Honeywell CMM GTCP36-280D

RELEASED FOR THE EXCLUSIVE USE BY: ASERCA AIRLINES

Honeywell TO:

Engines, Systems & Services Phoenix, Arizona

HOLDERS OF PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE, COMPONENT MAINTENANCE MANUAL, ATA NO. 49-26-49, REVISED MARCH 30, 2001.

THIS REVISED PUBLICATION IS ISSUED FOR USE IN SUPPORT OF THE FOLLOWING AIRCRAFT. ENGINE/ COMPONENT PART NO. 3800504-1

ENGINE MODEL NO. GTCP36-280[D]

AIRCRAFT APPLICATION MD-80

REVISION NO. 5 DATED FEBRUARY 28, 2005 This is a COMPLETE revision. The pages revised are listed below together with the Highlights of the revision. Due to the extent of the changes, this publication has been reprinted in its entirety. Please discard the entire manual of previous issue(s) and replace with this complete manual. This publication is distributed by: Honeywell Engines, Systems & Services Technical Data Distribution M/S 64-01/2101-201 P.O. Box 52170 Phoenix, AZ 85072-2170 To order a document, please go to our web-site at www.honeywelltechpubs.com Inquires of a technical nature regarding this publication should be directed to: Honeywell Engines, Systems & Services Customer Support Center M/S 26-06/2102-323 P.O. Box 29003 Phoenix, AZ 85038-9003 Phone: (Domestic) 800-601-3099 Phone: (International) 602-365-3099 Fax: 602-365-3343

UP200456

HIGHLIGHTS Subiect/Paqe

Description of Change

49-26-49

Updated specifications and vendor addresses throughout the manual. Added WARNINGS as required.

Title Page Page T-1

Updated to Revision 5.

Safety/Warranty/Liability Advisory Page SWLA-1/SWLA-2

Revised WARNING.

Record of Revisions Page RR-1/RR-2

Added Revision 5.

ATA NO. 49-26-49 Copying, use or disclosureof information on this pageis subjectto proprietaryrestrictions.


Honeywell

Engines, Systems & Services Phoenix, Arizona HIGHLIGHTS (CONT)

Subject/Pa,qe

Description of Chan.qe

Temporary Revisions Page TR-2

Added TRs 49-25 through 49-45.

Service Bulletin List Page SB-6 Page SB-7

Added SBs 49-7608 through 49-7734.

Pages SB-8 and SB-9

Revised SB list to incorporate Page SB-9.

List of Effective Pages Pages LEP-1 through LEP-6

Updated to Revision 5.

Table of Contents Page TC-1/I-C-2

Added Atlas entry.

Description and Operation Page 3

Revised Table 3.

Page 17/18

Revised Figure 8 (Sheet I of 2) to incorporate TR 49-43.

Testing and Faultlsolation Pages 101 through 103

UP200456

Added SB 49-7587. Added SBs 49-7596 through 49-7598.

Updated Table 101.

Page 103

Added Paragraph 1.B.(6) to incorporate TR 49-25. Revised Paragraphs 1.B.(6)(a), (b) and (c).

Page 108

Added Paragraph H. to incorporate TR 49-26.

Page 109

Revised Orifice PT Range.

Page 110

Added Fuel/Oil Pump leak limit to incorporate TR 49-42. Revised Table 103.

Page 117

Revised Paragraph l.H(1)(g).

Page 124

Revised Paragraph 1.P. to incorporate TR 49-27.

Page 126

Revised Paragraph 1.P(3)(f)2 to incorporate TR 49-28. Revised Paragraph 1.P.(3)(f)(2).

Page127

Revised Paragraph 1.Q. NOTE to incorporate TR 49-29. Reversed Paragraphs 1.Q and 1.Q.(1).

Pages 129 and 130

Revised figure to incorporate TR 49-30 and TR 49-31.

Pages 135 through 144

Revised table titles to incorporate TR 49-32 through TR 49-41.

ATA NO. 49-26-49 Copying,use or disclosureof informationon this pageis subjectto proprietaryrestrictions.

Hone vell


Engines, Systems & Sewices Phoenix, Arizona HIGHLIGHTS (CONT)

Subiect/Pa,qe

Description of Chan.qe

Disassembly Page 301 through 303

Updated Table 301.

Pages 392 through 395

Revised Figures 317 and 317A, Key to Figure 317 and Paragraphs 4.C.(3) and 4.C.(4) to incorporate SB 49-7660.

Pages 396 thmugh 398

Revised Figure 318, Key to Figure 318 and Paragraph 4.C.(5) to incorporate SB 49-7596.

Page 398.11

Revised Paragraph 4.C.(8) and Key to Figure 319A to incorporate SB 49-7598.

Page 398.19

Added SB 49-7587 reference in figure title.

Page 398.20

Added SB 49-7587 reference to Paragraph 4.D.(3).

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Assembly Pages 701 through 705

Updated Table 701.

Page 732

Revised Figure 706 (Sheet 1) to incorporate SB 497596.

Page 733

Revised Paragraph 4.A.(10) and Key to Figure 706 (Sheet 1) to incorporate SB 49-7596.

Page 734

Added Figure 706 (Sheet 2) to incorporate SB 497596.

Page 735

Added Key to Figure 706 (Sheet 2) and revised Paragraph 4.A.(11) to incorporate SB 49-7596.

Page 736

Added Figure 706 (Sheet 3) to incorporate SB 497596.

Page 747

Revised Paragraph 4.A.(13) to incorporate SB 497598.

Page 748

Added Figure 707A (Sheet 2) to incorporate SB 497598.

Page 750

Added Key to Figure 707A (Sheet 2) to incorporate SB 49-7598.

Page 752

Revised title of Figure 708 to incorporate SB 49-7660.

Page 753


Page 754

Added Key to Figure 708 to incorporate SB 49-7660.

ATA NO. 49-26-49 Copying,useor disclosureof informationonthis pageis subjectto proprietaryrestrictions.

Page 28/05 3 of

Hone vell


Engines, Systems & Services Phoenix, Arizona HIGHLIGHTS (CONT) Description of Chan,qe

Subjec~Paqe

UP200456

Assembly(Cont) Page 756

Revised title to Figure 708A to incorporate SB 497660.

Page 758

Revised title to Figure 708B to incorporate SB 497660.

Page 760

Revised title to Figure 708C to incorporate SB 497660.

Page 761

Revised Paragraph 4.A.(15) to incorporate SB 496940 and Key to Figure 708C to incorporate SB 497660.

Page 762

Revised title to Figure 708D to incorporate SB 497660.

Page 764

Added Figure 708D (Sheet 2) to incorporate SB 497660.

Page 766

Added Figure 708D (Sheet 3) to incorporate SB 497660.

Page 768

Added Figure 708E to incorporate SB 49-7660.

Page 769

Added Key to Figure 708E to incorporate SB 497660.

Pages 770 and 771


Page 780

Revised Paragraph 4.B.(1) and Figure 710.

Page 792

Revised Figure 714.

Page 793

Revised Paragraph 4.C.(1).

Page 796

Revised Paragraph 4.C.(2)(k).

Page 798

Revised Figure 716.

Page 798.1


Page 798.4

Revised Figu re 718.

Page 798.5


Page 798.6


ATA NO. 49-26-49 Copying,use or disclosureof informationon this pageis subjectto proprietaryrestrictions.

Hone vell


Engines, Systems & Services Phoenix, Arizona HIGHLIGHTS (CONT) Description of Chan.qe

Subiec~Paqe Assembly(Cont) Page 798.9

Revised Paragraph 4.D.(1).

Pages 798.42through 798.44

Added Figure 732A and new Paragraph 4.D.(13)(h) to incorporate TR 49-44. Revised Key to Figure 732A. Reidentified Paragraphs 4.D.(13)(h) through 4.D.(13)(i) to be 4.D.(13)(i) through 4.D.(13)(m) to incorporate TR 49-45.

Pages 798.56 and 798.57

Revised Figure 737. Revised Key to Figure 737. Revised Paragraph 4.D.(18) to incorporate SB 497454.

Page 798.61 and 798.62

Revised Paragraph 4.D.(20) and deleted Step (j).

Page 798.64

Deleted Figure 739A.

Page 798.65

Deleted Paragraph 4.D.(21 ) and Key to Figure 739A.

Page 798.68

Revised Figure 741.

Page 798.69

Revised Key to Figure 741.

Pages 798.70 and 798.71


Page 798.79


Page 798.94

Revised title to Figure 751A to incorporate SB 497587.

Page 798.95

Revised Paragraph 4.D.(32) to incorporate SB 497587.

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Storage Page 798.176

Revised Paragraph 5.B.(4).

A T A NO. 49-26-49 Copying, use or disclosure of information on this page is subject to proprietary restrictions.


Hone 'weil

Engines, Systems & Services Phoenix, Arizona

PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE PART NO. 3800504-1

COMPONENT MAINTENANCE MANUAL This document and all information and expression contained herein are the property of Honeywell International Inc., are provided in confidence, and may be used by persons required by Federal Aviation Regulation Part 21.50 to comply with any of the terms of these instructions. Except as set forth above, no person may, in whole or in part, use, duplicate or disclose this information for any purpose without the prior written permission of Honeywell International Inc.

This publication is distributed by: Honeywell International Inc. Engines, Systems & Services Cage Code (99193) Technical Publications

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For assistance Customer Support Center 800-601-3099 Outside North America call 602-365-3099

ATA NO. 49-26-49

Page T-1

Revised Feb 28/05 No. 5 Copyright 1991,2005 Honeywell International Inc. All rights reserved.


Honeywell

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] SAFETY ADVISORY

WARNING:

BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW THE HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO OBEY THE MANUFACTURERS' OR SUPPLIERS' RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR DISEASE.

This publication describes physical and chemical processes which can make it necessary to use chemicals, solvents, paints, and other commercially available materials. The user of this publication must get the Material Safety Data Sheets (OSHA Form 20 or equivalent) from the manufacturers or suppliers of the materials to be used. The user must know the manufacturer/supplier data and obey the procedures, recommendations, warnings and cautions set forth for the safe use, handling, storage, and disposal of the materials.

WARRANTY/LIABILITY ADVISORY WARNING:

HONEYWELL ASSUMES NO RESPONSIBILITY FOR ANY HONEYWELL EQUIPMENT WHICH IS NOT MAINTAINED AND/OR REPAIRED IN ACCORDANCE WITH HONEYWELL'S PUBLISHED INSTRUCTIONS AND/OR HONEYWELL'S FAA/FAR 36 REPAIR AUTHORIZATION. NEITHER DOES HONEYWELL ASSUME RESPONSIBILITY FOR SPECIAL TOOLS AND TEST EQUIPMENT FABRICATED BY COMPANIES OTHER THAN HONEYWELL.

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INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS OR DECREASE THE LIFE OF THE COMPONENTS. INCORRECTLY FABRICATED SPECIAL TOOLING OR TEST EQUIPMENT CAN RESULT IN DAMAGE TO THE PRODUCT COMPONENTS OR GIVE UNSATISFACTORY RESULTS.

49-26-49 Copying, use or disclosure of information on this page is subject to proprietary restrictions.


Hone) well

COMPONENT MAINTENANCE MANUAL GTCP36-280[D]

UP200456

RECORD OF REVISIONS REV NO.

ISSUE DATE

ORIG

Jul 22/91

1

Aug 31/92

2

Dec 16/94

3

Jun 30/97

4

Mar 30/01

5

Feb 28/05

DATE INSERTED

BY

REV NO.

ISSUE DATE

DATE INSERTED


BY


Honeywell

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] RECORD OF TEMPORARY REVISIONS

TR NO.

PAGE NO.

ISSUE DATE

49-1

796

Jan 10/94

49-2

797

Jan 10/97

49-3

398.25

Aug 11/95

49-4

788

Aucj 11/95

49-5

109

Jan 30/96

49-6

127

Jan 30/96

49-7

304

May 15/98

49-8

107

May 25/99 Jan 18/99

49-9 49-10

2

Sep 24/99

49-11

127

Feb 14/00 Feb 14/00

49-12

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49-13

130

DATE INSERTED

BY

DATE REMOVED

BY

INCORPORATED INTO MANUAL BY REV NO.

(Replaced by TR 49-10)


Feb 14/00

49-14

Feb 14/00


49-15

Feb 14/00


49-16

126

Mar 15/00

49-17

128

Mar 15/00

49-18

129

Mar 15/00

49-19

134

Mar 15/00

49-20

135

Mar 15/00

49-21

136

Mar 15/00

49-22

137

Mar 15/00

49-23

142

Mar 15/00

49-24

143

Mar 15/00

49-26-49 Copying,use or disclosureof informationon this pageis subjectto proprietaryrestrictions.

Page TR-1 Feb 28/05


Honeywell


UP200456

RECORD OF TEMPORARY REVISIONS (CONT)

DATE INSERTED

DATE REMOVED

INCORPORATEDINTO MANUALBY REV NO.

TR NO.

PAGE NO.

ISSUE DATE

49-25

103

Octl~01

5

49-26

107

O~ 12/01

5

49-27

123

O~ 12~1

5

49-28

125

Oct12~1

5

49-29

126

Oct12~1

5

49-30

128

Oct12~1

5

49-31

129

O~ 12~1

5

49-32

134

Octl~01

5

49-33

135

O~ 12/01

5

49-34

136

O~ 12/01

5

49-35

137

Oct12~1

5

49-36

138

Oct12~1

5

49-37

139

Oct12~1

5

49-38

140

Octl~01

5

49-39

141

O ~ 12/01

5

49-40

142

O~ 12~1

5

49-41

143

Oct12~1

5

49-42

109

Oct 26/01

5

49-43

17/18

Dec 3/01

5

49-44

798.29

Aug 21/02

5

49-45

798.30

Aug 21~2

5

BY

BY


Page TR-2 Feb 28/05


Hone well

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] RECORD OF TEMPORARY REVISIONS (CONT)

UP200456

TR NO.

PAGE NO.

ISSUE DATE

DATE INSERTED

BY

DATE REMOVED

BY


INCORPORATEDINTO MANUAL BY REV NO.

Page TR-3 Feb 28/05


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RECORD OF TEMPORARY REVISIONS (CONT)

UP200456

TR NO.

PAGE NO.

ISSUE DATE

DATE INSERTED

BY

DATE REMOVED

BY

49-26-49 Copying, use or disclosureof informationon this pageis subjectto proprietaryrestrictions.

INCORPORATED INTO MANUAL BY REV NO.

Page TR-4 Feb 28/05


Honeywell


UP200456

SERVICE BULLETIN LIST SB NO.__~.

DATE INCORPORATED

TITLE

49-6554, Revl

Refer to ATA No. 49-26-45

Rework Fuel Control Unit, Part No. 3882825-5 to Part No. 3882825-6.

49-6579


Replace Electronic Control Unit, Part No. 2118814-1 and/or-2 with Part No. 2118814-3, (Improve Surge Control Valve Stability).

49-6593


Rework Load Compressor Impeller Assembly, Part No. 3822270-1 to Part No. 3822270-3.

49-6594

May 31/94 No. 49-26-45

Incorporate Load Compressor Impeller Assembly, Part No. 3822270-3 in place of Part No. 3822270-1.

49-6600


Replace Electronic Control Unit, Part No. 2118814-3 with Part No. 2118814-4.

49-6606


Secure Containment Segment Assemblies, Part No. 3826725-1 and Part No. 3826726-1.

49-6608


Replace/Rework Containment Shield Segment Assemblies, Part No. 3826725-1 to Part No. 3828853-1 and Part No. 3826726-1 to Part No. 3826854-1.

49-A6618, Rev 1


Inspection of GTCP36-280 APUs for evidence of fuel manifold leakage.

49-6632, Rev 2


Attach Dampers, Part No. 3810696-1 with Nycote 7- 11 coating to the Inlet Bellmouth of Engine Compressor Housing. (To Reduce Vibration Amplitude.)

49-6634, Rev 2

May 31/94

Replace/Rework Bleed/Surge Ducting System.

49-6648


Incorporate Improved Packings on Turbine Bearing Vent Tube and Turbine Bearing Lubrication Tube.

49-6652, Rev 1


Replace Fuel Control Unit, Part No. 3882825-5 with Part No. 3882825-6.

49-A6653, Rev 1


Replace Rotating Group, Part No. 3822303-5 with Part No. 3822436-1.

49-6655, Rev 1


Replace Inlet Guide Vane Actuator (IGVA), Part No. 3883220-2 with Part No. 3883220-3.

49-6658, Rev 1


Enhanced Maintainability and Product Improved Configuration of the GTCP36-280[D] Engine.

49-26-49 Copying, useor disclosureof informationon this pageis subjectto proprietaryrestrictions.

Page SB-1 Feb 28/05

Honeywell



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SERVICE BULLETIN LIST (CONT) SB NO.~.~.

DATE INCORPORATED

TITLE

49-6659



49-6689


Remove Lube Pump, Part No. 3880130-5 and Install Part No. 3880130-6.

49-6690


Rework Lube Pump, Part No. 3880130-5 to Part No. 3880130-6.

49-6699


Incorporate Line Replacement Transducer Assembly (Flow Sensor) and Motional Transducer (Monopole).

49-6707


Rework Cooling Fan Assembly, Part No. 3615133-1 to Part No. 3615133-3 and Part No. 3615133-2 to Part No. 3615133-4.

49-6711


Remove and Replace Fan Assembly, Part No. 3615133-1 and -2 with Part No. 3615133-3 and -4.

49-6717


Replace Gearbox Housing Assembly Matched Set, Part No. 3862983-3 with Part No. 3862983-4.

49-6718


Remove Turbine Plenum Insulation Blanket Set, Part No. 3846610-1 and Install Part No. 3846610-7.

49-6719


Replace Combustion Chamber, Part No. 3830349-4 with Part No. 3830387-1.

49-6721


Replace Oil Filler Cap, Part No. 194-518-9001 with Part No. 194-518-9004.

49-6732


Replace Surge Control Valve, Part No. 3290050-2 with Part No. 3290050-3.

49-6736


Rework/Install Improved Turbine Housing, Part No. 3846664-1 with Part No. 3846664-2.

49-6739


Replace Turbine Containment, Part No. 3846563-1 with Part No. 3846563-2 and Replace/Rework Turbine Nozzle Assembly, Part No. 3846450-5 with Part No. 3846450-6.

49-6742, Rev 1


Replace Gearbox Assembly, Part No. 3863019-1/-2 with Part No. 3863136-2.

49-6748, Rev 1


Replace Carbon Seal Assembly, Part No. 3826450-5 with Part No. 3826880-2.

49-6755, Rev 1


Rework Lube Pump Assembly, Part No. 3880130-6 to Repair Machining Discrepancy in the Pressure Indicator Port.


Page SB-2 Feb 28/05

Honeywell



UP200456

SERVICE BULLETIN LIST (CONT) SB NO_._~.

DATE INCORPORATED

TITLE

49-6759, Rev 1


Rework and/or Replacement of Surge Duct, Part No. 3616082-1 with Part No. 3616456-1.

49-6768, Rev 2


Rework the Turbine Housing Diffuser, Part No. 3846664-3 to 3846664-4.

49-6775, Rev 1

May 31/94

Replace Surge Duct, Part No. 3616082-2 or Part No. 3616456-1 with Part No. 3616447-1 and Stiffener, Part No. 3884890-1. Also rework or Replace Turbine (Plenum) Housing, Part No. 3846664-2 to Part No. 3846664-3.

49-6780


Replace Oil Cooler Supply Line, Part No. 3881377-1 with Part No. 3881447-1 and Oil Cooler Return Line, Part No. 3881378-1 with Part No. 3881448-1.

49-6782


Replace Load Compressor Impeller, Part No. 3822270-4 with Part No. 3822270-5.

49-6783, Rev I


Replace Turbine Rotor, Part No. 3842121-2 with Turbine Rotor, Part No. 3842345-1.

49-6804, Rev 1


Rework/Replace IGV Actuator Tube Assembly, Part No. 3810410-1 with/to Part No. 3810410-2.

49-6805, Rev 1

Mar 30/01

APU Gearbox Gearshaft Shimming Procedure to Reduce Rotor Seal Operating Face Load on Gearbox Assembly, Part No. 3863136-1/-2, Part No. 3862980-1/-2 and Part No. 3863019-1/-2.

49-6814, Rev 2


Rework Fuel Control Unit, Part No. 3882825-6 to Part No. 3882825-8.

49-6816


Replace Fuel Control Unit, Part No. 3882825-6 with Part No. 3882825-8.

49-6832, Rev 2


Replace Flexible Duct, Part No. 3884769-2 with Part No. 3884930-2 and Clamps, Part No. 211-546-9010 with Part No. 211-546-9108.

49-6840


Replace or Rework Turbine and Compressor Assembly, Part No. 3801082-3 with Part No. 3801082-4 and Replace Plumbing and Electrical Assembly, Part No. 3616215-1 with Part No. 3616519-1 to Incorporate Oil-Cooled Vent Tube Modification.

49-6850


Replace Static Pressure Sensor, Part No. 3884730-1 with Part No. 3884730-2.


Page SB-3 Feb 28/05


Hone vell


UP200456

SERVICE BULLETIN LIST (CONT) SB NO__.~.

DATE INCORPORATED

49-6851


Replace Tube Assembly, Part No. 3881378-1 with Part No. 3881448-1, Tube Assembly, Part No. 3881377-1 with Part No. 3881447-1, and Clamps, Part No. 211-592-9010 with Part No. 211-592-9014.

49-6856, Rev 3

No Effect

Rework of Containment Ring, Part No. 3846563-2.

49-6862


Add Sealant Between the Driven Compressor Shroud, Part No. 3826589-2 or 3826754-2 and the IGV Cover, Part No. 3810324-1.

49-6883

Jun 30/97

Replace Omni "C" Seal, Part No. 3846520-1 and Bearing Spacer, Part No. 3846523-1 with Turbine Bearing Spacer, Part No. 3846640-1.

49-6886


Rework/Replace Inlet Guide Vane Housing Assembly (IGV), Part No. 3810316-2 to/with Part No. 3810316-4.

49-6887, Rev 2


Rework Fan Rotor, Part No. 3884664-1 to Part No. 3884664-3, Containment Ring, Part No. 3615122-1 to Part No. 3615122-2, Fan Assembly, Part No. 3614663-3 to Part No. 3614663-5 and Seal Housing, Part No. 3614670-2 to Part No. 3614670-3.

49-6888


Replace Cooling Fan Assembly, Part No. 3615133-3 to Part No. 3615133-5 and Part No. 3615133-4 to Part No. 3615133-6.

49-6905, Rev 1


Replace/Rework Engine Compressor Housing Assembly, Part No. 3826823-1/-2/-3 to Part No. 3826823-4.

49-6920


Replace Electronic Control Unit (ECU), Part No. 2118814-5 with Part No. 2118814-6.

49-6939


Rework the Oil-Fill Housing Assembly, Part No. 3863058-2/-3 to Part No. 3863058-4.

49-6940, Rev 2

Jun 30/97

Rework to Clamp Gear Seal Rotor and Change Gearbox Assemblies, Part No. 3862980-3 to -4, or 3863019-2 to -3, or 3863136-2 to -4, or 3863136-3 to -5.

49-6952


Replace Shutoff Butterfly Valve, Part No. 109382-34 with Part No. 109382-36.

49-6962, Rev I


Rework Fuel Control Assembly, Part No. 3882825-8 to Part No. 3882825-9.

49-6967, Rev 1


Replace/Rework Turbine Bearing Carrier Assembly, Part No. 3846612-1 with/to Part No. 3846612-2 or Part No. 3846521-4 with/to Part No. 3846521-5.

TITLE


Page SB-4 Feb 28/05

Hone3well



UP200456

SERVICE BULLETIN LIST (CONT) SB NO.

DATE INCORPORATED

TITLE

49-7051


Replace Surge Control Valve, Part No. 3920050-3 with Part No. 3290050-4.

49-7054


Replace Fuel Control Assembly, Part No. 3882825-8 with Part No. 3882825-9.

49-7095, Rev 2


Replace Load Compressor Bellows Seal Assembly, Part No. 3826880-2 with Part No. 3826880-3.

49-7104


Rework Turbine Housing, Part No. 3846664-3/-4 to Part No. 3846664-5 and Replace Union, Part No. MS24392J8 with Part No. 3616822-1.

49-7117


Replace Combustion Chamber, Part No. 3830387-1 with Part No. 3830387-3

49-7152, Rev 1


Replace Turbine Rotor, Part No. 3842121-2 or 3842345-1 with Dual Alloy Turbine Rotor, Part No. 3842146-1.

49-7166, Rev I

No Effect

Provides Instructions to Perform a Buffer Air Blockage Test to Check for a Blocked Buffer Supply Port Internal to the Load Compressor Bearing Carrier.

49-7201


Replace Turbine Backshroud Shims, Part No. 3846480-1/-2/-3/ -4/-5 with Part No. 3846670-1/-2/-3/-4/-5.

49-7258, Rev 1


Replace Bolt, Part No. MS9565-09 with Part No. MS9565-08.

49-7270, Rev 3


Replace Clutch, Part No. 3610945-1 with Part No. 3617044-1.

49-7307, Revl


Incorporate Curvic Seal Gasket, Part No. 3617088-1.

49-7309


Rework Lube Clutch Restrictor, Part No. 3611869-9 to Part No. 3611869-8 and Part No. 3862961-2 to Part No. 3862961-1.

49-7390, Rev 1


Rework Compressor Housing, Part No. 3826823-4 to Part No. 3826823-3.

49-7398, Rev I

No Effect

Provides Instructions for a One-Time Inspection of the Total Pressure Transducer, Part No. 3876084-1/-2, Differential Pressure Transducer, Part No. 3876085-4 and Inlet Pressure Transducer, Part No. 3876035-4.


Page SB-5 Feb 28/05


Hone vell


UP200456

SERVICE BULLETIN LIST (CONT) SB NO.__~.

DATE INCORPORATED

TITLE

49-7445


Replace Turbine Backshroud, Part No. 3613968-2 with Part No. 3846688-1.

49-7454


Replace IGV Assembly, Part No. 3810316-1/-2/-3/-4 with Part No. 3810910-1 and Incorporate IGV Cavity Seal, Part No. 3810916-1 and Support Ring, Part No. 3617448-1.

49-7462


Rework Bridge Hoist Assembly, Part No. 3616174-1 to Part No. 3616174-2.

49-7473


Incorporate Load Compressor Containment Shield Kit, Part No. 3617748-2.

49-7493, Rev 1

No Effect

Provides Instructions for a One-Time Inspection of Turbine Wheel, Part No. 3842146-1.

49-7565



49-7574


Rework Transducer Assembly, Part No. 3884833-1 to Part No. 3884833-2.

49-7578


Replace Elbow, Part No. MS24394J4 and Nut, Part No. AN924-4J with Union, Part No. AN815-4J, Packing, Part No. M83248-1-904 with CRES Seal, Part No. 362-015-9111 and Incorporate Swivel Fitting, Part No. MS51521B4S.

49-7581


Replace Differential Pressure Transducer, Part No. 3876085-4 with Part No. 3876085-5.

49-7587


Replace Load Compressor Impeller, Part No. 3822270-4/5 with Part No. 3822587-1.

49-7596, Rev 1

Feb 28/05

Provides the instructions and authorization for incorporating an improved Gearshaft Assembly, Part No. 3860769-2, Carbon Face Seal, Part No. 3863007-1 and associated hardware in place of Gearshaft Assembly, Part No. 3860769-1 and Lip Seal, Part No. 3862734-1

49-7598

Feb 28/05

Rework the Gearbox Housing Assembly, Part No. 3863135-1/-2 by adding material to oil jet bosses and machining to new dimensional requirements to accept an Oil Jet, Part No. 3863543-1. Add O-rings, Part Nos. M83248-1-012 and M83248-1-014 to the jet. Secure the jets using a Retainer, Part No. M27426-4104D.

49-7603

No Effect

Provides the procedure for reworking Flow Divider Assembly, Part No. 3883687-1 to Part No. 3883687-2.

49-26-49

Copying, use or disclosureof information on this pageis subjectto proprietaryrestrictions.

Page SB-6 Feb 28/05


Hone vell


UP200456

SERVICE BULLETIN LIST (CONT) SB NO~

DATE INCORPORATED

49-7608

No Effect

Provides the procedure for reworking Wire Harness Part No. 3888259-1 to Part No. 3888259-2 by pulling a single wire from the P1 connector and tying it back to the wire bundle. Replaced by Service Bulletin 49-7682

49-7610

No Effect

Provides the procedure for reworking Wire Harness, Part No. 3888259-2 to Part No. 3888259-1 by re-inserting the DMM power wire into the P1 connector. Replaced by Service Bulletin 49-7682

49-7628

No Effect

Provides the procedure for reworking Oil Fill Housing/Scupper Assembly, Part No. 3863058-1 or 3863658-4 to Oil Fill Housing Assembly, Part No. 3863058-6 or 3863058-5.

49-7646, Rev I

No Effect

Provides the procedure to remove and replace Packing, Part No. 3615648-1 with Seal Part No. 3617970-1.

49-7660

Feb 28/05

Provides authorization and instructions to replace Spacer, Part No. 3616659-1/-2 and Rotor, Part No. 3616658-1 with Drive Ring, Part No. 3861113-1, Rotor, Part No. 3861114-1 and Packing, Part No. $3225-032. Replace Retaining Nut, Part No. 3616663-1 with Part No. 3861111-1. Replace Seal, Part No. 3614502-1 or Part No. 3863029-1 with Seal, Part No. 38635451 or Part No. 3863544-1, respectively.

49-7669

No Effect

Provides authorization and instructions to Replace Seal Assembly, Part No. 3826450-5 or 3826880-3 and Seal Rotor, Part No. 3822169-1 with Seal Assembly, Part No. 3827514-4 and Hydropad Rotor, Part No. 3822549-1.

49-7682

No Effect

Provides authorization and instructions to disconnect the P11 connector install Cap, Part No. M83723/59-114RN on the P11 connector, install Cap, Part No. M83723/60-114RN on the DMM connector, and secure the P11 connector using Clamp, Part No. 211-592-9216, Bracket, Part No. MS9592-054, Bolt, Part No. MS9556-05 and Nut, Part No. MS21043-3. Replaces Service Bulletins 49-7608 and 49-7610.

49-7692

No Effect

Incorporate Starter Clutch Assembly, Part No. 3860813-4 in place of Part No. 3860813-3 on Gearbox, Part No. 3863136-2/4 or Part No. 3860798-6 in place of Part No. 3860798-5 on Gearbox, Part No. 3863019-3.

49-7734

No Effect

Provided instructions for removing and replacing DART Rotor, Part No. 3842146-1 with Part No. 3842146-2.

TITLE

49-26-49 Copying, use or disclosureof information on this pageis subjectto proprietaryrestrictions.

Page SB-7 Feb 28/05


.Honeywell


UP200456

SERVICE BULLETIN LIST (CONT) SB NO~

DATE INCORPORATED

GTE0741


To update packings to new specifications.

GTE0807


To provide authority for the use of Packing, Part No. MS9386-177 in place of Part No. MS9386-171.

GTE0808, Rev 1


To authorize use of Motional Transducer, Part No. 3878058-2 as an alternate part in place of Part No. 3878058-3. (CANCELED)

GTE0826


To provide authority to use Bolt, Part No. MS9557-22 in place of MS9557-14.

