (6).
(3)
Lubricate packing (5) with engine oil (PWC03-001) and install on cover.
(4)
Install cover (4), washers (2), bracket (3), and nuts (1). Torque nuts 32 to 36 lb.in.
(3.62-4.07 Nm).
(5)
72-01-50
OIL SYSTEM - SERVICING
Page 305/306
Mar 03/2000
General
A.
B.
Refer to 72-00-00, SERVICING, for draining, filling, flushing and replenishing the engine
oil.
WARNING:
WARNING:
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC04-001
PWC05-089
PWC05-295
PWC06-032
Oil, Engine
Grease, Synthetic
Lockwire
Lockwire (may be used instead of PWC05-089)
Compound, Anti-galling and Antiseize
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 401
Nov 09/2001
3.
Special Tools
Special tools are identified in procedural text by part number in parentheses.
4.
Tool No.
Name
PWC37093
PWC37303
PWC37614
PWC37651
PWC37728
PWC37952
PWC37953
PWC37981
Crimper
Pusher/Puller
Adapter
Puller
Puller
Puller
Puller
Puller
5.
Main Oil Tank Chip Collector , Strainer and Associated Parts (Ref. Fig. 401)
A.
Removal
WARNING:
(1)
Chip Detector
(a) If installed, disconnect electrical harness from chip detector (1).
(b) Remove chip detector (1).
NOTE: 1. Replacement of the chip detector packings (2) is only necessary if a
visual inspection (nicks, cuts, etc.) shows they are damaged.
NOTE: 2. Packing (3), located inside chip detector valve, is not normally
removed at maintenance.
(2)
Chip detector (1) and packings (2) are removed when oil is drained.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 402
Nov 09/2001
B.
Installation
(1)
Install valve. Torque 175 to 200 lb.in. (19.78-22.60 Nm) and secure with
lockwire (PWC05-089) or (PWC05-295).
(g) Lubricate packings (2) with engine oil (PWC03-001) and install on chip detector
(1).
CAUTION: AFTER INSTALLATION, ENSURE VISUALLY OR BY FEEL, THAT
SCALLOP ON CHIP DETECTOR IS IN LINE WITH FLAT ON CHIP
DETECTOR VALVE HEXAGON.
(h) Install detector (1). Rotate detector 90 degrees clockwise to locked position.
WARNING:
(2)
(i)
(j)
Chip Detector
(a) Lubricate packing (5) with engine oil (PWC03-001) and install on chip detector
valve (4).
(b) Install valve. Torque 175 to 200 lb.in. (19.78-22.60 Nm) and secure with
lockwire (PWC05-089) or (PWC05-295).
(c) Lubricate packings (2) with engine oil (PWC03-001) and install on chip detector
(1).
CAUTION: AFTER INSTALLATION, ENSURE VISUALLY OR BY FEEL, THAT
SCALLOP ON CHIP DETECTOR PLUG IS IN LINE WITH FLAT ON
CHIP DETECTOR VALVE HEXAGON.
(d) Install detector (1). Rotate detector 90 degrees clockwise to locked position.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 403
Nov 09/2001
6
7
4
5
8
9
10
11
TYPICAL
LOCKED POSITION
C38775
Main Oil Tank Chip Detector, Strainer and Associated Parts - Removal/Installation
Figure 401
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 404
Nov 09/2001
Chip Detector
Packing
Packing
Chip Detector Valve
Packing
Bolt
Washer
Adapter
Packing
Strainer
Packing
RGB Chip Detector, Strainer and Associated Parts (Ref. Fig. 402)
A.
Removal
WARNING:
(1)
Chip Detector
(a) Disconnect electrical harness from chip detector (1) (Ref. AMM).
(b) Remove chip detector (1).
NOTE: 1. Replacement of the chip detector packings (2) is only necessary if a
visual inspection (nicks, cuts, etc.) shows they are damaged.
NOTE: 2. Packing (3), located inside chip detector valve, is not normally
removed at maintenance.
(2)
Chip detector (1) and packings (2) are removed when oil is drained.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 405
Nov 09/2001
5
8
9
10
6
7
2
3
4
TYPICAL
LOCKED POSITION
C38774B
Reduction Gearbox Chip Detector, Strainer and Associated Parts - Removal/Installation
Figure 402
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 406
Nov 09/2001
Chip Detector
Packing
Packing
Chip Detector Valve
Packing
Nut
Washer
Adapter
Packing
Strainer
(e) Remove adapter (8) using puller (PWC37728). Discard packing (9).
(f)
B.
Installation
WARNING:
(1)
(e) Install chip detector valve. Torque 175 to 200 lb.in. (19.78-22.60 Nm). Secure
with lockwire (PWC05-089) or (PWC05-295).
(f)
Lubricate packings (2) with engine oil (PWC03-001) and install on chip detector
(1).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 407
Nov 09/2001
(i)
(2)
Chip Detector
(a) Lubricate packings (2) with engine oil (PWC03-001) and if required, install on
chip detector (1).
CAUTION: AFTER INSTALLATION, ENSURE VISUALLY OR BY FEEL, THAT
SCALLOP ON CHIP DETECTOR IS IN LINE WITH FLAT ON CHIP
DETECTOR VALVE HEXAGON.
(b) Install detector (1). Rotate plug 90 degrees clockwise to locked position.
(c) Connect electrical harness (Ref. AMM).
(d) Carry out a leak check (Ref. Adjustment/Test).
7.
Oil Pressure Differential Switches (Pressure and Scavenge) (Ref. Fig. 403)
A.
Removal
WARNING:
B.
(1)
(2)
Installation
(1)
(2)
Install switch and indicator, torque 45 to 55 lb.in. (5.09-6.22 Nm) and secure with
lockwire (PWC05-089) or (PWC05-295).
WARNING:
8.
(3)
(4)
(2)
(3)
Remove bolts (6) and plate (7). Raise transfer tube (4) using pusher/puller
(PWC37303) clear of pressure regulating valve assembly (1).
(4)
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 408
Nov 09/2001
(5)
Remove transfer tubes (2, 4) and packing (3, 5). Discard packings.
NOTE:
B.
Loosen nuts (19, 23, 25) and remove tee (18, 22), elbow (24), packings (21, 27,
29) and backup rings (20, 26, 28). Discard packings and backup rings.
WARNING:
(2)
Remove bolts (2, 3), washer (5), bracket (4), cover (1) using puller (PWC37651),
packing (6) and spacer(s) (7). Discard packing.
NOTE:
C.
For replacement of restrictor (30) and plug (31) (Ref. fig. 405), refer to
Approved Repairs.
(3)
(4)
Remove valve sleeve (12), using puller (PWC37952) and packings (10, 11). Discard
packings.
(5)
(6)
Assembly
(1)
Lubricate with engine oil (PWC03-001) packing (16) and install on sleeve cover
(15).
(2)
Install sleeve cover and retaining ring (14) in valve sleeve (12).
(3)
(4)
Lubricate packings (10, 11) with engine oil (PWC03-001) and install on sleeve (12).
(5)
(6)
Lubricate packing (6) with engine oil (PWC03-001) and install on cover (1).
(7)
Install spring sleeve (9), spring (8), spacer(s) (7), cover (1), bracket (4), washer (5)
and bolts (2, 3). Torque bolts 32 to 36 lb.in. (3.62-4.07 Nm) and safety with wire
(PWC05-089) or (PWC05-295).
NOTE:
(8)
To obtain correct oil pressure (Ref. 05-10-00), the number of spacers (7)
varies between one minimum and six maximum. Reassemble using the
original spacers (Ref. Subpara. B., step (2)) and adjust if necessary during
test (Ref. 72-00-00).
Install tees (18, 22), elbow (24), nuts (19, 23, 25), backup rings (22, 26, 28) and
packings (21, 27, 29) (Ref. 72-00-00, MAINTENANCE PRACTICES). Torque nuts
fingertight.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 409
Nov 09/2001
1
2
3
PRESSURE FILTER
2
3
SCAVENGE FILTER
C63442
Oil Pressure Differential Switches (Pressure and Scavenge) - Removal/Installation
Figure 403
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 410
Nov 09/2001
Switch
Packing
Packing
Lubricate packings (3, 5) with engine oil (PWC03-001) and install on transfer tubes
(2, 4), respectively.
(2)
Install transfer tube (2) in regulating valve (1) and transfer tube (4) in filter bypass
and relief valve housing, ensuring that both bottom in their respective bores.
(3)
Install regulating valve assembly (1), washers (8) and nuts (9). Torque nuts 32 to
36 lb.in. (3.62-4.07 Nm).
(4)
Lower transfer tube (4) into regulating valve assembly (1) and install plate (7) and
bolts (6). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
Lubricate ferrules and tube nuts using a minimal amount of oil (PWC03-001) and
loosely connect oil check valve tube at elbow (11). Torque nut 70 to 80 lb.in.
(8.0-9.0 Nm).
NOTE:
Torque tube nut 270 to 300 lb.in. (30.51-33.90 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
Lubricate ferrules and tube nuts using a minimal amount of oil (PWC03-001) and
loosely connect pressure sensing tube at tee (10). Torque nut 38 to 42 lb.in.
(4.29-4.75 Nm).
NOTE:
Torque pressure sensing tube nut 90 to 100 lb.in. (10.17-11.30 Nm) and secure with
lockwire (PWC05-089) or (PWC05-295).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 411
Nov 09/2001
4
6
7
5
3
3
8
9
10
11
12
C63448C
Oil Pressure Regulating Valve - Removal/Installation
Figure 404
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 412
Nov 09/2001
Removal
NOTE:
The pressure oil check valve is not adjustable in the field. The valve can be
replaced by a new or serviceable valve for troubleshooting or disassembled for
cleaning.
WARNING:
(1)
(2)
(3)
(4)
Remove pressure relief valve cover and filter element (Ref. Servicing).
(5)
(6)
(7)
Remove bolts (5), oil pressure valve assembly (6) and packing (7). Discard
packing.
(8)
Loosen nut (8) and remove elbow (9), packing (11), backup ring (10) and nut (8).
Discard packing and backup ring.
(9)
Remove nipples (12, 14) and packings (13, 15). Discard packings.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 413
Nov 09/2001
10
11
12
13
16
15
14
17
5
3
7
20
21
19
27
18
29
26
28
30
32
23
25
31
22
24
VIEW
C63449C
Oil Pressure Regulating Valve - Disassembly/Assembly
Figure 405
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 414
Nov 09/2001
Cover
Bolt (3022876)
Bolt (3116607-01)
Bracket
Washer
Packing
Spacer(s)
Spring
Sleeve
Packing
Packing
Valve Sleeve
Valve
Retaining Ring
Sleeve Cover
Packing
Housing
Tee
Nut
Backup Ring
Packing
Tee
Nut
Elbow
Nut
Backup Ring
Packing
Backup Ring
Packing
Restrictor
Plug
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 415
Nov 09/2001
1
9
8
10
11
7
17
18
19
20
22
21 23
25
13
24
12
15
14
16
2
FW
P32
C79705
Pressure Oil Check Valve - Removal/Installation
Figure 406
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 416
Nov 09/2001
B.
(10)
Remove bolts (16), cover (17), packing (18), washers (24), spring (19) and piston
(20). Discard packing. Record number of washers.
(11)
Remove sleeve (21) using puller (PWC37953), and packings (22, 23). Discard
packings.
Installation
(2)
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 417
Nov 09/2001
(3)
Install cover and bolts (16). Torque bolts 32 to 36 lb.in. (3.62-4.07 Nm) and secure
with lockwire (PWC05-089) or (PWC05-295).
(4)
Lubricate and install packings (13, 15) on nipples (12, 14), respectively.
(5)
Install nipple (12) and torque 110 to 120 lb.in. (12.43-13.56 Nm).
(6)
Install nipple (14) and torque 200 to 225 lb.in. (22.60-25.43 Nm).
(7)
Lubricate nut (8), backup ring (10), packing (11) and threads of elbow (9).
(8)
(9)
Lubricate packing (7) and install on oil pressure valve assembly (6).
(10)
Install valve assembly and bolts (5). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
Lubricate ferrule and tube nut threads with engine oil (PWC03-001) and connect
tube (3) nut. Torque 450 to 500 lb.in. (50.85-56.50 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
(12)
Lubricate ferrule and tube nut threads with engine oil (PWC03-001) and connect
tube (2) nut. Torque 270 to 300 lb.in. (30.51-33.90 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
(13)
Lubricate ferrule and tube nut threads with engine oil (PWC03-001) and loosely
connect tube (1) nut. Torque nut (8) 145 to 155 lb.in. (16.39-17.52 Nm).
NOTE:
Torque tube (1) nut 450 to 500 lb.in. (50.85-56.50 Nm) and secure with lockwire
(PWC05-089) or (PWC05-295).
(15)
(16)
Install pressure relief valve cover and filter element (Ref. Servicing).
(17)
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 418
Nov 09/2001
WARNING:
(18)
10.
(19)
(20)
Removal
(1)
Remove nut and bolt securing electrical harness to bracket (5) (Ref. 72-01-10).
(2)
Remove nut (1) and bolt (2) securing bracket (4) to support.
B.
(3)
(4)
Remove cover (6) and packing (7) using puller (PWC37651). Discard packing.
(5)
Remove spring (8), valve (9) and packing (10). Discard packing.
(6)
Remove sleeve (11) and packing (12) using puller (PWC37981). Discard packing.
Installation
(1)
(2)
Install sleeve.
(3)
(4)
(5)
(6)
Install cover, brackets (4, 5) and nuts (3). Torque nuts 32 to 36 lb.in. (3.62-4.07 Nm).