GTE0860


To eliminate possibility of bolt interference, and install correct size packing.

GTE0861


To replace Oil Packing, Part No. 3615769-12 with Part No. 561-515-0018.

GTE0888


To provide authority to use Gasket, Part No. 3830351-1 in place of Preformed Packing, Part No. 3830189-1.

GTE0899


To provide authority to use Clamp, Part No. 211-502-9030 in place of 211-592-9010.

GTE0933


To provide authority to use Insert, Part No. 423-603-9032 in place of 423-603-9012.

GTE0937, Rev 1


To provide authority to use Load Compressor Impeller, Part No. 3822270-4 in place of Part No. 3822270-5 for Rotating Group, Part No. 3822436-3.

GTE0951


To provide authority to use Low Oil Pressure Switch, Part No. 3876186-3 as an alternate part for Part No. 3876186-4 on existing applications.

GTE0957


To provide authority to use Insert, Part No. MS21209C0815L in place of MS21209C0815.

GTE0959


To provide authority to use Packing, Part No. M83248-1-151 in place of M83248-1-150.

GTE0963


To provide authority to replace Packing, Part No. NAS1532C3E and Part No. $8990-008 with Part No. 3615648-1.

GTE0967


To provide authority to use Packing, Part No. 3615648-1 in place of Part No. NAS1523C3E.

TITLE


Page SB-8 Feb 28/05


Honeywell


UP200456

SERVICE BULLETIN LIST (CONT) SPB NO...~

DATE INCORPORATED

TITLE

GTE0970


To provide authority to use Flow Divider Valve Assembly, Part No. 3882835-4 as an alternate for Part No. 3882835-3.

GTE0979


To authorize use of Ignition Exciter, Part No. 3888000-3 as an alternate part for Part No. 3888000-2.

GTE0983


To provide authority to use Labyrinth Seal Housing Assembly, Part No. 3827040-1 in place of Part No. 3826776-1.

GTE0998


To authorize the use of Data Memory Module, Part No. 304643-2 in place of Data Memory Module, Part No. 304643-1.

GTE1029


To authorize use of Starter Clutch Assembly, Part No. 3860798-4.

GTE 1094


To provide authority to use Starter Motor, Part No. 2000866-2, Series 4MR1 in place of Part No. 2000866-2, Series 4.


Page SB-9/SB-10 Feb 28/05

Hone veli


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] LIST OF EFFECTIVE PAGES

SUBJECT

PAGE

DATE

Title Page

T-1

Feb 28/05

SWLA-1 SWLA-2

Feb 28/05 Blank

RR-1 RR-2

Feb 28/05 Blank

TR-1 TR-2 TR-3 TR-4

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05

SB-1 SB-2 SB-3 SB-4 SB-5 SB-6 SB-7 SB-8 SB-9 SB-10

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Blank

Safety/ Warranty/ Liability Advisory

Record of Revisions

Record of Temporary Revisions

Service Bulletin List

List of Effective Pages

Table of Contents

UP200456

Introduction

LEP-1 LEP-2 LEP-3 LEP-4 LEP-5 LEP-6

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05

TC-1 TC-2

Feb 28/05 Blank

INTRO-1 INTRO-2 INTRO-3 INTRO-4 INTRO-5 INTRO-6 INTRO-7 INTRO-8 INTRO-9 INTRO-10

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05

SUBJECT

Description and Operation

Testing and Fault Isolation

PAGE

DATE

INTRO-11 INTRO-12 INTRO-13 INTRO-14

Feb 28/05 Feb 28/05 Feb 28/05 Blank

1 2 3 4 5 6 7 8 9 10 11FO 12 13 FO 14 15 FO 16 17 FO 18 19 FO 2O 21 22

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Blank Feb 28/05 Blank Feb 28/05 Blank Feb 28/05 Blank Feb 28/05 Blank Feb 28/05 Blank

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05

49-26-49 Copying,use or disclosureof informationon this page is subjectto proprietaryrestrictions.

Page LEP-1 Feb 28/05


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SUBJECT

UP200456

Disassembly

PAGE

DATE

124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 • 155 156 157 158 159 160 161 162

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Blank

301 302 303 304 305 306 307 308 309 310 311 312 313

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 • Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05

SUBJECT

PAGE

DATE

314 315 316 317 318 319 320 321 322 323 324 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05



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RELEASED FOR THE EXCLUSIVE USE BY: ASERCA AIRLINES COMPONENT MAINTENANCE MANUAL

GTCP36-280[D] LIST OF EFFECTIVE PAGES

UP200456

SU BJ ECT

PAGE

DATE

368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 398.1 398.2 398.3 398.4 398.5 398.6 398.7 398.8 398.9 398.10 398.11 398.12 398.13 398.14 398.15 398.16 398.17 398.18 398.19 398.20 398.21 398.22


PAGE

DATE

398.23 398.24 398.25 398.26 398.27 398.28 398.29 398.30 398.31 398.32 398.33 398.34 398.35 398.36 398.37 398.38 398.39 398.40 398.41 398.42

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Blank

Cleaning

401 402 403 404 405 406 407 408 409 410 411 412

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Blank

Check

501 502

Feb 28/05 Blank

Repair

601 602

Feb 28/05 Blank

701 702 703 704 705 706 707 708 709 710 711 712

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05

SUBJECT

Assembly (With Storage)




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UP200456

SUBJECT

PAGE

DATE

713 714 715 716 717 719 720 721 722 723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 738 739 740 741 742 743 744 745 746 747 748 749 750 751 752 753 754 755 756 757 758 759 760 761 762 763 764 765 766


SUBJECT

PAGE

DATE

767 768 769 770 771 772 773 774 775 776 777 778 779 780 781 782 783 784 785 786 787 788 789 790 791 792 793 794 795 796 797 798 798.1 798.2 798.3 798.4 798.5 798.6 798.7 798.8 798.9 798.10 798.11 798.12 798.13 798.14 798.15 798.16 798.17 798.18 798.19 798.20 798.21





Honeywell


UP200456

SUBJECT

PAG E

DATE

798.22 798.23 798.24 798.25 798.26 798.27 798.28 798.29 798.30 798.31 798.32 798.33 798.34 798.35 798.36 798.37 798.38 798.39 798.40 798.41 798.42 798.43 798.44 798.45 798.46 798.47 798.48 798.49 798.50 798.51 798.52 798.53 798.54 798.55 798.56 798.57 798.58 798.59 798.60 798.61 798.62 798.63 798.64 798.65 798.66 798.67 798.68 798.69 798.70 798.71 798.72 798.73 798.74


SUBJECT

PAG E

DATE

798.75 798.76 798.77 798.78 798.79 798.80 798.81 798.82 798.83 798.84 798.85 798.86 798.87 798.88 798.89 798.90 798.91 798.92 798.93 798.94 798.95 798.96 798.97 798.98 798.99 798.100 798.101 798.102 798.103 798.104 798.105 798.106 798.107 798.108 798.109 798.110 798.111 798.112 798.113 798.114 798.115 798.116 798.117 798.118 798.119 798.120 798.121 798.122 798.123 798.124 798.125 798.126 798.127





Honeywell


SUBJECT

UP200456

Fits and Clearances

PAGE

DATE

798.128 798.129 798.130 798.131 798.132 798.133 798.134 798.135 798.136 798.137 798.138 798.139 798.140 798.141 798.142 798.143 798.144 798.145 798.146 798.147 798.148 798.149 798.150 798.151 798.152 798.153 798.154 798.155 798.156 798.157 798.158 798.159 798.160 798.161 798.162 798.163 798.164 798.165 798.166 798.167 798.168 798.169 798.170 798.171 798.172 798.173 798.174 798.175 798.176

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05

801 802

Feb 28/05 Feb 28/05

SUBJECT

Special Tools, Fixtures and Equipment

PAGE

DATE

803 804 805 806

Feb 28/05 Feb 28/05 Feb 28/05 Blank

901 902 903 904 905 906

Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05 Feb 28/05



Honeywell



T A B L E OF C O N T E N T S SECTION

PAGE

Introduction .....................................................................................................................................

INTRO-1

Description and Operation ........................................................................................................................... Testing and Fault Isolation ......................................................................................................................

1 101

UP200456

Automatic Test Requirements (ATLAS) (Not Applicable) Disassembly ............................................................................................................................................

301

Cleaning ...................................................................................................................................................

401

Check ......................................................................................................................................................

501

Repair ......................................................................................................................................................

601

Assembly (With Storage) .........................................................................................................................

701

Fits and Clearances .................................................................................................................................

801

Special Tools, Fixtures and Equipment ...................................................................................................

901


Page TC-1/TC-2 Feb 28/05


Hone vell

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] INTRODUCTION

.

General This publication gives maintenance instructions for the equipment shown in Table 1 which is made by: Honeywell Engines, Systems, and Services, Phoenix, AZ. This publication is written to the Air Transport Association Specification 100. The same exploded view illustrations are shown in DISASSEMBLY, CHECK, REPAIR, and ILLUSTRATED PARTS CATALOG (IPC), ATA No. 49-26-49. These illustrations are numbered in the same sequence in each section. For example, Figure 301 in DISASSEMBLY is the same as Figure 1 in the IPC. A note is used to keep the figure number sequence if any illustration is not used in a section.

.

Equipment Identification The configuration of the equipment is shown by the part number, series number, and change number stamped on the identification plate. Compare this information with the information shown in Table 1 (through last alpha suffix). Special procedures or illustrations necessary for each configuration will be identified by a part number, a service bulletin number (Pre SB-, Post SB-) or a code symbol. Procedures and illustrations not identified apply to all configurations of the equipment.

.

Measurement Conversion If measurements, weights, dimensions, pressure or torque values are changed to metric equivalents, they are shown in parentheses after the United States measurements.

.

Temperature Temperatures shown in degrees Fahrenheit use the symbol F. Celsius (centigrade) is shown with the symbol (C).

.

Applicable Publications

UP200456

The nomenclature, part number, and publication number of any component publication applicable to the unit is shown in Table 2.


Page INTRO-1 Feb 28/05


Honeywell .


Codin.q System The purpose of the effectivity system is to identify non-interchangeable changes. These changes are caused by modifications to the basic unit. This makes it necessary to reidentify the end unit. For example, Part No. 123456-1 becomes Part No. 123456-2. A single code is given to each different part number and dash number. If no codes are shown in the text, the procedures apply to all the units. If one or more codes are shown for a part number, the procedure in the text will apply only to the coded parts. The Equipment Identification List, Table 1, shows the part number and code for each unit part number.

.

Performance Check of Technical Data When possible, and to make sure the procedures in the sections of the technical manuals are correct a performance check is done of the procedures in the manual. The sections shown below have been performance checked at the manufacturer's overhaul facility.

UP200456

Section

Date

49-26-49 Copying, use or disclosureof informationon this page is subjectto proprietaryrestrictions.


Hone3 vell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 1. Equipment Identification List For Part No. 3800504-1

Code Symbol

Service Bulletin

Series No.

Change No.

Description

1

1

Original Configuration

2

1 and 3 3

3

4

Incorporate Improved Flow Divider Valve Assembly

1,3 and 4, 7 4

Provide Longer Hose Assembly

7

Provide New Rotating Group Assembly

49-6594

Incorporate New Primary and Secondary Fuel Manifolds

49-A6618

10

Incorporate New Surge Ducts For Better Fit

49-6634

12

Incorporate Improved Blanket To Correct Potential Interference

49-6718

13

Incorporate Improved Lube Pump

49-6689

1,3,4,7, and 11 11 1,3,4,7,11, and 10, 12, 13

UP200456

6

1,3,4,7,10, 11,12,13, and 17,20,23




Honeywell

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 1. Equipment Identification List For Part No. 3800504-1 (Cont)

Code Symbol

Series No.

7

Change No. 17

Incorporate -2 Engine Assembly at Customer Request

49-6658

20

Incorporate Improved Fan Assembly to Preclude Possible Interference

49-6711

23

Incorporate Power Section with Bellmouth Housing

49-6632

Incorporate Shimadzu Gearbox

49-6742

Incorporate Turbine & Compressor Assembly with Improved Face & Rotor Seals and Stub Shaft Containment

49-6719, 49-6739, 49-A6653, 49-6782

1;3,4,7,10, 11, 12, 13, 17, 20, 23 and 29 29

8

1,3,4,7,10,11, 12, 13, 17, 20, 23, 29 and 16 16

UP200456

9

Service Bulletin

Description

1,3,4,7,10,11, 12,13,16,17,20, 23,29 and 21, 25,26,27,30 21

Incorporate New Engine Bridge Hoist

25

Provide Improved Rotating Group and Impeller




Hone) vell


Code Symbol

Series No.

10

Change No. 26

Authorizes use of 561-515-0022 Packing in Place of M83248-1-112 Packing for Improved Packing Life

49-6648

27

Incorporate Fuel Control for Improved Reliability

49-6652

30

Incorporate Improved Surge Control Valve

49-6732

Provide an Improved Surge Exhaust Duct

49-6759

Incorporate Improved Turbine Wheel

49-6783

Incorporate Improved Turbine Housing

49-6736

1,3,4,7,10,11, 12,13,16,17,20, 21,23,25,26,27 30 and 33 33

11

1,3,4,7,10,11, 12, 13, 16, 17, 20, 21,23, 25, 26, 27, 30, 33 and 34 34

12

1,3,4,7,10,11, 12,13,16,17,20, 21,23,25,26,27, 30,33,34 and 24 24

UP200456

Service Bulletin

Description




Honeywell


Code Symbol

Series No.

Change No.

13

1,3,4,7,10,11, 12, 13, 16, 17, 20, 21, 23, 24, 25, 26, 27, 30, 33, 34 and 35 35

14

16

Provide Flex Lines for Easier Maintainability

49-6780

37

Provide Improved Surge Duct

49-6775

39

Provide Static Pressure Sensor Adjustment Range

49-6850

Provide Reduced Seal Friction and Carbon Face Wear

49-6748

1,3,4,7,10,11, 12,13,16,17,20, 21,23,24,25,26, 27,30,33,34,35, 36 and 37,39

1,3,4,7,10,11, 12,13,16,17,20, 21,23,24,25,26, 27,30,33,34,35, 36,37,39 and 41 41

UP200456

Incorporate Improved Plenum

1,3,4,7,10,11, 12, 13, 16, 17, 20, 21,23, 24, 25, 26, 27, 30, 33, 34, 35 and 36 36

15

Service Bulletin

Description




Hone3 vell


Code Symbol

Series No.

Change No.

17

1,3,4,7,10,11, 12, 13, 16, 17, 20, 21, 23, 24, 25, 26, 27, 30, 33, 34, 35, 36, 37, 39, 41 and 42 42

18

UP200456

19

Description

Service Bulletin

Provide Reinforced Exhaust Diffuser

49-6768

1,3,4,7,10,11, 12, 13, 16, 17, 20, 21, 23, 24, 25, 26, 27, 30, 33, 34, 35, 36, 37, 39, 41,42 and 45, 46 45

Provide Oil Cooled Vent Tube

49-6840

46

Provide Improved Fuel Control

49-6816

1,3,4,7,10,11, 12,13,16,17,20, 21,23,24,25,26, 27,30,33,34,35, 36,37,39,41,42,45, 46 and47, 48,49 47

Provide Gearbox Shimming to Relieve Carbon Seal Load

49-6805

48

Provide Improved Fan Rotor

49-6888

49

Provide Improved Bonding of Damper Strip

49-6632



Hone)well



Code Symbol

Series No.

Change No.

20

1,3,4,7,10,11, 12, 13, 16, 17, 20, 21,23, 24, 25, 26, 27, 30, 33, 34, 35, 36, 37, 39, 41,42, 45, 46, 47, 48, 49 and 51,53

UP200456

21

Service Bulletin

Description

51

Provide Improved IGV Bushing

49-6804

53

Provide Improved Linkage

49-6862

1,3,4,7,10,11, 12, 13, 16, 17, 20, 21,23, 24, 25, 26, 27, 30, 33, 34, 35, 36, 37, 39, 41,42, 45, 46,47,48,49,51,53 and 52,54,56,57,58, 59,60,62,63,64,65, 66,67,69 52

Provide Improved Turbine Bearing Spacer

49-6883

54

Provide Improved Surge Bleed Duct

49-6832

56

Provide Improved Compressor Housing Assembly

49-6905

57

Provide Improved Oil Scupper

49-6904

58

Provide Improved IGV Housing



Hone well



Code Symbol

Series No.

UP200456

No Series

Change No.

Description

Service Bulletin

59

Provide Improved Isolation Valve

49-6930

60/61

Provide Improved Gearbox Assembly

49-6940

62

Provide Improved Turbine Bearing Carrier

49-6967

63

Provide Improved FCU

49-6962

64

Provide Improved SCV

49-7051

65

Provide Improved Turbine Housing to Provide Gearbox Pressure Reduction

49-7104

66

Provide Improved Stationary Oil Seal Assembly

49-7095

67

Provide Improved Combustion Chamber

49-7117

69

Provide Improved Dual Alloy Turbine Wheel

49-7152

5

Incorporate Improved Surge Valve Kicker Hardware

49-6579

8

Incorporate Improved ECU

49-6660

19

Provide Improved IGV Actuator

49-6655

22

Provide Improved Start Motor

32

Provide Improved Transfer Tube in Gearbox

38

Provide Improved Surge Exhaust Duct

40

Provide Improved LOP Switch



Hone vell



UP200456

Code Symbol

Series No.

Service Bulletin

Change No.

Description

43

Provide Improved Rotating Group

44

Provide Improved IGV Actuator Rod

55

Provide Improved Rotating Group Assy

68

Provide Improved Rotating Group

70

Remove/Replace Turbine Backshroud Shims, Part No. 3646480-1/-2/-3/-4/-5 with Part No. 3846670-1/-2/-3/-4/-5

71

Provide Improved Differential Pressure Transducer

49-7235

72

Provide Improved Delta P Transducer

49-7235

74

Incorporate Specific Bolt for Blind Hole

49-7258

77

Provide Improved Packing

49-7296


49-7201


Hone ell



UP200456

Code Symbol

Series No.

Change No.

Service Bulletin

Description

78

Rework/Replace Lube Clutch Restrictor, Part No. 3611869-9 to/with Lube Clutch Restrictor, Part No. 3611869-8 and Lube Clutch Restrictor, Part No. 3862361-2 to/with Lube Clutch Restrictor, Part No. 3862961-1

49-7309

79

Incorporation of L/C Impeller Curvic Seal Gasket, Part No. 3617088-1

49-7307

80

Replace/Rework Engine Compressor Housing Assembly, Part No. 3826823-4 to 3826823-3

49-7390

81

Installation of Inlet Guide Vane (IGV) Assembly, Part No. 3810910-1, IGV Cavity Seal, Part No. 3810916-1, and Support Ring, Part No. 3617448-1

49-7454

83

Replace Turbine Backshroud, Part No. 3613968-2 with Turbine Backshroud, Part No. 3846688-1

49-7445

84

Provide for Load Compressor Containment Ring

49-7473

85

Eliminate Oil Leakage from Oil Vent Fitting

49-7578

86

Provide identity for units incorporating Rotating Group Assembly, Part No. 3822436-2 (Improved Load Compressor Impeller)

49-7587

87

Replace Transducer Assembly, Part No. 3884833-1 with Part No. 3884833-2

49-7574



Honeywell



UP200456

Table 2. Applicable Publications List

Nomenclature

Part No.

Publication

Type

Gas Turbine Engine Assembly

3800504-1

49-26-45 49-26-47 49-26-51

IPC MM IRM

Data Memory Module

304643-1 304643-2

49-60-61

CMM/IPL

De-Oil Valve

3876166-1

49-91-47

CMM/IPL

Electronic Control Unit

2118814-1 2118814-3 2118814-4 2118814-5 2118814-6 2118814-7

49-61-50

CMM/IPL

Fan Assembly

3615133-2 3615133-4 3615133-6

49-51-75

CMM/IPL

Fuel Flow Divider

3882835-1 3882835-3 3882835-4

49-32-07

CMM/IPL

Fuel Control Assembly

3882825-5 3882825-6 3882825-8 3882825-9

49-30-97

CMM/IPL

Ignition Exciter

3888000-1 3888000-2 3888000-3

49-40-39

CMM/IPL

Inlet Guide Vane Actuator

3883220-2 3883220-3 3886182-1

49-50-02

CMM/IPL

49-50-06

CMM/IPL

Load Control Valve

109382-34-1 109382-36-1

49-50-40

CMM/IPL

Lube Pump Assembly

3880130-5 3880130-6

49-91-53

CMM/IPL

Oil Temperature Regulator

160466-1

49-94-18

CMM/IPL



Honeywell



UP200456

Table 2. Applicable Publications List (Cont) Nomenclature

Part No.

Publication

Type

Pressure Relief Valve

968214-17

49-31-09

CMM/IPL

Remote BITE Display

2118820-1

49-61-52

CM M/IPL

Starter Motor

2000866-2

49-41-08

CMM/IPL

Surge Control Valve

3290050-2 3290050-3 3290050-4

49-50-87

CMM/IPL

Transducer

3884714-1 3884833-1 3884833-2

49-51-83 49-51-91

CMM/IPL CMM/IPL


Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] DESCRIPTION AND OPERATION

.

General The gas turbine auxiliary power unit (APU) is a self-contained power unit. The APU is controlled by a system of automatic, pneumatic and electromechanical controls. The APU is designed to function as a combination shaft and pneumatic power source. Power output is ready for use while the aircraft is on the ground or in-flight. The physical operationai characteristics of the engine are listed in Table 1. Approved engine oils are listed in Table 2.

Table 1. Leading Particulars

NOTE:

This APU is designed for operation with a customer-furnished air-cooled generator.

Rated Output Shaft Power ......................................................................................................60 HP (continuous) 90 HP (max. generator continuous) 120 HP (five minutes) 145 HP (five seconds) Rated Output Shaft Speed ..................................................................................................................6,000 RPM Maximum Turbine Exhaust Gas Temperature at Rated Output ................................................................................1216F (103F at sea level) Maximum Allowable Speed ...............................................................................................................69,204 RPM Maximum Oil Consumption Rate ...................................................................................10 cc/hour (0.0106 qt/hr) Oil Pressure Limits for Manual and Idle Operation ...............................................................65 ___5psig (nominal) 28 +_2 psig (automatic LOP shutdown) Usable Oil Capacity .............................................................................................Total sump capacity 6.1 quarts. Approximately 3.4 quarts depletion to automatic shutdown. Frequency of Oil Change .........................................................................................Every 800 hours of operation Frequency of Oil Filter Change .........................................................................On condition. A Delta P indicator is provided to indicate when filter change is required. (500 hour minimum interval)

UP200456

Oil ......................................................................................................Synthetic-base. Lubricating Oil Type I per MIL-PRF-7808 and Type II per MIL-PRF-23699. (Refer to Table 2)

49-26-49 Copying, use or disclosure of information on this page is subject to proprietaryrestrictions.

Page 1 Feb 28/05

Hone vell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 1. Leading Particulars (Cont)

Fuel ......................................................................................................

Refer to Table 3 for list of approved fuels.

Minimum Fuel Inlet Pressure ....................................................................

10 to 55 psi for starting and operation.

Fuel Filter .......................................................................................................................................

10 micron filter

Power Supply ............................................................................................................................................

28 VDC

Table 2. Approved Engine Oils

Approved Lubricant Brand Name CAUTION:

Ambient Temperature Minimum Maximum F (C) F (C)

ANY SUBSTITUTION OR USE OF NON-APPROVED LUBRICANTS, OR MIXING OF BRANDS OR TYPES OF LUBRICANTS MAY CAUSE CONSIDERABLE ENGINE DAMAGE.

3 Centistoke Oils

Type I (Lubricant Specification MIL-PRF-7808) Aeroshell Turbine Oil 390 Brayco 880 Castrol 325 or 399 BP/Exxon Turbo oil 2389

-65 -65 -65 -65

(-54) (-54) (-54) (-54)

130 130 130 130

(54) (54) (54) (54)

-40 -40 -40 -40 -40 -40 -40 -40 -40 -40 -40

(-40) (-40) (-40) (-40) (-40) (-40) (-40) (-40) (-40) (-40) (-40)

130 130 130 130 130 130 130 130 130 130 130

(54) (54) (54) (54) (54) (54) (54) (54) (54) (54) (54)

5 Centistoke Oils Type II (Lubricant Specification MIL-PRF-23699) Aeroshell Turbine Oil or Royco 500 Aeroshell Turbine Oil or Royco 555 Aeroshell Turbine Oil or Royco 560 Castro15000 Exxon Turbo Oil 2197 BP/Exxon Turbo Oil 2380 Hatcol 3611 Mobil Jet Oil II Mobil Jet Oil 254 Mobil Jet Oil 291 Royco 899 7.5 Centistoke Oil

UP200456

Castrol 98

-40 (-40)

130 (54)


Page 2 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 3. Approved Fuels Fuel Inlet Temperatures for Starting and Operation Minimum Maximum F (C) F (C)

Fuel .NOTE:

This APU is designed for operation with a customer-furnished air-cooled generator.

American Fuels MIL-DTL-5624 JP-4 JP-5

-40 (-40) -30 (-34)

135 (57) 135 (57)

MIL- DTL-83133 JP-8

-30 (-34)

135 (57)

ASTMD-1655 Jet A Jet A-1 Jet B

-30 (-34) -30 (-34) -40 (-40)

135 (57) 135 (57) 135 (57)

British Fuels DERD 2486 DERD 2494 DERD 2498

-40 (-40) -30 (-34) -30 (-34)

135 (57) 135 (57) 135 (57)

Canadian Fuels CAN 2-3.22-77 CAN 2-3.23-77 3-GP-24g

-40 (-40) -30 (-34) -30 (-34)

135 (57) 135 (57) 135 (57)

IATA Fuels 1978 (Kerosene Type) 1978 (JP-4 Type)

-30 (-34) -40 (-40)

135 (57) 135 (57)

French Fuels Air 3405/C Air 3407/B

-30 (-34) -40 (-40)

135 (57) 135 (57)

.

Description The APU will supply the aircraft with:

UP200456

Pneumatic power for aircraft main engine starting (MES) Pneumatic power for cabin air conditioning Shaft power to drive an electrical generator

49-26-49 Copying, use or disclosure of informationon this page is subjectto proprietaryrestrictions.

Page 3 Feb 28/05

HoneTwell



Cooling air for the generator/APU lubrication oil The APU has two modules. The power section/load compressor A gearbox with accessories. The APU uses a single-shaft gas turbine power section directly driving the load compressor and gearbox. The power section and load compressor are mounted together on a single shaft supported by two bearings as shown in Figure 1. Figure 2 shows the four major parts that make up the entire hot end of the APU. Only two of the four parts, the turbine nozzle and rotor, are exposed to full turbine temperature.

A3800504MM21

UP200456

APU Incorporates a Simple Single-Shaft Design (Typical) Figure 1


Page 4 Feb 28/05

Hone~vell


COMPONENT MAINTENANCEMANUAL GTCP36-280[D]

TURBINE PLENUM WITH INTEGRAL EXHAUSTDUCT

COMBOSl ./

\ \ /

\

\

/" f

\

'\//

/

/-

NOZZLEASSY TURBINE ROTOR X3800504DO169

UP200456

APU Has Only Four Major Hot End Parts Figure 2


Page 5 Feb 28/05

Honeywell



The APU gearbox is a wet sump modular assembly design interfaced with the load compressor and incorporates the following accessory drive pads: Generator assembly Oil pump/fuel control Starter motor assembly Cooling fan assembly. The accessory gearbox is designed as a module and is removable from the APU with all gears, bearings and seals in place. The Electronic Control Unit (ECU) provides a full-authority, microprocessor-based electronic control system, contained in a single box, remotely mounted from the APU in an environment compatible with electronic equipment. The four major parts of the APU hot end are: Turbine rotor Nozzle assembly Combustor Turbine plenum with integral exhaust duct. Figure 3 shows detailed items and their locations on the APU, to maximize accessibility and maintainability to the APU. Power Section The APU power section is shown in Figure 4. The power section is a single-shaft design employing a single stage centrifugal compressor and radial inflow turbine. The single main shaft that ties the power section compressor and turbine to the load compressor is supported by two bearings: -

A roller bearing aft of the gearbox A ball bearing between the power section compressor and turbine.

Carbon seals are used in the front and rear bearing cavities. The load compressor bearing incorporates a buffered carbon face seal while the turbine bearing uses a pair of carbon ring seals.

UP200456

The carbon seals provide more positive sealing than labyrinth seals, which results in lower oil consumption and improved heat rejection.


Page 6 Feb 28/05

HoneTwell



Refer to Figure 5 for lubricating system schematic, Figure 6 for fuel system schematic, Figure 7 for the pneumatic system schematic and Figure 8 (Sheets 1 and 2) for the wiring diagram. 3.

Operation The APU START is initiated from the APU master control panel located in the aircraft cockpit. The APU master switch is placed to START momentarily and spring loads to RUN. Electrical power is supplied to the Electronic Control Unit (ECU) and energizes the aircraft boost pump, fuel solenoid, and the APU inlet door actuator. Starter motor engagement is delayed until the APU inlet door has opened and a door position signal is received by the ECU. A drop in DC volts is seen when the starter engages. The ECU accomplishes a pre-start bit check to verify operational readiness. The de-oil solenoid is allowed to open if oil temperature is low enough to require de-oiling. At 7% speed, the ECU: Energizes the ignition system Opens the fuel valve on the fuel control assembly Establishes the correct metered fuel level for APU lightoff When combustion occurs, the operator will notice a rise in EGT. Based on a speed rate increase, the ECU is programmed to schedule starting fuel flow to effect smooth, efficient APU starts and maximize turbine life. If EGT exceeds the programmed schedule, fuel flow is reduced to prevent overtemperature shutdowns. As the APU reaches 40% speed, the ECU commands the inlet guide vanes to open to a 22 degree angle, which allows sufficient airflow to cool the load compressor components. At 50% speed the starter is de-energized and voltage should return to normal. At 60% speed the de-oil solenoid is de-energized and closes and oil pressure should build to normal limits.

UP200456

When the APU is at 95% of governed speed, ignition is terminated and some protection circuits are armed. The generator and pneumatic bleed system are now ready to load and EGT will begin to stabilize.


Page 7 Feb 28/05

Hone~veil

°'o~#'



I,~ (~ 0

'..~

SURGECONTROL VALVE FUELCONTROL ELEMENT

OIL PUMP

FRONTVIEW

FAN DE-OIL ASSEMBLY SOLENOID

INLET GUIDE VANEACTUATOR

TRANSDUCER ASSEMBLY

LOAD CONTROL VALVE

LI

COOLER

/

OIL FILTER/ ELEMENT

OIL SUMP TEMPERATURE SENSOR

LOW OIL PRESSURE SWITCH

EXCITER

LEFT SIDE VIEW X3800504MM186

UP200456

APU External Features (Code A) Figure 3


Page 8 Feb 28/05

Hone veil

OILFILL PORT



I

OIL LEVEL

~%

~

~)

SIGHTGLASS

STARTERMOTOR "SURGECONTROL VALVE FUELCONTROL ASSEMBLY OILPUMP

FRONT VIEW

FAN DE-OIL ASSEMBLY SOLENOID

/

SENSOR

INLETGUIDE VANEACTUATOR LOADCONTROL VALVE

)--\ OILFILTER ELEMENT

NSDUCER PRESSURE TEMPERATURE ASSEMBLY ASSEMBLY ASSEMBLY EXCITER SENSOR LEFT SIDE VIEW

X3800504MM187

UP200456

APU External Features (Code B) Figure 3A

49-26-49

Copying, use or disclosure of information on this page is subject to proprietary restrictions.