(7)
Install bolt (2) and nut (1) to secure bracket (4) to support. Torque nuts 36 to
40 lb.in. (4.07-4.52 Nm).
(8)
Install bolt and nut securing electrical harness to bracket (5) (Ref. 72-01-10).
(9)
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 419
Aug 13/2004
1
5
7
6
8
10
11
12
C63443
Filter Bypass and Relief Valve - Removal/Installation
Figure 407
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 420
Nov 09/2001
B.
12.
Nut
Bolt
Nut
Bracket
Bracket
Cover
Packing
Spring
Valve
Packing
Sleeve
Packing
Removal
(1)
(2)
Remove nuts (1, 4), washers (5), adapters (2, 6) and packings (3, 7). Discard
packings.
Installation
(1)
(2)
Orienting 4 degree angle as shown, install adapter and nuts (1); torque nuts 32 to
36 lb.in. (3.62-4.07 Nm).
(3)
(4)
Install adapter, washers (5) and nuts (4); torque nuts 32 to 36 lb.in. (3.62-4.07 Nm).
(5)
Removal
WARNING:
(a) Cut lockwire and loosen coupling nuts of tubes (11, 13, 14, 15).
(b) Remove nuts (1), bolts (2, 3, 4, 12), spacer (5) and clamp assemblies (9, 10).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 421
Nov 09/2001
RIGHT SIDE
A
1
HOLE A
HOLE
7
LEFT SIDE
5
6
4 DEGREES
VIEW AT
C69156
Oil Cooler and Heat Exchange Adapters - Removal/Installation
Figure 408
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 422
Nov 09/2001
Nut
Adapter
Packing
Nut
Washer
Adapter
Packing
(c) Remove nuts (16, 31), bolts (17, 33), and clamp assemblies (18, 30 32).
(d) Remove tube assemblies (11, 13, 14, 15), and gasket (6). Discard gasket.
(e) Remove transfer tube (7) and packings (8). Discard packings.
(2)
Installation
(a) Lubricate packings (8) and install on transfer tube (7).
(b) Install transfer tube into the installed long transfer tube in the turbine support
case.
NOTE:
Install tube assemblies (11, 13, 14 15). Do not torque tube nuts.
(g) Install clamp assemblies (9, 10, 18, 30, 32), spacer (5), bolts (2, 3, 4, 12) and
nuts (1). Do not torque nuts.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 423
Nov 09/2001
19
8
23
24
15
27
26
14
1
29
17
16
(REF.)
13
18
9
30
28
11
12
25
FW
1
33
32
31
10
20
(REF.)
13 (REF.)
22
34
35
21
DETAIL
DETAIL
C63440C
Oil Pressure Tubes - Removal/Installation
Figure 409
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 424
Nov 09/2001
Nut
Bolt
Bolt
Bolt
Spacer
Gasket
Transfer Tube
Packing
Clamp Assembly
Clamp Assembly
Tube Assembly
Bolt
Tube Assembly
Tube Assembly
Tube Assembly
Nut
Bolt
Bolt
Tube Assembly
Nut
Bolt
Clamp Assembly
Bolt
Packing
Tube Assembly
Tube Assembly
Bolt
Packing
Tee
Clamp Assembly
Nut
Clamp Assembly
Bolt
Thrust wire
Tube Coupling Nut
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 425
Nov 09/2001
(j)
Install bolts (17, 33) and nuts (16, 31). Torque nuts (17) 36 to 40 lb.in.
(4.07-4.52 Nm).
Torque tube nut on tube assembly (13, 14) 90 to 100 lb.in. (10.17-11.30 Nm).
Secure with lockwire (PWC05-089) or (PWC05-295).
Removal
(a) Disconnect clamps of electrical wiring harness (Ref. 72-01-10,
REMOVAL/INSTALLATION).
WARNING:
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 426
Nov 09/2001
(d) Remove bolts (23), tube assembly (19) and packing (24). Discard packing.
(2)
Installation
(a) Lubricate with engine oil (PWC03-001) and install packing (24) on tube
assembly (19).
CAUTION: LUBRICATE TUBE ASSEMBLY FERRULE AND NUT THREADS,
USING A MINIMAL AMOUNT OF OIL (PWC03-001). THIS WILL
REDUCE STRESS ON THE TUBE ASSEMBLY. EXCESSIVE STRESS
CAN OCCUR WHEN THE FERRULE AND TUBE NUT THREADS
ARE NOT LUBRICATED.
CAUTION: HOLD ELBOW SECURELY IN POSITION WHEN TORQUING TUBE
NUT.
(b) Lubricate ferrule and tube nut thread using a minimum amount of oil
(PWC03-001) and install tube assembly (19) and bolts (23). Torque tube nut
450 to 500 lb.in. (50.85-56.60 Nm) and secure with lockwire (PWC05-089) or
(PWC05-295). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
(c) Install clamp assembly (22), bolt (21) and nut (20). Torque nut 36 to 40 lb.in.
(4.07-4.52 Nm).
NOTE:
No. 1 and 2 Bearing Oil Pressure Tube Assembly (Ref. Fig. 409)
(1)
Removal
WARNING:
Installation
(a) Lubricate packing (28) with engine oil (PWC03-001) and install on tube
assembly (26).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 427
Nov 09/2001
Fuel Heater to Fuel-cooled Oil Cooler Oil Tube Assembly (Ref. Fig. 410)
(1)
Removal
(a) Remove mechanical fuel control (MFC) and pump assembly (Ref. 72-01-40,
REMOVAL/INSTALLATION).
(b) Remove bolt (5) and clamp assembly (4).
(c) Disconnect tube (2) at oil cooler.
(d) Remove nuts (3), tube assembly and packing (1). Discard packing.
(2)
Installation
(a) Lubricate packing (1) with engine oil (PWC03-001) and install on tube (2).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 428
Nov 09/2001
(d) Install mechanical fuel control (MFC) and pump assembly (Ref. 72-01-40,
REMOVAL/INSTALLATION).
(e) Carry out a leak check (Ref. Adjustment/Test).
E.
Fuel-cooled Oil Cooler to RGB Oil Tube Assembly (Ref. Fig. 411)
(1)
Removal
(a) Remove nut (6), bolt (5) and clamp assembly (4).
(b) Remove nuts (3), bracket (7), tube assembly (2) and packing (1). Discard
packing.
(2)
Installation
(a) Lubricate packing (1) with engine oil (PWC03-001) and install on tube
assembly (2).
CAUTION: LUBRICATE TUBE ASSEMBLY FERRULE AND NUT THREADS,
USING A MINIMAL AMOUNT OF OIL (PWC03-001). THIS WILL
REDUCE STRESS ON THE TUBE ASSEMBLY. EXCESSIVE STRESS
CAN OCCUR WHEN THE FERRULE AND TUBE NUT THREADS
ARE NOT LUBRICATED.
(b) Lubricate ferrule and tube nut threads using a minimal amount of oil and install
tube assembly, bracket (7) and nuts (3). Torque tube nut fingertight and nuts 36
to 40 lb.in. (4.07-4.52 Nm).
(c) Install clamp (4), bolt (5) and nut (6). Torque nut 36 to 40 lb.in. (4.07-4.52 Nm).
CAUTION: HOLD ADJACENT FITTING SECURELY IN POSITION WHEN
TORQUING TUBE NUT.
(d) Torque tube nut at fuel-cooled oil cooler 650 to 700 lb.in. (73.45-79.10 Nm) and
elbow nut 190 to 210 lb.in. (21-24 Nm). Secure with lockwire (PWC05-089) or
(PWC05-295).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 429
Nov 09/2001
B
2
2
3
VIEW
VIEW
B
C17581A
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 430
Nov 09/2001
Packing
Tube Assembly
Nut
Clamp Assembly
Bolt
Removal
(a) Remove mechanical fuel control and pump assembly (Ref. 72-01-40,
REMOVAL/INSTALLATION).
(b) Remove bolts (2), tube assembly (3) and packings (1). Discard packings.
(2)
Installation
(a) Lubricate packings (1) and install on tube assembly (3).
(b) Install tube assembly and bolts (2). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
(c) Install mechanical fuel control and pump assembly (Ref. 72-01-40,
REMOVAL/INSTALLATION).
(d) Carry out a leak check (Ref. Adjustment/Test).
G. Low and Main Oil Pressure Sensing Tube Assemblies (Ref. Fig. 413)
(1)
Removal
(a) Remove nuts (3, 9), spacer (4), bracket (11) and bolts (5, 6, 10) from tube
assembly (7).
WARNING:
(b) Cut lockwire and disconnect coupling nuts from tubes (1, 2, 7).
(c) Remove tube assemblies (1, 2, 7).
(d) Remove clamps (8) from the tube.
(e) Remove nuts (14, 18), tees (13, 17), backup rings (15, 19) and packings (16,
20). Discard packings.
(2)
Installation
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 431
Nov 09/2001
DETAIL
A
2
4
A
6
C63317
Fuel-cooled Oil Cooler to RGB Oil Tube Assembly - Removal/Installation
Figure 411
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 432
Nov 09/2001
Packing
Tube Assembly
Nut
Clamp Assembly
Bolt
Nut
Bracket
(a) Install tees (13, 17), nuts (14, 18), backup rings (15, 19) and packings (16,
20) according to standard procedure (Ref. 72-00-00, STANDARD
PRACTICES). Torque nuts fingertight.
CAUTION: LUBRICATE TUBE ASSEMBLY FERRULE AND NUT THREADS,
USING A MINIMAL AMOUNT OF OIL (PWC03-001). THIS WILL
REDUCE STRESS ON THE TUBE ASSEMBLY. EXCESSIVE STRESS
CAN OCCUR WHEN THE FERRULE AND TUBE NUT THREADS
ARE NOT LUBRICATED.
(b) Lubricate ferrule and tube nut threads using a minimal amount of oil and install
tube assembly (7). Torque fingertight.
(c) Install bracket (11), bolt (10) and nut (9) on clamp (12). Torque nut 36 to
40 lbf.in. (4.07-4.52 Nm).
(d) Install clamps (8) on tube assembly (7).
(e) Install bolt (5), nut (3), and secure clamp (8) to bracket (11). Torque nut 36 to
40 lbf.in. (4.07-4.52 Nm).
(f)
Install bolt (6), spacer (4) and nut (3), and secure clamp (8) to bracket. Torque
nuts 36 to 40 lbf.in. (4.07-4.52 Nm).
(j)
Secure nuts (14, 18) and tube nuts for tube assemblies (1, 2, 7) with lockwire
(PWC05-089) or (PWC05-295).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 433
Nov 09/2001
C14804
Rear Inlet Case Oil Pressure Tube - Removal/Installation
Figure 412
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 434
Nov 09/2001
Packing
Bolt
Tube Assembly
Removal
(a) Remove airframe component, as required, at bracket (10).
(b) Disconnect oil pressure tube at clamp assembly (9) (Ref. Para. 12. A.) and
wiring harness (Ref. 72-01-10).
(c) Remove bolts (6).
(d) Slide adapters (4) along tube assemblies (7, 8).
(e) Remove tube assemblies.
(f)
(2)
Remove packings (2, 3, 5), adapters (4), clamp assembly (9) and collars (1)
from tube assemblies. Discard packings.
Installation
(a) Install collars (1) on tube assemblies (7, 8).
NOTE:
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 435
Nov 09/2001
6
7
5
2
11
10
17
18
19
12
20
16
15
14
13
1
C69456B
Low and Main Oil Pressure Sensing Tube Assemblies - Removal/Installation
Figure 413
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 436
Nov 09/2001
Tube Assembly
Tube Assembly
Nut
Spacer
Bolt (MS9556-06)
Bolt (MS9208-10)
Tube Assembly
Clamp
Nut
Bolt (MS9556-06)
Bracket
Clamp
Tee
Nut
Ring, Backup
Packing
Tee
Nut
Ring, Backup
Packing
Removal
(a) Remove nuts (9), bolts (8, 10) and clamps assemblies (7).
(b) Remove bolts (6), tube assembly (4), gasket (5) and packing (3). Discard
packing and gasket.
(c) Remove transfer tube (2) and packings (1). Discard packings.
(2)
Installation
(a) Lubricate packings (1) and install on transfer tube (2).
(b) Install transfer tube (2) into the installed long transfer tube in the turbine
support case.
CAUTION: MAKE SURE NOT TO DAMAGE THE PACKING ON THE SMALL
TRANSFER TUBE WHEN YOU INSTALL THE GASKET.
(c) Install gasket (5) over transfer tube (2) up to the face of the long transfer tube
in the turbine support case.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 437
Nov 09/2001
1
3
7
4
6
6
3
9
1
5
4
10
C63318
No. 3, 4 and 5 Bearing Oil Scavenge Tubes - Removal/Installation
Figure 414
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 438
Nov 09/2001
Collar
Packing
Packing
Adapter
Packing
Bolt
Tube Assembly
Tube Assembly
Clamp Assembly
Bracket
Install clamps (7), bolts (8, 10) and nuts (9). Torque nuts 36 to 40 lb.in.
(4.07-4.52 Nm).
NOTE:
Removal
(a) DELETED
(b) Remove nut (9), bolt (8) and clamp assembly (7).
(c) Remove bolts (5, 6), tube assembly (3), retaining plate (4) and packings (1, 2).
Discard packings.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 439
Nov 09/2001
1
2
3
10
5
7
9
6
C38472A
No. 6 and 7 Bearing Oil Scavenge Tube - Removal/Installation
Figure 415
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 440
Nov 09/2001
Packing
Transfer Tube
Packing
Tube Assembly
Gasket
Bolt
Clamp Assembly
Bolt
Nut
Bolt
Installation
(a) Lubricate packings (1, 2) and install on tube assembly (3).