Page 9 Feb 28/05


Honeywell


I

I |

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DIFFUSER ~

o .@

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_[11

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A3801082MM2

UP200456

APU Power Section Employs a Single Stage Compressor and Turbine (Typical) Figure 4


Page 10 Feb 28/05


Honeywell


TO TAILPIPE VENT

LOWOIL PRESSUR SWITCH

FUEL POWERED ACTUATOR

AIR / OIL SEPARATOR OIL TEMPERATUREREGULATOR

li

--[11

AIRCOOLED GENERATOR

~1~ FANAIR FLOW

B B NC SOLENOID VALVE (DE-OIL)

,THERMALBYPASS VALVE ~HOWN HO~

I IQJ

PRESSURE

SCAVENGE

E

\ --1

FUEL

OILPRESSURE RELIEFVALVE

GEARBOX

GRAVITYFILL WITHSCUPPER

REGULATING VALVE FILTERBYPASS VALVE

LEGEND: ¢)

¢) ~

[~ GEARCASEAIR o LUBEPUMPREGULATEDPRESSURE LUBEPUMPINLET

DIFFERENT~L PRESSURE INDICATOR

FILTER

SIGHT GLASS

SCAVENGEPUMPDISCHARGE SENSOR

SCAVENGEPUMPINLET GEARCASEVENTAIR

| MAGNETIC PLUG LUBEPUMP PUMPINLET ASSEMBLY (SCAVENGE) REGULATED (SEALING) (SCREENED) PRESSURE AND DRAINPLUG TESTPORT

UP200456

Lubrication System Schematic (Typical) Figure 5


Page 11/12 Feb 28105

A3800504MM125


Hone) vell


VANEACTUATOR

DRAIN PORT

(-6PORT)

VANESCLOSE

(-6PORT) ACTUATOR PRESSURE ,REOULATOI

ACTUATOR

-e--

RETURN

VALVE

COMBUSTOR

ACTUATOR

TORQUEMOTOR METERINGVALVE, , ~ PRESSURIZING FUEL

VA~ES OPEN

SUPPLY

N~]~~ 1

.'-I TESTPORT /(-3 PORT)

SHUTOFF SOLENOID N.O.~

',

HIGH PRESSURE /"FUEL. FILTER

POWER

DRIVEN COMPRESSOR

- m ~m

OIL PUMP AND VALVE ASSEMBLY FILTER

NOZZLE

GEARBOX

BYPASS SEAL DRAIN (-6 PORT) -IIGH~RESSURE FUELPUMP

/

L

DIFFERENTIAL PRESSURE REGULATOR

/

db

(-~PORT)N

SCREEN

.__________d_(SELFBYPASSI"C)

.

m

"(-4PORT)

RELIEFVALVE

/ CONTROL FUEL INLET

,,/t4 PORT)

FUEL

DIFFERENTIAL PRESSURE INDICATOR

(-BPORT)

STARTSEQUENCE

ll-maL'--mJ I "~'~"INLET FILTER

DRAINVALVE FLOW DIVIDER SECONDARY AND DRAINVALVES

UP200456

Fuel System Schematic (Typical) Figure 6


Page 13/14 Feb 28/05

DRAINPORT (-6 PORT) A3000505MM56


Honeywell


•

•

•

•

•

•

•

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•

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CONTROL~..~.

TOTAILPIPE VENT

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"'"~, ~_~

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!

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UP200456

Pneumatic System Schematic (Typical) Figure 7


Page 15/16 Feb 28/05

I

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INDICATOR _

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A3800504MM126


Honeywell


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UP200456

Wiring Diagram (Schematic) (Typical) Figure 8 (Sheet 1 of 2)


Page 17/18 Feb 28/05

To 88

X3800504DO213


Hone:~n~vell

COMPONENT

MAINTENANCE

MANUAL

GTCP36-280[D]

ECU

.

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SURGEVALVE FUEL CONTROL TORQUE MOTOR TORQUE MOTOR

SPEED SENSOR I_VOT

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UP200456

Wiring

Diagram (Schematic) (Typical) F i g u r e 8 (Sheet 2)


Page 19/20 F e b 28/05

9

X3800504MM46

Honeywell



4 ~ K E Y TO FIGURE 8 (SHEETS 1 AND 2)

ABBREVIATIONS

CONNECTORS

A/C AL ARINC

P1

APU CH P2 ECU EGT IGV LCIT LC PT LMES LOP P/O RMES S/D BATT XMIT REC PWR TM SIG AP

AIRCRAFT ALUMEL WIRE AERONAUTICAL RADIO INCORPORATED AUXILIARY POWER UNIT CHROMEL WIRE COMPRESSOR INLET PRESSURE ELECTRONIC CONTROL UNIT EXHAUST GAS TEMPERATURE INLET GUIDE VANE LOAD COMPRESSOR INLET TEMPERATURE LOAD COMPRESSOR TOTAL PRESSURE LEFT MAIN ENGINE START LOW OIL PRESSURE PART OF RIGHT MAIN ENGINE START SHUTDOWN BATTERY TRANSMIT RECEIVE POW ER TORQUE MOTOR SIGNAL DIFFERENTIAL PRESSURE

P2 P3 P4 P5 P6 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20

UP200456

P21

APU TO ECU INTERFACE CONNECTOR 223-685-9001 APU TO ECU INTERFACE CONNECTOR 223-685-9002 APU TO A/C INTERFACE CONNECTOR MS3459KT28-21 P RAM DOOR INTERLOCK SWITCH CONNECTOR MS3476L12-3S DOOR ACTUATOR CONNECTOR MS3476L12-10S IGNITION UNIT CONNECTOR MS3459L10SL-3S LOP SWITCH CONNECTOR M83723/95R803N FUEL SOLENOID VALVE CONNECTOR M83723/95R8036 DE-OIL SOLENOID VALVE CONNECTOR M83723/95R1203N DATA MEMORY MODULE CONNECTOR M83723/95R1415N SURGE VALVE TM CONNECTOR M83723/95R1005N FUEL CONTROL TM CONNECTOR M83723/95R1203N IGV ACTUATOR CONNECTOR M83723/95R1407N P2 SENSOR CONNECTOR M83723/95R 1407N LC PT SENSOR CONNECTOR M83723/95 R14076 LC AP SENSOR CONNECTOR M83723/95R1407N OIL TEMPERATURE SENSOR CONNECTOR MS3459L12S-3S SPEED SENSOR NO. 1 CONNECTOR M83723/95R1005N SPEED SENSOR NO. 2 CONNECTOR M83723/95R1005N LOAD CONTROL VALVE CONNECTOR MS3459L10SL-3S


Page 21/22 Feb 28/05


Honeywell

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] TESTING AND FAULT ISOLATION

.

Testing A.

Equipment and Materials Table 101 shows the equipment and materials necessary to do the tests. Table 101. Equipment and Materials

Equipment/Material NOTE:

Description/Manufacturer

Equivalentequipment/material can be used.

Instrumented bleed duct (834662-1)

Required for bleed air flow measurement.

Honeywell Engines, Systems & Services, Ground Support Equipment 717 N. Bendix Drive South Bend, IN 46628-1000 (574) 231-3987

Airflow measuring section (MF05DS)

Required for bleed air flow measurement.

Daniels Flow Products, 9753 Pinelake Dr, Houston, TX 77055

Electrical power DC (DCR40-25B)

External 28 vdc independent of the APU electrical system. Required to operate the starter motor relays and igniter circuit.

Sorensen, 767 Island Pond Road, Manchester, NH 03103

Electronic control unit (ECU) (2118814-5)

Controls the functions of the APU starter motor, ignition


UP200456

unit, fuel flow divider and fuel control during starts. Controls speed, EGT, and overtemperature protection. Engine stand mounts (834389-1, 834390-1,834119-2)

Used to adapt the APU to the portable stand assembly.


Bleed duct elbow (834131-1)

Setup with thermocouples.


Exhaust gas temperature meter (AN25MO2-TP-I-K-F-A)

Required for APU EGT thermocouple check and engine performance verification.

Analogic Corp, 8 Centennial Drive, Peabody, MA 01961

49-26-49

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Page 101 Feb 28/05

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COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 101. Equipment and Materials (Cont)

Equipment/Material


Fuel

MIL-T-6524, Grade JP-4 or JP-5 or ASTM D-1655-75T, Jet A or Jet B. Filtered and supplied at 110F (43C) (max) and 10 to 55 psi (20,36 to 112 Hg)

Shaft loading device or waterbrake

Required to apply shaft load of 100 shp/5 or more.

Supplied by customer. Generator Part No. 9765252-6 Waterbrake Part No. WA200

Inlet duct assembly (834400-1)

Refer to Figure 102. Required to measure inlet air temperature.


Lubrication

Synthetic-base lubricating oil, Type 11 (5 centistokes).

Portable stand assembly (833565-2)

Used to support the APU during test and removal or installation

UP200456

of components.


Vibration pickups (3) (6222S-50A)

Required for gearbox, load compressor, and turbine section.

Bruel and Kjaer Inst Co., 2117 S. 48th St., Suite 107, Tempe, AZ 85282

Exhaust tailpipe (834611-1 )

Required for exhaust gas temperature.


49-26-49 Copying, use or disclosure of informationon this pageis subjectto proprietaryrestrictions.

Page 102 Feb 28/05


Honeywell


Equipment/Material


Vibration accelerometer mounts (834134-1/-2/-3)

Required for measuring exhaust gas temperature.


Surge valve positioning sensor (2024323-1)

Required for surge valve position indication.


1.

g.

General instructions.

(1)

Approved engine oils are given in DESCRIPTION AND OPERATION, Table 2.

(2)

Engine test requirements and operating limits are given in Table 102.

(3)

Complete and accurate record of all test information must be kept on a test record and performance data sheet. A separate set of records and data sheets must be used for each engine and kept as a permanent record on the engine. A sample test record sheet and performance data sheet are supplied.

(4)

Calculation may be necessary to change certain values to standard values. When such calculations are necessary, the instructions, charts, curves, tables or other data are given in the text. NOTE:

(5)

All instrumentation must be carefully calibrated against recognized standards. Manometer must be zeroed or set to barometer reading as applicable, at least once a day. Any error more than accuracy limits given in Table 102 must be corrected before testing.

(6)

Test release criteria are provided for three APU test categories. The depth of repair identifies the categories as follows: (a)

(b)

UP200456

All instrumentation and gages used in the test and fault isolation, must be calibrated and accurate.

Light repair. Continue-time (WPG) inspection criteria apply. 1

External work only (electrical harness, LRUs, plumbing)

2

Partial gearbox disassembly

3

Any combination of the above

Medium repair. Continue-time (WPG) inspection criteria apply. 1

Complete gearbox disassembly

2

Partial or complete load compressor disassembly only


Page 103 Feb 28/05


Hone) well 1.

B.

(6)

(b)

(c)

COMPONENT MAINTENANCE MANUAL GTCP36:280[D] 3

partial or complete power section disassembly only

4

Complete disassembly of any or all sections (gearbox, compressor, and turbine) to repair a specific discrepancy affecting APU operation with all other parts reused as removed

5

Any combination of the above

Heavy repair - IRM inspection criteria applies.

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1

Complete load compressor and power section disassembly, where exposed detail parts are inspected per IRM requirements. This has previously been called an "overhaul" unit or "heavy repair" or "zerotime" unit


Page 104 Feb 28/05


Hone vell


PRESSURE TRANSDUCERS *USEOFFLOWCONTROLORIFICE ORVENTURIOPTIONAL.

[]

LABBLEEDDUCT

T

.-,=1

FUEL C~NTF

X~O~O~TI~

UP200456

GTCP36-280[D] General Test Setup Schematic (Typical) Figure 101


Page 105 Feb 28/05


Honeywell


~ l n KEY TO FIGURE 101

I-I 1 BLEEDAIR ORIFICE AP 2 BLEEDAIR ORIFICE INLET PRESSURE 3 BLEEDAIR TOTAL PRESSURE 4 BLEEDAIR ORIFICE INLET TEMPERATURE 5 COMPRESSOR INLET TEMPERATURE 6 BLEEDAIR TEMPERATURE 7 FUEL INLET TEMPERATURE 8 CELL EXHAUST GASAVERAGE TEMPERATURE (12) 9 UNIT EXHAUST GAS TEMPERATURE (4)

O

10 11 12 13 14 15 16 17 18 19 20

UNIT VIBRATION (3) UNIT SPEED OIL DISCHARGE PRESSURE OIL DISCHARGE TEMPERATURE FUEL INLET PRESSURE GENERATOR LOAD OR DYNO TORQUE FUEL FLOW FUEL PUMP DISCHARGE PRESSURE EXHAUST STATIC PRESSURE OILSUMP PRESSURE OIL SUMP TEMPERATURE

EQUIPMENT IDENTIFICATION

1 TEST CELL MANUAL FLOW CONTROL VALVE 2 ORIFICE MEASURING SECTION 3 LAB EXHAUST DUCT 4 BLEEDAIR VALVE (NOT SHOWN) 5 ELECTRIC START MOTOR 6 FUEL ROTAMETER 7 VIBRATION PICKUP (3) 8 SPEED PICKUP (2)

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TEST PARAMETERS

11 12 13 14 15 16 17 18 19 20

OIL GRAVITY FILL PORT FUEL FILTER LAB BLEED AIR DUCT ELECTRONIC CONTROL UNIT LAB LOAD CELL 24 VDC ELECTRICAL SUPPLY TERMINALS (NOT SHOWN) FUEL SUPPLY OIL FILTER MAGNETIC DRAIN PLUG ELECTRICAL HARNESS


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Hone~vell

C O M P O N E N T MAINTENANCE MANUAL GTCP36-280[D]

/1 10.39 (263,~06MM)

=

m

,q

|

f

ii

10THERMOCOUPLES 10 PRESSURES 15.00IN. (381,000MM) TOPVIEW 0.125IN. I

t

2.500 IN.

I

!

I

J

~

D

D

D

t

1~

0.125IN.

~, 6.I IN. SIDEVIEW A3800504TT129

UP200456

Part No. 834400-1 Inlet Duct Assembly Figu re 102


Page 107 Feb 28/05


Hone} vell .

C.


Test conditions. Conduct all tests at existing laboratory conditions of temperature, pressure and humidity, using the test equipment and instrumentation listed in steps (D) and (E) below.

D.

Test equipment. Provide the laboratory test equipment listed in Table 101. Figure 101 shows a schematic diagram of the test setup, and Figure 102 shows the Inlet Duct Assembly Part No. 834400-1.

E.

Instrumentation. Provide standard instrumentation to measure the parameters shown in Table 102. All instrumentation must be calibrated. Disconnect any malfunctioning thermocouples. Only one failed probe for each of the measured parameters is permissible during performance data acquisition.

F.

Operating limits. During all operating conditions, observe the limits of Table 103. EGT trim and shutdown schedules are referenced in Figures 103, 104, 105, and 106 for starting, ECS, and MES operating conditions. Monitor APU parameters continuously during operation and review test data carefully for any of the following conditions: (1)

Unit EGT spread greater than 80F (44C).

(2)

Oil sump pressure greater than 25 in. H20 for overhauled units and 33 in. H20 for repaired or continued time units. (Except when cell valve is closed). NOTE:

G.

If any vibration exceeds 0.65 in./sec at any time during the testing, reject the APU and call Engineering disposition.

APU History Data. Before starting the APU, record the Data Memory Module (DMM) APU history data, (SN, HR, CY, and BDCY) under the HST DATA menu on the ECU display. Disconnect the DMM connector (P11, APU wiring harness) for acceptance testing.

H.

Limited Test Requirements.

Test Section

Check

Light #, ,/ ,/ ,z ,/ ,/

Medium

Heavy

J 1.H. (2) (b) Motoring, positive oil pressure ,/ ,/ 1.H. (2) (c) Leaks, vibration ,,/ ,/ 1.1.(1) Run-in ,/ J l.J. Oil filter and magnetic plug ,/ ,/ I.N. LRU BITE test ,z ,/ 1.O. Surge control system ,/ I.P. Performance check ,z ,/ I.Q. IGV adjustment * Optional, based on experience and judgment of the repair facility. Use Medium Repair release limits.

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** Optional unless complete load compressor or complete power section disassembly required


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Honeywell


Table 102. Equipment and Instrumentation Check List for GTCP36-280[D] Mechanical and Performance Checkout Parameter

Range

Barometric pressure Cell pressure Cell temperature Engine Speed Waterbrake torque (if applicable) Generator current (if applicable) Generator voltage (if applicable) Generator electrical power (if applicable) Oil pressure Oil sump pressure Oil sump temperature Fuel inlet temperature, 1 probe at TFM

13 to 15 psia 12 to 17 psia -65 to 130F 0 to 100,000 rpm 0 to 1000 in. Ibs shp 0 to 1500 amps 0 to 300 vac 0 to 100 kW 0 to 100 psig 0 to 100 in. H20 0 to 500F 0 to 150F

xl x x x xl x x x x x x

Fuel flow, 2 TFM APU inlet air temperature, 10 probes Orifice PT Orifice AP Orifice TT Flow sensor PT Flow sensor AP

0 to 2.5 gpm -65 to 130F 0 to 20 psia z 0 to 5 psid 0 to 500F 0 to 75 psia 0 to 5 psid

x1 x x x x x x

x x x x x

Bleed temperature, 4 probes (minimum)

0 to 500F

x1

x

Bleed PT, 5 probes (minimum) EGT - l a b rake, 12 probes EGT - high response (optional) EGT - Unit

0 to 100 psia 0 to 1500F 0 to 2000F

x1 x x

x x

0 to 1500F

x1

x

0 to 1500F +_2.5 psig

x1

x x

0 to 1 in./sec 0 to 100% open 31.6 to 32.4F Thumbwheel Thumbwheel

x x

1

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2 Exhaust static pressure, 4 probes Vibration Gearbox, load compressor, and turbine areas displacement Cell valve position 32F reference Bleed orifice diameter Bleed duct diameter

Console

x x

49-26-49 Copying, use or disclosureof informationon this page is subject to proprietaryrestrictions.

Digital x x x x x

x x x x x

x x x

Page 109 Feb 28/05


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Table 102. Equipment and Instrumentation Check List for GTCP36-280[D] Mechanical and Performance Checkout (Cont) Parameter Fuel specific gravity Fuel lower heating value Test condition Surge valve position IGV position Unit LCIT 1 2

Range Thumbwheel Thumbwheel Thumbwheel 0 to 100% closed 0 to 100 degrees -65 to 130F

Console x x x x x x

Digital x x x x x x

Only if manual data is recorded. Only if cell bleed control valve is upstream of measuring orifice. If valve is downstream, range becomes 0 to 60 psig (0 to 414 kPa).

Table 103. Operating Limits

Type

(1)

Limit

Remarks

Leakaqe (a)

(b)

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Tolerance

Fuel

1 drop per minute --

Maximum

1.

Plenum drain

See Remarks

Fuel leakage from the plenum drain is permitted only after a false start or blowout.

2.

Fuel/oil pump

1 drop per 10 minutes Maximum

3.

Fuel flow divider

1 drop per minute

Maximum

4.

IGV actuator

1 drop per minute

Maximum

1.

Fuel/oil pump

Zero

Maximum

At the seal drain port.

2.

Generator seal

2 cc/hr (0.002 qt/hr)

Maximum

Measured at the bottom of the gearbox generator mount flange.

Measured after 5 minutes operation when residual fuel from previous fuel manifold purge on shutdown has drained. Fuel from manifold purging during APU shutdown normally drains through this port into ecology tank.

Oil

49-26-49 Copying,use or disclosureof informationon this page is subject to proprietaryrestrictions.

Page 110 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 103. Operating Limits (Cont)

Type

Tolerance

Remarks

(2)

Light-off time

17 sec after 7% speed

Maximum

Any condition.

(3)

Oil pressure (normal)

65 psig (448,5 kPa)

_+5 psig (_+34,5 kPa)

Measured at oil pump discharge port.

Oil pressure (shutdown)

30-35 psig (207,0-241,50 kPa)

Maximum

Measured at oil pump discharge.

(4)

Oil pressure fluctuation (under steadystate operating conditions)

_3 psi (+_20,7 kPa)

Maximum

Measured at oil pump discharge.

(5)

Starter-motor duty cycle

3 consecutive starts or attempts

Maximum

3 starts per hour maximum with 1 minute minimum between attempts.

(6)

Lube-oil consumption

10 cc/hr (.0106 qt/hr)

Maximum

Verified by gearbox pressure less than 25 in. H20 and visual.

(7)

Temperatures 130F (54C) 325F (163C) Refer to Figures 103,104

Maximum _+7F -+25F

Refer to Figures 105,106

+_25F

(a) (b) (c) (d)

UP200456

Limit

Inlet air Oil (shutdown) Exhaust gas temperature (MES/ ECS operation) Exhaust gas temperature during acceleration

Measured at oil temp sensor Shutdown limit and T5 trim limits shown. Shutdown limit and T5 trim limits shown.

49-26-49

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COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 103. Operating Limits (Cont)

Type (8)

Limit

Tolerance

Rotor Speeds (a)

Continuous recommended operation (NORMAL)

62,553 rpm

+_0.25%

(b) (c)

In-flight (HI-SPEED) Absolute maximum

63,830 rpm 65,625 rpm 68,890 rpm

+_0.25% +_0.25% +_0.25%

(d)

Speed Variation Steady State

+_200 rpm

+_200 rpm

(9)

0.65 in./sec

EGT Spread Temperature spread between #1 and #2 Thermocouple rakes

UP200456

Overspeed shutdown. Backup overspeed shutdown. No instantaneous speed deviation will exceed the limit. No amplitude modulation rate in a one second time period will exceed the limit. Repetition rate must be lower than 2 Hz.

Vibration Gearbox, load compressor, and turbine pickups 110 to 2000 Hz "z" direction

(10)

Remarks

60F (15.5C) Overhaul 80F (26.6C) On condition

Maximum Maximum

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Honeywell


ECS2-PACKMODE 1280

I

1

I

I

NOTES: 1. PERFORMANCEMODELMV280D3NTACOM. 2. SEA LEVELINSTALLEDSTATICCONDITIONS. ,, 1240 - 3. EGT IS UPSTREAMOF LOADCOMPRESSOR (9 SURG" BLEED. uJ

J

r~

2 1220

I

' " ~ 1200 n--

J

J

J

o

Z rr~ tY

1180

1160

1140 -50

1320

0 LLI ,.-.,

-30

-10

I

I

10 30 50 70 T2, COMPRESSORINLETTEMPERATURE,DEGF

90

110

130

MESMODE

I

I

NOTES: 1. PERFORMANCEMODELMV280D3NTACOM. 2. SEA LEVELINSTALLEDSTATICCONDITIONS. 1300 - 3. EGT IS UPSTREAMOF LOADCOMPRESSOR SURGli BLEED.

LU-

~1280

J

U.I

~._-w 0 ~

,,, ~ 1260 ¢Y

J

J

J

J

" 1240 IJJ

¢',n

¢Y

1220

1200 -50

-30

-10

10

30

50

70

90

110

130

T2, COMPRESSORINLETTEMPERATURE,DEG F A3800504TT3

UP200456

Governed Speed EGT Trim Schedules Figure 103


P a g e 113 Feb 28/05


Honeywell


1380

1360 LL

(.9 ILl UUn,,

~340

f

tY LLI

13_

J

~_-LU

(D~-'" ~320 rv-1-

r~ uu

N300 m

2 1280

1260 -50

-30

-10

10

30

50

70

90

110

130

T2, COMPRESSORII~_ETTEMPERATURE,DEC F NOTES: 1. PERFORMANCE MODEL MV280D3N'rACOM. 2. SEA LEVEL INSTALLED STATIC CONDITIONS. 3. EGT IS UPSTREAM OF LOAD COMPRESSOR SURGE BLEED. 4. APU SHUTDOWN OCCURS IF EGT EXCEEDS THIS SCHEDULE.

A3B00504TT4

UP200456

Governed Speed EGT Overtemperature Shutdown Schedule Figure 104


Page 114 Feb 28/05


Hone3 vell


1800 --

17oo

(

B

1600-1540 1500 1420

I.L

(.9

1400 1360

1280 1240 1200

1200 1160

1160

1000

I

I

I

I

20

50

60

70

1

I

75 80

N, PERCENT

I

I

I I

85

90

95 98 A3800516TT2

UP200456

E G T Trim Schedule During Timed Acceleration Figure 105


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Honeywell

COMPONENT MAINTENANCE MANUAL 'GTCP36-280[D]

2000

1900

1900

1800

1784

LL

LM

1668

1600 1552

0

1460

1400

I

I

I

I

I

I

I

50

60

70

8O

88

100

120

N, PERCENT A3800516TTI

UP200456

EGT Overtemperature Shutdown Schedule During Timed Acceleration Figu re 106


Page 116 Feb 28/05

Hone vell .

H.



Test setup. (1)

Make APU ready for test as follows. Refer to Figure 101. (a)

Use 834389-1,834390-1, and 834119-2 engine stand mounts to attach APU to 833565-2 portable stand assembly.

(b)

Install engine in test facility so that all sides, top and bottom of APU are easy to get to for installation and connection of test equipment compressor. Air inlet and turbine exhaust must be free of blockage.

(c)

Remove surge exhaust duct, surge bleed duct, coupling clamp, clamps, support strut, bolts and nuts.

(d)

Install the exhaust tailpipe (834611-1 ), inlet duct, (834400-1), instrumented bleed duct (834662-1), surge bleed and oil cooler exhaust ducts, surge valve positioning sensor (2024323-1) and required instrumentation. Clamp surge valve position sensor to housing with a "C" clamp and attach the helicoil to the rotating shaft flex coupling.

(e)

Connect the APU to the test cell digital acquisition system, if applicable. Check all instrumentation and plumbing for proper location and connection. Service and prime the APU with oil. Duct the oil cooler discharge air out of the test cell.

(f)

Disconnect the ecology tank for the test.

(g)

Supply one of the fuels listed below to the APU inlet at a pressure of 10 to 55 psig. MIL-DTL-5624, Grade JP-4 or JP-5 ASTM D-1655-75T, Jet A or Jet B

(2)

(h)

Use an approved type MIL-PRF-23699 lubrication oil. A synthetic-base lubricating oil Type II (5 centistokes) to service the APU. 6 quart capacity.

(i)

Provide a 28 vdc electrical power supply to the APU.

U)

Select Speed Set display on ECU front panel and confirm that ECU is set on NORMAL speed. If it is set on HI speed, reprogram to NORMAL speed.

BITE Interrogation.

UP200456

(a)

If the customer ECU was returned with the APU, record the BITE information (CUR RCD and all five HISTORY records, including numeric error codes ) must be recorded in the test log.


Page 117 Feb 28/05


Honeywell

1.

H.

(2)


WARNING:

THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DEENERGIZED AND GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT TERMINAL.

CAUTION:

DO NOT EXCEED OPERATING LIMITS SPECIFIED IN TABLE 103. MAKE SURE THAT VIBRATION MEASURED AT GEARBOX AND POWER SECTIONS DOES NOT EXCEED .65 INCH PER SECOND DURING ACCELERATION AND STEADY STATE.

(b)

Disconnect the igniter lead (Figure 313, item 120), de-oil solenoid (Figure 306, item 90) and the fuel supply to the unit. The electronic control unit will delay starter engagement for approximately two to four seconds.

NOTE:

DO NOT EXCEED STARTER MOTOR DUTY CYCLE. REFER TO TABLE 103.

CAUTION:

1

Set START switch to ON. Allow engine to motor, check oil pressure for positive pressure indication on oil pressure gage. NOTE:

2

If no oil pressure indication appears, stop engine and trouble shoot. Repeat step 1.

3

During engine roll down, listen for any unusual noises (evidence of rubbing or grinding). If excessive or unusual noises are evident, terminate test and trouble shoot to determine cause. Repeat test as necessary.

4

Connect igniter, de-oil solenoid valve, and the fuel supply to the unit. NOTE:

(c)

Make sure the ECU fault memory is clear.

Start the APU, check for stable combustion, leaks and vibration. NOTE:

UP200456

The engine will shut down automatically at approximately 17 seconds.

Leak from fuel plenum drain is acceptable during engine start.


Page 118 Feb 28/05

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I.



Run-In procedure. (1)

Disconnect the fuel solenoid connector plug (P9). NOTE:

The APU should be in NONESSENTIAL and GROUND modes throughout testing.

(a)

Motor the APU with the start motor until automatic shutdown occurs. Confirm normal rolldown after motoring, free of unusual noises or other indications of APU distress.

(b)

Connect the fuel solenoid connector plug (P9). NOTE:

WARNING:

(c)

If the oil fill cap is not removed, the oil level in the sight glass may not be correct.

(d)

Clear the ECU BITE memory and attempt an APU start. If the APU fails to start, interrogate the ECU CUR SDN and CUR FLTS records before turning the MASTER SWITCH OFF. Make sure NO FLAME and DMM are the only fault indication. If any other faults are indicated, record the fault numbers in the test log and determine their cause.

(e)

Repeat step (d) until the APU successfully starts and accelerates to governed speed. Apply bleed and shaft loads to verify correct function of APU and lab equipment. Monitor ECU APU DATA parameters to verify correct indications. Verify correct function of all lab instrumentation. After a minimum of 15 minutes run time, (overhaul only), shut down the APU. NOTE:

When operating the APU previous to the surge control check, make sure the cell valve is sufficiently open to prevent load compressor surge.

Oil filter and magnetic chip detector. WARNING:

(1)

UP200456

USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN.

With the oil fill cap removed, check the oil level. Top off the oil sump to the full mark on the sight glass. NOTE:

J.

Do not exceed the start motor duty cycle. (Refer to Table 103.)


Check the oil filter elements and magnetic chip detector. If the filter and/or detector is contaminated, change the filter and recheck after approximately 15 minutes of operation. If further contamination is observed, refer to appropriate engineering for disposition.


Page 119 Feb 28/05

Honeywell .

K.



Automatic start test.

CAUTION:

ALLOW THE STARTER TO COOL FOR A MINIMUM OF ONE HOUR AFTER THREE CONSECUTIVE START ATTEMPTS.

During at least one start, make sure that no abrupt increase in starter voltage occurs prior to reaching cutout speed. L.

Acceleration time. During three automatic starts, make sure the APU starts and accelerates to governed speed within 60 seconds. Record the time required to attain governed speed on data sheet.

M.

Surge Control System. (1)

Calibrate the APU surge control system as follows: (a)

Install a block-off plate at the surge bleed duct/surge control valve interface. Disconnect the load control valve (LCV) connector plug (P21). Connect the LCV to a control panel dc switch and activate the switch. NOTE:

Power the LCV open whenever the block-off plate is installed. Starting the APU with the LCV closed will cause load compressor surge.

(b)

With the cell valve sufficiently open to prevent load compressor surge, start the APU and apply bleed load in MES mode.

(c)

Close the cell valve to attain 60 (+0.5, -0.0) Ib/min discharge bleed corrected airflow. Allow the APU to stabilize at this point.

(d)

Calculate AP/PT = DP + PT, using DP and PT from the ECU display.

(e)

If AP/PT is greater than 0.0574, rotate the static pressure probe counterclockwise according to the following equation, where N is the number of notches on the static pressure probe: N(notches) = (AP/PT - 0.0535) + 0.0025

(f)

If AP/PT is less than 0.0505, rotate the static pressure probe clockwise according to the following equation where N is the number of notches on the static pressure probe:

UP200456

N(notches) = (0.0535 - AP/PT) + 0.0025


Page 120 Feb 28/05

Hone well 1.

M.

N.

(1)


(g)

Repeat steps (d) through (f) until AP/PT is between 0.0505 and 0.0574. Record the final discharge bleed corrected airflow and AP/PT in the test log.

(h)

Lockwire the static pressure probe locking bolt in accordance AS567.

(i)

Remove the block-off plate and reconnect the LCV connector plug (P21).

LRU BITE test. (1)

After completing the surge control system calibration, clear the ECU BITE memory and make sure that DMM is the only fault displayed. If any other faults occur during acceptance testing, interrogate the ECU, record the fault number(s) in the test log, and determine their cause(s). To prevent loss of BITE memory, always interrogate the BITE memory before turning the MASTER SWITCH OFF. NOTE:

O.

If the ECU BITE flags any fault other than DMM during acceptance test, record the fault number in the acceptance test log and determine the cause.

Surge control system verification. (1)

UP200456


Verify the correct function of the load compressor surge control system, as follows: (a)

Start the APU and allow it to accelerate to governed speed.

(b)

With the cell valve sufficiently open to prevent load compressor surge, apply a bleed load in MES mode.

(c)

Connect the LCIT thermocouple simulator lead to the breakout box LCIT connector. Set T2 on the ECU display equal to the lab average inlet temperature (T2 +_2F).

(d)

Close the cell valve to the point at which the surge valve just begins to open (97.0 to 99.9 percent closed -- if the SCV opens beyond this range, reopen the cell valve and perform this step again). Allow the APU to stabilize for 30 seconds at this point.

(e)

Record the discharge corrected bleed airflow (WBCDNA) on test data sheet. Discharge corrected bleed airflow at the surge valve crack point must be within the tolerances indicated in Figure 107.


Page 121 Feb 28/05

Honeywell

UP200456

1.

O.

(1)

(f)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Use the surge valve positioning sensor (2024323-1) to adjust the cell valve to attain 63 +_2 Ib/min discharge corrected bleed airflow (WBCDNA). Close the cell valve as rapidly as possible with normal lab position control. Make sure the SCV opens to successfully prevent load compressor surge.

49-26'49 Copying, use or disclosure of information on this page is subject to proprietaryrestrictions.

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Honeywell


61

60

o9 0ILl: : < 5 0

~8

o~ I-0

57

56

55 30

40

50

60

70

90

80

100

110

APULABAVERAGEINLETTEMPERATURE(I"2),F NOTES: 1. PHOENIXAMBIENTCONDITIONS,UNINSTALLED. 2. NOMINALMESSURGEVALVESCHEDULE. 3. CRACKPOINTTOLERANCEIS ±22 LB/MIN. 4. MODELMV280D3CUSTOMERDECKNTACOM.

A3800504TT5

UP200456

Surge Valve Crack Point Figure 107


Page 1 23 Feb 28/05

Hone well 1.

O.

P.

(1)



(g)

Repeat step (f) from a discharge bleed airflow of 30 to 35 Ib/min.

(h)

Remove the block-off plate and reconnect the LCV connector plug (P21).

Performance test procedure (Optional for light Repairs). NOTE: (1)

(2)

All performance tests are performed at NORMAL speed. No Load Performance. (a)

Start the APU and allow it to accelerate to governed speed.

(b)

Allow all monitored APU parameters to stabilize with APU AIR OFF and no shaft load.

(c)

Record digital performance data or complete the test data sheet.

Environmental Control System (ECS) two-pack standard mode performance. Refer to Table 104. (a)

Apply a shaft load of 60 (+3.0, -0.0) shp/8, as follows: For electrical loading, KWe = 40 (+2.0, -0.0) (PCELL/14.7) Where: KWe = Generator load, KW P Cell = Absolute cell pressure, psia Power factor = 1.0 Generator efficiency = 0.85 For waterbrake loading, T = 630 (+32, -0) (PCELL/14.7) Where: T = Waterbrake torque, in.-Ibs.

UP200456

NOTE:

Load changes must be applied instantaneously. All data must be recorded with the digital acquisition system, or manually recorded if the digital system is not available.


Page 124 Feb 28/05

Honeywell 1.

P.

(2)



(b)

Activate the APU AIR, RIGHT PACK and LEFT PACK switches. (The RECIRCULATING FAN switch must be OFF.) Make sure the APU is in the STANDARD mode. (The asterisk must be next to STANDRD under APU MODE on the ECU display: *STANDRD.)

(c)


(d)

Adjust the cell valve to attain 56.2 (+_0.5), Ib/min discharge corrected bleed airflow.

(e)

Allow all APU measured parameters to stabilize.

(f)

Record digital performance data or complete the test data sheet and make sure: The setpoint parameters (T2 on the ECU display, WBCDNA, and SHPSL) are within the required tolerances. The sea level, 103F, installation corrected data (PBCOR, WBCOR, EGTCOR, and WFCOR) meets or exceeds the ECS 2-pack standard requirements. Refer to Table 105 (overhaul) or Table 107 (continued time).

UP200456

(3)

Main Engine Start (MES) performance. Refer to Table 104. (a)

Apply a shaft load of (60 +3.0, -0.0) shp (as in step 1.Q.(1)(a)).

(b)

Activate the APU AIR switch and the RIGHT M r s and/or LEFT MES switch(es).

(c)


(d)

Adjust the cell valve to attain 39.7 (+_0.5), Ib/min discharge corrected bleed airflow.

(e)

Allow all APU measured parameters to stabilize.


Page 125 Feb 28/05

Hone vell

UP200456

1.

P.

(3)

(f)



Record digital performance data or complete the test data sheet and make sure: 1

The setpoint parameters (T2 on the ECU display, WBCDNA, and SHPSL) are within the required tolerances.

2

The sea level, 103F, installation corrected data (PBCOR, EGTCOR, and WFCOR) meets or exceeds requirements. (Refer to Table 106 (Heavy Repair) or Table 108 (Medium Repair).


Page 126 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 104. Performance Load Specifications

Mode

0001 0002

Ready to Load Two-Pack Standard ECS

60 + 3/-0

56.2 _+0.5

0003

MES

60 + 3/-0

39.7 _+0.5

NOTE:

1.

Shaft Load, shp/6

0

If digital data is not available, refer to paragraph 1. R. (2) for performance load specification calculations.

e.

IGV adjustment. (Heavy Repair units only). NOTE:

(1)

The corrected bleed pressure (PBCOR) must be within the minimum and maximum tolerances of Table 105 for Heavy Repairs and Table 107 for Medium Repairs. The IGVs may be adjusted according to the following paragraphs to meet these requirements. IGV may not be adjusted on continued-time units. After IGV adjustment, acceptance tests must be reaccomplished. Adjustment of IGV position (allowed on Heavy Repair only). (a)

Remove the IGV actuator assembly and associated tubing.

(b)

If corrected bleed pressure (PBCOR) is below the minimum requirement, open IGVs by adjusting the IGV actuator nut counterclockwise a maximum of one full turn. (The bleed pressure will increase approximately 0.25 psi per IGV degree, 1/4 turn.) NOTE:

UP200456

Disch Corr Airflow Ib/min

Test Condition

After IGV adjustment, paragraph I.P. must be repeated in its entirety.

(c)

If the corrected bleed pressure (PBCOR) is above the maximum requirement, close the IGVs by adjusting the IGV actuator nut clockwise as necessary to reduce corrected bleed pressure to below the maximum requirement. (The bleed pressure will decrease approximately 0.25 psi per IGV degree, 1/4 turn.)

(d)

Install the IGV actuator assembly and tubing.


Page 127 Feb 28/05

Honeywell 1.

a.



Performance Data Correction. (1)

(2)

Digital Data Acquisition System Performance Data Correction.

(a)

If the digital acquisition system is available, instruct the digital operator to reduce the data and provide FULL LOGS and QUICK LOOKS. Carefully review the FULL .LOGS and QUICK LOOKS to make sure the measured parameters are within the limits of paragraph 1.F.

(b)

Once the data has been verified to be accurate and acceptable, use the applicable data sheets (Figure 108) to record performance data.

Manual Performance Data Correction. (a)

To manually record and correct performance data, use the applicable data sheet equations (Figure 108) to record performance data. Use Data sheet 1 for overhaul or Data sheet 2 for continued-time units. Use Data sheets 3 and 4 for units with QEC or sheets 5 and 6 for units without QEC.

UP200456

NOTE:

The calculations on Test Data Sheet correct the bleed pressure (PB), bleed airflow (WB), delta pressure across the APU (APU AP), and fuel flow (WF) for ambient pressure (delta(8) correction) to simulate sea level conditions. In addition, PB, WB, bleed temperature (TB), EGT and WF are corrected for temperature (lapse rate correction) to simulate 103F ambient temperature. (The lapse rate corrections account for IGV scheduling as well as ambient temperature effects.) EGT and WF are also corrected for APU AP to remove effects of the lab inlet and exhaust ducting. PB, WB, TB, EGT and WF are then corrected for aircraft installation effects. Finally if the corrected bleed pressure (PBCOR) is above the minimum requirement, EGT and WF are corrected to simulate power section performance with a minimum specification load compressor.


Page 128 Feb 28/05


Hone vell


HEAVY REPAIR ACCEPTANCETEST DATA SHEET GTCP36-280(D) APU PIN 3800504-1

Date Unit SIN APU Outline No. ECU PIN

S/N**

.Slave** 2-Pack Std. ECS Mode*

MES Mode*

OHDS Line

Parameter Name

"14"

PBCOR

Bleed Pressure, psia

47.0 (min)

50.2 (min)

"18"

WBCOR

Bleed Airflow, Ib/min

139.0(min)

NIR

*26*

EGTCOR

Exhaust Gas Temperature, F (Adjustedto min. bleed pres.)

1170 (max)

1200 (max)

*34*

WFCOR

Fuel Flow, Ibthr (Adjustedto min. bleed pres.)

252 (max)

260 (max)

Description

Required

Corrected

Required

Corrected

* Performance data have been adjusted to S.L., 103 F, installed conditions ** Indicate "lab slave" and ECU SIN when applicable "XX" Data from OHDSAutomatic starts check: #1 ~ Surge control valve crack point:

see: #2 ~ s e c :

#-3 ~ s e c

Ib/min

Total number of starts (during T.I.): Total operating time (during T.I.):

hrs:min

UNIT STATUS:

ACCEPT [ ]

REJECT [ ]

We certify the above data are ~'ue and correct, and in addition, the unit has successfully met all other test requirements specified in the latest revision of the applicable test specification indicated above. Signature

Date

Technician Supervisor Checked By X3800504TT214

UP200456

Sample Test Data Sheet Figure 108 (Sheet 1 of 6)


Page 129 Feb 28/05


Hone3 well


MEDIUM REPAIR ACCEPTANCETEST DATA SHEET GTCP36-280(D) APU P/N 3800504-1

Date Unit S/N APU Outline No. ECU PIN OHDS Line

S/N**

Parameter Name

Slave** 2-Pack Std. ECS Mode*

DessdpUon

Required

MES Mode*

Corrected

Required

"14"

PBCOR

Bleed Pressure, psia

47.0 (min)

50.2 (min)

"18"

WBCOR

Bleed Airflow, Iblmin

139.0 (min)

N/R

*26*

EGTCOR

Exhaust Gas Temperature, F (Adjustedto rain. bleed pres.)

1180 (max)

1210 (max)

*34*

WFCOR

Fuel Flow, Ib/hr (Adjustedto min. bleed pres.)

254.0 (max)

261.0 (max)

Corrected

* Performance data have been adjusted to S.L., 103 F, installed conditions ** Indicate "lab slave" and ECU SIN when applicable "XX" Data from OHOS~,.utomaticstarts check: #1 Surge cenb'ol valve crack point:

sec: #2

sec: #-3

sec

Ib/min

total number of starts (during T.I.): I'otal operaling time (during T.I.):

hrs:min

LINITSTATUS:

ACCEPT [ ]

REJECT [ ]

,We certify the above data are lrue and correct, and in addition, the unit has successfully met all other test requiremerJts specified in the latest revision of the applicable test specification indicated above. Signature

Date

Technician Supervisor Checked By X3800504TT215

UP200456

Sample Test Data Sheet Figure 108 (Sheet 2)

49-26-49 Copying, use or disclosure of information on this page is subjectto proprietary restrictions.

Page 130 Feb 28/05


Hone3 vell


ACCEPTANCETESTDATASHEET GTCP36-280(D)APU P/N3800504-1 WITHQEC DATE:

TESTCELL

UNITP/N

UNITS/N

TECHNICIAN

READY 2-PACKSTD MES TOLOAD ECS MODE MC)FII=

OPERATIONALDATA: TIME

DIGITALTIMEOF FIRSTSCAN

GEARBOX/LOADCOMPRESSORKURBINEVIBRATION

HRS/MIN IN/SEC

OILSUPPLYTEMPERATURE

SUMPTEMP,ORLUBEPUMPINLETTEMP.

OILSUPPLYPRESSURE

LUBEPUMPDISCHARGEPRESSURE

I

II

I

II

F PSIG INH20

GEARBOXPRESSURE PERFORMANCEDATA: * 1*

PCEL

CELLPRESSURE

PSlA

* 2"

PS58

EXHAUSTSTATICPRESSURE(AVG)

PSIA

T2

T2 - APU INLET TEMP. (AVG)

F -.-,,,%,,,.°,,,,

LB/MIN :.;.:.-...:..-...: ;.;.;.....1.:..'. PSL~ .......-.-,.-.::-...:

"3" WBDNA BLEEDAIRFLOW ' 4" * 5"

PB

BLEEDPRESSURE(AVG)

TB

BLEEDTEMPERATURE(AVG)

PIGV

INLETGUIDEVANEPOSITION

F SCHEDULEDUSINGT2

DEGREES :!:i:~i:i:i:i:

WBCDNA CORRECTEDDISCHARGEAIRFLOW 56.2 PPM(ECS):39.7PPM(MES):-0.0/+0.5 LB/MIN TBORFA BLEEDAIR ORIFICETEMP.(AVG)

F

PBORFA BLEEDAIR ORIFICEPRESSURE

PSlA

PDBORA BLEEDAIR ORIFICEAEP

PSlD

:::::.::.:-_::..:: ;:::::.'-.':::.'...':: :'.:::.::':':':-: .,

. . . .

,,.

,,,.,.-,,,,.,,%,

"8"

TD50

LABEGT(AVG)

F

TTDEA

UNITEGT#1

F

TTDEB

UNITEGT#2

F

" 7" WFPPH FUELFLOW(AVG) "8" SHPGEN SHAFTLOAD XNL

SHAFTSPEED

i:i:i:i:i:i:i:i:i

LB/HR 60/DELTA(RTL= 0): -0.0I+3.0

SHP

GOVERNEDSPEEDOF 63.830RPM

RPM X3800504TT180

UP200456

Sample Test Data Sheet F i g u r e 108 ( S h e e t 3)


P a g e 131 Feb 28/05


Hone) well

COMPONENT

MAINTENANCE GTCP36-280[D]

MANUAL

ACCEPTANCETEST DATASLEET GTCP~2S00:)] A~U P/N 3800504-1 WITH QEC DATE:

TEST CELL

UNIT P~N

UNITS/N

TECHNICIAN READY 2-PACKSTD MES TO LOAD ECS MODE MODE

CALCULATIONS: "9"

DELTA

"1" 114.696

SHAFT LOAD- SEA LEVEL *I(Y'

APU DELTAP/DELTA

*il*

SEA LEVELBLEEDPRESSURE

*12"

BLEEDPRESS. LAPSERATECORR.

"13"

INSTALLATIONEFFECTON PB

"8" ('9"

SHP

~{~!~t~!

('1"-'2.) 1"9*

PSIA iii!!!iiiiiiiiii!

*4* t*¢J*

PSIA iiiiiiiiiiiiiiiii

:::::::::::::::=:

"14= PBCOR SEA LEVEL103FBLEEDPRESSURE "15"

SEA LEVELBLEEDAIRFLOW

*16"

BLEEDFLOW LAPSERATECORR.

*t7"

INSTALLATIONEFFECTON WB

"18" WBOOR WB- S.L. INSTALLED103F "ll)' BLEEDTEMP.LAPSERATECORR_ "20* TBCOR. TB- S.L. INSTALLED103F

USE T2 IN TABLE109 (ECS)AND 110 (MES)

PSIA !CORRECTS FROMTESTED BARETO INSTALLED PSIA

~iiiiiiiHiiiii!i 0.0

=11"+'12.+'13"

PS~A ~i~i~i~iil

*3*/'9"

LB~IIN iiii~iiiiiiiiiil

USE T2 IN TABLE 109 (ECS)AND 110 (MES) CORRECTS FROMTESTED BARETO INSTALLED *15" ÷'16"+*17"

LB/MIN

LB~N ;iiiiii~E{~E~Eiii 0.0 :::::::::::=::;;

0.0

I_B/MIH !~!!!ii!!!!!!!!!i

USE T2 IN TABLE 109 (ECS)AND 110 (MES) "5" +'19"

0.O

.,,,,.=..,.,..,,

,,,.,,=,,,,=,,,,

F

~i!iiii"ii"iii |l|||lllllllllll;

"21"

EGTLAPSERATECORRECTION

USE T? IN TABLE109 (EOS)AND 110 (MES)

F

iiiii!iiii!!~!~!i

"22*

APU/EPCORRECTIONONEGT

USE "10" IN TABLE 1l i (ECS)AND 112 ~ES)

F

|i|iiii!iiiii|iil

*23*

INSTALLATIONEFFECTON EGT

CORRECTS FROMTESTED BARETO INSTALLED

F

"~iiiii!!!ii'~i!i

*24*

EGT- S.L INST.103F

*25*

EXCESSBLEEDPRESS.CORR.ON EGT

*'26" EGTCOR EGT- S.L INST.103F(~ MIN PB

9

12

1.7

2.3

"6" +'21" +'22.* "23" USE *14" IN TABLE113 OECS)AND 114 (MES) •24=.,25.

F

~i~iiii~iii~i~ii

::::::::ll]llllll llll'~lllllllllll

::=:::::==::=::::

"7"/'9"

LB/HR i~iiiiiiiiiiiii!

FUEL FLOW LAPSERATECORR.

USE T? IN TABLE 109 (EP~)AND 110 (MES}

LB/HR ii~ii~i~i~ili~ii

APU IEP CORRECTIONON WF

USE *10" INTABLE 111 (ECS)AND 112 (MES)

LB~HR ~!!!iiiiiiiiiiiii

"27"

SEA LEVELFUELFLOW

"28" *29* *3O*

INSTALLATIONEFFECTON WF

"31"

WF - S.L. INST. I03F

*32"

EXCESSBLEEDPRESS.CORR.ON WF

*33*

FUEL LOWERHEATINGVALUE RATIO *34* WFCOR WF-S.L. INST.103F@ MIN P3

CORRECTS FROMTESTED BARETO INSTALLED LB,,I-IR !!i!!!i!!!!!!!!!! "2? -* "28~ + "29= * '30=

USE"14"INTABLE113(ECS)AND114(IVIES)

LB R iiiiiiiiiiiiiiiil LB/HR iiiiiiiiiiiiiiiii

LATESTLABFLI-IVDIVIDEDBYIB,400BTU/LB

NONE ~iiiii~iiii~iil]

('31" + "32") x "33"

La~R iiiiiiiiiiii~iii •

* - DATATRANSFERREDTO TESTSHEET ~

DATANOT I~EEDED CA APPROVAl X3800504TT188

UP200456

Sample Test Data Sheet F i g u r e 1 0 8 ( S h e e t 4)


Page 132 Feb 28/05

Hone3 vell



ACCEPTANCETESTDATASHEET GTCP36-280(D)APU P/N3800504-1 WITHOUTQEC DATE:

TESTCELL

UNITPiN

UNITS/N

TFCHNICIAN

READY 2-PACKSTD MES TO LOAD ECS MODE MODE

OPERATIONALDATA: TIME

DIGITALTIMEOF FIRSTSCAN

GEARBOX/LOADCOMPRESSOR/TURBINEVIBRATION

HRS/MIN IN/SEC

OILSUPPLYTEMPERATURE

SUMPTEMP.ORLUBEPUMPINLETTEMP.

OILSUPPLYPRESSURE

LUBEPUMPDISCHARGEPRESSURE

/ I

1

1

I 1

F PSIG INH20

GEARBOXPRESSURE PERFORMANCEDATA: * 1*

PGEL

CELLPRESSURE

PSIA

"2"

PS58

EXHAUSTSTATICPRESSURE(AVG)

PSIA

T2

F

T2 - APU INLETTEMP.(AVG)

'3" WBDNA BLEEDAIRFLOW

LB~IN iiiiiiiiiiiiii~ii °,%°,.,°°%°,%,

' 4"

PB

BLEEDPRESSURE(AVG)

=5"

TB

BLEEDTEMPERATURE(AVG)

PIGV

INLETGUIDEVANEPOSITION

PSIA :-:.:-:.:-:-:-:.: F

::::::::::::::::: %%°.%%%....°

SCHEDULEDUSINGT2

DEGREES::::::~::::::::

WBCDNA CORRECTEDDISCHARGEAIRFLOW 56.2PPM (ECS):39.7PPM (MES):-0.0/+0.5 LB/MIN

* 6"

,.%%,°%=='=%, .,%%,,%%°.=,.

TBORFA BLEEDAIR ORIFICETEMP.(AVG)

F

PBORFA BLEEDAIR ORIFICEPRESSURE

PSIA

PDBORA BLEEDAIR ORIFICE/EP

PSID :::::::::::::::::

"rD50

LABEGT (AVG)

;:;:;:;:;:;:;:;:; ::::::::::::::::: %%=~'.%%"~%'

F

TTDF__A UNITEGT#1 TTDEB

UNITEGT#2

"7" WFPPH FUELFLOW(AVG) "8" SHPGEN SHAFTLOAD XNL

SHAFTSPEED

LB/HR 60/DELTA(RTL= 0): -0.0/+3.0

SHP

GOVERNEDSPEEDOF 63.830RPM

RPM X3800504TT41

UP200456

Sample Test Data Sheet Figure 108 ( S h e e t 5)


P a g e 1 33 Feb 28/05


Hone) well

COMPONENT

MAINTENANCE GTCP36-280[D]

MANUAL

ACCEPTANCETEST DATASHEET GTCP36-280(D)APU P/N 3800504-1 WITHOUT QEC DATE:

TEST CELL

UNIT PiN

UNIT S/N

TECHNICIAN READY 2-PACKSTD MES TO LOAD ECS MODE MODE

CALCULATIONS: *0-

DELTA

"1"I 14.696 :::||."~=i::=:::

SHAFTLOAD - SEA LEVEL "19.

~,PU/EP/DELTA

"11"

-~EALEVELBLEEDPRESSURE

"12"

BLEEDPRESS. LAPSERATE CORR.

'13"

NSTALLATIONEFFECTON PB

"8* 1"9"

SHP li:lli~i',li'.lll ==....;...,,,,,,,,,

('1"- *2*)I "9"

PSIA iiiiiiiii~iiiiii |=|====;=;==|===

*4* /*9*

PSlA iiiiiiiiii!i!iii

USET?INTABLE109(ECS)ANDi iO(IVIES)

PSIA "..T":'".-";'; Z~: ;:: ~_-_-_=_-_._-_-__•

====:=:====::===

"14" PBCOR ,;EA LEVEL103F BLEEDPRESSURE '15"

;EA LEVELBLEEDAIRFLOW

"16"

BLEEDFLOW LAPSERATE CORR.

"17"

NSTALLATION EFFECTON WB

CORRECTSFROMTESTEDBARETOINSTALLED PSIA iiiiiiiiiiiiiiii "11" +'12" +'13"

PSIA

- 1.96

*

.3"1"9"

LB/MIN .:_:'iiiiiiiiiiiiii

USE T? IN TABLE 109 (ECS)AND 110 (IVIES)

LB/MIN ii!i!iiiiiiiii!i

- 1.98

•

•j :....:;;: .=:.=:.=.=.=

"16. WBCOR NB-S.L. INSTALLED103F

"19"

3LEEDTEMP.LAPSERATECORR.

*20* TBCOR I'B-S.L. INST. 103F

3ORRECTS FROMTESTED BARETO INSTALLED LB/MIN

- 4.4

44

48

*15" ÷'16"+'17"

USE T2 IN TABLE 109 (ECS} AI~) 110 (MES)

F

i!!!¼.a.!!i!i!i!!i

"5"+'19"

F

iiiiiiiiiiii!iii

.21"

-GT LAPSE RATECORRECTION

USE T2 IN TABLE 109 (ECS)AND 110 (MES)

F

":-=':.~i.=P"L=!"="="~"="=

"22*

~PU/EP CORRECTIONON EGT

USE*10* IN TABLE 111 (ECS)AND 112 (MES)

F

"23*

!INSTALLATION EFFECTON EGT

CORRECTS FROMTESTED BARETO INSTALLED

*24*

EGT- S.L INST.103F

*25*

EXCESSBLEEDPRESS.CORR.ON EGT

F F F

*'26* EGTCOR EGT - S.L. INST. 1OGF@ MIN. PB

- 6.2 ||=|:|:|===|=."=|

"6"+'21"+'22"+'23" USE "14" IN TABLE 113 (ECS)AND 114 (MES) *24* + "25"

*27*

SEA LEVELFUEL FLOW

*28*

FUEL FLOW LAPSE RATECORR.

"7"I'9" USE T2 IN TABLE 109 (ECS) AND110(MES)

*29*

APU/EP CORRECTIONON WF

USE*I0* INTABLEI I I (ECS)AND112(MES)

IIIIIIIIII:IIIII

,:IT"I|.'|:'I|"

!!!!!!iiiiiiiiii ii!iiiiii!i!!ili ;.;= .;9" r.=; ;~ r. =.; r. r, iiiiiiiliiiiiiii III:IIIIIIIIIIII

i!ii!!iiiiii'-'ii ....... ,..,....=

iiiiiiiiiiiiiliii * llllll:ll~lillll LBtr-iR !!!!!!i!!iiiiiiii

*

F

ll:ll=:l='~==:".".==l

LB,I-IR !!iiiiiii~iiiii! llll;l:lllil:ll;l

LB/HR ""'~Y~"E~' i::llllli:iilll:

INSTALLATION EFFECTON WF

CORRECTSFROMTESTEDBARETOINSTALLED LBt,-tR iiiiii;.=.iiiiiiii

-8.2

-7.7

lllll:llillll¼:l

"31"

WF- S.L. INST. 103F

*27*+*28*+*29*+*30*

*32*

EXCESS BLEEDPRESS.CORR.ON WF

USE *14* IN TABLE 113 (ECS)AND 114 (MES)

FUEL LOWER HEATINGVALUE RATIO

LATEST LABFLHVDIVIDED BY 1B,400BTU/LB

LB~R iiiiiiiiiiiiiiii .............. LB,HR iii~iiiiiiiiiii III~IIIIIIIIIII

*34* WFCOR WF - S.L INST. 103F @ MIN. PB

('31" ÷'32") x'33" * - DATA TRANSFERREDTO TEST SHEET ~

NONE ii!iiii!i!i!!!i :..:..::l=.:::==".:l: LB/HR

iiiiiiiiii!iiiiii * DATANOT NEEDED

QAAPPROVAL X3800504TT40

UP200456

Sample Test Data Sheet Figure 108 (Sheet 6)


P a g e 134 F e b 2 8 /0 5


Honeywell

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Heavy Repairs Only

Table 105. Two-pack Standard Mode ECS Performance Load Requirements Symbol

PBCOR ('14")

Parameter Minimum Bleed Airflow Minimum Bleed Pressure Maximum Bleed Pressure

EGTcoR (*26*)

Maximum EGT

1170

F

WFCOR (*34*)

Maximum Fuel Flow

252.0

Ib/hr

W BCOR ('18*) PBCOR ('14")

Requirement

Units

139.0

Ib/min

47.0

psia

48.5

psia

Heavy Repairs Only Table 106. MES Performance Load Requirements

UP200456

Symbol

PBcoR ('14*)

Parameter Minimum Bleed Pressure

EGTcoR (*26*) WFCOR (*34*)

Requirement

Units

50.2

psia

Maximum EGT

1200

F

Maximum Fuel Flow

260.0

Ib/hr

49-26-49 Copying,useor disclosureof informationon this pageis subjectto proprietaryrestrictions.