(b) Install tube assembly, retaining plate (4), and bolts (5, 6). Torque bolts (5) 36 to
40 lb.in. (4.07-4.52 Nm) and bolt (6) 85 to 95 lb.in. (9.61-10.74 Nm).
(c) Install clamp assembly (7), bolt (8) and nut (9). Torque nut 36 to 40 lb.in.
(4.07-4.52 Nm).
(d) DELETED
(e) Carry out a leak check (Ref. Adjustment/Test).
14.
Removal
(a) Remove nut (1), washer (2), bolt (4), spacer (3), , and clamp assembly (10).
WARNING:
(c) Cut lockwire and remove blankets (11, 12, 13, 14).
(d) Remove bolts (5, 6), tube assembly (7) and gaskets (8, 9). Discard gaskets.
(2)
Installation
(a) Install gaskets (8, 9), tube assembly (7) and bolts (5, 6). Torque bolts (6) 85 to
95 lb.in. (9.61-10.64 Nm) and bolts (5) 36 to 40 lb.in. (4.07-4.52 Nm).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 441
Aug 13/2004
7
8
C17611B
Reduction Gearbox Oil Scavenge Tube - Removal/Installation
Figure 416
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 442
Nov 09/2001
Packing
Packing
Tube Assembly
Retaining Plate
Bolt
Bolt
Clamp Assembly
Bolt
Nut
DELETED
(b) Install blankets (11, 12, 13, 14). Secure with lockwire (PWC05-089) or
(PWC05-295).
(c) Install clamp assembly (10), bolt (4), spacer (3), , washer (2) and nut (1).
Torque nut 36 to 40 lb.in. (4.07-4.52 Nm).
(d) Install cap (15). Secure with lockwire (PWC05-089) or (PWC05-295).
B.
Removal
(a) Remove nuts (9), clamp assemblies (7, 11) and bolts (8, 10, 12).
(b) Remove nuts (6), tube assembly (4), gasket (5) and packing (3). Discard
packing and gasket.
(c) Remove transfer tube (2) and packings (1). Discard packings.
(2)
Installation
(a) Lubricate packings (1) and install on transfer tube (2).
(b) Install transfer tube (2) into the installed long transfer tube in the turbine
support case.
CAUTION: MAKE SURE NOT TO DAMAGE THE PACKING ON THE SMALL
TRANSFER TUBE WHEN YOU INSTALL THE GASKET.
(c) Install gasket (5) over transfer tube (2) up to the face of the long transfer tube
in the turbine support case.
(d) Lubricate packing (3) and install on tube assembly (4).
NOTE:
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 443
Aug 13/2004
3
9
10
4
15
13
14
11
7
12
USE 3 TO 5 FULL
TURNS OF LOCKWIRE
FOR EACH PAIR
OF EYELETS
C68202
No. 5 Bearing Vent Tube - Removal/Installation
Figure 417
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 444
Nov 09/2001
Nut
Washer
Spacer
Bolt
Bolt
Bolt
Tube Assembly
Gasket
Gasket
Clamp Assembly
Blanket
Blanket
Blanket
Blanket
Cap
Install clamp assemblies (7, 11), bolts (8, 10, 12) and nuts (9). Torque nuts 36
to 40 lb.in. (4.07-4.52 Nm).
NOTE:
15.
No. 6 and 7 Bearing Pressure, Vent and Scavenge Transfer Tubes (Ref. Fig. 419)
A.
Removal
(1)
Remove No. 6 and 7 bearing pressure, scavenge and vent tubes (Ref. Paras. 12.
A., 13. B. and 14. B.).
(2)
Remove No. 6 and 7 bearing pressure (1), vent (2) and scavenge (3) transfer
tubes.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 445
Nov 09/2001
9
12
4
11
9
10
9
8
1
7
2
13
5
4
C38365A
No. 6 and 7 Bearing Vent Tube - Removal/Installation
Figure 418
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 446
Nov 09/2001
Packing
Transfer Tube
Packing
Tube Assembly
Gasket
Nut
Clamp Assembly
Bolt
Nut
Bolt
Clamp Assembly
Bolt
T6 Harness/Bracket Assembly
Remove retaining rings (4), plates (5), seal rings (6) and gaskets (7, 9) from
transfer tubes. Discard seal rings and gaskets.
Installation
(1)
Install gaskets (9) on pressure oil transfer tube (1) and scavenge oil transfer tube
(3).
NOTE:
Install gaskets (7) on transfer tubes (1, 2, 3), using crimper (PWC37093).
(3)
Install seal rings (6), plates (5), and retaining rings (4) on transfer tubes.
(4)
Install strainer (8) in transfer tube (1), using a small amount of grease (PWC04-001)
to retain strainer in position.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 447
Nov 09/2001
2
6
5
4
VIEW A
8
9
1
4
6
7
4
6
5
1
3
C30163A
No. 6 and 7 Bearing Pressure, Vent and Scavenge Transfer Tubes - Removal/Installation
Figure 419
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 448
Nov 09/2001
Transfer Tube
Transfer Tube
Transfer Tube
Retaining Ring
Plate
Seal Ring
Gasket
Strainer
Gasket
Install transfer tubes (1, 2, 3). Torque transfer tubes 100 lb.in. (11.30 Nm). Remove
transfer tubes and examine gaskets to ensure each has 100% surface contact with
its seat. If contact is satisfactory, reinstall transfer tubes and torque 400 to
450 lb.in. (45.19-50.84 Nm). If contact is unsatisfactory, replace transfer tube gasket
and repeat assembly procedure.
NOTE:
16.
(6)
Install No. 6 and 7 bearing pressure, scavenge and vent tubes (Ref. Paras. 12. A.,
13. B. and 14. B.).
(7)
Oil Filler Cap, Neck and Tube Valve (Ref. Fig. 420)
A.
B.
Removal
(1)
(2)
Remove bolts (3), washer (4), cable (5), filler cap (1) and packing (2). Discard
packing.
(3)
(4)
Remove bolts (10), washers (11), filler neck (12) and packing (13). Discard packing.
Installation
(1)
Lubricate packing (13) with engine oil (PWC03-001) and install on filler neck (12).
(2)
Install oil filler neck (12), washers (11) and bolts (10). Torque bolts 36 to 40 lb.in.
(4.0-4.6 Nm).
(3)
Lubricate packing (7) with engine oil (PWC03-001) and install on tube valve (6).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 449
Nov 09/2001
3
5
3
6
10
8
11
12
10
11
13
C69030A
Oil Filler Cap, Neck and Tube Valve - Removal/Installation
Figure 420
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 450
Nov 09/2001
Filler Cap
Packing
Bolt
Washer
Cable
Tube Valve
Packing
Nipple
Packing
Bolt
Washer
Filler Neck
Packing
CAUTION: DO NOT USE BOLTS TO SEAT OIL FILLER TUBE VALVE. INSTALL VALVE
BY HAND TO ENSURE FULL FLANGE CONTACT. IF RESISTANCE IS
FELT, REMOVE AND INSPECT VALVE.
17.
(4)
(5)
Lubricate packing (2) with engine oil (PWC03-001) and install on filler cap (1).
(6)
Install filler cap (1), washer (4), free end of cable (5) and bolts (3). Torque bolts 36
to 40 lb.in. (4.0-4.6 Nm).
(7)
Lubricate packing (9) and install on nipple (8). Install nipple and torque 65 to
75 lb.in. (7.5-8.5 Nm). Secure with lockwire (PWC05-089) or (PWC05-295).
(8)
Removal
(1)
(2)
(3)
(4)
(5)
Remove plug (11), packing (12), bolts (13), washers (14), indicator (15), and gasket
(16). Discard packing.
(6)
Remove bolts (6), washers (10), bracket (7), adapter (17), and packing (18).
Discard packing.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 451
Aug 13/2004
2
3
7
17
16
15
18
13
14
10
12
9
8
11
C69032A
Oil Level Indicator - Removal/Installation
Figure 421
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 452
Nov 09/2001
Bolt (MS9556-06)
Nut
Bolt (MS9556-05)
Bolt (MS9489-06)
Bracket
Bolt (MS9556-09)
Bracket
Bolt (MS9556-08)
Bracket
Washer
Plug
Packing
Bolt (MS9556-12)
Washer
Indicator, Oil Level
Gasket
Adapter
Packing
Installation
(1)
Lubricate packing (18) with engine oil (PWC03-001) and install on adapter (17).
(2)
Install adapter (17), bracket (7), washers (10) and bolts (6). Torque bolts 36 to
40 lb.in. (4.07-4.52 Nm).
(3)
Install gasket (16), indicator (15), washers (14), and bolts (13). Torque bolts 36 to
40 lb.in. (4.07-4.52 Nm).
(4)
Lubricate packing (12) with engine oil (PWC03-001) and install on plug (11). Torque
plug 38 to 42 lb.in. (4.29-4.75 Nm).
(5)
Install bracket (9), and bolts (8). Torque bolts 36 to 40 lbf.in. (4.1-4.5 Nm).
(6)
Install bracket (5), bolts (1, 3, 4), and nut (2). Torque bolts and nut 36 to 40 lbf.in.
(4.1-4.5 Nm).
(7)
(8)
(9)
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 453
Aug 13/2004
18.
Removal
(1)
(2)
(3)
(4)
Remove relief valve assembly (3) and packing (4). Discard packing.
(5)
(6)
B.
19.
Installation
(1)
Lubricate packings (8) and install on transfer tube (7). Install transfer tube in valve
assembly (3).
(2)
Lubricate packings (6) and install on transfer tube (5). Install transfer tube in the
inlet case.
(3)
(4)
Install valve assembly (3), washers (2) and nuts (1). Torque nuts 75 to 85 lb.in.
(8.48-9.61 Nm).
(5)
Install clamp assembly (11), bolt (9) and nut (10) to bracket. Torque nut 36 to
40 lb.in. (4.07-4.52 Nm).
(6)
(7)
Disconnect and unclamp igniter cables as to not interfere with removal of pump
(Ref. 72-01-20).
(2)
Slide air inlet to scavenge pump oil transfer tube away from scavenge pump (Ref.
Approved Repairs).
(3)
Remove No. 6 and 7 bearing oil scavenge tube (Ref. Para. 13. B.).
(4)
Remove fuel line to flow divider and dump valve (Ref. 72-01-40).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 454
Nov 09/2001
B.
C.
(5)
Remove bolts (1), washers (2), scavenge pump assembly (3) and packings (4, 5).
Discard packings.
(6)
(7)
Remove air inlet-to-scavenge pump oil transfer tube (Ref. Approved Repairs).
Remove pump housing (1) from cover (9) and packing (2). Discard packing.
(2)
Remove tube assembly (3) and packings (4). Discard packings. Remove strainer
(10) from tube assembly.
(3)
Remove gears (5), woodruff keys (6), idler shaft (7) and driveshaft (8).
(2)
(3)
(4)
Freeze strainer (10) to -40C (-40F) for 5 minutes minimum. Install strainer in tube
assembly (3).
(5)
Lubricate packings (4) and install on strainer and tube assembly. Install strainer and
tube assembly.
(6)
D.
(7)
(8)
Lubricate packings and install on air inlet-to-scavenge pump oil transfer tube. Install
transfer tube in air inlet case (Ref. Approved Repairs).
(2)
Lubricate packings (7) and install on transfer tube (6). Install transfer tube.
(3)
(4)
Align holes with pins on rear inlet case, splines on driveshafts and install pump
assembly, washers (2) and bolts (1). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
(5)
Slide air inlet-to-scavenge pump oil transfer tube into position and secure with
retaining rings (Ref. Approved Repairs).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 455
Nov 09/2001
11
8
7
8
10
3
4
5
6
C17610
Oil Pump Pressure Relief Valve Assembly - Removal/Installation
Figure 422
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 456
Nov 09/2001
20.
Nut
Washer
Relief Valve Assembly
Packing
Transfer Tube
Packing
Transfer Tube
Packing
Bolt
Nut
Clamp Assembly
(6)
Install fuel line to flow divider and dump valve (Ref. 72-01-40).
(7)
Install No. 6 and 7 bearing oil scavenge tube (Ref. Para. 13. B.).
(8)
(9)
B.
C.
Remove oil pump pressure relief valve assembly (Ref. Para. 18.).
(2)
Remove reduction gearbox scavenge oil pump assembly (Ref. Para. 19.).
(3)
(4)
Remove pump assemblies (4) using adapter (PWC37614) (3) and puller (PWC37651)
(7).
(5)
Remove pressure pump housing (3), gears (4) and woodruff keys (5).
(2)
(3)
(4)
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 457
Nov 09/2001
6
3
7
C12199
Reduction Gearbox Scavenge Oil Pump - Removal/Installation
Figure 423
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 458
Nov 09/2001
Bolt
Washer
Scavenge Pump Assembly
Packing
Packing
Transfer Tube
Packing
(2)
(3)
Align pins and install cover (6), woodruff keys (5) and gears (4).
D.
(5)
Align holes with pins in cover and install pressure pump housing (3), washers (2)
and bolts (1) . Torque bolts in a diagonal sequence 36 to 40 lb.in. (4.07-4.52 Nm).
(6)
Lubricate packings (5, 6) and install on pump assemblies (4) and driveshaft.
(2)
Align holes with pins on rear inlet case and install pump assemblies in engine.
NOTE: 1. Bolts (1) and washers (2) are installed at assembly (Ref. Subpara.
C.).
NOTE: 2. To align splines, rotate driveshaft during assembly.
21.
(3)
Install reduction gearbox scavenge oil pump assembly (Ref. Para. 19.).
(4)
Install oil pump pressure relief valve assembly (Ref. Para. 18.).