Page 135 Feb 28/05


Honeywell

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Medium Repairs Only

Table 107. Two-pack Standard Mode ECS Performance Load Requirements Symbol WBCOR ('18") PBCOR ('14")

Parameter Minimum Bleed Airflow Minimum Bleed Pressure

Requirement

Units

139.0

Ib/min

47.0

psia

EGTcoR (*26*)

Maximum EGT

1180

F

WFcoR (*34*)

Maximum Fuel Flow

254.0

Ib/hr

Medium Repairs Only Table 108. MES Performance Load Requirements Symbol

UP200456

PBcoR ('14*)

Parameter Maximum Bleed Pressure

Requirement

Units

50.2

psia

EGTcoR (*26*)

Maximum EGT

1210.0

F

WFCOR (*34*)

Maximum Fuel Flow

261.0

Ib/hr


Page 136 Feb 28/05


Hone vell


Table 109. Two-pack ECS Standard Mode Lapse Rate Corrections, (Heavy and Medium Repairs)

UP200456

TAMB (F) 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

Delta Press (psia) 5.1 5.1 5.0 5.0 4.9 4.9 4.9 4.8 4.8 4.8 4.7 4.7 4.6 4.6 4.5 4.5 4.4 4.4 4.4 4.3 4.3 4.2 4.2 4.1 4.1 4.0 4.0 3.9 3.9 3.8 3.6 3.4 3.3 3.1 2.9 2.7 2.6 2.4 2.2 2.1 1.9 1.7 1.6 1.6 1.5 1.5

Delta Flow (Ib/min) 7.7 7.7 7.7 7.7 7.7 7.6 7.6 7.6 7.5 7.5 7.5 7.5 7.4 7.4 7.3 7,3 7.3 7.2 7.2 7.2 7.1 7.1 7.0 7.0 6.9 6.8 6.8 6.7 6.7 6.6 6.2 5.7 5.3 4.9 4.5 4.1 3.7 3.3 2.9 2.5 2.1 1.8 1.5 1.5 1.5 1.5

Delta Temp (F) 93 92 91 90 89 87 86 85 84 83 82 81 79 78 77 76 75 74 72 71 70 69 68 66 65 64 63 62 60 59 57 56 54 53 51 50 48 47 45 44 42 41 39 38 37 36

Delta Fuel Wf (Ib/hr) 5.9 6.1 6.3 6.5 6.7 6.9 7.1 7.3 7.5 7.7 7.9 8.0 8.2 8.4 8.5 8.7 8.8 9.0 9.1 9.3 9.4 9.5 9.7 9.8 9.9 10.0 10.1 10.3 10.4 10.5 10.1 9.8 9.5 9.2 8.9 8.7 8.4 8.1 7.8 7.5 7.2 7.0 6.7 6.5 6.4 6.2

Delta EGT (F) 223 221 219 217 216 214 212 210 208 206 205 203 201 199 197 195 193 191 189 187 185 183 181 179 177 175 172 170 168 166 163 159 156 153 149 146 142 139 135 132 128 124 121 118 114 111

TAMB (F)

Delta Press (psia)

Delta Flow (Ib/min)

Delta Temp (F)

Delta Fuel Wf (Ib/hr)

Delta EGT (F)

76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120

1.5 1.4 1.4 1.3 1.3 1.3 1.4 1.4 1.4 1.5 1.5 1.5 1.5 1.6 1.6 1.4 1.3 1.2 1.1 0.9 0.8 0.7 0.6 0.4 0.3 0.2 0.1 0.0 0.1 0.1 0.2 0.2 0.3 0.3 0.4 0.4 0.5 0.5 0.6 0.7 0.7 0.8 0.8 0.9 0.9

1.5 1.5 1.5 1.4 1.4 1.6 1.8 1.9 2.1 2.3 2.4 2.6 2.8 3.0 3.1 2.8 2.5 2.3 2.0 1.8 1.5 1.3 1.0 0.8 0.6 0.4 0.2 0.0 0.2 0.5 0.7 1.0 1.2 1.4 1.7 1.9 2.2 2.4 2.7 2.9 3.2 3.4 3.6 3.9 4.1

35 34 32 31 30 29 28 27 26 25 24 23 22 21 20 18 17 15 14 12 11 9 8 6 5 3 2 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17

6.0 5.8 5.6 5.4 5.1 5.3 5.4 5.5 5.6 5.7 5.8 6.0 6.0 6.1 6.2 5.7 5.2 4.7 4.2 3.7 3.2 2.8 2.3 1.8 1.4 0.9 0.4 0.0 0.2 0.4 0.6 0.8 1.1 1.3 1.5 1.8 2.0 2.2 2.5 2.7 2.9 3.2 3.4 3.6 3.8

108 104 101 97 93 91 88 86 83 80 78 75 72 69 66 61 56 51 46 41 36 31 26 21 16 10 5 0 -3 -6 -9 -11 -14 -16 -19 -21 -24 -26 -28 -31 -33 -36 -38 -41 -43


Page 137 Feb 28/05

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UP200456

Table 110. MES Mode Lapse Rate Corrections (Heavy and Medium Repairs)

TAMB (F)

Delta Press (psia)

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

-5.3 -5.3 -5.2 -5.2 -5.1 -5.1 -5.0 -4.9 -4.9 -4.8 -4.3 -3.9 -3.8 -3.8 -3.7 -3.7 -3.6 -3.6 -3.5 -3.5 -3.4 -3.3 -3.3 -3.2 -3.2 -3.1 -3.1 -3.0 -2.9 -2.9 -2.8 -2.8 -2.7 -2.7 -2.6 -2.6 -2.5 -2.5 -2.4 -2.4 -2.3 -2.3 -2.2 -2.2 -2.1 -2.0

Delta Flow (Ib/min) -14.8 -14.6 -14.4 -14.3 -14.1 -13.9 -13.7 -13.5 -13.4 -13.2 -12.7 -12.1 -12.0 -11.8 -11.6 -11.5 -11.3 -11.1 -11.0 -10.8 -10.6 -10.4 -10.3 -10.1 -9.9 -9.7 -9.5 -9.3 -9.1 -8.9 -8.7 -8.6 -8.4 -8.2 -8.1 -7.9 -7.7 -7.5 -7.4 -7.2 -7.0 -6.8 -6.6 -6.4 -6.2 -6.1

Delta Temp (F) 51 51 50 49 48 48 47 46 45 44 52 59 58 57 56 55 55 54 53 52 51 50 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27

Delta Fuel Wf (Ib/hr) -51.9 -51.2 -50.5 -49.8 -49.1 -48.5 -47.8 -47.2 -46.5 -45.9 -35.8 -26.5 -25.9 -25.4 -24.8 -24.3 -23.7 -23.2 -22.7 -22.2 -21.7 -21.2 -20.7 -20.2 -19.7 -19.2 -18.7 -18.2 -17.7 - 17.2 -16.8 -16.4 -15.9 -15.5 -15.1 -14.7 -14.2 -13.8 -13.4 -13.0 -12.6 -12.1 -11.7 -11.3 -10.9 -10.5

Delta EGT (F) 63 63 62 61 61 60 59 59 58 57 80 100 99 97 96 95 94 93 92 91 90 88 87 86 85 84 83 82 80 79 78 77 75 74 72 71 70 68 67 65 64 62 61 59 58 56

Delta Press (psia)

TAMB (F)

76 -2.0 77 -1.9 78 -1.9 79 -1.8 80 -1.7 81 -1.7 82 i -1.6 831-1.5 84 I -1.4 85 -1.4 86 -1.3 87 -1.2 88 -1.1 89 -1.1 90 [ -1.0 91 -0.9 92 -0.8 93 -0.8 94 -0.7 95 -0.6 96 -0.5 97 -0.5 98 -0.4 99 -0.3 100 , -0.2 P

i

101 L -0.2 102 ! -0.1 103 0.0 104 0.1 105 0.1 106 0.2 107 0.3 108 1 i 0.4 109 0.4 110 0.5 111 0.6 112 0.7 113 0.7 114 0.8 115 0.9 116 0.9 117 1.0 118 1.1 119 1.2 120 1.2

Delta Flow (lb/min) -5.9 -5.7 -5.5 -5.3 -5.1 -4.8 -4.6 -4.4 -4.2 -4.0 -3.8 -3.6 -3.3 -3.1 -2.9 -2.7 -2.5 -2.2 -2.0 -1.8 -1.6 -1.4 -1.1 -0.9 -0.7 -0.5 -0.2 0.0 0.2 0.4 0.6 0.8 1.1 1.3 1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.2 3.4 3.6

Delta Temp (F) 26 25 24 23 22 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4. 3 2 1 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17


Delta Fuel Wf (Ib/hr) -10.1 -9.7 -9.3 -8.9 -8.5 -8.1 -7.7 -7.3 -6.9 -6.5 -6.1 -5.7 -5.3 -4.9 -4.5 -4.1 -3.8 -3.4 -3.1 -2.7 -2.4 -2.0 -1.7 -1.3 -1.0 -0.7 -O.3 0.0 0.3 0.6 0.9 1.2 1.6 1.9 2.2 2.6 2.9 3.2 3.6 3.9 4.2 4.5 4.9 5.2 5.5

Delta EGT

(F) 55 53 51 5O 48 46 44 42 41 39 37 35 33 31 29 27 25 23 21 19 16 14 12 10 7 5 2 0 -3 -5 -8 -10 -12 -14 -16 -19 -21 -23 -25 -27 -29 -32 -34 -36 -38

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Honeywell



Table 111. Two-pack ECS Standard Mode APU Delta P EGT and Fuel Flow Corrections. (Heavy and Medium Repairs)

UP200456

APU Delta P (psia) -0.15 -0.14 -0.13 -0.12 -0.11 -0.10 -0.09 -0.08 -0.07 -0.06 -0.05 -0.04 -0.03 -0.02 -0.01 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23

Without QEC Delta EGT (F) -5.4 -5.0 -4.6 -4.3 -3.9 -3.5 -3.2 -2.8 -2.5 -2.1 -1.8 -1.4 -1.1 -0.7 -0.4 0.0 0.4 0.7 1.1 1.4 1.8 2.1 2.5 2.8 3.2 3.5 3.9 4.2 4.6 4.9 5.3 5.6 6.0 6.3 6.7 7.0 7.4 7.8 8.2

Delta Fuel Wf (Ib/hr) -1.10 -1.02 -0.94 -0.86 -0.78 -0.70 -0.62 -0.54 -0.46 -0.38 -0.30 -0.24 -0.18 -0.12 -0.06 0.00 0.08 0.16 0.24 0.32 0.40 0.46 0.52 0.58 0.64 0.70 O.76 0.82 0.88 0.94 1.00 1.08 1.16 1.24 1.32 1.40 1.48 1.56 1.64

APU Delta P (psia) -0.15 -0.14 -0.13 -0.12 -0.11 -0.10 -0.09 -0.08 -0.07 -O.O6 -0.05 -0.04 -0.03 -0.02 -0.01 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23

With QEC Delta EGT

(F) -6.0 -5.6 -5.2 -4.8 -4.4 -4.0 -3.6 -3.2 -2.8 -2.4 -2.0 -1.6 -1.2 -0.8 -0.4 0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.3 3.7 4.1 4.6 5.1 5.5 6.0 6.5 6.9 7.3 7.7 8.1 8.5 8.9 9.3 9.7

Delta Fuel Wf (Ib/hr) -1.00 -0.94 -0.88 -0.82 -0.76 -0.70 -0.64 -0.58 -0.52 -0.46 -0.40 -O.32 -0.24 -0.16 -0.08 0.00 0.08 0.16 0.24 0.32 0.40 0.46 0.52 0.58 0.64 0.70 0.80 0.90 1.00 1.10 1.20 1.28 1.36 1.44 1.52 1.60 1.68 1.76 1.84


Page 139 Feb 28/05

Honeywell



Table 111. Two-pack ECS Standard Mode APU Delta P EGT and Fuel Flow Corrections, (Heavy and Medium Repairs) (Cont)

APU Delta P (psia)

UP200456

0.24 0.25 0.26 O.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45

Without QEC Delta EGT

(F) 8.6 9.0 9.3 9.7 10.1 10.4 10.8 11.1 11.4 118 121 12.4 12.7 13.0 13.4 13.7 14.0 14.3 14.7 15.0 15.4 15.7

Delta Fuel Wf (Ib/hr) 1.72 1.80 1.88 1.96 2.04 2.12 2.20 2.26 2.32 238 244 2.50 2.56 2.62 2.68 2.74 2.80 2.86 2.92 2.98 3.04 3.10

APU Delta P (psia) 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43

With QEC Delta EGT

(F) 10.1 10.5 10.9 11.3 11.7 12.1 12.5 13.0 13.4 13.9 14.3 14.8 15.2 15.6 16.0 16.4 16.8 17.2 17.6 18.0

Delta Fuel Wf (Ib/hr) 1.92 2.00 2.08 2.16 2.24 2.32 2.40 2.48 2.56 2.64 2.72 2.80 2.88 2.96 3.04 3.12 3.20 3.30 3.40 3.50


Page 140 Feb 28/05

Hone vell

RELEASED FOR THE EXCLUSIVE USE BY: MANUAL ASERCA AIRLINES COMPONENT MAINTENANCE

GTCP36-280[D]

Table 112. MES Mode APU Delta P EGT and Fuel Flow Corrections. (Heavy and Medium Repairs)

APU Delta P (psia)

UP200456

-0.15 -0.14 -0.13 -0.12 -0.11 -0.10 -0.09 -0.08 -0.07 -0.06 -0.05 -0.04 -0.03 -0.02 -0.01 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17


(F) -5.3 -4.9 -4.6 -4.2 -3.9 -3.5 -3.2 -2.8 -2.5 -2.1 -1.8 -1.4 -1.1 -0.7 -0.4 0.0 0.4 0.7 1.1 1.4 1.8 2.2 2.6 2.9 3.3 3.7 4.1 4.4 4.8 5.1 5.5 5.8 6.1

Delta Fuel Wf (Ib/hr) -1.10 -1.02 -0.94 -0.86 -0.78 -0.70 -0.64 -0.58 -0.52 -0.46 -0.40 -0.32 -0.24 -0.16 -0.08 0.00 0.08 0.16 0.24 0.32 0.40 0.46 0.52 0.58 0.64 0.70 0.78 0.36 0.94 1.02 1.10 1.18 1.26

0.18

6.4

1.34

0.19 0.20 0.21 0.22 0.23

6.7 7.0 7.4 7.7 8.1

1.42 1.50 1.56 1.62 1.68

APU Delta P (psia) -0.15 -0.14 -0.13 -0.12 -0.11 -0.10 -0.09 -0.08 -0.07 -0.06 -0.05 -0.04 -0.03 -0.02 -0.01 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23

With QEC Delta EGT

(F) -6.0 -5.6 -5.2 -4.8 -4.4 -4.0 -3.6 -3.2 -2.8 -2.4 -2.0 -1.6 -1.2 -0.8 -0.4 0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.3 3.7 4.1 4.5 4.9 5.4 5.8 6.2 6.7 7.2 7.6 8.1 8.6 9.1 9.5 10.0

Delta Fuel Wf (Ib/hr) -1.00 -0.96 -0.92 -0.88 -0.84 -0.80 -0.72 -0.64 -0.56 -0.48 -0.40 -0.32 -0.24 -0.16 -0.08 0.00 0.08 0.16 0.24 0.32 0.40 0.48 0.56 0.64 0.72 0.80 0.88 0.96 1.04 1.12 1.20 1.28 1.36 1.44 1.52 1.60 1.68 1.76 1.84


Page 141 Feb 28/05

HoneTwell



Table 112. MES Mode APU Delta P EGT and Fuel Flow Corrections. (Cont) (Heavy and Medium Repairs)

APU Delta P (psia)

UP200456

0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45


(F) 8.4 8.8 9.1 9.5 9.8 10.2 10.5 10.9 11.3 11.7 12.1 12.5 12.9 13.3 13.6 14.0 14.4 14.8 15.2 15.5 15.9 16.3

Delta Fuel Wf (lb/hr) 1.74 1.80 1.88 1.96 2.04 2.12 2.20 2.26 2.32 2.38 2.44 2.50 2.56 2.62 2.68 2.74 2.80 2.90 3.00 3.10 3.20 3.30

APU Delta P (psia) 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43

With QEC Delta EGT

(F) 10.4 10.9 11.3 11.7 12.2 12.6 13.0 13.4 13.8 14.2 14.6 15.0 15.4 15.8 16.2 16.6 17.0 17.4 17.8 18.2

Delta Fuel Wf (Ib/hr) 1.92 2.00 2.08 2.16 2.24 2.32 2.40 2.50 2.60 2.70 2.80 2.90 2.98 3.06 3.14 3.22 3.30 3.37 3.43 3.50


Page 142 Feb 28/05


Honeywell


Table 113. Two-pack ECS Standard Mode EGT and Fuel Flow Corrections for Excess Corrected Bleed Pressure. (Heavy and Medium Repairs) APU PBCOR (psia)

UP200456

47.0 47.1 47.2 47.3 47.4 47.5 47.6 47.7 47.8 47.9 48.0 48.1 48.2 48.3 48.4 48.5 48.6 48.7 48.8 48.9

Delta Wf (Ib/hr) 0.0 -0.4 -0.8 -1.2 -1.6 -2.0 -2.3 -2.8 -3.3 -3.7 -4.0 -4.4 -4.8 -5.2 -5.6 -6.0 -6.4 -6.8 -7.2 -7.6

Delta EGT

(F) -2 -3 -5 -7 -8 -9 -11 -12 -14 -15 -16 -18 -19 -20 -22 -23 -24 -25 -27

APU PBCOR (psia) 49.0 49.1 49.2 49.3 49.4 49.5 49.6 49.7 49.8 49.9 50.0 50.1 50.2 50.3 50.4 50.5 50.6 50.7 50.8 50.9 51.0

Delta Wf (Ib/hr) -8.0 -8.4 -8.7 -9.0 -9.4 -9.7 -10.0 -10.4 -10.7 -10.4 -10.1 -10.5 -10.8 -11.1 -11.4 -11.7 -12.0 -12.3 -12.2 -12.5 -12.8


Delta EGT

(F) -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -41 -42 -42 -43 -44 -45 -46

Page 143 Feb 28/05


Honeywell


Table 114. MES Mode EGT and Fuel Flow Corrections for Excess Corrected Bleed Pressure. (Heavy and Medium Repairs) APU PBCOR (psia)

UP200456

50.2 50.3 50.4 50.5 50.6 50.7 50.8 50.9 51.0 51.1 51.2 51.3 51.4 51.5 51.6 51.7 51.8 51.9 52.0 52.1

Delta Wf (Ib/hr) 0.0 -0.3 -0.6 -0.9 -1.2 -1.6 -1.9 -2.2 -2.6 -2.9 -3.2 -3.5 -3.8 -4.1 -4.3 -4.6 -4.9 -5.2 -5.5 -5.9

Delta EGT

(F) -1 -2 -3 -5 -6 -7 -8 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -22

APU PBCOR (psia) 52.2 52.3 52.4 52.5 52.6 52.7 52.8 52.9 53.0 53.1 53.2 53.3 53.4 53.5 53.6 53.7 53.8 53.9 54.0 54.1 54.2

Delta Wf (Ib/hr) -6.2 -6.5 -6.8 -7.1 -7.4 -7.6 -7.9 -8.2 -8.5 -8.8 -9.2 -9.5 -9.8 -10.1 -10.4 -10.6 -10.9 -11.2 -11.4 -11.6 -11.8

Delta EGT


(F) -23 -24 -25 -26 -27 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -40 -41 -42 -43 -44

Page 144 Feb 28/05


Hone) well 1.

S.


Preservation. After completion of testing, complete the following: (1)

Prepare the APU for final leak check by removing unnecessary laboratory instrumentation and equipment.

WARNING:

T.


(2)

Replace the oil filter with a new element dipped in an approved oil.

(3)

Do a final five minute leak check.

(4)

Preserve the APU fuel system with M IL-L-6081, Grade 1010 or 1005 oil.

Miscellaneous requirements. (1)

Replacement of parts. Do not replace or adjust detail parts or assemblies once the APU has successfully completed the acceptance test.

(2)

Operating time and starts.

UP200456

Make sure that the total operating time and number of starts for all tests, including the preliminary APU runs or run-in, does not exceed 100 starts, or 25 hours of running at or above 50 percent of the normal-rated output. (3)

After completion of testing, reconnect the DMM connector (P11). Cycle the MASTER switch and make sure the APU history data (SN, HR, CY, and BDCY) are the same as previously recorded. (Refer to paragraph 1.H.).

(4)

Make sure that the ECU display does not flash and that no faults exist at completion of testing. (Refer to paragraph I.R.).


Page 145 Feb 28/05

Honeywell .



Fault Isolation NOTE:

Tests are to make sure the unit operates correctly when it is in for service. These tests will show if the unit is serviceable and/or if any maintenance is necessary. If the unit operates satisfactorily, the unit can be put in use again. These tests make sure the unit operates correctly after a repair or an overhaul has been completed, or after a long time in storage. All shutoff valves must be closed, air pressure set at zero, and the electrical power shutoff at the start of each test.

A.

Engine Engine (APU) fault isolation is shown in six tables: -

Table 116 identifies automatic shutdowns and component isolation.

-

-

Table 117 lists the actual BITE display mnemonics for automatic shutdowns.

-

Table 118 lists the BITE display mnemonics for the LRU faults.

-

Table 119 lists Power-up Test BITE Display Mnemonics. Table 120 lists Fault Display Definitions.

-

UP200456

B.

Table 115 lists all conditions for all shutdowns.

Pneumatic system. (1)

Always look at the BITE display readout before fault isolation.

(2)

If the ECS valves are not manually closed before a main engine start is tried, the APU could have low bleed pressure.

(3)

Low bleed pressure associated with high EGT is an indication the APU is low in power. The inlet guide vanes (IGV) will decrease bleed pressure and prioritize electrical power. Remove the APU.

(4)

Visually examine the surge control valve indicators during APU operation to make sure the valve butterfly plates are in their correct positions.


Page 146 Feb 28/05

Hone vell



Table 115. Shutdown Indicators and Existing Conditions

Shutdown Indicator

Existing Condition

OVERSPEED

N>107% SEC (ANALOG) (PRIMARY) N>109% SEC (DIGITAL) (BACKUP)

OVERTEMP

f(N) = T5>LIMIT + 1 SEC 7%LIMIT + 5 SEC N>95%

LO OIL PRESS

P OIL <33 PSI + N>95% + 15.5 SEC

HI OIL TEMP

T OIL >LIMIT + 95% + 20 SEC

NO ACCEL

N < 7 % FOR 15 SECONDS, OR N < 0.5% %/SEC AND N 95 % AND T5 > 400F + 12.55 SEC. FOR OIL TEMP < 5F AND N < 7 % AND N< 0 %/SEC FOR 6 SECONDS, OR N < 7 % FOR 25 SECONDS

AIRCRAFT SHUTDOWN

AIRCRAFT COMMANDED NORMAL SHUTDOWN

NO FLAME

N>7% + 17 SEC + T5<400F + ECU RUN VALID

REVERSE FLOW

N>50% + LCIT>350F + 5.0 SEC

SHUTDOWN FAIL

APU COMMANDED OFF > 90 SECS + N> 95%

DC LOSS OF POWER

SPEED DROOP < 4% DURING POWER LOSS

LOSS OF EGT SENSORS

BOTH EGT SENSOR OPEN + 0.5 SEC

UP200456

LOSS OF SPEED DETECTION

EITHER MONOPOLE ELEMENT + OTHER CONDITIONER FAIL OR BOTH MONOPOLE ELEMENTS FAIL OR TWO CONDITIONERS FAIL

ECU

ECU INTERNAL SYSTEM FAILURE

APU FIRE

APU FIRE INPUT IS ACTIVE

DOOR SHUTDOWN

APU FAILURE TO HOLD APU DOOR OPEN

49-26-49 Copying, use or disclosure of information on this page is subjectto proprietary restrictions.

Page 147 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 116. Automatic Shutdown Component Isolation

Automatic Shutdown Indication

Probable Cause

Corrective Action

APU FIRE

Aircraft Command

Check A/C MM.

DC LOSS

Aircraft System ECU Failure

Check APU power system. Replace ECU.

DISABLED

ECU Disabled

Replace ECU.

DOOR SDN

APU Door Failure

Replace door actuator.

EGTLOSS

Loss of EGT Signal from EGT 1 and EGT 2

Replace both EGT Sensors.

ECU

ECU

Replace ECU.

HIGH OIL TEMPERATURE

HOT Sensor

Replace HOT Sensor.

Incorrect Servicing

Fill oil system. Check overfill.

External Leakage

Repair any leaks.

Oil Cooler Ducts

Examine ducts for damage and attachment. Repair all damage.

Oil Cooler Assembly

Replace oil cooler.

Cooling Fan

~Replace cooling fan.

Fuel Control Unit (FCU)

Replace FCU.

ECU

Replace ECU.

Generator Shaft Shear

Replace generator.

ECU Circuit failure

Replace ECU.

UP200456

HW OVERSPEED


Page 148 Feb 28/05

Honeywell



Table 116. Automatic Shutdown Component Isolation (Cont) Automatic Shutdown Indication

Probable Cause

Corrective Action

IGV SHUTDOWN

Fuel Supply

Repair fuel supply.

Inlet Guide Vane (IGV) Actuator

Replace IGV actuator.

IGV Rod is Binding

Make sure the vanes can be moved freely.

Electronic Control Unit (ECU)

Replace ECU.

Incorrect Servicing

Check overfill condition. Fill oil system.

Oil Pressure Switch

Replace oil pressure switch.

Lube Pump

Replace lube pump.

Lube Pump Filter

Replace filter.

External Leakage

Repair any leaks.

De-oil Solenoid

If cold day condition exists, 20F (-6.67C) or Pd 4, replace the solenoid.

Plumbing

Make sure plumbing is free of obstructions.

Internal APU Failure

Check APU.

Internal APU Engine Damage

The APU engine must rotate freely. If resistance is felt or rubbing is heard, replace APU.

De-Oil Solenoid

If cold day condition exists, 20F (-6.67C) or Pd 4, replace solenoid.

LOW OIL PRESSURE

UP200456

NO ACCELERATION


Page 149 Feb 28/05

Hone) well



Table 116. Automatic Shutdown Component Isolation (Cont) Automatic Shutdown Indication

Probable Cause

Corrective Action

NO ACCELERATION (CONT)

Starter Motor

Replace starter motor.

Starter Clutch

Replace starter clutch.

Fuel Supply to Fuel Control Inlet Guide Vane (IGV) Adjustment

Check fuel supply and lines. Adjust IGV. (Refer to Figure 104)

Inlet Guide Vane Actuator



Replace FCU.

Flow Divider

Will not accelerate if secondary nozzles do not get fuel.

ECU

Faulty fuel schedule. Replace ECU.

Ignition System

Replace Ignition Box.

A/C Fuel System Blockage

Check A/C Fuel System.

FCU

Replace FCU.

ECU

Replace ECU.

OVERSPEED

Software Backup for Overspeed

Replace ECU.

OVERTEMPERATURE

Internal APU Engine Damage

The APU engine must rotate freely. If resistance is felt or rubbing is heard, replace APU.

Overload while on ground

Reduce APU load.

UP200456

NO FLAME


Page 150 Feb 28/05


Honeywell


Table 116. Automatic Shutdown Component Isolation (Cont)

Automatic Shutdown Indication

Probable Cause

Corrective Action

OVERTEMPERATURE (CONT)




Replace FCU.

Flow Divider

Replace flow divider.

ECU

Replace ECU.

Fuel Nozzles

Replace fuel nozzles.


Replace FCU.



Starter Motor

Replace starter motor.

Load Compressor Inlet Temperature Connection

If fault persists, examine wiring harness and repair as necessary.

Surge Control Valve (SCV)

Replace SCV.

ECU Failure

Replace ECU.

Loss of speed signal.

Replace monopoles.

OVERTEMPERATURE DURING START

REVERSE FLOW

UP200456

SPD LOSS


Page 151 Feb 28/05

Honeywell



UP200456

Table 117. Actual BITE Display Message'For Automatic Shutdowns Mnemonic

Definition of Shutdown

APU FIRE

APU compartment fire

DC LOSS

DC power loss

DISABLED

ECU disabled (ECU operating mode)

DOOR SDN

APU door driver failure

ECU SDN

ECU internal system failure

EGT LOSS

Both EGT thermocouples failed

HOT SDN

Hot oil temperature

HW OVSPD

Overspeed (hardware circuit detected)

IGV SDN

IGV shutdown

LOP SDN

Low oil pressure

NO ACCEL

No acceleration

NO FLAME

No flame

OVER SPD

Software backup overspeed

OVR TEMP

Overtemperature

RVR FLOW

Reverse flow

SHUTFAIL

Shutdown relay failure

SPD LOSS

Loss of both speed signals


Page 152 Feb 28/05

Hone vell



UP200456

Table 118. BITE LRU Fault Display Mnemonics

Mnemonic

LRU

APU DOOR

APU door driver

APU IGN

Ignition circuit

DOlL SOL

De-Oil solenoid

DMM

Data memory module

DP SNSR

Delta P sensor

ECU

ECU

EGTMETER

EGT meter

EGT 1

EGT thermocouple rake 1

EGT 2

EGT thermocouple rake 2

EGT 1 & 2

Both thermocouples failed

FC UNIT

Fuel control unit (fuel torque motor)

FIRESENS

APU engine compartment fire

FLT IND

Fault indicator

FUEL SOL

Fuel solenoid

HOLD RLY

95% Hold relay

IGV TM

Inlet guide vane (IGV) torque motor

LCV

Load control valve

LOP SW

Low oil pressure switch


Page 153 Feb 28/05

Hone3 well



UP200456

Table 118. BITE LRU Fault Display Mnemonics (Cont)

Mnemonic

LRU

LOP IND

LOP indicator failed

LVDT

IGV LVDT

MONO 1

Speed monopole 1 circuit

MONO 2

Speed monopole 2 circuit

MONO 1&2

Failed both speed signals

OIL TEMP

Oil temperature sensor

P2 SENSR

P2 (ambient pressure) sensor

PT SENSR

Total Pressure sensor

REM DISP

Remote BITE display

RPMMETER

% rpm meter

SCV TM

Surge control valve torque motor

STARTER

Starter motor

STRT RLY

Starter relay

T2 SNSR

T2 (ambient temperature) sensor


Page 154 Feb 28/05

Honeywell



UP200456

Table 119. Power-up Test BITE Display Mnemonics

Mnemonic

Test Failure

PROM FLT

PROM failure

RAM FLT

RAM failure

TIME FLT

Real-time overun

CPU FLT

CPU failed


Page 155 Feb 28/05

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UP200456

Table 120. Fault Display Definitions Error Code

Definition

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2O 21 22 23 24 25 26 27 28 29 3O 31 32 33 34 35 36 37 38 39 4O

Divide by 0 Bad interrupt Background EEPROM RAM image Test Failed EEPROM write did not take Fuel solenoid stuck open Loss of DC power A/D conversion not complete DMM download verify failed Spare Spare Keep-alive counter Keep-alive prestart Keep-alive didn't clamp off fuel Keep-alive powerdown A card overspeed reference C card overspeed reference TEST A card freq TEST C card freq A card overspeed reference C card overspeed reference TEST A card freq TEST C card freq A card overspeed C card overspeed Overspeed didn't clamp fuel flow H/W O/S S/W O/S Speed A F/D interrupt not received Speed A F/D interrupt not received Speed C F/D interrupt not received Speed C F/D interrupt not received TEST A F/D interrupt not received TEST C F/D interrupt not received OSREF A F/D interrupt not received OSREF C F/D interrupt not received Spare Spare Speed 1A low Speed 2A low Speed 1C low


Page 156 Feb 28/05


Honeywell


UP200456

Table 120. Fault Display Definitions (Cont)

Error Code

Definition

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 64 65 68 69 72 73 76 77 78 79 80 81 82

Speed 2C low Monopole A low Monopole C low One conditioner from each, no shutdown One or more conditioners from each, shutdown Monopole A V bit high Monopole A V bit high EGT 1 high EGT 1 low EGT 1 high EGT 1 low EGT 1 open EGT 2 high EGT 2 low EGT 2 high EGT 2 low EGT 2 open Both EGT 1 and EGT 2 failed Both EGT 1 and EGT 2 failed Ref 28 less than 7V or Ref 28 more than 48V High oil temperature OILT high OILT low T-2 high T-2 low Cold junction compensation high Cold junction compensation low Pressure sensor reference bit high Pressure sensor reference bit low Delta pressure high Delta pressure low Delta pressure high (only if BLEEDON = 0) Delta pressure low (only if BLEEDON = 1) Total pressure high


Page 157 Feb 28/05

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UP200456

Table 120. Fault Display Definitions (Cont) Error Code

Definition

83 84 85 86 87 88 89 90 91 93 95 97 99 101 103 105 107 109 112 113 114 115 116 117 118 119 120 121 122

Total pressure low Total pressure high Total pressure low Ambient pressure high Ambient pressure low Ambient pressure high Ambient pressure low LVDT primary voltage high LVDT primary voltage low Refc ground voltage high Refc bias voltage low A/D 10 volt reference low A/D 10 volt card A reference low A/D 10 volt card A reference low A/D 10 volt card A reference low A/D 10 volt card A reference low A/D 10 volt card A reference low A/D 0 volt reference high 5 volt reference high 5 volt reference low Monopole C V bit high Monopole C V bit high Fuel torc ue motor on current high Fuel torc ue motor on current low Fuel torc ue motor on voltage high Fuel torc ue motor on voltage low Fuel torc ue motor off current high Fuel torc ue motor shorted Fuel tore ue motor off voltage high


Page 158 Feb 28/05

Honeywell



UP200456


Error Code

Definition

124 125 126 127 128 129 130 131 132 134 135 136 137 138 139 140 141 142 144 145 146 148 149 150 151 152 153 154 155 156 157 158 159 161 163 164

Fuel torque motor over current Fuel torque motor failed to turn off Surge valve torc ue motor on current high Surge valve torc ue motor on current low Surge valve torc ue motor on voltage high Surge valve torc ue motor on voltage low Surge valve torc ue motor off current high Surge valve torc ue motor shorted Surge valve torc ue motor off voltage high Surge valve torc ue motor over current Surge valve torc ue motor failed to turn off Inlet guide vane torque motor on current high Inlet guide vane torque motor on current low Inlet guide vane torque motor on voltage high Inlet guide vane torque motor on voltage low Inlet guide vane torque motor off current high Inlet guide vane torque motor shorted Inlet guide vane torque motor off voltage high Inlet guide vane torque motor over current Inlet guide vane torque motor failed to turn off Both P2 and PT sensors failed EGT meter over current EGT meter failed to turn off One conditioner from each, no shutdown One conditioner from each, no shutdown RPM meter over current RPM meter failed to turn off Low oil pressure switch fail Low oil pressure occurred LVDT secondary coil bit APU fire APU fire Only have mono 2 hi conditioner, shutdown Continuous RAM test failed DMM off voltage high DMM on voltage low


Page 159 Feb 28/05

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UP200456


Error Code

Definition

165 166 169 170 171 172 175 176 177 178 181 182 183 184 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206

DMM on overcurrent DMM off overcurrent DEOIL solenoid on voltage low DEOIL solenoid off voltage high DEOIL on overcurrent DEOIL off overcurrent DOOR solenoid on voltage low DOOR solenoid off voltage low DOOR on overcurrent DOOR off overcurrent FUELSOL solenoid on voltage low FUELSOL solenoid off voltage high FUELSOL on over current FUELSOL off over current IGN unit on voltage low IGN unit off voltage high IGN unit on over current IGN unit off over current No accel shutdown No accel shutdown No accel shutdown No accel shutdown No accel shutdown No accel shutdown No flame shutdown No flame shutdown No flame shutdown No flame shutdown Fuel torque motor on voltage low IGV torque motor on voltage low Fuel torque motor on voltage high Spare LOPIND on overcurrent LOPIND off overcurrent


Page 160 Feb 28/05

Honeywell



UP200456

Table 120. Fault Display Definitions (Cent)

Error Code

Definition

207 208 209 210 211 212 213 214 215 216 217 218 219 221 222 223 224 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 246 248

Spare Spare Spare Spare Fault indicator on overcurrent Fault indicator off overcurrent Spare Spare Start relay on voltage low Start relay on overcurrent Start relay off overcurrent Starter motor on voltage low Starter motor off voltage high HOLD relay on voltage low HOLD relay off voltage high HOLD relay on over current HOLD relay off over current LCV on voltage low LCV off voltage high LCV on overcurrent LCV off overcurrent IGV shutdown IGV shutdown IGV shutdown RBD terminal parity error Overtemp shutdown 1 Overtemp shutdown 2 Overtemp shutdown 3 Overtemp shutdown 4 Overtemp shutdown 5 Spare No accel No accel No accel No accel No accel No accel Error to log starter LRU


Page 161 Feb 28/05

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UP200456


Error Code

Definition

249 250 251 252 253 254 255

Spare Loss of DC power Reverse flow shutdown RBD Ioopback failed ECB is disabled Shutdown failure ARINC Ioopback failed


Page 162 Feb 28/05


Honeywell

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] DISASSEMBLY

.