(5)
Removal
(1)
(2)
(3)
Remove elbows (3, 7, 15), adapter (11) and nuts (4, 8, 12, 16). Discard backup
rings (5, 9, 13, 17) and packings (6, 10, 14, 18).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 459
Nov 09/2001
C12198A
Reduction Gearbox Scavenge Oil Pump - Assembly/Disassembly
Figure 424
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 460
Nov 09/2001
B.
Pump Housing
Packing
Tube Assembly
Packing
Gears
Woodruff Keys
Idler Shaft
Driveshaft
Cover
Strainer
(4)
(5)
Remove bolts (19, 23), washers (21, 22, 24) and mounting bracket assembly (25).
(6)
Remove nuts (26), bolts (27, 28), washers (29) and bracket (30).
Installation
(1)
(2)
Install oil cooler assembly and bolts (1). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
(3)
Install nuts (4, 8, 12, 16), backup rings (5, 9, 13, 17), packings (6, 10, 14, 18),
elbows (3, 7, 15) and adapter (11) according to Chapter 72-00-00,
MAINTENANCE PRACTICES. Torque nuts fingertight.
(4)
Install fuel tubes (Ref. 72-01-40, REMOVAL/INSTALLATION) and oil tubes (Ref.
Para. 12. D. and E.).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 461
Nov 09/2001
C12197A
No. 6 and 7 Bearing Scavenge Oil Pump/Pressure Oil Pump - Removal/Installation
Figure 425
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 462
Nov 09/2001
Bolt
Washer
Adapter
Pump Assemblies
Packing
Packing
Puller
22.
(6)
(7)
B.
Removal
(1)
(2)
Remove bolts (11, 18), nuts (12) and clamp assemblies (10) .
(3)
Remove nuts (3, 17), bracket (16), tube (2) and packing (1). Discard packing.
(4)
Remove retaining rings (15) and washers (14). Slide cover (13).
(5)
Remove bolts (8), nuts (9), gasket (7), tube (6), flexible coupling (5) and packings
(4). Discard packings.
Installation
(1)
Install tube (6), gasket (7), bolts (8) and nuts (9). Torque fingertight.
(2)
(3)
Lubricate packings (4) with engine oil (PWC03-001) and install on flexible coupling
(5).
(4)
Lubricate packing (1) with engine oil (PWC03-001) and install on tube (2).
(5)
Install flexible coupling, tube, bracket (16) and nuts (3, 17). Torque nut (17) 150 to
170 lb.in. (16.95-19.21 Nm) and nuts (3) 36 to 40 lb.in. (4.07-4.52 Nm).
(6)
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 463
Nov 09/2001
5
4
6
8
10
11
9
8
2
1
C12200A
No. 6 and 7 Bearing Scavenge Oil Pump/Pressure Oil Pump - Assembly/Disassembly
Figure 426
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 464
Nov 09/2001
Bolt
Washer
Pressure Pump Housing
Gear
Woodruff Key
Cover
Scavenge Pump Housing
Gear
Woodruff Key
Driveshaft
Idler Shaft
CAUTION: ENSURE TUBE ASSEMBLIES (2) AND (6) ARE ALIGNED WITH
COUPLING (5) BEFORE SECURING CLAMPS (10).
(8)
Install clamp assemblies (10) on tube (2), bolts (11, 18) and nuts (12). Torque bolts
36 to 40 lb.in. (4.07-4.52 Nm).
NOTE:
23.
B.
Removal
(1)
(2)
Remove nuts (5), bolts (3, 4), clamp (8), grommet (9), clamp assembly (7) and
spacer (6).
(3)
Remove bolts (10), tube assembly (12) and gasket (11). Discard gasket.
(4)
Installation
(1)
Install gasket (2) and nipple (1). Torque nipple 450 to 550 lb.in. (50.85-62.15 Nm).
Lubricate ferrule and tube nut of tube assembly (12), using a minimal amount of oil
(PWC03-001).
(3)
Install gasket (11), tube assembly (12), bolts (10) . Do not torque bolts or tube nut.
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 465
Nov 09/2001
90 1 IN.
RELATION TO
ENGINE AXIS
11
30
0 1 IN.
RELATION TO
ENGINE AXIS
3
7
VIEW
30 1 IN.
RELATION TO
ENGINE AXIS
15
14
16
13
17
12
23
18
25
23
10
24
26
11
5
8
24
3
29
30
15
27
21
20
28
22 30
19
VIEW
22
C38605
Fuel-cooled Oil Cooler and Mounting Bracket - Removal/Installation
Figure 427
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 466
Nov 09/2001
Bolt
Oil Cooler Assembly
Elbow
Nut
Backup Ring
Packing
Elbow
Nut
Backup Ring
Packing
Adapter
Nut
Backup Ring
Packing
Elbow
Nut
Backup Ring
Packing
Bolt
Terminal Lead
Washer
Washer
Bolt
Washer
Bracket Assembly
Nut
Bolt
Bolt
Washer
Bracket
Install grommet (9), clamp (8), clamp assembly (7), bolts (3, 4), spacer (6) and
nuts (5). Torque nuts 36 to 40 lb.in. (4.07-4.52 Nm).
NOTE:
Torque bolts (10) 27 to 30 lb.in. (3.05-3.39 Nm) and tube assembly (12) nut 90
to 100 lb.in. (10.17-11.29 Nm). Secure tube nut with lockwire (PWC05-089) or
(PWC05-295).
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 467
Nov 09/2001
8
6
13
7
4
12
15
14
18
9
5
16
10
11
10
12
17
C63331
Accessory Gearbox Breather Tube Assembly - Removal/Installation
Figure 428
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 468
Nov 09/2001
Packing
Tube
Nut
Packing
Coupling
Tube
Gasket
Bolt
Nut
Clamp Assembly
Bolt
Nut
Cover
Washer
Retaining Ring
Bracket
Nut
Bolt
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 469
Nov 09/2001
1
13
DETAIL
A
C63332
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 470
Nov 09/2001
Nipple
Gasket
Bolt
Bolt
Nut
Spacer
Clamp Assembly
Clamp
Grommet
Bolt
Gasket
Tube Assembly
Pressure Oil Tube Assembly
Cap
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 471
Nov 09/2001
10
11
13
14
3
13
7
6
5
8
4
C37270A
Intercompressor Case Oil Drain - Removal/Installation
Figure 429 (Sheet 2)
72-01-50
OIL SYSTEM - REMOVAL/INSTALLATION
Page 472
Nov 09/2001
General
A.
2.
These instructions provide information necessary for the adjustment/test of engine oil
system components.
Consumable Materials
Not Applicable
3.
Special Tools
Not Applicable
4.
5.
Adjustment/Test
A.
B.
Start engine, run for two minutes 55 psid or higher oil pressure. Shut down engine
(Ref. AMM).
(2)
(3)
Start engine, run for five minutes at G.I. Shut down engine (Ref. AMM).
(2)
(3)
72-01-50
OIL SYSTEM - ADJUSTMENT/TEST
Page 501/502
Oct 20/2000
General
A.
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-062
PWC05-190
PWC11-002
PWC11-027
PWC11-031
PWC11-032
PWC11-048
Special Tools
Not Applicable
4.
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 601
Jan 24/2006
Name
Steel bar, 3-oz. (85.05 g)
Tapered plugs
5.
Inspection
A.
General
(1)
B.
(2)
(3)
The bubble-point test is not a cleaning procedure. The test is carried out
to ensure the filter body is undamaged and the element not punctured.
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 602
Jan 24/2006
PRESSURE
GAGE
AIR
PRESSURE
INLET
AIR
REGULATOR
BLEED
VALVE
NEEDLE
VALVE
AIR
FILTER
MANOMETER
ELEMENT
ADAPTER
P1
P2
SOLVENT
TRANSPARENT
TANK
FILTER
ELEMENT
PLUG
VACUUM
SCALE
h = MANOMETER READING
P1= PRESSURIZED AIR
P2= ATMOSPHERIC AIR
P1
MANOMETER
FLUID
ALTERNATE TYPES
OF MANOMETERS
C32394
RGB Scavenge and Cleanable Main Oil Filter Elements - Bubble Point Test
Figure 601
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 603
Jan 24/2006
WARNING:
Install element in fluid tank using a suitable plug to seal open end of core.
Maintain approximately 12 in. (12.7 mm) between fluid surface and top of
filter during bubble test.
Open air regulator until pressure gage reads 5 to 6 psig (34.47-41.37 kPa).
Open needle valve and gradually increase air pressure until manometer
water reading is equivalent to the following values; 6.0 in. (15.2 cm) for
the pressure filter and 8.0 in. (20.3 cm) for the scavenge filter. No bubbles
must escape from the filter mesh before the applicable value is
exceeded.
NOTE:
Check bore seals if bubbles escape from locations other than filter
mesh before the applicable value given above is exceeded.
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 604
Jan 24/2006
10
C.
Transfer Tube
(1)
D.
E.
Rotate element slowly and watch for air bubbles. If no bubble stream
appears, increase pressure by opening needle valve. When a stream
of bubbles appears, reduce pressure until bubbles stop, then slowly increase
pressure until bubble stream begins again. The manometer reading is the
difference between lower and upper level of fluid or twice the distance from
the fill line to fluid line after pressurization. The reading when the stream
begins must be 6.0 in. (15.2 cm) for pressure filter and 8.0 in. (20.3 cm) for
scavenge filter of water minimum. Replace filter element if the requirement
is not met.
Inspect for general damage and wear. Touch up damaged surface coatings (Ref.
Cleaning/Painting).
(2)
Do not use a screwdriver or other hard metal objects to push the flapper
valve inwards for the O-ring inspection.
Verify the inside of the oil filler neck for evidence of oil.
(g) Replace the oil filler valve assembly if an oil leak is found.
NOTE:
F.
Make sure the oil filler cap is re-installed following flapper valve seal
check engine run.
Spur Gears
(1)
Inspect for general damage and wear. Stone raised metal, using sharpening stone
(PWC05-062).
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 605
Jan 24/2006
C106018
Oil Filler and Check Valve Inspection
Figure 602
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 606
Jan 24/2006
Inspect for general damage and wear. Stone raised metal, using sharpening stone
(PWC05-062).
Patch-making Procedure
CAUTION: DO NOT USE PATCH-MAKING PROCEDURE AS A CLEANING
PROCEDURE FOR FILTER ELEMENTS.
(a) Remove filter element (oil pressure or RGB scavenge) from engine (Ref.
Servicing).
(b) Using suitable tapered plugs, seal inner cavity of filter element.
(c) Place filter in cylindrical container.
WARNING:
Ensure there are no deposits left on filter. If there is, secure container
cover and continue shaking.
Install new filter patch (PWC05-190) in filter patch holder and place over a
suitable container (2 liters min.).
Flush out all possible loose particles which may still be in container by pouring
some teksol (PWC11-048) or petroleum solvent (PWC11-027) into it, shaking,
then emptying into filter patch holder.
(j)
Remove filter patch from filter patch holder and place in patch receptacle.
Identify sample with type of filter, engine serial number and hours run.
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 607
Jan 24/2006
(k) If any debris is found (particles large enough to be trapped by filter patch),
send sample to laboratory for material spectrographic analysis.
NOTE:
(l)
Remove plugs from filter element (ensure the preformed packing does not drop
inside the element).
WARNING:
(m) Dry filter element using clean compressed air at 29 psig (200 kPa).
(n) Install filter element (oil pressure or RGB scavenge) on engine (Ref. Servicing).
(2)
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 608
Jan 24/2006
I.
Chip Detector Circuit Completion, Debris on Oil Filters and/or Filter Impending Bypass
Warnings
(1)
An impending by-pass indication does not necessarily mean that the oil filter
was by-passed. An assessment of the amount of contamination can indicate
whether a by-pass has actually occurred. If debris is found on most of the surface
of the filter element, associated housing and the chip detector strainer, it can
considered that a by-pass has occurred.
General
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 609
Jan 24/2006
(a) Turbomachinery chip detector circuit completion associated with main oil filter
bypass (Ref. Note 1) requires engine removal (Ref. Note 2).
NOTE: 1. An assessment of the amount of contamination can indicate whether
a bypass has actually occurred. If the oil filters are cleaned or
replaced at regular intervals as recommended by P&WC and debris
is deposited on most of surface of filter element, associated
housing, chip detector and strainer, it can be considered that a
bypass has occurred. This is not true in cases where the by-pass
indicator is used to determine when the filters should be cleaned or
replaced.
NOTE: 2. After an engine/module change due to bearing/gear distress, it is
recommended that the replacement engine have an oil-filter patch
check carried out after 50 hours. This is to ensure bearing/gear
material from the original failure has not contaminated the
replacement engine due to incomplete flushing of the airframes/propeller
oil system(s). If magnetic material is found, repeat patch check
after 50 hours. If the amount of material is reduced, repeat patch
check at 50-hour intervals until no magnetic material is found. The
time between patch checks should revert to the standard interval
after the second consecutive clean patch check. If the amount of
magnetic material increases or if magnetic material is found
after the second clean patch check, the maintenance action required
for debris in oil system must be carried out.
NOTE: 3. All debris particles should be sent to a laboratory for analysis.
Take note that contaminant material such as carbon particules are
not considered debris.
NOTE: 4. Unless otherwise specified, review of the laboratory results should
be done within 50 FH of debris discovery for the correct disposition
of the engine/module.
(b) Allowable/Non-allowable Debris definitions
1
Allowable Debris
v Small quantity of hair-like filaments (fuzz) or powder, providing there has
been no prior history of debris (allowable or non-allowable) within the
last 400 hours
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 610
Jan 24/2006
J.