Equipment and Materials A.

Table 301 shows the equipment and materials necessary for disassembly. Table 301. Equipment and Materials

Equipment/Material NOTE:


Equivalent equipment/material can be used.

Bearing and puller plate set (Part No. 833123-1)

*

Bearing and puller plate set (Part No. 833980-9)

*

Bearing carrier puller (Part No. 2024292-1)

*

Bearing puller (Part No. 2024020-1)

*

Bearing removal adapter (Part No. 2024015-1)

*

Bearing removal adapter (Part No. 2024016-1 )

*


*

Bearing puller plate set (Part No. 833123-102)

*

Bearing puller plate set (Part No. 833123-105)

*

Bearing removal adapter set (Part No. 833130-1)

*


*


*


*


*


*


*


*


*


*

UP200456

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment 717 N. Bendix Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987


Page 301 Feb 28/05

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Equipment/Material


Bearing removal fixture (Part No. 2024014-4) Bearing removal and installation fixture (Part No. 2024019-1 ) Bearing removal and installation fixture (Part No. 833986-1) Bearing removal fixture (Part No. 833440-1) Bearing removal plate (Part No. 833985-2) Bearing removal tool (Part No. 833092-3) Bearing removal tool (Part No. 835550-1) Bearing support fixture (Part No. 833987-1) Coupling puller (Part No. 833429-1) Engine cart (Part No. 835332-1 ) Gearbox housing adapter (Part No. 2024003-1) Generator adapter puller (Part No. 2024293-1) Generator drive gear seal puller (Part No. 2024287-1) Idler shaft puller (Part No. 2024080-1) Labrinth seal removal Fixture (Part No. 835587-1) Lip seal puller (Part No. 2024285-1) Lip seal puller (Part No. 2024297-1) Load compressor diffuser puller (Part No. 2024230-1 ) Lube pump puller (Part No. 2024308-1)

*

Maintenance stand (Part No. 287750-1)

*

UP200456

• Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment 717 N. Bendix Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987

49-26-49


Page 302 Feb 28/05



, HoneTwell

Table 301. Equipment and Materials (Cont) Equipment/Material


Medium duty proto puller (Model No. 4020C) Oil pickup tube puller (Part No. 2024084-1 ) Plenum puller (Part No. 833186-1) Portable gas turbine engine stand (Part No. 833565-3) Power section fixture assy (Part No. 2024008-1 ) Power section lift fixture (Part No. 833431-1 ) Seal removal fixture (Part No. 2024018-1 ) Seal removal fixture (Part No. 835607-1) Shaft stretching fixture (Part No. 833094-1) Spanner wrench (Part No. 2024465-1 ) Stand assembly support adapter (Part No. 833426-1) Stand assembly support adapter(Part No. 834119-2) Stand assembly support adapter (Part No. 834389-1) Stand assembly support adapter (Part No. 834390-1) Starter clutch puller (Part No. 834397-1 ) Starter cover puller (Part No. 2024291-1 ) Transfer tube puller (Part No. 833434-1) Tube puller (Part No. 2024084-1) Tube puller (Part No. 2024228-1) Tube installation adapter (Part No. 833184-1) *Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment 717 N. Bendix

UP200456

Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987


Page 303 Feb 28/05

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Initial Disassembly Procedures A.

Before the engine can be disassembled, the procedures that follow must be done. (1)

Remove all hardware that holds the engine to the shipping container, crate, skid or other support.

WARNING:

Remove the engine from the shipping container with the use of 833431-1 -lift fixture and a hoist attached to the hoisting point.

(3)

Install 834119-2, 834389-1 and 834390-1 stand assembly support adapters on the gearbox mount points and the mount bracket.

(4)

Lower the engine into a 833565-3 portable gas turbine engine stand and attach it to the stand.

(5)

Remove the hoist from the hoisting point.

(6)

USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT, IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN.

Use a container to catch the oil and remove the magnetic drain plug from the gearbox. Discard the packing. Install the magnetic drain plug with a new packing. NOTE:

When using the 835332-1 vertical maintenance stand, be sure to install the 2024008-1 fixture assembly to secure the power section to the stand.

General Disassembly Procedures WARNING:

NOTE:

UP200456

MAKE SURE HOIST BAR AND RING ARE CORRECTLY ATTACHED AND OPERATE SAFELY PRIOR TO APU INSTALLATION OR REMOVAL. DO NOT STAND DIRECTLY BELOW APU DURING INSTALLATION OR REMOVAL AS THE HOIST BAR OR RING COULD BREAK, RESULTING IN SERIOUS BODILY INJURY OR DEATH.

(2)

WARNING:

.


THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENERGIZED AND GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT TERMINAL. Do not disassemble tube assemblies, hose assemblies, wiring harness assemblies, riveted assemblies, staked or press-fit parts (except seals and bearings) or remove nameplates, modification plates, lubrication plates, decals, studs, or their Iockrings, or thread inserts, unless specifically required in the text or necessary for replacement of a part. If disassembly or removal is necessary, proceed in a manner consistent with good shop practice.

A.

Disassemble in a dry, well lighted, dust free room.

B.

Be careful to prevent damage to parts that can be used again.


Page 304 Feb 28/05


Honeywell WARNING:

.



C.

Apply lubricating oil to parts and put them in a protective container to prevent corrosion until the parts can be cleaned and examined.

D.

Do not disassemble any staked, welded, riveted, soldered, swaged, or press fit assemblies or remove plates, passage hole plugs, or threaded inserts unless replacement is necessary.

E.

Examine all bearings for roughness, brinelling, and damaged races or retainers. These conditions can be an indication of possible damage.

F.

Remove all protective caps, plugs, and closures before disassembly of the unit.

G.

Make a record of the quantities and thickness of the shims and washers. This will help when you assemble the part.

H.

Removal of electrical connectors. Disassembly of details of the plumbing and electrical installation shall be accomplished as accessible and "feasible" during removal of engine section components from the engine. Note routing of tubing electrical wiring harness and location and manner of attaching clamps. Tag tubing and electrical gaskets. (Refer to Figures 302 through 308B.)

NOTE:

(1)

Remove threaded connectors. CAUTION:

(2)

TO PREVENT DAMAGE TO CONNECTORS, DO NOT USE TOO MUCH FORCE. DO NOT PULL ON THE ATTACHED WIRES.

(a)

Use connector pliers to loosen the coupling rings.

(b)

Pull on the plug body and turn the coupling ring until the connector is apart.

(c)

Use caps or plastic bags to keep dirt and unwanted material out of the receptacles.

Remove the bayonet connector. (a)

Turn the coupling ring in a counterclockwise direction to remove the bayonet connector.

UP200456

Honeywell recommends that the parts found in Table 302 be replaced at each disassembly. However, actual replacement of parts may be done on in-service experience.


Page 305 Feb 28/05


Honeywell


UP200456

Table 302. Parts to be Replaced at Each Disassembly Figure No.

Item No.

302

Nomenclature

Quantity

120, 280, 310, 330, 340, 360, 380, 390, 430

Packing

13

302A

130, 160, 180, 220, 260, 280

Packing

7

302B

130, 160, 180, 220, 260, 28O

Packing

7

303

8O

Packing

1

303A

30, 40, 150, 170

Packing

6

303B

30, 40, 150, 170

Packing

6

304

90, 100, 150, 260, 290

Packing

7

304A

100, 160, 240,290, 310

Packing

10

304B

100, 160, 240, 290, 310

Packing

10

305

160, 200

Packing

3

305A

50, 150

Packing

4

305B

50, 150, 210, 210A

Packing

5

306

110, 170, 230, 240

Packing

7

306A

40, 150, 180, 270, 350, 38O

Packing

9

306B

40, 150, 180, 270, 350, 38O

Packing

9

307A

90

Packing

1

307B

9O

Packing

1

308A

120, 210

Packing

3


Page 306 Feb 28/05


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UP200456

Table 302. Parts to be Replaced at Each Disassembly (Cont) Figure No.

Item No.

Nomenclature

Quantity

308B

120, 210

Packing

3

3O9

100, 110, 180

Packing

3

309A

100, 110, 180

Packing

3

310

100

Packing

1

310A

100, 310

Packing

3

311

80, 180, 220

Packing

3

311A

80, 180, 220

Packing

3

312

30, 50, 90, 130, 190, 210, 220

Packing

9

313

40, 80, 90

Packing

3

314

130

Packing

1

314A

130

Packing

1

315

10, 20, 50, 70

Packing

4

316

50, 80, 120, 130, 165, 180, 220, 260, 290, 310

Packing

11

316A

50, 80, 150, 160, 200, 220, 250,290

Packing

8

317

70, 90

Packing

2

317A

40, 70

Packing

2

318

40, 240, 360

Packing

3

318A

40, 240, 290, 330

Packing

4

319

90, 140, 160, 180, 245, 270, 310

Packing

7


Page 307 Feb 28/05


Honeywell


UP200456

Table 302. Parts to be Replaced at Each Disassembly (Cont) Figure No.

Item No.

319A

Nomenclatu re

Quantity

50, 90, 110, 200, 220, 37O

Packing

7

321

105

Packing

1

322

30, 40, 90, 150, 160

Packing

10

323

40, 41,42, 110

Packing

5

325

130, 140, 150, 330, 340, 350

Packing

6

326

20, 150, 160 280

Packing Gasket, Seal Curvic

3 1

327

120

Packing

19

327A

150

Packing

19


Page 308 Feb 28/05

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Disassembly Procedures Refer to TESTING AND FAULT ISOLATION to find the condition of the unit and the level of disassembly necessary to repair the unit.

NOTE:

Obvious steps or procedures necessary to disassemble the engine, such as removal of Iockwire, attaching parts, or simple components are omitted from the text. Removal of plumbing, electrical and external parts installation may be accomplished whenever parts are accessible. In general, disassembly must be accomplished in sequence of index numbers assigned to individual exploded views. Variations from this sequence and special processes or methods are specifically mentioned in the text. The following general procedures should be observed throughout the disassembly operations. A.

Disassemble the plumbing and electrical installation.

UP200456

(1)

Remove components of plumbing and electrical installation (Refer to Figures 302 through 308B) and replace as required in accordance with good shop practice. During removal, note must be made of the routing of wiring, tubing and hoses, and manner of attaching clamps for reference at assembly. Plumbing fittings, lines, and wiring harness connectors and terminals, must be tagged as removed to help in assembly.


Page 309 Feb 28/05

Honeywell



10 20 110 410

250 430

350

10 20 110 ~10

. . . .

43O 220

24O 430 (BEHINDFILTER) 70 80 140 140 330 340

A 10 20 110 450

90 120 400

20 100 370 380

o

o ~//"':::B B130

60

40 390 280 ' ~ 320 ~ . 460 ~ ,

25O 310 " - ~ '

10 50 190 200

10 20 180 420

300

10 20 180 420

1() / 20 170 150 210

10 270 20 280 150 290 420

~ 160

10 20 150 420

10 20 150 420

10 20 150 410

X3800504PL140

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3615682) (Code A) (Partial Breakdown) Figure 302 NOTE:

Figure 301 intentionally omitted.


Page 310 Feb 28/05


Hone eli


~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180. 190. 200. 210. 220. 230.

NUT (IPC FIG. 2) BOLT ELBOW TUBE ASSY BOLT TUBE ASSY TUBE ASSY TUBE ASSY TUBE ASSY TUBE ASSY CLAMP PACKING TUBEASSY BOLT CLAMP TUBEASSY TUBE ASSY CLAMP CLAMP SPACER CLAMP TEE UNION

TO FIGURE 302

240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360. 370. 380. 390. 400. 410. 42O. 430. 440. 45O. 460.

REDUCER NUT UNION ELBOW REDUCER PACKING NUT TUBE ASSY PACKING UNION PACKING PACKING UNION PACKING RETAINER PACKING PACKING BOLT CLAMP CLAMP PACKING REDUCER CLAMP TUBE ASSY


Page 311 Feb 28/05


Hone vell

230

240


250 260

270 280 ~ 0

10 100 110 310

270 280 300

i

210 220 200

170 180 190

20 150 160

140 20 120 130

10 90 100 110

10 20 70 80

60

50

10

30

330

A A3800504PL187

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 302A

49-26-49 Copying, use or disclosureof information on this page is subject to proprietaryrestrictions.

Page 312 Feb 28/05


Honeywell


~lm KEY TO FIGURE 302A

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170.

NUT (IPC FIG. 2A) BOLT TUBE ASSY CLAMP WIRE HARNESS REDUCER CLAMP CLAMP CLAMP SPACER BOLT TUBE ASSY PACKING TUBE ASSY TUBE ASSY PACKING ELBOW

180. 190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330.

PACKING NUT TUBE ASSY UNION PACKING TUBE ASSY TUBE ASSY TUBE ASSY PACKING REDUCER PACKING DE-OIL SOLENOID VALVE TUBE ASSY CLAMP CLAMP CLAMP


Page 313 Feb 28/05


Hone)~vell

~0


2~ 2~

2~

10 100 110 310

270 270 280 290 280 300

Y

J

210

~"~----~

i 170 -

150 -

~/ /

,./

/ 120 130 340

10 90 100 110

10 20 70 80

60

50

10 20 40

30

10

--I---~.--~ •;~\-,

[k

~-"

A A3800504PL196

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 302B


Page 314 Feb 28/05

Hone vell



~KEY

UP200456

10. 20. 30. 4O. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170.

NUT (IPC FIG. 2B) BOLT TUBE ASSY CLAMP WIRE HARNESS REDUCER CLAMP CLAMP CLAMP SPACER BOLT TUBE ASSY PACKING TUBEASSY TUBEASSY PACKING ELBOW

TO FIGURE 302B 180. 190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340.

PACKING NUT TUBE ASSY UNION PACKING TUBE ASSY TUBE ASSY TUBE ASSY PACKING REDUCER PACKING DE-OIL SOLENOID VALVE TUBE ASSY CLAMP CLAMP CLAMP BOLT


Page 315 Feb 28/05

Honeywell



10 20 30 50 I

10 20 40 130

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@ 10 20 30 120

10 20 30 120

t J

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~ 10 20 7O 110

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/

1t0

UP200456

X3800504PL141

Disassemble the Plumbing and Electrical Installation (Part No. 3615682) (Code A) (Partial Breakdown) Figure 303


Page 316 Feb 28/05

Honeywell



4~KEY

UP200456

10. 20. 30. 40. 50. 7O.

NUT (IPC FIG. 3) BOLT CLAMP CLAMP CLAMP BRACKET

TO FIGURE 303

80. 90. 100. 110. 120. 130.

PACKING ELBOW NUT CLAMP CLAMP BRACKET


Page 317 Feb 28/05


Honeywell

20 60

UP200456

180


10 20 50 110

40 30 70 80

130 160 170

130 140 150

10 20 110 120

10 2O 110 120

A3800504PL188



Page 318 Feb 28/05


Hone) well



UP200456

10. 20. 30. 40. 5O. 6O. 70. 80. 90.

NUT (IPC FIG. 3A) BOLT PACKING PACKING CLAMP TUBE ASSY TUBE ASSY TUBE ASSY" TUBE ASSY

100. 110. 120. 130. 140. 150. 160. 170. 180.

UNION CLAMP BRACKET SCREW TUBE RETAINER PACKING TUBE RETAINER PACKING TUBEASSY


Page 319 Feb 28/05


Honeywell

20

40 70

/

180


30 8O

/

10 20 9O

100

/

200 190 130 160 170

210

130 140 150

5O

10 20 110

1:,10

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10 20 110 120

A3800504PL197

UP200456



Page 320 Feb 28/05

Hone) well



~1~ KEY TO FIGURE 303B

UP200456

10. 20. 3O. 40. 50. 60. 70. 80. 90. 100. 110.

NUT (IPC FIG. 3B) BOLT PACKING PACKING CLAMP TUBE ASSY TUBE ASSY TUBE ASSY" TUBE ASSY UNION CLAMP

120. 130. 140. 150. 160. 170. 180. 190. 200. 210.

BRACKET SCREW TUBE RETAINER PACKING TUBE RETAINER PACKING TUBEASSY TEE TUBE ASSY TUBEASSY

49-,26-49 Copying,use or disclosureof informationon this page is subjectto proprietaryrestrictions.

Page 321 Feb 28/05


Hone) well


~oo~.~ 150

i----'

J

30

.

:

•

/ ~ /

;I F E T ' ~ ,

!

t

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10 30 330 340

100 130 310,

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UP200456



Page 322 Feb 28/05

Hone vell



41~ KEY TO FIGURE 304

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170.

NUT (IPC FIG. 4) BOLT CLAMP CLAMP HOSEASSY TUBEASSY NUT ELBOW PACKING PACKING PRESSURE RELIEFVALVE TEE TUBE NUT NUT PACKING ELBOW SCREW

180. RETAINER 190. PACKING 200. RETAINER 210. TUBEASSY 220. TUBEASSY 230. UNION 240. TUBE ASSY 250. CLAMP 260. PACKING 270. CLAMP 280. BRACKET 290. PACKING 300. REDUCER 310. ELBOW 320. CLAMP 330. SPACER 340. BOLT


Page 323 Feb 28/05


Honeywell


UP200456

THIS PAGE INTENTIONALLY LEFT BLANK


Page 324 Feb 28/05


Honeywell


10

2o C 3O ~~ --.~

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10 30 40 50 70

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X3800504PL143

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Disassemble the Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 304A (Sheet 1 of 2)


Page 325 Feb 28/05


Hone) well


170 250 260 360

270 280 290

310 350

300 310

310 340 330

310 320

B

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10 20 30

10 20 30

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UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 304A (Sheet 2)


Page 326 Feb 28/05

Honeywell



41~ KEY TO FIGURE 304A

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180.

NUT (IPC FIG. 4A) BOLT CLAMP SPACER BOLT CLAMP CLAMP BRACKET NUT PACKING ELBOW BRACKET CLAMP CLAMP REDUCER PACKING BOLT CLAMP

190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360.

BRACKET BRACKET CLAMP TUBE ASSY REDUCER PACKING RETAINER BOLT NUT ELBOW PACKING UNION PACKING REDUCER TEE UNION NUT REDUCER


Page 327 Feb 28/05

Honeywell



UP200456



Page 328 Feb 28/05


Honeywell


10

2o C

" 30 '1 \

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20 30 60

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A X3800504PL143

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 304B (Sheet 1 of 2)

49-26-49 Copying, use or disclosure of information on this page is subject to proprietaryrestrictions,

Page 329 Feb 28/05


gone vell


170 2,50 260 360 270 280 290

310 350

300 310 33O

310 320

10 20 70

10 20 3O :0

10 2O 3O 140

UP200456

A3800504PL190

Disassemble the Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 304B (Sheet 2)


Page 330 Feb 28/05

Honeywell



~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180.

NUT (IPC FIG. 4B) BOLT CLAMP SPACER BOLT CLAMP CLAMP BRACKET NUT PACKING ELBOW BRACKET CLAMP CLAMP REDUCER PACKING BOLT CLAMP

TO FIGURE 304B

190. 200. 210. 220. 230. 240. 250. 260. 270. 28O. 290. 300. 310. 320. 330. 340. 350. 360.

BRACKET BRACKET CLAMP TUBE ASSY REDUCER PACKING RETAINER BOLT NUT ELBOW PACKING NIPPLE PACKING REDUCER TEE UNION NUT REDUCER


Page 331 Feb 28/05



Honeywell

10

10

10

20 40

40 180 220

20 30 40

60

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X3800504PL145

UP200456


49-26-49 C o p y i n g , u s e o r d i s c l o s u r e o f i n f o r m a t i o n o n this p a g e is s u b j e c t to p r o p r i e t a r y restrictions.

Page 332 Feb 28/05

Honeywell




UP200456

10. 20. 30. 40. 60. 7O. 80. 90. 100. 110. 120.

NUT (IPC FIG. 5) BOLT CLAMP CLAMP CLAMP TUBE ASSY TUBE ASSY BRACKET CLAMP ELBOW NUT

130. CLAMP 140. TEE 150. REDUCER 160. PACKING 170. CLAMP 180. CLAMP 190. CLAMP 200. PACKING 210. UNION 220. SPACER 230. BOLT


Page 333 Feb 28/05

Hone) well



UP200456



Page 334 Feb 28/05

Honeywell



10 20 70

\ , !

!

i

Ill,/" / I

'1---90 f ¢

10: ' 70 110 120 130

""~t ~'i 10 20 80 100

f A

7O 8O A3800504PL191

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 305A (Sheet 1 of 2)

49-26-49 • Copying, use or disclosure of information on this page is subject to proprietary restrictions.

Page 335 Feb 28/05


Hone) well


10 20 80 100

A

140 150

150 160 170

50 180

--.--I~

10 70 80 110 120

10

10

10

10

20

20

20

20

70 100

70

70 100

190 200

120

A A3800504PL192

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 305A (Sheet 2)


Page 336 Feb 28/05

Honeywell




UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100.

NUT (IPC FIG. 5A) BOLT TUBE ASSY ELBOW PACKING NUT CLAMP CLAMP TUBE ASSY CLAMP

110. BOLT 120. SPACER 130. CLAMP 140. PLUG 150. PACKING 160. NUT 170. ELBOW 180. UNION 190. BRACKET 200. CLAMP


Page 337 Feb 28/05

Honeywell



UP200456



Page 338 Feb 28/05


Honeywell


170A 170B

210A

10 20 70

160 210

170

i

\

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511

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. . . . . . . ,i_

#I

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J 10 70 110 120 130

10 20 80 100

10 20 70 80

X3800504PL189

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 305B (Sheet 1 of 2)


Page 339 Feb 28/05

Honeywell



10 20 80 100

A

150 160 170

140 1~

50 1;~

,.-~

t f

I

10 70 80 110 120

t0 20 70 100

10 20 70

10 20 70 100

8O 110 120

10 20 190 200

1

A

t~..~__)

A

A3800504PL199

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 305B (Sheet 2)

49-26-49 Copying,use or disclosureof information on this pageis subjectto proprietaryrestrictions.

Page 340 Feb 28/05

Honeywell



~KEY

UP200456

10. 20. 3O. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140.

NUT (IPC FIG. 5B) BOLT TUBE ASSY ELBOW PACKING NUT CLAMP CLAMP TUBE ASSY CLAMP BOLT SPACER CLAMP PLUG

TO FIGURE 305B

150. PACKING 160. NUT 170. ELBOW 170A. UNION (POST SB 49-7578) 170B. SWIVEL FITTING (POST SB 49-7578) 180. UNION 190. BRACKET 200. CLAMP 210. PACKING 210A. SEAL (POST SB 49-7578)


Page 341 Feb 28/05

Hone vell

10 20 40 GO



20 200 240

10 30 40 70

90

10 4O 60 70 250 120l / /

1~

10 20 40 5;

10 20 40 80

140

\ I

\

100/

/

110

220 230

210 '

/17() [ _ , = J - 1 5\0

170 180

t / 190

~

\

160 170

10 3O 70 25O

250 260

X3800504PL147

UP200456


49-26-49


Page 342 Feb 28/05

Hone vell



~KEY

UP200456

10. 20. 30. 4O. 50. 60. 70. 80. 90. 100. 110. 120. 130.

NUT (IPC FIG. 6) BOLT CLAMP CLAMP CLAMP CLAMP SPACER CLAMP DE-OIL SOLENOID REDUCER PACKING TUBE ASSY TUBEASSY

TO FIGURE 306

140. TUBE ASSY 150. TEE 160. REDUCER 170. PACKING 180. REDUCER 190. LOP SWITCH 200. RETAINER 210. TUBE ASSY 220. UNION 230. PACKING 240. PACKING 250. BOLT 260. RETAINER


Page 343 Feb 28/05

Hone vell



t0 90 110 120 190

10 120 200 210 220

40

260 240

10 10 90 20 110 280 120

250

20 170 180 160

10 20 120 130

10 90 100 110

80

70

60

40 50

30 40

10 20 120 130

10 20 130

10 90 110 190 280

320 360 330 370 350 380 390

320 330 340 350

A3800504PL193

UP200456



Page 344 Feb 28/05

Honeywell




UP200456

10. 20. 30. 40. 50. 60. 7O. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180. 190. 200.

NUT (IPC FIG. 6A) BOLT REDUCER PACKING LOP SWITCH TEE UNION TUBE ASSY BOLT CLAMP SPACER CLAMP CLAMP UNION PACKING UNION RETAINER PACKING CLAMP BOLT

210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360. 370. 380. 390.

CLAMP SPACER REDUCER TUBE ASSY TEE TUBE ASSY PACKING CLAMP CLAMP BOLT IGVTUBE RETAINER BOLT TUBE RETAINER TUBE ASSY PACKING TUBE ELBOW NUT PACKING TUBE ASSY


Page 345 Feb 28/05


Honeywell


10 90 110 120

10 120 200 210

40

19o

220

~

260

24o

2~

10 9O 110 120

10 20 280

~0

r?

i

J f

t' 20 170 180

310

160 140 140 150

10 ~

2O 120 130

/ 10 100 110

80

70

60

40

30

10

5O

4O

2O 120 130

10 20 130

10 9O 110 190 280

320

360

320

33O

37O

33O

350 390

380

340

350 A3800504PL200

UP200456



Page 346 Feb 28/05


Hone well


~ l ~ KEY TO FIGURE 306B

NUT (IPC FIG. 6B) BOLT REDUCER PACKING LOP SWITCH TEE UNION TUBE ASSY BOLT CLAMP SPACER CLAMP CLAMP UNION PACKING UNION RETAINER PACKING CLAMP BOLT

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180. 190. 200.

210. 22O. 23O. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360. 370. 380. 390.


49-26-49 ',


Page 347 Feb 28/05


Hone~vell


10 2O

,

\

. . . . .

\\

\

~=,=

---------~--..d./-~-"---"~,..

",-%.

-

A

A

i X3800504PLi48

UP200456

Disassemble the Plumbing and Electrical Installation (Part No. 3615682) (Code A) (Partial Breakdown) Figure 306C

49-26-49 Copying, use or disclosure of information on this page is subjectto proprietaryrestrictions.

Page 348 Feb 28/05


Hone vell


41~ KEY TO FIGURE 306C

UP200456

10. 20.

NUT (IPC FIG. 7) BOLT

30. 40.

CLAMP BRACKET


Page 349 Feb 28/05


Honeywell


30 40 120

11o~ ,i

t

@ "+"

i 4

i

!

;_

!-T:~ ill

!

@

80 90 100

10 20 60

30 40 50

70

UP200456

A3800504PL194


49-26-49 Copying, use or disclosure of information on this page is subjectto proprietaryrestrictions.

Page 350 Feb 28/05


HoneTwell


~ I ~ KEY TO FIGURE 307A

UP200456

10. 20. 30. 40. 50. 6O.

NUT (IPC FIG. 7A) BOLT SPACER CLAMP BOLT CLAMP

70. 80. 90. 100. 110. 120.

BRACKET NUT PACKING ELBOW HOSE ASSY BOLT

49-26-49


Page 351 Feb 28/05


Honeywell


30 40 120

11o~ .,I

|

I I

/

@

1

I

1

.',i

80 90 100

10 20 60 70

!

30 40 50 A3800504PL194

UP200456



Page 352 Feb 28/05


Hone) well


~KEY

UP200456

10. 20. 30. 40. 50. 60.

NUT (IPC FIG. 7B) BOLT SPACER CLAMP BOLT CLAMP

TO FIGURE 307B 70. 80. 90. 100. 110. 120.



Page 353 Feb 28/05

Hone) well

j ,o...



10 4O 5O

3O

,;.-r-

|

B

A

A

B

III )i I

~J

A3B00504PL106

UP200456



Page 354 Feb 28/05

Hone vell



~KEY

UP200456

10. 20. 30. 4O.