Thin, shiny rolled flakes with feathered edges and more than
0.020 in. (0.508 mm) in size are generated when bearing
surfaces break down due to excessive load (spalling). The outer
surface of the flakes is highly polished and may show parallel
impressions. The inner surface has a rough wavy or granular
texture. After the bearing surface breaks down, the underlying
material disintegrates and chips with dark, coarse and irregular
shapes are produced.
Remove and inspect chip detector and filters. Carry out patch-making procedure on
relevant filter and collect any debris from chip detector (Ref. Subpara. H.).
(2)
(3)
If the debris is allowable, clean and install filters, strainer, chip detector strainer(s)
and chip detectors. Record category, type and origin of debris. Send debris to an
approved laboratory (Ref. 72-00-00, Maintenance Practices). The engine can be
returned to service, pending the results of the laboratory analyzed debris (Ref.
Para. M.).
(4)
If the debris is non-allowable category 2 or 3, record the category, type and origin
of debris. Send debris for analysis to an approved laboratory (Ref. 72-00-00,
Maintenance Practices). If debris originates from the Turbomachinery Module,
proceed to Para. K.; if not, proceed to Para. L..
(5)
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 611
Jan 24/2006
K.
If the above criteria are not met, remove the affected RGB (Ref. Para. I.,
step (1), Note 2).
If the Turbomachinery module has a history of generating debris (within 400 hours),
proceed as follows:
(a) Review the results of last laboratory analysis.
NOTE:
(b) If results showed bearing material (Ref. Para. M.), remove turbomachinery (Ref.
Para. I., step (1), Note 2).
(c) If results did not show bearing material and quantity of debris is not increasing
or turbomachinery is not consistently generating debris. Clean and install chip
detector, chip detector strainers, strainers and filter. Return engine to
service (Ref. Note). Check airframe condition panel (if applicable) for chip
detector circuit completion or remove and inspect turbomachinery chip
detector/collector daily for 50 FH. Remove and inspect main oil filter for debris
after 50 hours. If no debris is found, refer to Para. M. when most recent
debris analysis is available. If debris is found, review the results of last laboratory
analysis before next flight, refer to step M..
NOTE:
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 612
Jan 24/2006
TYPICAL
SHAPE OF
FRAGMENTS
0.043
0.038
0.235
0.230
0.235
0.230
0.078
0.071
SECTION AA
MATERIAL REF. AMS 5504
SECTION AA
MATERIAL REF. AMS 5504
PRESB21619
POSTSB21619
C28291A
No. 9 Bearing Keywasher Debris
Figure 603
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 613
Jan 24/2006
TYPICAL
SHAPE OF
FRAGMENT
0.115
REF.
0.100
REF.
DETAIL A
0.019 0.025
SECTION BB
MATERIAL REF. AMS5510
C100338
Tab Washer Debris
Figure 604
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 614
Jan 24/2006
MISSING CASTELLATION
(ONE MISSING MAX.)
NO. 9 BEARING
RETAINING NUT
C107917
No. 9 Bearing Reatining Nut Debris - Missing Castellation
Figure 605
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 615
Jan 24/2006
Return engine to service. Check airframe condition panel (if applicable) for
chip detector circuit completion or remove and inspect turbomachinery chip
detector/collector daily for 50 FH. Remove and inspect oil filters after 50
flight hours. If no debris is found, refer to Para. M. when most recent debris
analysis is available. If debris is found, review the results of last laboratory
analysis before next flight, refer to Para. M..
L.
Drain and flush engine (Ref. 72-00-00, SERVICING) and powerplant oil
system (Ref. AMM),
Clean and install chip detectors, strainers and oil filters (Ref.
Removal/Installation)
Fill engine (Ref. 72-00-00, SERVICING) and powerplant oil system (Ref.
AMM).
Remove and inspect Main chip detectors, chip detector strainers, strainers
and filters (Ref. Removal/Installation).
If debris is found, replace turbomachinery module (Ref. Para. I., step (1),
Note 2).
If the RGB module has a history of generating debris (within 400 hours), proceed
as follows:
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 616
Jan 24/2006
(b) If results showed bearing material and origin was determined to be from the
RGB and not the PCU or O/S governor and hydraulic pump, then RGB
should be removed within 50 hours of currently reported debris (Ref. Para. L.)
(Ref. Para. I., step (1), Note 2).
NOTE:
(c) If results showed bearing material and origin was determined to be from the
PCU or O/S governor and hydraulic pump, replace the defective accessory.
(d) If results did not show bearing material or is unknown, and the quantity of
debris is increasing or the RGB is consistently generating debris, schedule
RGB removal within 50 FH of the current reported debris.
(e) If results did not show bearing material and quantity of debris increasing or the
RGB is not consistently generating debris, clean and install chip detector and
filter. Return engine to service. Check airframe condition panel (if applicable) for
chip detector circuit completion or remove and inspect chip detector/collector
after 10 FH and after 50 FH. Remove and inspect oil filters for debris after 50
flight hours. If no debris is found, refer to Para. M. when most recent debris
analysis is available. If debris is found, review the results of last laboratory
analysis within 25 FH of the initial finding of the current reported debris,
refer to Para. M..
(2)
If the RGB module has no history of generating debris (within 400 hours), proceed
as follows:
(a) Clean and install RGB chip detectors, chip detector strainers, strainers and
filters (Ref. Removal/Installation).
(b) Run engine at 80% torque for 10 minutes (Ref. AMM).
(c) Remove and inspect RGB chip detectors, chip detector strainers, strainers and
filters (Ref. Removal/Installation).
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 617
Jan 24/2006
(d) If no debris is found, clean and install filters, strainers, chip detector strainer(s)
and chip detectors. Return engine to service. Check airframe condition panel (if
applicable) for chip detector completion or remove and inspect chip
detector/collector after 10 FH and after 50 FH. Remove and inspect oil filter for
debris after 50 flight hours. If no debris is found, refer to Para. M. when
most recent debris analysis is available. If debris is found, review the results of
last laboratory analysis within 25 FH of the initial finding of the current
reported debris, refer to Para. M..
(e) If debris is found, proceed as follows:
1
Drain and flush engine (Ref. 72-00-00, SERVICING) and powerplant oil
system (Ref. AMM)
Clean and install chip detectors and oil filters (Ref. Removal/Installation).
Fill engine (Ref. 72-00-00, SERVICING) and powerplant oil system (Ref.
AMM).
Remove and inspect RGB chip detectors, chip detector strainers, strainers
and filters (Ref. Removal/Installation).
If debris is found, and the origin was determined to be from the RGB,
remove the RGB module within 50 hours of currently reported debris (Ref.
Para. L.). If the origin is from the PCU or O/S governor and hydraulic
pump, replace the accessories (Ref. Para. I., step (1), Note 2).
NOTE:
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 618
Jan 24/2006
(1)
(c) If RGB has no previous history of generating debris, the engine can continue in
service. Inspect the RGB chip detector after 50 flight hours. If no debris found,
the engine can continue in service. If debris is found, replace the RGB
within 50 flight hours of the most currently reported debris (Ref. Para. I., step
(1), Note 2).
NOTE:
(2)
(3)
If debris is not allowable and gear material is found, carry out an inspection of the
following components (depending on which chip detector the material was found)
(Ref. 72-00-00, INSPECTION/CHECK):
(a) Reduction Gearbox Module
v First-stage gears
(b) Turbomachinery Module
v Angle-drive gearbox gears
v Oil-pump drive gears
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 619
Jan 24/2006
If material found is not gear material and/or labyrinth seal material (AMS5504 or
AMS5613 or AMS5663), refer to 72-00-00, Material Specification and Common
Contaminants Tables to determine origin of debris. If possible remedy per
maintenance manual instructions or return to an approved overhaul facility.
(5)
(6)
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 620
Jan 24/2006
(c) A borescope inspection through the NL pulse pickup probe port at the bottom
of the intercompressor case air plenum to check for abradable seal material
(Ref. 72-00-00, INSPECTION/CHECK). In addition, the tip of the pickup probe
must be checked for magnetic material which could indicate No. 3 or 4
bearing distress.
(d) A borescope inspection through the bottom T6 thermocouple port (Ref.
72-00-00, INSPECTION/CHECK) to check for soot, carbon or oil in the area
around No. 6 and 7 bearing housing and at the bottom of the interturbine duct.
(e) To minimize the possibility of bearing failure and to facilitate decision making
when the origin of the seal material is not discovered during the above
inspections, operators may, at their discretion, carry out a borescope inspection
of No. 5 bearing cavity through the oil scavenge port (Ref. 72-00-00,
INSPECTION/CHECK) to check for labyrinth seal, bearing and bearing cage
deterioration.
NOTE:
(7)
If module is not found acceptable after inspections in step (6), remove module/engine
(Ref. Para. I., step (1), Note 2).
(8)
If module is found acceptable during the inspections in step (6), the engine may
remain in service. Check airframe condition panel (if applicable) for chip detector
circuit completion or remove and inspect chip detector/collector daily for 50 FH. If
labyrinth seal material is found and is the major or minor contaminant (Ref. step
(5), NOTE 1), remove and return engine to an approved overhaul facility for an
inspection to be carried out.
(9)
(10)
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 621
Jan 24/2006
The most probable sources of this contamination are silver-plated nuts and the
towershaft bevel gears. This type of contamination is acceptable and the engine can
continue in service with no special inspection required.
v Magnesium - Chips
The most probable source of this contamination is the Reduction Gearbox and
could be caused by bearing outer races fretting in the housing bores or by gears
touching the housings (this indicates the gears are in an abnormal running
position). If this type of contamination is found, the engine can continue in service
providing an oil filter patch check is carried out every 250 hours and the
amount of magnesium chips is monitored. If the amount of contamination increases,
the reduction gearbox should be replaced.
v Carbon - Particles
The most common non-metallic contamination is carbon particles caused by
thermal breakdown of the oil due to hot spots in the engine. This type of
contamination is acceptable and the engine can continue in service with no special
inspections required.
v Silica - Particles
Silica contamination indicates that dirt or atmospheric pollutants may have
entered the oil system via labyrinth seal pressurized air and/or while replenishing
the oil. Excessive amounts of silica can indicate blocked cooling air passages
and worn labyrinth seals. To restore the silica content to normal levels, an oil
change is required. The engine can continue in service providing oil consumption
and ITT/T6 are within limits.
v Copper - Fragments
Usually found with fiber insulating material and paint chips in the reduction
gearbox scavenge filter and AC generator scavenge strainer. Ferrous material
may also be found on the AC generator chip detector. This type of contamination
is caused by failure of the AC generator gearbox.
N.
Refer to borescope ICC air plenum inspection (Ref. 72-00-00, ENGINE INSPECTION/CHECK) and troubleshooting chart Oil on Flanges E and/or F,
(Ref. 72-00-01, ENGINE - FAULT ISOLATION)
(1)
(2)
Inspect the bottom of the cavity for bolts and/or keywashers, if any bolts and/or
keywashers are found, do a borescope inspection of the HP impeller shroud
retaining bolts (Ref. 72-00-00, ENGINE - INSPECTION/CHECK).
(3)
If no oil found, install the ICC drain tube (Ref. Removal/Installation) and return
engine to service.
(4)
If oil is found, install the ICC drain tube (Ref. Removal/Installation) and carry out a
5-minute engine run at ground idle (GI) (Ref. 72-00-00, ADJUSTMENT/TEST).
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 622
Jan 24/2006
(5)
Remove ICC drain tube (Ref. Removal/Installation) and collect any oil accumulated.
(6)
Inspect the ICC drain tube for flow restriction. If any, rectify/replace the ICC drain
tube (Ref. Removal/Installation).
(7)
If no oil is found, install ICC drain tube (Ref. Removal/Installation) and return
engine to service.
(8)
(9)
6.
(i)
If less than 5 ml of oil is collected, engine may be returned to service after the
chip detector is checked for continuity. If the circuit is complete, carry out the
procedure for chip detector circuit completion (Ref. 72-00-01, FAULT
ISOLATION). If the circuit is not complete, return engine to service.
(j)
Check
A.
Chip Detector
(1)
Functional Check
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 623
Jan 24/2006
(a) Connect ohmmeter across detector output terminals and place suitable steel
bar across magnet poles. Circuit resistance must be less than 0.5 ohm.
(b) Check security of output terminal pins and condition of potting compound. If
pins are loose or if compound is cracked, reject detector.
(c) Insulation resistance between any terminal pin and case must be greater than
2 megohms at 45 volts AC or DC. Check, using test set.
(d) The chip detector magnets must be capable of lifting a 4-ounce (113.40 g)
steel bar.
(2)
Operational Check
(a) Place suitable steel bar across magnet poles and check for circuit continuity.
(b) Check security of output terminal pins and condition of potting compound. If pins
are loose or if compound is cracked, reject detector.
(3)
B.
Spring Compression
(1)
(2)
(3)
C.
(2)
Verify that the nut cannot be turned by hand. If the nut can be turned by hand, do
as follows:
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 624
Jan 24/2006
(a) Check for the minimum breakaway torque using suitable torque wrench set at
2 lbf.in. (0.23 Nm). If the Oil Filler Cap Assembly shows any movement of the
self-locking nut during that check, replace the self-locking nut as follows:
D.
Mark the position of the nut, count and mark the remaining threads on the
bolt for reference. Remove the nut and discard
Install the new nut at the same position as previously identified. Install the
oil filler cap and check the spring loaded feature for positive spring action
as in step (1).
E.
Drain Valve
(1)
(2)
72-01-50
OIL SYSTEM - INSPECTION/CHECK
Page 625/626
Jan 24/2006
2.
General
A.
B.