NUT (IPC FIG. 8) BOLT CLAMP CLAMP

TO FIGURE 308

50. 60. 70.

BOLT SPACER WIRING HARNESS


Page 355 Feb 28/05

Honeywell



10 3O 40

100 110 120

120 130

'I

150

20 150 160

!i,Ji

I

I I

170 180 i ~ 190

UP200456

10 2O 5O 90

80

70

60

10 30 40 50

220

200 210 A3800504PLt95



Page 356 Feb 28/05

Honeywell




10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110.

NUT (IPC FIG. 8A) BOLT BOLT SPACER CLAMP TUBE ASSY VALVE ASSY TUBE ASSY CLAMP NUT ELBOW

120. 130. 140. 150. 160. 170. 180. 190. 200. 210. 220.

PACKING UNION BOLT BRACKET CLAMP TUBE ASSY TEE TUBE CLAMP UNION PACKING TUBE ASSY

UP200456

~t

49-26-49

Copying, use or disclosureof informationon this page is subjectto proprietaryrestrictions.

Page 357 Feb 28/05

Honeywell



10 20 50

10 20 ,50 230

10 30 40

10 20 50 90

80

70

80

100 110

120

1t

130

10 30 40 50

220

200 210 A3800504PL201

UP200456



Page 358 Feb 28/05

Hone vell



~11 KEY TO FIGURE 308B

UP200456

10. 20. 30. 4O. 50. 60. 7O. 8O. 90. 100. 110. 120.

NUT (IPC FIG. 8B) BOLT BOLT SPACER CLAMP TUBE ASSY VALVEASSY TUBE ASSY CLAMP NUT ELBOW PACKING

130. 140. 150. 160. 170. 180. 190. 200. 210. 220. 230.

UNION BOLT BRACKET CLAMP TUBEASSY TEE TUBE CLAMP UNION PACKING TUBE ASSY BRACKET


Page 359 Feb 28/05

Honeywell



-

,'•'•"10

190 \

100 110

30

f

20 %.

\

2 '%,

,

I

/ 1,o--+~..~.j-~ / ~--'--'50

j30

~

160- - ~ , / '

30

X3800504PL6

UP200456

(Pre SB 49-6658, 6699) Disassemble the Engine Assembly (Code A) (External Components) (Partial Breakdown) Figure 309

49-26-49 Copying, use or disclosureof information on this pageis subjectto propdetaryrestrictions.

Page 360 Feb 28/05

Hone vell .

B.



Disassemble the engine assembly. (1)

(Pre SB 49-6658, 6699) Disassemble the external components. (Refer to Figure 309.) (a)

Remove bolts (10), fan inlet duct (20), clamps (30) and oil cooler duct (40).

(b)

Remove clamp (50), fan exit duct (60), bolts (70), washers (80), oil cooler fan assembly (90) and packings (100, 110). Discard packings. Refer to ATA No. 49-51-75 for disassembly of the oil cooler fan assembly (90).

(c)

Remove nuts (120), bolts (130), pressure sensor (140), bolts (150) and sensor bracket (160).

(d)

Remove oil sump temperature sensor (170) and packing (180) from engine assembly (190). Discard packing.

~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100.

BOLT FAN INLET DUCT CLAMP OIL COOLER DUCT CLAMP FAN EXIT DUCT BOLT WASHER OILCOOLER FANASSY PACKING

TO FIGURE 309 110. 120. 130. 140. 150. 160. 170.

PACKING NUT BOLT PRESSURE SENSOR BOLT SENSOR BRACKET OIL SUMP TEMPERATURE SENSOR 180. PACKING 190. ENGINEASSY


Page 361 Feb 28/05

Hone) vell



- ~ ' ~ 10

250

1@0 1110 80

220 210~,~

! ~ ~/30

t

I

/"-

i"

2oo~

"[]1

30 40

190

A X3800504PL7

UP200456

(Post SB 49-6658, 6699) Disassemble the Engine Assembly (Code B) (External Components) (Partial Breakdown) Figure 309A

49-26-49 Copying, use or disclosureof information on this page is subjectto proprietaryrestrictions•

Page 362 Feb 28/05

Honeywell 4.

g.



Disassemble the engine assembly. (2)

(Post SB 49-6658, 6699) Disassemble the external components. (Refer to Figure 309A.) (a)

Removebolts (10), fan inlet duct (20), clamps (30) and oil cooler duct (40).

(b)

Removeclamp (50), fan exit duct (60), bolts (70), washers (80), oil cooler fan assembly (90) and packings (100, 110). Discard packings. Refer to ATA No. 49-51-75 for disassembly of the oil cooler fan assembly (90).

(c)

Removebolts (190) and transducer assy (200).

(d)

Removebolts (210, 220, 230) and bracket (240).

(e)

Removeoil sump temperature sensor (170) and packing (180) from engine assembly (250). Discard packing.

4111 KEY TO FIGURE 309A

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110.

BOLT FAN INLET DUCT CLAMP OIL COOLER DUCT CLAMP FAN EXIT DUCT BOLT WASHER OIL COOLER FAN ASSY PACKING PACKING

170. OIL SUMPTEMPERATURE SENSOR 180. PACKING 190. BOLT 200. TRANSDUCER ASSY 210. BOLT 220. BOLT 230. BOLT 240. BRACKET 250. ENGINEASSY


Page 363 Feb 28/05


Honeywell


170 180

I

\ ~/10

25O

15

~Tt ~ I -

/

'

70

120 " -

_/10

130--~

,,/15 140

~./10 lO0

'~

110 90

X3800504PL8

UP200456

(Pre SB 49-6634, 6658, 6699) Disassemble the External Components (Code A) (Partial Breakdown) Figure 310


Page 364 Feb 28/05


Hone vell 4.

B.

(3)


(Pre SB 49-6634, 6658, 6699) Disassemble the external components. (Refer to Figure 310.) (a)

Remove coupling clamps (10, 20), gaskets (15), nuts (30), bolts (40), bleed duct support bracket (50), bleed duct elbow (60) and load control valve (70). Refer to ATA No. 49-50-40 for disassembly of the load control valve (70).

(b)

Remove bleed duct support bracket (80), bolts (90), packing (100), bleed duct (110), bolts (120), transducer assembly (130) and flow sensor gasket (140). Discard packing. Refer to ATA No. 49-51-83 for disassembly of the transducer assembly (130). NOTE:

Do not remove cap screws (150) and identification plate (160) unless it is damaged.

(c)

Remove bolt (170) and pressure sensor tube (180).

(d)

Remove drilled head bolts (190), immersion thermocouples (200) and thermocouple gaskets (210).

~1~ KEY TO FIGURE 310 10. 15. 20. 30. 4O. 50. 60. 70. 80.

UP200456

90. 100. 110. 120. 130.

COUPLING CLAMP GASKET COUPLING CLAMP NUT BOLT BLEED DUCT SUPPORT BRACKET BLEED DUCT ELBOW LOAD CONTROL VALVE BLEED DUCT SUPPORT BRACKET BOLT PACKING BLEED DUCT BOLT TRANSDUCER ASSY

140. 150. 160. 170. 180. 190. 20O. 210. 220. 230. 240. 250. 260. 270. 280. 290.

FLOW SENSOR GASKET CAP SCREW IDENTIFICATION PLATE BOLT PRESSURE SENSOR TUBE DRILLED HEAD BOLT IMMERSION THERMOCOUPLE THERMOCOUPLE GASKET BOLT IGNITION EXCITER INSULATOR FLATHEAD SCREW IGNITION BOX BRACKET NUTPLATE DRILLED HEAD BOLT ENGINE ASSY


Page 365 Feb 28/05


Honeywell


WARNING:

4.

B.

(3)

(e)

Remove bolts (220, 280), ignition exciter (230), insulator (240), flathead screws (250) and ignition box bracket (260) from engine assembly (290). NOTE:

UP200456


Disconnect ignition lead before removing ignition exciter. Do not remove nut plates (270) unless they are damaged.


Page 366 Feb 28/05


Honeywell


'80

40

t A

I

40

5o

20

\

(o ED>A

~, , ~ J _ _ ~

180 190

2O0

,r.-250

10

./ ....

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0504PL9

UP200456

(Post SB 49-6634, 6658, 6699) Disassemble the External Components (Code B) (Partial Breakdown) Figure 310A (Sheet 1 of 2)


Page 367 Feb 28/05


Hone~vell


I

I

330 340 350

~ -..__~2)

330

\ 33O

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320 ~ ~

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X3B00504PL49

UP200456

(Post SB 49-6634, 6658, 6699) Disassemble the External Components (Code B) (Partial Breakdown) Figure 310A (Sheet 2)


Page 368 Feb 28/05

Hone3 well 4.

B.

(4)



(Post SB 49-6634, 6658, 6699) Disassemble the external components. (Refer to Figure 310A.) (a)

Remove screw (270), washer (280) and cover (290) from flow sensor (300).

(b)

Remove bolts (120), flow sensor (300) and gasket (130) from bleed duct (110).

(c)

Remove bolts (330), Iockwasher (340), seal (350), packings (310) and pressure static sensor (320) from flow sensor (300). Discard packings.

(d)

Remove coupling clamps (10, 20), gaskets (15), nuts (30), bolts (40), bleed duct support struts (50, 80), bleed duct elbow (60) and load control valve (70). Refer to ATA No. 49-50-40 for disassembly of the load control valve.

(e)

Remove bolts (90), packing (100), bleed duct (110) from engine assy (360). Discard packing. NOTE:

Do not remove cap screws (140) and identification plate (150) unless damaged.

~ l n KEY TO FIGURE 310A

UP200456

10. COUPLING CLAMP 15. GASKET 20. COUPLING CLAMP 30. NUT 40. BOLT 50. BLEED DUCT SUPPORT STRUT 60. BLEED DUCT ELBOW 70. LOAD CONTROL VALVE 80. BLEED DUCT SUPPORT STRUT 90. BOLT 100. PACKING 110. BLEED DUCT 120. BOLT 130. FLOW SENSOR GASKET 140. CAP SCREW 150. IDENTIFICATION PLATE 160. BOLT 170. PRESSURE SENSOR TUBE

180. 190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360.

DRILLED HEAD BOLT IMMERSION THERMOCOUPLE THERMOCOUPLE GASKET BOLT IGNITION EXCITER INSULATOR FLATHEAD SCREW IGNITION BOX BRACKET NUTPLATE SCREW WASHER COVER FLOW SENSOR PACKING PRESSURE STATIC SENSOR DRILLED HEAD BOLT LOCKWASHER SEAL ENGINE ASSY


Page 369 Feb 28/05

Hone vell



WARNING:

4.

B.

(4)

(f)

Remove bolts (210), ignition exciter (220), insulator (230), flathead screws (240) and ignition box bracket (250). NOTE:

UP200456


Disconnect ignition lead before removing ignition exciter. Do not remove nut plates (260) unless they are damaged.

(g)

Remove bolt (160) and pressure sensor tube (170).

(h)

Remove drilled head bolts (180), immersion thermocouples (190) and thermocouple gaskets (200).


Page 370 Feb 28/05

Hone~vell



UP200456


"49-26-49 Copying, use or disclosure of information on this page is subject to proprietary restrictions.

Page 371 Feb 28/05


Hone vell 210


190

146 "--~ ~

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UP200456

(Pre SB 49-6742, 6658, 6699) Disassemble the External Components (Code A) (Partial Breakdown) Figure 311


Page 372 Feb 28/05

Honeywell 4.

B.

(5)


GTCP36-280[D]

(Pre SB 49-6742, 6658, 6699) Disassemble the external components. (Refer to Figure 311 .) WARNING:


(a)

Remove bolts (10), washers (20) and oil temperature regulator assembly (oil cooler) (30).

(b)

Remove bolts (40, 45) and oil cooler bracket (50). NOTE:

Do not remove nut plates (55) unless they are damaged.

(c)

Remove coupling clamp (60), starter motor (70) and packing (80). Discard packing. Refer to ATA No. 49-41-08 for disassembly of the starter motor (70).

(d)

Remove nut (90), bolts (100, 120), washers (110, 130) and hoist bridge (140) from gearbox assembly (230) and engine assembly (240). NOTE:

Do not remove bolt (145), ring hoist (146) or insert (147) unless they are damaged.

(e)

Remove bolt (150), washer (160), motional transducer (170) and packing (180). Discard packing.

(f)

Remove bolt (190), tube retainer (200) sump vent fitting (210) and packing (220) from engine assembly (240). Discard packing. NOTE:

Do not remove caution label (235) unless damaged.

~lm KEY TO FIGURE 311

UP200456

10. BOLT 20. WASHER 30. OIL TEMPERATURE REGULATOR ASSY (OIL COOLER) 40. BOLT 45. BOLT 50. OIL COOLER BRACKET 55. NUTPLATE 60. COUPLING CLAMP 70. STARTER MOTOR 80. PACKING 90. NUT 100. BOLT 110. WASHER 120. BOLT

130. 140. 145. 146. 147. 150. 160. 170. 180. 190. 200. 210. 220. 230. 235. 240.

WASHER HOIST BRIDGE BOLT HOIST RING INSERT BOLT WASHER MOTIONALTRANSDUCER PACKING BOLT TUBE RETAINER SUMP VENT FITTING PACKING GEARBOXASSY CAUTION LABEL ENGINEASSY

49-26-49

Copying, use or disclosure of informationon this page is subjectto proprietaryrestrictions.

Page 373 Feb 28/05


Honeywell


210

190

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UP200456

(Post SB 49-6742, 6658, 6699) Disassemble the External Components (Code B) (Partial Breakdown) Figure 311A

49-26-49 Copying,use or disclosureof informationon this page is subjectto proprietaryrestrictions,

Page 374 Feb 28/05


Hone) well 4.

B.

(6)


(Post SB 49-6742, 6658, 6699) Disassemble the external components. (Refer to Figure 311A.) WARNING:


(a)

Remove bolts (10), washers (20) and oil temperature regulator assembly (oil cooler) (30).

(b)

Remove bolts (40, 45) and oil cooler bracket (50). NOTE:

Do not remove nut plates (55) unless they are damaged.

(c)

Remove coupling clamp (60), starter motor (70) and packing (80). Discard packing. Refer to ATA No. 49-41-08 for disassembly of the starter motor.

(d)

Remove nut (90), bolts (100, 120), washers (110, 130) and hoist bridge (140) from gearbox assembly (230) and engine assembly (280).

(e)

Remove bolt (150), washer (160), motional transducer (170) and packing (180). Discard packing.

(f)

Remove bolt (190), tube retainer (200) sump vent fitting (210) and packing (220). Discard packing. NOTE:

(g)

Do not remove caution label (240) unless damaged.

Remove bolts (250), pressure sensor (260), bolts (10) and sensor bracket (270).

~

UP200456

10. BOLT 20. WASHER 30. OIL TEMPERATURE REGULATOR ASSY (OIL COOLER) 40. BOLT 50. OIL COOLER BRACKET 55. NUTPLATE 60. COUPLING CLAMP 70. STARTER MOTOR 80. PACKING 90. NUT 100. BOLT 110. WASHER 120. BOLT 130. WASHER

KEYTO FIGURE311A 140. 150. 160. 170. 180. 190. 200. 210. 220. 230. 240. 250. 260. 270. 280.

HOIST BRIDGE BOLT WASHER MOTIONAL TRANSDUCER PACKING BOLT TUBE RETAINER SUMP VENT FITTING PACKING GEARBOX ASSY CAUTION LABEL BOLT PRESSURE SENSOR SENSOR BRACKET ENGINEASSY


Page 375 Feb 28/05

Honeywell



7O

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X3800504PL48

UP200456

Disassemble the External Components (Partial Breakdown) Figure 312


Page 376 Feb 28/05

Hone vell 4.

B.

(7)



Disassemble the external components. (Refer to Figure 312.) (a)

Remove coupling clamp (10), fuel control assembly (20) and packing (30). Discard packing. Refer to ATA No. 49-30-97 for disassembly of the fuel control assembly (20).

(b)

Remove plug (40) and packing (50). Discard packing.

(c)

Remove tube nuts (60, 100), lube pump adapters (70, 110) and packings (90, 130). Discard packings. NOTE:

Do not remove inserts (80, 120) unless they are damaged.

(d)

Remove bolts (140, 160), washers (150), and lube pump (170) from engine assembly (230). Refer to ATA No. 49-91-53 for disassembly of the lube pump.

(e)

Remove transfer tubes (180, 200) and packings (190, 210, 220). Discard packings.

~

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120.

COUPLING CLAMP FUELCONTROLASSY PACKING PLUG PACKING TUBE NUT LUBE PUMP ADAPTER INSERT PACKING TUBE NUT LUBE PUMP ADAPTER INSERT

KEYTO FIGURE 312 130. 140. 150. 160. 170. 180. 190. 200. 210. 220. 230.

PACKING BOLT WASHER BOLT LUBE PUMP TRANSFER TUBE PACKING TRANSFER TUBE PACKING PACKING ENGINEASSY


Page 377 Feb 28/05

Hone~vell



\

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X~O~O~LI4

UP200456



Page 378 Feb 28/05

Hone vell 4.

B.

(8)



Disassemble the external components. (Refer to Figure 313.) WARNING:


(a)

Remove nuts (10), washers (20), gearbox assembly (30) and oil packing (40) from engine assembly (200). Discard packing.

(b)

Remove bolts (50), washers (60), flow divider valve assembly (70), packings (80, 90) and unions (100, 110). Discard packings. Refer to ATA No. 49-32-07 for disassembly of the flow divider valve assembly.

WARNING:


(c)

Removeigniter lead (120), igniter plug (130) and metal gasket (140).

(d)

Remove nuts (160, 180), sleeves (170, 190) and ecology drain tank (150).


UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100.

NUT WASHER GEARBOXASSY OIL PACKING BOLT WASHER FLOW DIVIDER VALVE FUEL PACKING FUEL PACKING UNION

110. 120. 130. 140. 150. 160. 170. 180. 190. 200.

UNION IGNITER LEAD IGNITER PLUG METALGASKET ECOLOGY DRAIN TANK NUT SLEEVE NUT SLEEVE ENGINEASSY


Page 379 Feb 28/05


Honeywell


PLENU~'30~~~.R (EF) rURBINE

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X3B00504PL53 UP200456

(Post SB 49-6634 and 6675) Disassemble the External Components (Code B) (Partial Breakdown) Figure 314

49-26-49 Copying, use or disclosureof information on this page is subjectto proprietaryrestrictions•

Page 380 Feb 28/05

HoneTwell 4.

B.

(9)



(Post SB 49-6634 and 6675) Disassemble the external components. (Refer to Figure 314.) (a)

Remove coupling clamps (30), surge duct (20), nut (60), bolt (70), support strut (55), exhaust surge duct (40), clamps (10), surge control valve (50) and surge bleed duct (45).

(b)

Remove nut (60), bolts (190), bracket (210) and stiffener (200) from turbine and compressor assembly (160).

(c)

Removenut (110), PCD tee (120) and air packing (130). Discard packing.

(d)

Remove primary manifold (140) and secondary manifold (150) from fuel nozzle assy.

(e)

Removeplumbing and electrical (170) from engine assembly (220).

~1~ KEY TO FIGURE 314

UP200456

10. 20. 30. 40. 45. 50. 55. 60. 70. 110. 120. 130.

CLAMP SURGE DUCT COUPLING CLAMP EXHAUST SURGE DUCT SURGE BLEED DUCT SURGE CONTROL VALVE SUPPORT STRUT NUT BOLT NUT PCD TEE PACKING

140. PRIMARY FUEL MANIFOLD 150. SECONDARY FUEL MANIFOLD 160. TURBINE AND COMPRESSOR ASSY 170. PLUMBINGAND ELECTRICAL 180. WASHER 190. BOLT 200. STIFFENER 210. BRACKET 220. ENGINEASSY


Page 381 Feb 28/05

Hone)~vell



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180

,j?% 110

120

X3800504PL16

UP200456

(Pre SB 49-6634 and 6775) Disassemble the External Components (Code A) (Partial Breakdown) Figure 314A

49-26-49


Page 382 Feb 28/05

Hone vell 4.

B.

(10)

RELEASED FOR THE EXCLUSIVE USE BY:MANUAL ASERCA AIRLINES COMPONENT MAINTENANCE

GTCP36-280[D]

(Pre SB 49-6634 and 6675) Disassemble the external components. (Refer to Figure 314A.) (a)

Remove clamps (10), surge exhaust duct (20), coupling clamp (30), surge duct (40), surge control valve (50), nut (60), bolt (70), bleed duct support brackets (80, 90) and surge valve bracket (100).

(b)

Remove primary fuel manifold (140) and secondary fuel manifold (150)from turbine and compressor assembly (160).

(c)

Removenut (110), PCD tee (120) and air packing (130). Discard packing.

(d)

Removeplumbing and electrical (170) from engine assembly (180).

~ CLAMP SURGE EXHAUST DUCT COUPLINGCLAMP SURGE DUCT SURGE CONTROL VALVE NUT BOLT BLEED DUCT SUPPORT BRACKET 90. BLEED DUCT SUPPORT BRACKET

UP200456

10. 20. 30. 40. 50. 60. 70. 80.

KEYTO FIGURE 314A 100. 110. 120. 130. 140. 150.

SURGE VALVE BRACKET NUT PCD TEE PACKING PRIMARYFUEL MANIFOLD SECONDARYFUEL MANIFOLD 160. TURBINE AND COMPRESSOR ASSY 170. PLUMBING AND ELECTRICAL 180. ENGINEASSY


Page 383 Feb 28/05

Honeywell



110

IOOB 2O

\

70 5O

\ \\

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10 80

100

3O X3800504PL149

UP200456



Page 384 Feb 28/05

Honeywell 4.

B.

(11)



Disassemble the external components. (Refer Figure 315.) (a)

Remove packings (10, 20) from turbine and compressor assembly (110). Discard packings.

(b)

Remove retaining ring (30) and spacer (40).

(c)

Remove packing (50). Discard packing.

(d)

Remove quill shaft (60) and packing (70). Discard packing.

(e)

Remove bolts (80), washers (90) and IGV actuator (100 or 100B) from turbine compressor assembly (110). Refer to ATA No. 49-50-02 for disassembly of IGV actuator assembly.


UP200456

10. 2O. 30. 4O. 50. 60. 70.

PACKING PACKING RETAINING RING SPACER PACKING QUILL SHAFT PACKING

80. 90. 100. 100B. 110.

BOLT WASHER IGV ACTUATOR IGV ACTUATOR TURBINEAND COMPRESSOR ASSY


Page 385 Feb 28/05


Hone)~vell


IOA

C>

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130 330

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170

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190 X3800504PL18

UP200456

Disassemble the Gearbox Assembly (Part No. 3863019) (Code A) (Partial Breakdown) Figure 316

49-26-49

Copying, use or disclosureof information on this page is subjectto proprietaryrestrictions.

Page 386 Feb 28/05

Honeywell 4.

C,



Disassemble the gearbox assembly. (1)

(Part No. 3863019) Disassemble the gearbox assembly components. (Refer to Figure 316.) WARNING:


(a)

Remove oil fill cap (10 or 10A), ring (15), bolts (20), washers (30), sight glass (40) and packing (50). Discard packing.

(b)

Remove bolt (60), washer (70), scupper oil fill housing (90) and packing (80). Discard packing.

(c)

Remove retaining ring (230), oil tube assembly (240), with 2024084-1 tube puller, packing (260) and filter screen (250). Discard packing.

(d)

Remove plug (300) and magnetic plug (280). Remove packings (290, 310) and discard.

(e)

Remove bolts (190), washers (200), sump cover (210) and packing (220). Discard packing.

(f)

Remove bolts (140), washers (150), temperature sensor adapter (160) and packing (165). Discard packing.

(g)

Remove metal plug (170) and packing (180). Discard packing.

~ 10. 10A. 15. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160.

KEYTO FIGURE 316

OIL FILL CAP OIL FILL CAP RING BOLT WASHER SIGHT GLASS PACKING BOLT WASHER PACKING SCUPPER OIL FILL HOUSING SCREW OILCOVER PLATE PACKING PACKING BOLT WASHER TEMPERATURE SENSOR ADAPTER

165. 170. 180. 190. 200. 210. 220. 230. 240. 250. 260. -270. 280. 290. 300. 310. 320. 330.

PACKING METAL PLUG PACKING BOLT WASHER SUMP COVER PACKING RETAINING RING OIL TUBE ASSY FILTER SCREEN PACKING MAGNETIC DRAIN PLUG MAGNETIC PLUG PACKING PLUG PACKING IDENTIFICATION PLATE GEARBOX ASSY

UP200456

- ITEM NOT ILLUSTRATED


Page 387 Feb 28/05


Hone vell 4.

C.

(1)

(h)

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Remove screws (100), oil cover plate (110) and packings (120, 130). Discard packings.

UP200456

NOTE:

Do not remove identification plate (320) from gearbox assembly (330) unless the gearbox assy is damaged. The nameplate must stay with the gearbox.


Page 388 Feb 28/05


Honeywell


UP200456

THIS PAGE INTENTIONALLYLEFT BLANK


Page 389 Feb 28/05


Honeywell


10

@ 40

SO

8O<

160 270

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. X3800504PL19

UP200456

Disassemble the Gearbox Assembly (Part No. 3863136) (Code B) (Partial Breakdown) Figure 316A

49-26-49


Page 390 Feb 28/05


Hone) vell 4.

C.


Disassemble the gearbox assembly. (2)

(Part No. 3863136) Disassemble the gearbox assembly components. (Refer to Figure 316A.) WARNING:


(a)

Remove oil fill cap (10), bolts (20), washers (30), oil sight indicator (40) and packing (50). Discard packing.

(b)

Remove bolts (60), washers (70), oil fill housing scupper (90) and packing (80). Discard packing.

(c)

Remove retaining ring (260), and filter screen (270) from gearbox (300).

(d)

Remove magnetic drain plug (280) and packing (290). Discard packing.

(e)

Remove retaining ring (230), sump cover (240) and packing (250). Discard packing.

(f)

Remove bolts (170), washers (180), temperature sensor adapter (190) and packing (200). Discard packing.

(g)

Remove metal plug (210) and packing (220). Discard packing.

(h)

Remove screws (130), oil cover plate (140) and packings (150, 160). Discard packings.

41~ KEY TO FIGURE 316A 10. 20. 30. 40. 50. 60. 70. 80. 90. -100. -110. -120. 130. 140. 150.

OIL FILL CAP BOLT WASHER OIL SIGHT INDICATOR PACKING BOLT WASHER PACKING OIL FILL HOUSING SCUPPER HOUSING SCREEN SCUPPER SCREW OIL COVER PLATE PACKING

160. 170. 180 190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300.

PACKING BOLT WASHER TEMP SENSOR ADAPTER PACKING METAL PLUG PACKING RETAINING RING SUMP COVER PACKING RETAINING RING FILTER SCREEN MAGNETIC DRAIN PLUG PACKING GEARBOX ASSY

UP200456



Page 391 Feb 28/05


Hone~well 100C


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150~ . ~ 140 200 210

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UP200456

X3800504DY218

Disassemble the Gearbox Assembly Components (Part No. 3863019) (Code A) (Partial Breakdown) Figure 317


Page 392 Feb 28/05

Honeywell 4.

C.

(3)



(Part No. 3863019) Disassemble the gearbox assembly components. (Refer to Figure 317.) (a)

Removeslave nuts (10), washers (20), generator pad cover (30), bolts (40A), washers (50), flanged seal assembly (60), shim (65) and packing (70). Discard packing.

CAUTION:

GENERATORGEARSHAFT ASSEMBLY MAY FALL OUT AFTER ADAPTER (80) IS REMOVED. DO NOT LET GEARSHAFT ASSEMBLY FALL OUT.

(b)

Removehi-torque screws (85). Use 2024293-1 puller with 2024254-1 adapter to remove generator adapter (80). Remove and discard packing (90).

(c)

Removegearshaft (150) from gearbox assembly (200). NOTE:

Do not remove plug (160) and insert (140) from gearshaft (150) unless damaged.

(d)

(Pre SB 49-6940) Remove seal rotor (100) from gearshaft (150).

(e)

(Pre SB 49-6940) Remove tetra seal (110) from rotor seal (100).

(f)

(Post SB 49-6940/7660) Straighten the bent tab of the locking tab (220) and use spanner wrench (2024465-1) to remove retaining nut (210) from gearshaft (150).

(g)

(Post SB 49-6940) Remove the locking tab (220), rotor seal (100A) and spacer (135A) from the gearshaft (150).

(h)

(Post SB 49-7760) Remove locking tab (220), rotor seal (100C) and drive ring (100D) from gearshaft (150).

(i)

(Post SB 49-7760) Remove packing (100E) from drive ring (100D). Discard packing.

(j)

Use a 833985-2 bearing puller plate set and a 833978-1 bearing removal adapter to remove generator roller bearings (120) from gearshaft (150).

~ 10. 20. 30. 40A. 50. 60. 65. 70. 80. 85. 90. 100. 100A.

SLAVE NUT WASHER GENERATOR PAD COVER BOLT WASHER FLANGEDSEALASSY SHIM PACKING GENERATORADAPTER SCREW PACKING SEAL ROTOR SEAL ROTOR (POST SB 49-6940) 100C. DRIVE RING (POST SB 49-7660)

KEYTOFIGURE317 100D. 100E. 110. 120. 135A. 140. 150. 160. 200. 210. 220.

ROTOR (POST SB 49-7660) PACKING (POST SB 49-7660) TETRA SEAL GENERATOR ROLLER BEARING SPACER (POST SB 49-6940) INSERT GEARSHAFT PLUG GEARBOXASSY RETAINING NUT (POST SB 49-6940) LOCKINGTAB (POST SB 49-6940)

UP200456

-ITEM NOT ILLUSTRATED


Page 393 Feb 28/05

Honeywell


GTCP36-280[D]

IOOD IOOE '~ 1 0 0 C ~ ~

150 140 120 1~00B105 190 \

~'~

/

200

180

160

j 110

120 \.

\

150--.~i 140 "~.

X3800504DY219

UP200456

(POST SB 49-7660) Disassemble the Gearbox Assembly Components (Part No. 3863136) (Code B) (Partial Breakdown) Figure 317A

49-26-49

Copying,useor disclosureof informationonthispageis subjectto proprietaryrestdctions.

Page 394 Feb 28/05

Honeywell 4.

C.

(4)



(Part No. 3863136) Disassemble the gearbox assembly components. (Refer to Figure 317A.) (a)

Removeretaining ring (10), shim (20), seal assy (30) and packing (40). Discard packing.

CAUTION:

GENERATORGEARSHAFT ASSEMBLY MAY FALL OUT AFTER ADAPTER (50) IS REMOVED. DO NOT LET GEARSHAFT ASSEMBLY FALL OUT.

(b)

Removehi-torque screws (75). Use 2024293-1 puller with 2024254-1 adapter to remove generator adapter (50). Remove packing (70), retaining ring (80) and shim (90). Discard packing.

(c)

Removegearshaft (150) from gearbox assembly (180). NOTE:

Do not remove plug (160) and insert (140) from gearshaft (150) unless damaged.

(d)

(Pre SB 49-6940) Remove rotor seal (100A) from gearshaft (150).

(e)

(Pre SB 49-6940) Remove tetra seal (110) from rotor seal (100A).