Before cleaning, a sample of metal particles found on chip detectors or oil filters should
be retained for source determination.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-037
PWC11-002
PWC11-011
PWC11-013
PWC11-027
PWC11-031
PWC11-032
PWC11-033
PWC11-054
PWC11-055
PWC13-001
Enamel
Trichloroethane 1-1-1 (inhibited)
Cleaner
Compound, Carbon Removing
Solvent, Petroleum
Cleaner, Engine Parts
Solvent, Degreasing
Degreaser, Liquid
Cleaner, Aqueous (Low Foam)
Degreasing, Aqueous (Wax Remover)
Primer
Special Tools
Not Applicable
4.
Remarks
Electrosonic cleaner
Soft brush
Stiff bristle brush and/or spray equipment
Ultrasonic cleaner
Back-flushing fixture
72-01-50
OIL SYSTEM - CLEANING/PAINTING
Page 701
Oct 20/2000
5.
Cleaning
WARNING:
WARNING:
NOTE:
A.
General
(1)
B.
With the exception of the items specifically mentioned, clean all parts with
petroleum solvent (PWC11-027) or cleaner (PWC11-031) and blow dry with filtered
compressed air at 29 psig (200 kPa) maximum.
Ensure packings, if fitted, are removed from bore of filter element and
discarded.
72-01-50
OIL SYSTEM - CLEANING/PAINTING
Page 702
Nov 09/2001
WARNING:
Spray flush filters from the outside to the inside with aqueous cleaner
solution (PWC11-054), heated at 57 to 63 C (135-145F) with a maximum
pressure of 30 PSIG.
Remove from bath and carefully remove a plug from one end of the filter.
Using protective gloves, back-flush the filter (from the inside to the outside)
and rotate filter element 90 degrees after each three minutes of cleaning
operation, while providing 1 to 3 gallons per minute at 30 PSIG Max. for ten
minutes Min.
Remove the back-flush fixture and filter element from tank and with
protective glooves remove the filter.
Using protective gloves, carefully remove all remaining plugs from bore.
72-01-50
OIL SYSTEM - CLEANING/PAINTING
Page 703
Oct 20/2000
WARNING:
(2)
Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(c) Immerse the filter element in cleaner (PWC11-031) for 30 minutes Min.
Maintain temperature at 21C (70F) or heat cleaner to 45C (113F) Max.
WARNING:
(d) Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(e) Spray flush filters with aqueous cleaner (PWC11-033), heated at 21C (70F),
using one part cleaner to three parts water.
WARNING:
(f)
Dry element with clean filtered air at 29 psig (200 kPa) maximum.
72-01-50
OIL SYSTEM - CLEANING/PAINTING
Page 704
Oct 20/2000
WARNING:
(h) Fill tank to approximately 14 in. (6.350 mm) below edge with degreaser solvent
(PWC11-032).
(i)
(j)
(k) Using protective gloves, immerse the filter element horizontally in the ultrasonic
or electrosonic bath
(l)
Back-flush the filter element using 1 to 3 gallons per minute (3.78-11.35 liters)
at 30 psig (206.9kPa) for ten minutes, rotating filter 180 degrees while
back-flushing.
NOTE:
DELETED.
(m) Using protective gloves, remove element from tank and plugs from bore.
WARNING:
(n) Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(o) Inspect filter element (Ref. Inspection/Check).
(3) METHOD 3: Ultrasonic clean filter using solvent (PWC11-002) (Alternative Method)
NOTE:
(a) Ensure packings, if fitted, are removed from bore of filter element and discarded.
CAUTION: FAILURE TO PLUG CENTER OF THE FILTER ELEMENT CAN
RESULT IN CONTAMINATION OF THE INTERIOR. OIL FLOW IS
FROM THE OUTSIDE TO THE INSIDE, THE INTERIOR BEING THE
CLEAN SIDE.
(b) Plug the centers of the filter element by inserting a tapered rubber or plastic
plugs of the appropriate size into the bores.
(c) Place filter element horizontally in ultrasonic cleaner tank.
72-01-50
OIL SYSTEM - CLEANING/PAINTING
Page 705
Oct 20/2000
WARNING:
(d) Fill tank to approximately 14 in. (6.350 mm) below edge with solvent
(PWC11-002).
(e) Operate the cleaner for 10 to 15 minutes. Use protective gloves, rotate the filter
element 90 degrees after every three minutes of cleaning operation.
(f)
Remove the filter element from the tank and install on a back-flush fixture.
C.
(i)
Dry element with clean filtered air at 29 psig (200 kPa) maximum.
(j)
(2)
WARNING:
(3)
Dry strainers/screen with clean filtered air at 29 psig (200 kPa) maximum.
(4)
72-01-50
OIL SYSTEM - CLEANING/PAINTING
Page 706
Oct 20/2000
D.
Carbon Removal
WARNING:
(1)
(c) Fill tank with water to 85% of operating volume and stir.
(d) Heat solution to 82 to 93C (180-200F).
(e) Fill tank with water to 100% of operating volume and stir to mix.
(2)
Procedure
CAUTION: DO NOT USE SOLUTION TO REMOVE CARBON FROM
COMPONENTS MADE FROM SINGLE CRYSTAL MATERIAL.
(a) Soak component in solution at 82 to 93C (180-200F) for 30 to 90 minutes.
(b) Pressure rinse with cold water over tank, then dip rinse in a separate tank and
follow with a pressure rinse.
(c) Rinse in hot water at 66 to 93C (150-200F).
WARNING:
(1)
Clean rear of sight glass using cleaner (PWC11-011), or equivalent, and a soft
brush.
72-01-50
OIL SYSTEM - CLEANING/PAINTING
Page 707
Oct 20/2000
(2)
6.
Painting
A.
Procedure
(1)
Repair damaged painted surfaces using one coat each of primer (PWC13-001) and
enamel (PWC05-037).
NOTE:
72-01-50
OIL SYSTEM - CLEANING/PAINTING
Page 708
Oct 20/2000
General
A.
These instructions provide the information necessary to achieve the approved repairs of
components of the engine oil system.
B.
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC05-019
PWC05-061
PWC05-101
Oil, Engine
Compound, Lapping
Cloth, Abrasive, Coated, Crocus
Cloth, Abrasive (320 grit)
Special Tools
Special tools are identified in procedural text by part number in parentheses.
4.
Tool No.
Name
PWC34520
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 801
Mar 11/2005
5.
Approved Repairs
A.
B.
Tubes
(1)
(2)
No. 6 and 7 Bearing Oil Pressure, Vent and Scavenge Tubes Super B Nut Replacement
(Ref. Fig. 801)
CAUTION: TAKE CARE NOT TO DAMAGE NIPPLE.
(1)
Remove wire (2) from nut (1). Discard nut and wire.
(2)
C.
D.
Using lockwire to secure the head of the thrust wire pin to the nut is
optional. If required, the head can be removed (cut off) to prevent
interference with adjacent components. The nut which is retained by the
thrust wire will be more difficult to replace if the head is removed.
Air Inlet-to-Scavenge Pump Oil Transfer Tube Seal Replacement (Ref. Fig. 802)
(1)
(2)
Slide tube (2) in either direction to clear end from inlet case or scavenge pump.
(3)
(4)
(5)
(6)
Blend out nicks, burrs, scratches, pits and corrosion using abrasive cloth
(PWC05-101) followed by polishing with crocus cloth (PWC05-061).
(2)
(3)
(4)
(5)
Dress mating surfaces using a lapping plate and lapping compound (PWC05-019).
(6)
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 802
Sep 03/99
E.
Valves
(1)
F.
Lap valve faces and seats using a lapping plate and lapping compound (PWC05-019)
to obtain 360-degree contact.
Oil Pressure Regulating Valve Tee Restrictor Replacement (Ref. Fig. 803)
(1)
Remove plug (1) using puller (PWC34520 rev.B - Replaced by PWC50781 and
PWC50782). Discard plug.
(2)
(3)
Check that hole diameter of tee (3) is 0.1875 to 0.1880 in. (4.76-4.77 mm).
(4)
Ensuring replacement plug and restrictor are clean and dry, insert restrictor (2) in
tee (3) using puller (PWC34520 rev. B - Replaced by PWC50781 and PWC50782).
Install plug (1) in tee using puller (PWC34520 rev. B - Replaced by PWC50781 and
PWC50782).
(6)
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 803
Mar 11/2005
C11214A
Super B Nut Replacement
Figure 801
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 804
Sep 03/99
Nut
Wire
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 805
Sep 03/99
C63335
Air Inlet Case to Scavenge Pump Oil Transfer Tube Seal Replacement
Figure 802
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 806
Sep 03/99
Retaining Ring
Transfer Tube
Packing
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 807
Sep 03/99
1
2
C63340
Oil Pressure Regulating Valve Tee Restrictor Replacement
Figure 803
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 808
Sep 03/99
Plug
Restrictor
Tee
72-01-50
OIL SYSTEM - APPROVED REPAIRS
Page 809/810
Sep 03/99
General
A.
WARNING:
WARNING:
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC03-001
PWC04-003
PWC05-076
PWC05-089
PWC05-256
PWC05-295
PWC06-007
PWC06-036
PWC11-014
Oil, Engine
Grease, Synthetic
Oil, Penetrating
Lockwire
Enhancer, Contact, Electrical
Lockwire (may be used instead of PWC05-089)
Coating, Film Lubricant
Compound, Lubricating
Alcohol, Isopropyl
Special Tools
Special tools are identified in procedural text by part number in parentheses.
Tool No.
Name
PWC54001
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 401
Mar 11/2005
4.
Tool No.
Name
PWC54201
PWC54401
PWC56384
PWC58104
Wrench
Wrench
Wrench
Wrench
5.
B.
Removal
(1)
(2)
(3)
(4)
(5)
(6)
Installation
NOTE: 1. Lubricate bolts and face of nuts adjacent to washers with coating (PWC06-007).
NOTE: 2. Install washers and nuts on the side of brackets (16) facing into engine.
(1)
Install negative bus-bar (1) with split at location shown. Install bolt (4), washer (6)
and nut (8). Torque nut 26 to 30 lb.in. (2.94-3.39 Nm).
(2)
Install bolt (9), washer (6), T6 thermocouple rear electrical cable lead (Ref. Para.
7.) and nut (8). Torque nut 26 to 30 lb.in. (2.94-3.39 Nm).
(3)
Install positive bus-bar (2) with split at location shown. Install screw (10), washer (5)
and nut (7). Torque nut 18 to 20 lb.in. (2.03-2.26 Nm).
(4)
Install screw (3), washer (5), T6 thermocouple rear electrical cable lead (Ref. Para.
7.) and nut (7). Torque nut 18 to 20 lb.in. (2.03-2.26 Nm).
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 402
Mar 11/2005
TDC
LOCATION OF
BUSBAR SPLITS
25
24
17
28
26
16
FLANGE
27
K REAR VIEW
3
21
9
22
23
POSTSB21686
17
19
18
2
24
12
13
20
15
5
6
8
11
6
14
4
7
8
10
C86970
Negative and Positive Bus-bars and Immersion Thermocouples - Removal/Installation
Figure 401 (Sheet 1 of 2)
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 403
Oct 18/2002
Negative Bus-bar
Positive Bus-bar
Screw
Bolt
Washer
Washer
Nut
Nut
Bolt
Bolt
Nut
Bolt
Lockplate
Nut
Screw
Bracket
Nut
Washer (Pre-SB21686)
Plate (Pre-SB21686)
Plate (Pre-SB21686)
Thermocouple (Pre-SB21686)
Gasket (Pre-SB21686)
Adapter (Pre-SB21686)
Gasket
T6 Thermocouple (Post-SB21686)
Sealing Plate (Post-SB21686)
Sealing Plate (Post-SB21686)
Washer (Post-SB21686)
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 404
Oct 18/2002
SECTION
AA
C66060
Assembled Configuration
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 405
Oct 18/2002
6.
(5)
Install screws (3), washers (5) and nuts (7). Torque nuts 18 to 20 lb.in.
(2.03-2.26 Nm).
(6)
(7)
Install thermocouple terminals (Ref. Para. 6.) and carry out insulation resistance
test (Ref. Inspection/Check).
A.
Removal
(1)
(2)
Pre-SB21686
(a) Remove nuts (17), washers (18) and plates (19, 20).
(b) Remove nuts (11), bolts (12) and lockplates (13).
(c) Remove nuts (14), bolts (15) and lockplates (13).
(d) Install wrench (PWC54401) on thermocouple adapters (23).
CAUTION: BEFORE REMOVAL, LUBRICATE THERMOCOUPLE THREADS
WITH PENETRATING OIL (PWC05-076). DO NOT USE WD40.
BACK-OFF THERMOCOUPLE BY A QUARTER TURN FREQUENTLY
DURING REMOVAL PROCEDURE.
CAUTION: HOLD WRENCH (PWC54401) SECURELY IN POSITION WHEN
UNTORQUING THERMOCOUPLES.
(e) Remove T6 thermocouples (21) and gaskets (22) using wrench (PWC54201).
Discard gaskets.
NOTE: 1. T6 thermocouples which can only be removed with the adapter due
to excessive bending of the stem are recommended to be discarded
and replaced with a new thermocouple.
NOTE: 2. Scratches, grooves or rubs on the thermocouple stem less than
0.010 in (0.254 mm) deep are acceptable. Function check
thermocouple to verify its serviceability (Ref. Inspection/Check).
NOTE: 3. Adapters with loose, damaged or missing sealing rings are
recommended to be discarded and replaced with new adapters.
(f)
If required, remove adapters (23) and gaskets (24) using wrench (PWC54401).
Discard gaskets.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 406
Oct 18/2002
(3)
Post-SB21686
CAUTION: BEFORE REMOVAL, LUBRICATE THERMOCOUPLE THREADS
WITH PENETRATING OIL (PWC05-076). DO NOT USE WD40.
BACK-OFF THERMOCOUPLE BY A QUARTER TURN FREQUENTLY
DURING REMOVAL PROCEDURE.
(a) Remove T6 thermocouples (25) and gaskets (24) using wrench (PWC54401) or
(PWC56384). Discard gaskets.
B.
Installation
(1)
(2)
Experience has shown three different 0.500-20 UNJF-3B taps are used in
the most effective cleaning procedure. The first pass is made with a worn
tap, the second with a newer tap and the third with a brand new tap
modified by the removal of the tapered end. This ensures the complete
thread is cleaned.
Pre-SB21686
CAUTION: DO NOT USE ENGINE OIL ON THREADS OF IMMERSION
THERMOCOUPLES. OIL WILL CAUSE IMMERSION
THERMOCOUPLES TO BOND IN TURBINE SUPPORT CASE.
CAUTION: MAKE SURE THE T6 THERMOCOUPLE STEEL BRAID DOES NOT
CONTACT ANY ADJACENT PART(S).
(a) If removed, install adapters (23) as follows:
1
(b) Install gaskets (22) in the groove of the installed adapters (23).
NOTE:
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 407
Mar 11/2005
Post-SB21686
CAUTION: DO NOT USE ENGINE OIL ON THREADS OF IMMERSION
THERMOCOUPLES. OIL WILL CAUSE IMMERSION
THERMOCOUPLES TO BOND IN TURBINE SUPPORT CASE.
CAUTION: MAKE SURE THE T6 THERMOCOUPLE STEEL BRAID DOES NOT
CONTACT ANY ADJACENT PART(S).
(a) Install gaskets (24) on thermocouples (25).
(b) Apply a thin coat of lubricating compound (PWC06-036) to thermocouple
threads.
(c) Install thermocouples using wrench (PWC54401) or (PWC56384). Torque
thermocouples 75 to 80 lb.in. (8.48-9.04 Nm).
(4)
Install plates (19, 20) (Pre-SB21686) or (26, 27) (Post-SB21686), washers (18)
(Pre-SB21686) or (28) (Post-SB21686) and nuts (17). Torque nuts 23 to 26 lb.in.
(2.60-2.94 Nm).
NOTE: 1. Install plate (20) or (27) with radius facing inwards and plate (19) or (26)
with radius facing outwards.
NOTE: 2. Plates (20) have retaining edges, ensure plates (19) press against them.
(5)
Do the following:
(a) Pre-SB21686
CAUTION: HOLD TERMINALS SECURELY AT 90-DEGREE ANGLE TO
BUS-BAR WHEN TORQUING SCREW OR NUT.
1
(b) Post-SB21686
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 408
Mar 11/2005
(6)
7.
B.
Removal
(1)
Remove nuts (1, 2) and disconnect instrumentation (15), T6 harness leads (16) and
rear cable leads (13) at terminal (14).
(2)
Remove nuts (3, 6), bolts (4, 7) and washers (5, 8).
(3)
Remove nut (9), bolt (10), lockplate (11) and rear T6 cable (13).
Installation
(1)
Install T6 rear cable leads (13), bolts (4, 7), washers (5, 8) and nuts (3, 6). Torque
bolt (4) 18 to 20 lb.in. (2.03-2.26 Nm) and bolt (7) 26 to 30 lb.in. (2.94-3.39 Nm).
(2)
Install T6 rear cable leads (13), T6 harness leads (16), instrumentation leads (15)
and nuts (1, 2) at terminal (14). Torque nut (1) 24 to 40 lb.in. (2.8-4.6 Nm) and nut
(2) 15 to 20 lb.in. (1.7-2.2 Nm).
(3)
Install T6 rear cable bracket, bolt (10) and nut (9). Torque bolt 25 to 28 lb.in.
(2.83-3.16 Nm).
NOTE:
8.
Include immersion thermocouple lead (12) and lockplate (11) at bolt (10).
Removal
WARNING:
(1)
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 409
Oct 18/2002
13
11
10
14
12
16
15
5
3
C79824
T6 Thermocouple Rear Electrical Cable - Removal/Installation
Figure 402
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 410
Oct 18/2002
B.
Nut
Nut
Nut
Bolt
Washer
Nut
Bolt
Washer
Nut
Bolt
Lockplate
Thermocouple Lead
T6 Rear Cable
Terminal
Instrumentation Wiring Harness
T6 Thermocouple Trim Harness
(2)
(3)
Remove bolts (2), probe (1) and packings (3, 4). Discard packings.
Installation
NOTE:
(1)
(2)
Install probe and bolts (2). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
WARNING:
(3)
(4)
Let the liquid flow downward on each pin to make a thin film.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 411
Oct 18/2002
6
7
8
1
4
2
3
RIGHT SIDE
LEFT SIDE
C30375B
NL Speed Sensor Probe and NL Sensor Port Sealing Tube - Removal/Installation
Figure 403
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 412
Oct 18/2002
Probe
Bolt
Packing
Packing
Bolt
Sealing Tube
Packing
Packing
Install harness electrical connector P33. Torque connector coupling nut by hand
until witness band(s) on mating receptacle is/are covered. It is recommended to
further torque connector coupling nuts, using one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
9.
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
(6)
(7)
Post-SB21269: Use heat gun to heat shrink harness sleeves over plugs. Connector
joints to be covered as shown on Fig. 406.
Removal
(1)
Remove bolts (5), sealing tube (6) and packings (7, 8). Discard packings.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 413
Oct 18/2002
B.
10.
Installation
(1)
Lubricate packings (7, 8) with engine oil (PWC03-001) and install on sealing tube
(6).
(2)
Install sealing tube and bolts (5). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
B.
Removal
(1)
Remove nuts (10, 11) and electrical wiring harness leads at bracket (19).
(2)
Remove nuts (14, 15, 16), disconnect engine harness leads at terminal block (18)
and remove resistor (17).
(3)
Remove nuts (6), bolts (4, 5), clamps (8) and grommets (9) from tube assembly (7).
(4)
(5)
Installation
(1)
Install terminal block (18), bolts (3) and nuts (2). Torque nuts 85 to 95 lb.in.
(9.61-10.74 Nm).
(2)
Lubricate packing (13) with engine oil (PWC03-001) and install on thermocouple
(12).
(3)
Install thermocouple. Torque 90 to 100 lb.in. (10.17-11.30 Nm). Secure with lockwire
(PWC05-089) or (PWC05-295).
Install thermocouple leads, resistor (17), engine harness leadsand nuts (14, 15, 16)
at terminal block (18). Torque nuts (15, 16) 25 to 30 lb.in. (2.83-3.39 Nm) and nut
(14) 20 to 25 lb.in. (2.26-2.83 Nm).
Install harness (1), clamps (8), grommets (9), bolts (4, 5) and nuts (6) to clamp on
tube assembly (7). Torque nuts 36 to 40 lb.in. (4.07-4.82 Nm).
NOTE:
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 414
Oct 18/2002
(6)
Install harness leads and nuts (10, 11) at bracket (19). Torque nut (10) 25 to
30 lb.in. (2.83-3.39 Nm) and nut (11) 20 to 25 lb.in. (2.26-2.83 Nm).
NOTE: 1. Include wiring harness leads where shown.
NOTE: 2. Include T6 thermocouple rear electrical cable at nuts (10, 11).
11.
Removal
WARNING:
B.
(1)
(2)
(3)
Remove bolts (3), probes (1, 2) and packings (4). Discard packings.
Installation
NOTE:
Before connecting plugs, install harness sleeves (PWC05-273) over plugs. The
use of sleeves is optional.
(1)
(2)
Install probes and bolts (3). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
WARNING:
(3)
(4)
Let the liquid flow downward on each pin to make a thin film.
Install harness electrical connectors P5, P14. Torque connector coupling nut by
hand until witness band(s) on mating receptacle is/are covered. It is recommended
connector coupling nuts are further torqued using one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 415
Oct 18/2002
4
5
4
4
6
8
9
7
6
4
4
12
8
9
2
13
10
11
19
5
8
9
6
P24
15
8
14
16
17
18
C63342B
T6 Thermocouple Trim Harness - Removal/Installation
Figure 404
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 416
Oct 18/2002
T6 Harness
Nut
Bolt
Bolt
Bolt
Nut
Tube Assembly
Clamp
Grommet
Nut
Nut
Thermocouple
Packing
Nut
Nut
Nut
Resistor
Terminal Block
Bracket
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
(6)
Use of insulating tape (PWC05-105) to wrap the connector joints is optional (Ref.
Fig. 406).
(7)
If installed, use a heat gun to heat shrink harness sleeves over plugs. Connector
joints to be covered as shown on Fig. 406.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 417
Oct 18/2002
P5
P14
3
C14721B
NH Speed Sensor Probes (No. 1 and 2) - Removal/Installation
Figure 405
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 418
Oct 18/2002
Probe
Probe
Bolt
Packing
Removal
WARNING:
B.
(1)
(2)
(3)
(4)
Remove bolts (2), brackets (4), sensor (1) and packing (3). Discard packing.
Installation
NOTE:
Before connecting plugs, install harness sleeves (PWC05-273) over plugs. The
use of sleeves is optional.
(1)
Lubricate packing (3) with oil (PWC03-001) and install on sensor (1).
(2)
Install sensor, brackets (4) and bolts (2). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).
WARNING:
(3)
(4)
Let the liquid flow downward on each pin to make a thin film.
Install connector and rotate it by hand 1/4 turn clockwise until a click is heard which
indicates the connector is in the locked position. Do not use a torque wrench or
pliers to apply torque.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 419
Oct 18/2002
TAPE / SLEEVE
COVERAGE ZONE
0.500 IN.
MIN.
(12.7 mm)
0.250 IN.
MIN.
(6.35 mm)
TAPE / SLEEVE
COVERAGE ZONE
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 420
Mar 11/2005
0.500 IN.
(12.7 mm)
MIN.
TAPE / SLEEVE
COVERAGE ZONE
C62304A
Protective Tape/Heat ShrinK - Installation Zone
Figure 406 (Sheet 2)
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 421
Mar 11/2005
2
1
3
P7
1
4
2
4
2
C17745A
No. 1 and 2 Torque Monitor Sensors - Removal/Installation
Figure 407
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 422
Oct 18/2002
13.
Sensor
Bolts
Packing
Bracket
(6)
Use of insulating tape (PWC05-105) to wrap the connector joints is optional (Ref. Fig.
406).
(7)
If installed, use a heat gun to heat shrink harness sleeves over plugs. Connector
joints to be covered as shown on Fig. 406.
Removal
WARNING:
B.
(1)
(2)
(3)
Installation
NOTE:
(1)
Before connecting plugs, install harness sleeves (PWC05-273) over plugs. The
use of sleeves is optional.
Install gasket (2) and sensor (1). Torque sensor 65 to 75 lb.in. (7.35-8.48 Nm) and
secure with lockwire (PWC05-089) or (PWC05-295).
WARNING:
(2)
(3)
Let the liquid flow downward on each pin to make a thin film.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 423
Oct 18/2002
P4
1
C14761B
T1.8 Sensor - Removal/Installation
Figure 408
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 424
Oct 18/2002
Sensor
Gasket
Install harness electrical connector P4. Torque connector coupling nut by hand until
witness band(s) on mating receptacle is/are covered. It is recommended connector
coupling nuts are further torqued using one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
14.
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
(5)
Use of insulating tape (PWC05-105) to wrap the connector joints is optional (Ref.
Fig. 406).
(6)
If installed, use a heat gun to heat shrink harness sleeves over plugs. Connector
joints to be covered as shown on Fig. 406.
Removal
WARNING:
(1)
(2)
(3)
Remove nuts (2), sensor probe (1) and packing (3). Discard packing.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 425
Oct 18/2002
2
3
P9
C14755B
NP Speed Sensor Probe - Removal/Installation
Figure 409
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 426
Oct 18/2002
Probe
Nut
Packing
Installation
NOTE:
Before connecting plugs, install harness sleeves (PWC05-273) over plugs. The
use of sleeves is optional.
(1)
Lubricate packing (3) with engine oil (PWC03-001) and install on sensor probe (1).
(2)
Install sensor probe and nuts (2). Torque nuts 32 to 36 lb.in. (3.62-4.07 Nm).
WARNING:
(3)
(4)
Let the liquid flow downward on each pin to make a thin film.
Install harness electrical connector plug P9. Torque connector coupling nut by hand
until witness band(s) on mating receptacle is/are covered. It is recommended
connector coupling nuts are further torqued using one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 427
Oct 18/2002
15.
Use of insulating tape (PWC05-105) to wrap the connector joints is optional (Ref.
Fig. 406).
(7)
If installed, use a heat gun to heat shrink harness sleeves over plugs. Connector
joints to be covered as shown on Fig. 406.
B.
16.
(6)
Removal
(1)
(2)
(3)
Remove bolts (1), clamps (2) and low oil pressure sensor (3). Remove clamps (2)
from sensor.
(4)
Remove bolts (4), clamps (5) and main oil pressure sensor (6). Remove clamps (5)
from sensor.
Installation
(1)
(2)
Install bolts (4), clamps and main oil pressure sensor (6). Torque bolts 36 to
40 lbf.in. (4.07-4.52 Nm).
(3)
(4)
Install bolts (1), clamps and low oil pressure sensor (3). Torque bolts 36 to 40 lbf.in.
(4.07-4.52 Nm).
(5)
(6)
Removal
WARNING:
(1)
(2)
(3)
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 428
Oct 18/2002
B.
Installation
NOTE:
Before connecting plugs, install harness sleeves (PWC05-273) over plugs. The
use of sleeves is optional.
(1)
Lubricate packing (2) with oil (PWC03-001) and install on sensor (1).
(2)
(3)
WARNING:
(4)
(5)
Let the liquid flow downward on each pin to make a thin film.
Install harness electrical connector P37. Torque connector coupling nut by hand
until witness band(s) on mating receptacle is/are covered. It is recommended
connector coupling nuts are further torqued using one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
(7)
Use of insulating tape (PWC05-105) to wrap the connector joints is optional (Ref.
Fig. 406).
(8)
If installed, use a heat gun to heat shrink harness sleeves over plugs. Connector
joints to be covered as shown on Fig. 406.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 429
Oct 18/2002
2
3
6
C69185A
Low and Main Oil Pressure Sensors - Removal
Figure 410
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 430
Oct 18/2002
Bolt
Clamp
Low Oil Pressure Sensor
Bolt
Clamp
Main Oil Pressure Sensor
Removal
WARNING:
B.
(1)
(2)
(3)
Installation
NOTE:
Before connecting plugs, install harness sleeves (PWC05-273) over plugs. The
use of sleeves is optional.
(1)
Lubricate packing (2) with oil (PWC03-001) and install on sensor (1).
(2)
(3)
WARNING:
(4)
(5)
Let the liquid flow downward on each pin to make a thin film.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 431
Oct 18/2002
P37
1
2
C79519
Fuel Temperature Sensor - Removal/Installation
Figure 411
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 432
Oct 18/2002
Sensor
Packing
Install harness electrical connector P32. Torque connector coupling nut by hand
until witness band(s) on mating receptacle is/are covered. It is recommended
connector coupling nuts are further torqued using one of the following methods:
CAUTION: DO NOT USE STEEL-JAWED PLIERS TO TIGHTEN CONNECTORS.
(a) Method 1, Mini-strap Wrench (PWC58104) or (Glenair TG70)
1
Mini-strap wrench has a design slip torque of 100 lb.in. (11.3 Nm).
Soft-jawed pliers have a design slip torque of 100 lb.in. (11.3 Nm).
(7)
Use of insulating tape (PWC05-105) to wrap the connector joints is optional (Ref.
Fig. 406).
(8)
If installed, use a heat gun to heat shrink harness sleeves over plugs. Connector
joints to be covered as shown on Fig. 406.
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 433
Oct 18/2002
P32
FW
C79520
Oil Temperature Sensor - Removal/Installation
Figure 412
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 434
Oct 18/2002
Sensor
Packing
72-01-60
PERFORMANCE INDICATING SYSTEM - REMOVAL/INSTALLATION
Page 435/436
Oct 18/2002
General
A.
2.
Consumable Materials
Not Applicable
3.
Special Tools
Not Applicable
4.
5.
Inspection
A.
Procedure
(1)
6.
Inspect for obvious defects. Replace defective parts for which no repair is given.
Check
A.
72-01-60
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Page 601
Mar 11/2005
FLANGE
13
C
12
B
STUD IDENTIFICATION
AT TERMINAL BLOCK
11
7
8
13
10
INSTALLATION AT FLANGE
FLANGE
6
4
5
3
14
2
INSTALLATION AT FLANGE
C80382
T6 Thermocouple Trim Electrical Cable - T6 Check
Figure 601
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 602
Mar 11/2005
Nut
Nut
T6 Leads
Rear Cable Leads
Airframe Leads
Terminal Block
Nut
Nut
Nut
Resistor
Thermocouple Lead
Thermocouple Lead
Terminal Block
Instrumentation Wiring Harness Lead
At terminal block (6), remove nuts (1, 2) and disconnect wiring harness leads
(5). Reinstall nuts (1, 2). Torque nut (1) 20 to 25 lb.in. (2.26-2.83 Nm) and
nut (2) 25 to 30 lb.in. (2.83-3.39 Nm).
At terminal block (13), remove nuts (7, 8) and resistor (10). Reinstall
thermocouple lead (11) and nuts. Torque nuts 25 to 30 lb.in. (2.83-3.39 Nm).
Connect test leads studs identified A and B to the harness leads and
record resistance value.
Add the two recorded values together and divide by two to find the correct
resistance. Continuity resistance between studs identified as A and B must
be 9.19 to 11.40 ohms.
NOTE:
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 603
Mar 11/2005
(2)
(c) Check bus-bars and support brackets for obvious defects such as cracks,
sharp bends and nicks.
(3)
Check 3 (thermocouples)
(a) After a T6 thermocouple failure (maximum 1 thermocouple), engines can
continue in service for a maximum of 150 flight hours for scheduling purposes
only, providing that:
1
The immediate effect of the thermocouple failure did not reduce the ITT
(T6) on ECTM. This ensures the indicated temperature is equal to or
higher than the ITT prior to the thermocouple failure.
The failed thermocouple leads (both chromel and alumel) are disconnected
from the bus-bar and completely cut off before the engine is returned to
service.
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 604
Mar 11/2005
Add the two recorded values together and divide by two to find the
actual resistance. The resistance must be between 0.4 and 1.4 ohms.
NOTE:
(4)
Connect one terminal on each probe to a test set in turn. Connect the
other test set lead to the Turbine Support Case. Resistance must be 2
megohms minimum at 45 volts AC or DC.
Perform Check 4 (Ref. Para. A., step (4)) and repeat step a, above.
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 605
Mar 11/2005
(5)
Check 5 (harness)
NOTE:
(a) Remove nut (8, 9), disconnect thermocouple leads (12) at stud C and install a
slave lead between studs C and B (terminal block (13)). Reinstall nuts and
torque nut (8) 25 to 30 lb.in. (2.83-3.39 Nm) and nut (9) 20 to 25 lb.in.
(2.26-2.83 Nm).
NOTE:
(6)
(7)
PART NO.
RESISTOR CLASS
ST3114-01
CL0
INFINITY
ST3114-02
CL5
500
ST3114-03
CL10
300
ST3114-04
CL15
200
ST3114-05
CL20
150
ST3114-06
CL25
125
ST3114-07
CL30
100
ST3114-08
CL35
85
ST3114-09
CL40
70
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 606
Mar 11/2005
PART NO.
RESISTOR CLASS
ST3114-10
CL45
63
ST3114-11
CL50
55
ST3114-12
CL55
50
ST3114-13
CL60
45
ST3114-14
40
ST3114-15
35
ST3114-16
30
ST3114-17
25
ST3114-18
42
ST3114-19
- (see NOTE)
38
ST3114-20
- (see NOTE)
36
ST3114-21
- (see NOTE)
34
ST3114-22
- (see NOTE)
32
ST3114-23
- (see NOTE)
28
ST3114-24
- (see NOTE)
26
ST3114-25
- (see NOTE)
24
ST3114-26
- (see NOTE)
22
ST3114-27
- (see NOTE)
20
ST3114-28
- (see NOTE)
18
ST3114-29
- (see NOTE)
16
ST3114-30
147
ST3114-31
140
ST3114-32
137
ST3114-33
130
ST3114-34
121
ST3114-35
117
ST3114-36
110
ST3114-37
105
ST3114-38
95.3
ST3114-39
90.9
ST3114-40
80.6
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PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 607
Mar 11/2005
RESISTOR CLASS
RESISTANCE VALUE
(OHMS 2% AT 21C (70F))
ST3114-41
75
ST3114-42
66.5
ST3114-43
59
CLASS
RESISTANCE
IN OHMS AT 21C (70F)
OPTIONAL PARTS
ST3152-01
20 megohms - Infinity
ST3144-01 OR ST3151-01
ST3152-02
ST3144-02 OR ST3151-02
ST3152-03
10
ST3144-03 OR ST3151-03
ST3152-04
15
ST3144-04 OR ST3151-04
ST3152-05
20
ST3144-05 OR ST3151-05
ST3152-06
25
ST3144-06 OR ST3151-06
ST3152-07
30
ST3144-07 OR ST3151-07
ST3152-08
35
ST3144-08 OR ST3151-08
ST3152-09
40
ST3144-09 OR ST3151-09
ST3152-10
45
ST3144-10 OR ST3151-10
ST3152-11
50
ST3144-11 OR ST3151-11
ST3152-12
55
ST3144-12 OR ST3151-12
ST3152-13
60
ST3144-13 OR ST3151-13
ST3152-14
70
ST3144-14 OR ST3151-14
ST3152-15
80
ST3144-15 OR ST3151-15
ST3152-16
90
ST3144-16 OR ST3151-16
ST3152-17
100
ST3144-17 OR ST3151-17
Install removed components (Ref. Removal/Installation and AMM) and carry out
Check 1 to confirm T6 system functions correctly.
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 608
Mar 11/2005
B.
(2)
C.
Torque Sensors
(1)
(2)
D.
T1.8 Sensor
CAUTION: TO PREVENT DAMAGE WHICH COULD AFFECT ELECTRICAL
CONTACTS, DO NOT INSERT PROBES INTO CONNECTOR SOCKETS
OR ATTACH CLIPS TO CONNECTOR PINS.
(1)
RESISTANCE (ohms)
84.10 0.35
88.53 0.28
92.96 0.22
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PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 609
Mar 11/2005
E.
RESISTANCE (ohms)
97.36 0.21
100.00 0.20
101.75 0.20
106.12 0.21
110.47 0.22
114.83 0.23
119.15 0.27
123.47 0.31
127.77 0.35
132.05 0.39
136.34 0.44
138.90 0.50
(2)
Continuity using ohmmeter: resistance from pins 1 to 2, 0.5 ohm maximum; from
pin 4 to body, 0.5 ohm maximum.
(3)
Insulation resistance using test set: resistance from pins 1 and 3 together to
housing, not less than 2 megohms at 45 volts DC or AC.
(2)
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 610
Mar 11/2005
F.
(a) Pin A to pin B resistance (Input): _________ ohms. Limit: 1000 ohms
(b) Pin C to pin D resistance (Output): __________ ohms. Limit: 2000 ohms
(2)
The minimum insulation resistance between all circuit points tied together
and the case shall be 40 megohms at 500 VDC.
If the reading exceeds 40 megohms before the two minutes delay has
ended, and it is steady or increasing, then the test can be terminated
at that point. Record the value.
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 611
Mar 11/2005
H.
The minimum insulation resistance between all circuit points tied together
and the case shall be 40 megohms at 500 VDC.
If the reading exceeds 40 megohms before the two minutes delay has
ended, and it is steady or increasing, then the test can be terminated
at that point. Record the value.
72-01-60
PERFORMANCE INDICATING SYSTEM - INSPECTION/CHECK
Page 612
Mar 11/2005
General
A.
2.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-101
PWC11-027
PWC11-031
Special Tools
Not Applicable
4.
5.
Cleaning
A.
General
WARNING:
(1)
With the exception of items specifically mentioned, clean parts with petroleum
solvent (PWC11-027) or cleaner (PWC11-031).
NOTE:
B.
72-01-60
PERFORMANCE INDICATING SYSTEM - CLEANING/PAINTING
Page 701
Sep 03/99
C.
T6 Thermocouple
(1)
(2)
72-01-60
PERFORMANCE INDICATING SYSTEM - CLEANING/PAINTING
Page 702
Sep 03/99
2.
General
A.
These instructions provide the information necessary to achieve the approved repairs of
components of the engine performance indicating system.
B.
Consumable Materials
The consumable materials listed below are referred to in this section. For more data, refer to
the CONSUMABLE MATERIALS section at the beginning of this manual.
WARNING:
3.
READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE
MATERIALS. SOME MATERIALS CAN BE DANGEROUS.
Item No.
Name
PWC05-066
PWC05-110
PWC05-294
Insulating Tape
Lockwire
Lockwire (may be used instead of PWC05-110)
Special Tools
Not Applicable
4.
5.
Procedure
(1)
(2)
Wrap insulating tape (PWC05-066) around harness covering all of the damaged
area as shown.
(3)
Ensure that wire overlaps tape and contacts harness braid at each end of
repair.
72-01-60
PERFORMANCE INDICATING SYSTEM - APPROVED REPAIRS
Page 801
Sep 03/99
INSULATING TAPE
X
1/3 X
C4960C
Harness Braid Repair
Figure 801
72-01-60
PERFORMANCE INDICATING SYSTEM - APPROVED REPAIRS
Page 802
Sep 03/99
6.
(4)
(5)
After final turn of wrapping, insert wire A through loop as shown. Cut off surplus
end B of wire so that length is approximately one-third of repair length. Pull loop
end C until wire at A is snug and end B of wire has just disappeared underneath final
turn of wrappings. Then cut wire end C flush.
(6)
Procedure
(1)
Removal
(a) Remove nuts (1, 5), washers (6, 7), bushing (2, 8), studs (3, 9) and pad (4).
(2)
Installation
(a) Install pad (4), bushings (2, 8), studs (3, 9), washers (6, 7) and nuts (1, 5).
Torque nut (1) 25 to 30 lb.in. (2.83-3.39 Nm) and nut (5) 20 to 25 lb.in.
(2.26-2.83 Nm).
7.
T1.8 Sensor
A.
Procedure
(1)
72-01-60
PERFORMANCE INDICATING SYSTEM - APPROVED REPAIRS
Page 803
Sep 03/99
1
7
8
5
9
2
4
3
C70256
Thermocouple Harness Terminal Repair
Figure 802
72-01-60
PERFORMANCE INDICATING SYSTEM - APPROVED REPAIRS
Page 804
Sep 03/99
Nut
Bushing
Stud
Pad
Nut
Washer
Washer
Bushing
Stud
72-01-60
PERFORMANCE INDICATING SYSTEM - APPROVED REPAIRS
Page 805/806
Sep 03/99