(f)

(Post SB 49-6940/7660) Straighten the bent tab of the locking tab (200) and use spanner wrench (2024465-1) to remove retaining nut (190) from the gearshaft (150).

(g)

(Post SB 49-6940) Remove the locking tab (200), rotor seal (100B) and spacer (105) from the gearshaft (150).

(h)

(Post SB 49-7660) Remove locking tab (220), rotor seal (100C) and drive ring (100D) from gearshaft (150).

(i)

(Post SB 49-7660) Remove packing from drive ring (100D). Discard packing.

(j)

Use a 833980-9 bearing puller plate set and a 833135-203 bearing removal adapter to remove generator roller bearing (120) and generator ball bearing (170) from gearshaft (150).

~ RETAINING RING SHIM SEAL ASSY PACKING GENERATORADAPTER PIN PACKING SCREW RETAINING RING SHIM ROTOR SEAL ROTOR SEAL (POST SB 49-6940) 105. SPACER (POST SB 49-6940)

UP200456

10. 20. 30. 4O. 50. -60. 70. 75. 80. 90. 100A. 100B.

KEYTOFIGURE317A 100C. 100D. 100E. 105. 110. 120. 140. 150. 160. 170. 180. 190. 200.

ROTOR SEAL (POST SB 49-7660) DRIVE RING (POST SB 49-7660) PACKING (POST SB 46-7660) SPACER (POST SB 49-6940) TETRA SEAL GENERATOR ROLLER BEARING INSERT GEARSHAFT PLUG GENERATOR BALL BEARING GEARBOX ASSY RETAINING NUT (POST SB 49-6940) LOCKING TAB (POST SB 49-6940)



Page 395 Feb 28/05

Hone~vell

20



60

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40

50

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240 210 230

200

~~'% "°,j i 120

232

dl~ : 4 0 ~ 5 0

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360

X3800504PL229

UP200456


49-26-49

Copying,useor disclosureof informationonthispageis subjectto proprietaryrestrictions.

Page 396 Feb 28/05

Hone vell 4.

c.

(5)




Remove bolts (10, 15), washers (20), starter cover assembly (30) with 2024291-1 puller and packing (40). Discard packing.

(b)

Remove starter gearshaft assembly (70) and spring washer (120).

(c)

Use a 833980-9 bearing puller plate set and 833130-1 bearing removal adapter set and remove starter ball bearings (60) from starter gearshaft assembly (70).

(d)

Remove retaining ring (50), spring washer (130) and shims (140, 150) from starter gearshaft assembly (70).

(e)

Remove splined shaft assembly (90) from starter gearshaft assembly (70) using 834397-1 puller.

(f)

Using a medium duty proto puller with a 834826-1 bearing removal plate and a 833999-1 and 833135-203 bearing removal adapter set, remove starter ball bearings (80) from splined shaft assembly (90).

~1~ KEY TO FIGURE 318 10. 15. 20. 30. 40. 50. 60. 70. 80. 90. -100. 110. 120. 130. 140. 150. 160. 170. 180.

BOLT BOLT WASHER STARTER COVER ASSY PACKING RETAINING RING STARTER BALL BEARING STARTER GEARSHAFT STARTER BALL BEARING SPLINED SHAFT ASSY PLUG CLUTCH SPRING WASHER SPRING WASHER SHIM SHIM RETAINING RING LUBE CLUTCH RESTRICTOR LIP SEAL

190. 200. 210. -210.A. 220. 230. 230A. 232. 234. 236. 238. 240. 330. 340. 350. 360. 370. 410.

BOLT WASHER COMPOUND IDLER ADAPTER COMPOUND IDLER ADAPTER (POST SB 49-7596) INSERT LIP SEAL CARBON SEAL (POST SB 49-7596) PACKING (POST SB 49-7596) SHIM (POST SB 49-7596) SHIM (POST SB 49-7596) SHIM (POST SB 49-7596) PACKING BOLT WASHER COVER ASSY PACKING RETAINING RING GEARBOX ASSY

UP200456



Page 397 Feb 28/05

Hone vell 4.

C.

(5)



(g)

Use 834397-1 starter clutch puller to remove clutch (110). Remove retaining ring (160) and use 2024285-1 lip seal puller to remove lip seal (180).

(h)

(Pre SB 49-7596) Remove bolts (190), washers (200) and compound idler adapter (210) with lip seal (230) using a 2024297-1 seal removal fixture. Remove packing (240) and discard. (Post SB 49-7596) Remove bolts (190), washers (200), compound idler adapter (210A), packing (232), shims (234, 236, 238), packing (240) and carbon seal (230A) using a 2024018-1 carbon seal removal fixture. Discard packings. NOTE:

UP200456

(i)

Do not remove insert (220) unless damaged.

Remove bolts (330), washers (340), cover assembly (350) with packing (360) and retaining ring (370)from gearbox assembly (410). Discard packing.


Page 398 Feb 28/05

Hone)~vell



UP200456



Page 398.1 Feb 28/05


Hone vell


\

4O

\

\

\

\

\ ..~~'*'~'~"t ~,_~ '70

90

380

100

~, ~ \ ~ ,

<. I.... /

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170

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I

270

300

I '~ "~J - i \ ~ , , .

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.11

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320 X~00~L~

UP200456

Disassemble the Gearbox Assembly Components (Part No. 3863136) (Code B) (Partial Breakdown) Figure 318A


Page 398.2 Feb 28/05


Hone) vell 4.

C.

(6)



Remove bolts (10), washers (20), and starter adapter (30) using a 2024291-1 puller and packing (40). Discard packing.

(b)

Remove starter gearshaft assembly (80), spacer (170) and spring washer

(180). (c)

Use a 833123-105 bearing puller plate set and 833130-200 bearing removal adapter set to remove starter ball bearings (70) from starter gearshaft (80).

(d)

Remove retaining ring (60), shims (130, 140, 150) and spring washer (160) from starter gearshaft assembly (80).

(e)

Remove splined shaft assembly (100) from starter gearshaft assembly (80) using a 834397-1 puller.

(f)

Using a medium duty proto puller with a 834826-1 bearing removal plate and a 834622-9 and 833999-1 bearing removal adapter set, remove starter ball bearings (90) from splined shaft assembly (100).

(g)

Remove clutch (120) with 834397-1 starter clutch puller. NOTE:

Do not remove lube clutch restrictor (190) unless damaged.

~

UP200456

10. 20. 30. 40. 60. 70. 80. 90. 100. 120. 130. 140. 150. 160. 170. 180. 190. 200.

BOLT WASHER STARTER ADAPTER PACKING RETAINING RING STARTER BALL BEARING STARTER GEARSHAFT STARTER BALL BEARING SPLINED SHAFTASSY CLUTCH SHIM SHIM SHIM SPRING WASHER SPACER SPRING WASHER LUBE CLUTCH RESTRICTOR BOLT

KEYTO FIGURE 318A 210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360. 370. 380.

WASHER COMPOUND IDLER ADAPTER INSERT PACKING SHIM SHIM SHIM SEAL PACKING BOLT WASHER LUBE PUMP COVERASSY PACKING RETAINING RING SHIM SHIM SHIM GEARBOX ASSY


Page 398.3 Feb 28/05


Hone) well 4.

C.

(6)

(h)

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Remove bolts (200), washers (210), compound idler adapter (220), packing (290), shims (350, 360, 370) seal (280), shims (250, 260, 270) and packing (240). Discard packing.

UP200456

NOTE:

Do not remove insert (230) unless damaged.

(i)

Use 2024018-1 seal removal fixture to remove seal (280) from adapter (220).

(J)

Remove bolts (300), washers (310), cover assembly (320) with packing (330) and retaining ring (340) from gearbox assembly (380). Discard packing.


Page 398.4 Feb 28/05


Hone~vell


UP200456



Page 398.5 Feb 28/05


Hone~vell


/,

270 , , ~

260....1./~+,,~° . I

.

430

25O

/

~----~------~/"

~ " . 0 420

450 I

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170 160 150

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70

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/4 ,(~-',~k~% L~ . / ~ r

110

X3800504PL153

30

UP200456


49-26-49

Copying, use or disclosureof informationon this pageis subjectto proprietaryrestrictions.

Page 398.6 Feb 28/05

Hone vell 4.

C.

(7)




Remove bolt (230), washer (235), plug (240) and packing (245). Discard packing.

(b)

Remove plug (260) and packing (270). Discard packing.

(c)

Remove bolt (10), washer (20), screws (30) and bearing retainer (40).

(d)

Remove bolts (50), washers (60) and bearing carrier (100). NOTE:

(e)

Do not remove inserts (105) unless damaged.

Remove transfer tube assembly (110) with assembled items (130) and packing (140). Discard packing.

~lm KEYTO FIGURE 319

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 105. 110. 130. 140. 150. 160. 170. 180. 190. 200. 210A. 220A. 230.

BOLT WASHER SCREW BEARING RETAINER BOLT WASHER SCREW HIGH SPEED PINION JET PACKING BEARING CARRIER INSERT TRANSFER TUBE ASSY SUPPORT PACKING BOLT PACKING GENERATOR IDLER SHAFT PACKING GENERATOR IDLER GEAR ASSY GENERATOR IDLER SPACER WASHER NUT BOLT

235. 240. 245. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360. 380. 390. 400. 410. 420. 430. 440. 450.

WASHER PLUG PACKING GEARBOX HOUSINGASSY PLUG PACKING BOLT WASHER TRANSDUCER PORT COVER PACKING RING HS PINION ROLLER BEARING HS PINION GEAR ROLLER BEARING AIR/OIL SEPARATOR PIN COLLAR COMPOUND IDLER GEAR GEARSHAFT ASSY PLUG LUBE GEARASSY EXPANSION PLUG BALL BEARING


Page 398.7 Feb 28/05

Honeywell 4.

c.

(7)



(f)

Remove high speed pinion gear (340) from gearbox housing assembly (250).

(g)

Remove screws (70), high speed pinion jet (80) and packing (90). Discard packing.

(h)

Remove retaining ring (320).

(i)

Use a 833980-9 bearing puller plate set and a 833978-2 bearing removal adapter set to remove pinion roller bearings (330) from pinion gear (340).

(J)

Remove bolt (280), washer (290), transducer port cover (300) and packing (310). Discard packing.

(k)

Remove bolt (150), packing (160) and generator idler shaft (170) using a 2024080-1 puller, with packing (180). Discard packings.

(i)

Use 833986-1 removal / installation fixture and 833987-1 support fixture to remove the generator idler gear assembly (190), generator idler spacer (200), nut (220A) and washer (210A) from gearbox housing (250).

(m)

Remove roller bearing (350) using 833984-1 bearing removal adapter and 833985-2 bearing removal plate, air-oil separator (360), idler gear (400) and gearshaft assembly (410). NOTE:

(n)

Use a 2024014-1 bearing removal plate and 833984-1 bearing removal adapter to remove the air-oil separator (360) from idler gearshaft assembly (410).

(o)

Remove retaining rings (IPC Fig. 40, Item 10)from generator idler gear assembly (190). Use 833986-1 bearing removal fixture and 833987-1 bearing support fixture to remove the bearings (IPC Fig. 40, Item 20) from idler gear (IPC Fig. 40, Item 50). Remove spacers (IPC Fig. 40, Item 30, 40).

(P)

Remove lube gear assembly (430) from gearbox housing assembly (250). Using a 833123-102 bearing puller plate and 833974-1 bearing puller adapter, remove ball bearings (450) from lube gear (430). NOTE:

UP200456

Do not remove pins (380), collar (390) or plug (420) unless damaged.

Do not remove expansion plug (440) unless necessary.

49-26-49

Copying,use or disclosureof informationon this pageis subject to proprietaryrestrictions.

Page 398.8 Feb 28/05


Honeywell


UP200456



Page 398.9 Feb 28/05


Hone) well


160

380

34O

I

33O

/

_

L

J

250 310

320

33O I

I

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210

50

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60

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',~~.~~]~. 140~+'130 k3

12°

X3800504PL124

UP200456

Disassemble the Gearbox Assembly Components (Part No. 3863136) (Code B) (Partial Breakdown) Figure 319A (Sheet 1 of 2)


Page 3 9 8 . 1 0 Feb 28/05


Honeywell 4.

c.

(8)



Remove bolt (170), washer (20), transducer port cover (360) and packing (370). Discard packing.

(b)

Remove bolt (60) and washer (70), plug (80) and packing (90) from gearbox assembly (380). Discard packing.

(c)

Remove transfer tube (100) and packing (110). Discard packing.

(d)

Remove bolts (10), washers (20) bearing carrier (30), retaining ring (120), transfer tube assembly (40) and packing (50). Discard packing.

(e)

Remove pinion gear (140) from gearbox assembly (380).

(f)

Remove retaining ring (150) from other end of high speed pinion gear assembly (140).

(g)

Use a 833980-9 bearing puller plate set and a 833978-2 bearing removal adapter set to remove high speed pinion roller bearings (130) from high speed pinion gear (140).

(h)

Remove bolt (230), packing (220) and generator idler shaft (210) using a 2024080-1 puller, with packing (200). Discard packings.

~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 370. 170.

BOLT WASHER BEARING CARRIER TRANSFER TUBEASSY PACKING BOLT WASHER PLUG PACKING TRANSFER TUBE PACKING RETAINING RING HS PINION ROLLER BEARING HS PINION GEAR RETAINING RING NUT PACKING BOLT

TO FIGURE 319A (SHEET 1) 180. 190. 200. 210. 220. 230. 240. 250. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360. 380.

GENERATOR IDLER SPACER GENERATOR IDLER GEARASSY PACKING GENERATOR IDLER SHAFT PACKING BOLT COMPOUND IDLER BEARING AIR-OILSEPARATOR PIN COLLAR LGE COMPOUND IDLER GEAR COMPOUND IDLER GEARSHAFT PLUG COMPOUND IDLER BEARING LUBE PUMP BALL BEARING EXPANSION PLUG LUBEGEARASSY TRANSDUCER PORT COVER GEARBOX ASSY


Page 398.11 Feb 28/05


Honeywell


,

..<

140

\15o

160

130 ~ . ~ ~ " ~ ,i ~

130

140

A

160

X3800504PL221

UP200456

Disassemble the Gearbox Assembly Components (Part No. 3863136) (Code B) (Partial Breakdown) Figure 319A (Sheet 2)


Page 398.12 Feb 28/05


Hone vell 4.

C.

(8)


(i)

Use 2024019-1 removal/installation fixture to remove the generator idler gear assembly (190), generator idler spacer (180), nut (160) and washer (20) from gearbox housing assembly (380).

(J)

Remove compound idler bearings (240, 320) using 833984-1 bearing removal adapter and 2024020-1 bearing removal plate, air-oil separator (250), large compound idler gear (290) and compound idler gearshaft assembly (300). NOTE:

Do not remove pin (270), collar (280) or plug (310) unless damaged.

(k)

Use a 2024014-1 bearing removal plate and 833984-1 bearing removal adapter to remove the air-oil separator (250) from compound idler gearshaft (300).

(1)

Remove retaining ring (IPC Fig. 40, Item 10)from generator idler gear assembly (190). Use 2024019-1 bearing removal fixture to remove the bearing (IPC Fig. 40, Item 20) from idler gear (IPC Fig. 40, Item 30).

(m)

Remove lube gear assembly (350) from gearbox assembly (380).

(n)

Using a 833123-102 bearing puller plate and 833974-1 bearing puller adapter, remove lube pump ball bearings (330) from lube gear assembly (350). NOTE:

(o)

Do not remove expansion plug (340) unless necessary.

(Post SB 49-7598) Remove retainer (160), oil jet (130), and packings (140, 150). Discard packings.

~lm KEYTO FIGURE 319A (SHEET2)

UP200456

130. OIL JET (IPC FIG. 33A) (POST SB 49-7598) 140. PACKING (POST SB 49-7598)

150. GENERATOR IDLER SPACER (POST SB 49-7598) 160. RETAINER (POST SB 49-7598)

49-26-49


Page 398.13 Feb 28/05

Honeywell



UP200456



Page 398.14 Feb 28/05


Honeywell


20D

\

20B

/

3O

\ \

20C 20F

\ 20E

X3800504PL26

UP200456

Disassemble the Turbine and Compressor Assembly Components (Partial Breakdown) Figure 320


Page 398.15 Feb 28/05


Hone vell 4.

D.


Disassemble the turbine and compressor assembly. (1)

Disassemble the turbine and compressor assembly components. (Refer to Figure 320.) (a)

Remove turbine plenum blankets (20B through 20F) from turbine and compressor assembly (30).


UP200456

20B. SIDE BLANKET 20C. FLANGE BLANKET 20D. FLANGE BLANKET

20E. SIDE BLANKET 20F. UPPER BLANKET 30. TURBINE AND COMPRESSOR ASSY


Page 398.16 Feb 28/05


Honeywell


/

ic:i 40 ,-4--t 20

4-t30

l~

/12o 0

1

J

60

\ 10

110

X3800504PL27

UP200456



Page 398.17 Feb 28/05

Honeywell 4.

D.

(2)



Disassemble the turbine and compressor assembly components. (Refer to Figure 321 .) (a)

Remove inlet duct assembly (10), quick coupler strap assembly (20), T-bolt strap assembly (30) and seal (40) from turbine and compressor assembly (150). .NOTE:

(b)

Remove bolts (80), washers (90), data memory module (100) and packing (105). Discard packing. .NOTE:

(c)

Do not remove rivets (50, 130) and nutplates (60, 140) unless damaged.

Do not remove nut (70) unless damaged.

Remove screws (110) and compressor inlet screen (120).


UP200456

10. INLET DUCTASSY 15. INLET DUCT BAFFLE 20. QUICK COUPLER STRAP ASSY 30. T-BOLTSTRAPASSY 40. SEAL 50. RIVET 60. NUTPLATE 70. NUT 80. BOLT

90. 100. 105. 110. 120.

WASHER DATAMEMORY MODULE PACKING SCREW COMPRESSOR INLET SCREEN 130. RIVET 140. NUTPLATE 150. TURBINEAND COMPRESSOR ASSY


Page 398.18 Feb 28/05

HoneTwell



; /t

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.

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t.( '

,

!

!

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41)

e~.Z) ,,

SO

X3800504PL156

UP200456

(Post SB 49-7473, Pre SB 49-7587) Disassemble the Turbine and Compressor Assembly Components Figure 321A


Page 398.19 Feb 28/05


Hone vell 4.

D.

(3)


(Post SB 49-7473, Pro SB 49-7587 ) Disassemble the turbine and compressor assembly components. (Refer to Figure 321A.) (a)

Remove bolts (70, 80, 90, 100, 110).

(b)

Remove bracket (60), flange (50), and shield segments (20, 30, 40).

~

KEYTO FIGURE 321A

UP200456

20. TOP CONTAINMENT SHIELD SEGMENT (IPC, 49-26-45, FIGURE 26A) 30. SIDE CONTAINMENT SHIELD SEGMENT 40. BOTTOM CONTAINMENT SHIELD SEGMENT 50. CONTAINMENT SHIELD FLANGE

60. 70. 80. 90. 100. 110.

CONTAINMENT SHIELD BRACKET BOLT BOLT BOLT BOLT BOLT

49-26-49


Page 398.20 Feb 28/05

Honeywell



170 100

90 8~)

--

5O

\

II 70 60

/

4O 30

160

20

10

t 150

140 130 1:1 110

X3800504PL28

UP200456


49-26-49

Copying, use or disclosureof informationon this page is subject to proprietaryrestrictions.

Page 398.21 Feb 28/05

Hone veli 4.

D.

(4)



Disassemble the turbine and compressor assembly components. (Refer to Figure 322.)

(a)

Remove bolt (10), temperature sensor (20), and packings (30, 40) from turbine and compressor assembly (170). Discard packings.

(b)

Remove lock pin (50), locking plate (60), bolt (70), fuel nozzle assembly (80), gasket (90), and fuel nozzle shroud (100). Discard packings.

(c)

Remove clevis (110), screw (120), nut (130), tube assembly (140), and packings (150, 160). Discard packings.

4~lm KEY TO FIGURE 322

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90.

BOLT TEMPERATURE SENSOR PACKING PACKING LOCK PIN LOCKING PLATE BOLT FUEL NOZZLE ASSY GASKET

100. 110. 120. 130. 140. 150. 160. 170.

FUEL NOZZLE SHROUD CLEVIS SCREW NUT TUBEASSY PACKING PACKING TURBINEAND COMPRESSOR ASSY

49-26-49

Copying, use or disclosure of informationon this pageis subjectto proprietaryrestrictions.

Page 398.22 Feb 28/05

Honeywell



30A 42

30

75 120

60 50

110 100

111 70

~, J "

80

=-,-~,',~ f

10 -""~ 90 X3800504PL190

UP200456



Page 398.23 Feb 28/05

Hone vell 4.

D.

(5)




(a)

Remove upper bolts (10), washers (20), vent fitting (30 or 30A) and packings (40 or 41 and 42). Discard packings.

(b)

(Pre SB 49-6840) Remove metal gaskets (50) and oil scavenge tube shield (60). Use 833184-1 tube removal fixture and remove oil scavenge tube (70). (Post SB 49-6840) Remove metal gaskets (50) and oil scavenge tube shield (60). Use 833184-1 tube removal fixture and remove oil scavenge tube (75). Discard packings.

(c)

Remove lower bolts (10), washers (20), lube adapter assembly (80) and packing (40). Discard packing.

(d)

Remove metal gaskets (50) and oil scavenge tube shield (60).

(e)

Remove oil pressure tube (100) and packings (110). Discard packings.

(f)

Use 833184-1 tube removal fixture and remove oil scavenge tube (70). NOTE:



UP200456

10. 20. 30. 30A. 40. 41. 42. 50. 60.

BOLT WASHER VENT FITTING VENT FITTING (POST SB 49-6840) PACKING PACKING (POST SB 49-6840) PACKING (POST SB 49-6840) METAL GASKET OIL SCAVENGE TUBE SHIELD

70. OIL SCAVENGE TUBE 75. OIL COOLED SCAVENGE VENT TUBE ASSY (POST SB 49-6840) 80. LUBE ADAPTER ASSY 90. INSERT 100. OIL PRESSURE TUBE 110. PACKING 120. TURBINE AND COMPRESSOR ASSY


Page 398.24 Feb 28/05



Hone~vell

110

\

10

/

'

10/20/80

/

/

2o

. .~ \ /

\

\

120 t30

"~ 140

X3800504PL30

UP200456



Page 398.25 Feb 28/05

Hone)well 4.

D.

(6)


GTCP36-280[D]


Remove nuts (10), washers (20), bolts (30, 40) and hoist mount (50).

(b)

Remove bolts (60, 70), engine mount spacer (80), left aft engine mount (90), and right aft engine mount (100).

(c)

Remove turbine plenum assembly (110), combustion chamber (120) and turbine seal (130) from turbine and compressor assembly (140).

~lill KEY TO FIGURE 324

UP200456

10. 20. 30. 40. 50. 60. 7O. 80.

NUT WASHER BOLT BOLT HOIST MOUNT BOLT BOLT ENGINE MOUNT SPACER

90. 100. 110. 120. 130. 140.

LEFTAFT ENGINE MOUNT RIGHTAFT ENGINE MOUNT TURBINE PLENUMASSY COMBUSTION CHAMBER TURBINE SEAL TURBINEAND COMPRESSOR ASSY


Page 398.26 Feb 28/05

Hone) well

37\



,

"" 25% 240

J

~J

> f"

i

j

330 340

'35o ~32O

290

~'~. 1 0 % t l

\

",

270

zso

, 180 170

\

38o

160

f

39O

"~..

v \ 3O0 150 130,

.~

110 J

120~,~ 140"~_ ,

10

X3800504PL31

UP200456



Page 398.27 Feb 28/05

-Honeywell 4.

D.

(7)




Unstake nut (10).

CAUTION: (b)

DO NOT APPLY MORE THAN 3900 PSIG (26910,0 KPA) RAM PRESSURE.

Use 833094-1 shaft stretching fixture and apply 2790 psig (19251,0 kPa) to permit the round nut to be loosened. NOTE:

If unable to loosen nut (10), pressure can be increased in 50 psig (345,0 kPa) increments, but not more than 3900 psig (26910,0 kPa) total pressure.

(c)

Remove shaft (20), bolts (30) and compressor bearing carrier assembly (40).

(d)

Remove nuts (50), washers (60), bearing carrier assembly (70) with assembled items (80, 90, 100, 110).

~11 KEY TO FIGURE 325

UP200456

10. NUT 20. SHAFT 30. BOLT 40. CPRSR BEARING CARRIER ASSY 50. NUT 60. WASHER 70. BEARING CARRIERASSY 80. PIN 90. PASSAGE PLUG 100. PIN 110. PIN 120. VENT TUBE 130. PACKING 140. PACKING 150. AIR PACKING 160. SPACER 170. CPRSR BEARING SPRING 180. SPACER 200. RETAINER

210. CARBON RING 220. SEAL 230. WASHER 240. WAVE SPRING WASHER 250. HOUSING 270. CPRSR DRIVEN COUPLING SEAL ASSY 280. SPRING PIN 290. LABYRINTH SEAL 300. CPRSR DRIVEN INSULATOR 310. SEAL HOUSING ASSY 320. INSERT 330. PACKING 340. PACKING 350. PACKING 370. CURVIC RING SEAL 380. CPRSR SEALROTOR 390. ROLLER CYLINDER BEARING 400. TURBINE AND COMPRESSOR ASSY

49-26-49

Copying, use or disclosureof information on this pageis subjectto proprietaryrestrictions.

Page 398.28 Feb 28/05

Honeywell 4.

D.

(7)



(e)

Remove vent tube (120), packings (130, 140, 150), spacer (160), compressor bearing spring (170) and spacer (180). Discard packings.

(f)

Remove retainer (200), carbon ring (210), seal (220), washers (230), wave spring washers (;~0)~and housing (250).

(g)

Remove compressor driven coupling seal assembly (270) with assembled items (280, 290) and compressor driven insulator (300).

(h)

Remove seal housing assembly (310), packings (330, 340, 350), and curvic seal ring (370). Discard packings. NOTE:

UP200456

(i)


Remove compressor seal rotor (380) and roller cylinder bearing (390) from turbine and compressor assembly (400).


Page 398.29 Feb 28/05

Honeywell



UP200456



Page 398.30 Feb 28/05

Hone3~well



140

170

110 /

12o7 f

130

I'

J

/ / / ~.. T

-,,.,,ram

/

\

J

f

/

f

f

3O

/

\ ~ ' " 10 X3800504PLI55

UP200456



Page 398.31 Feb 28/05

Hone vell 4.

D.

(8)




(a)

Remove load compressor diffuser (10), packing (20), special bolts (30), and compressor rotor assembly (50). Discard packing.

(b)

(Pre SB 49-A6653) Remove turbine support shaft (60).

(c)

Remove nuts (70), washers (80) and driven compressor scroll (90).

(d)

Remove screws (110), washers (120), driven compressor shroud (130), packings (150, 160). NOTE:

Do not remove inserts (140) unless necessary.

(e)

Remove IGV cover assembly (210), inlet guide vane housing assembly (170), cotter pin (180), spring pin (190), and IGV shaft assembly (200).

(f)

(Pre SB 49-A6653) Remove compressor shaft (230), turbine shaft support (240), retaining ring (250) and turbine shaft support (260) from turbine and compressor assy (270). (Post SB 49-A6653) Remove compressor shaft (230A) from turbine and compressor assy (270). Remove curvic seal gasket (280) from compressor shaft (230A). Discard gasket.


UP200456

10. 20. 30. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150.

LOAD COMPRESSOR DIFFUSER PACKING SPECIAL BOLT COMPRESSOR ROTORASSY TURBINE SHAFT SUPPORT NUT WASHER DRIVEN COMPRESSOR SCROLL COMPRESSOR SCROLL LINER SCREW WASHER DRIVEN COMPRESSOR SHROUD INSERT PACKING

160. 170. 180. 190. 200. 210. 230. 230A. 240. 250. 260. 270. 280.

PACKING INLET GUIDE VANE HOUSING ASSY COTTER PIN SPRING PIN IGV SHAFT ASSY IGV COVER ASSY COMPRESSOR SHAFT COMPRESSOR SHAFT TURBINE SHAFT SUPPORT RETAINING RING TURBINE SHAFT SUPPORT TURBINE AND COMPRESSOR ASSY GASKET, SEAL CURVIC (POST SB 49-7307)


Page 398.32 Feb 28/05

Honeywell



/

,.o.,y/y f ~ / . ~ ~ ~oo..,~

A3800504PL78

UP200456

(Post SB 49-6608) Disassemble the Turbine and Compressor Assembly Components (Partial Breakdown) Figure 327


Page 398.33 Feb 28/05

Hone) vell 4.

D.

(9)



(Post SB 49-6608) Disassemble the turbine and compressor assembly components. (Refer to Figure 327.) (a)

Remove bolts (10, 30), washers (20) and containment shield segment assemblies (40, 50).

(b)

Remove nuts (60), washers (70), compressor inlet housing (100), shims (110) and packings (120) from turbine and compressor assembly (130). Discard packings. NOTE:

Do not remove bolts (45, 55) unless damaged.

~11~1 KEY TO FIGURE 327

10. 20. 30. 40. 45. 50.

UP200456

55. 60.

BOLT WASHER BOLT CONTAINMENT SHIELD SEGMENT ASSY BOLT CONTAINMENT SHIELD SEGMENT ASSY BOLT NUT

70. WASHER 80. INLET ADAPTER 90. PLENUM SEAL 100. COMPRESSOR INLET HOUSING 110. SHIM 120. PACKING 130. TURBINE AND COMPRESSOR ASSY


Page 398.34 Feb 28/05


Hone)~vell


""" 1

..,,.

/

•

ao,,~

~

20.

.

.~_:'>'~!

10,~ " ~

".,..

\.

120

(

,x/

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.,*"'70

140 60

lO0----b~lOL

"---40 X3800504PL33

UP200456

(Pre SB 49-6608) Disassemble the Turbine and Compressor Assembly Components (Partial Breakdown) Figu re 327A

49-26-49


398.35

Page Feb 28/05

Honeywell 4.

D.

(10)



(Pre SB 49-6608) Disassemble the turbine and compressor assembly components. (Refer to Figure 327A.)

(a)

Remove bolts (10, 100), washers (20) and containment shield segment assemblies (40, 70).

(b)

Remove bolts (10, 30), washers (20), compressor inlet housing (110), shims (120), plenum inlet seal (130), inlet adapter (140) and packings (150)from turbine and compressor assembly (160). Discard packings. _NOTE:

Do not remove rivets (50, 80) and nutplates (60, 90) unless damaged.

4~KEY 10. 20. 30. 40. 50. 60. 70.

UP200456

80.

BOLT WASHER BOLT CONTAINMENT SHIELD SEGMENT ASSY RIVET NUTPLATE CONTAINMENT SHIELD SEGMENT ASSY RIVET

TO FIGURE 327A 90. 100. 110. 120. 130. 140. 150. 160.

NUTPLATE BOLT COMPRESSOR INLET HOUSING SHIM PLENUM INLET SEAL INLET ADAPTER PACKING TURBINE AND COMPRESSOR ASSY

49-26-49


Page 398.36 Feb 28/05

Honeywell



130

70

~

fJ ~ 120

=

X3800516PL139

UP200456



Page 398.37 Feb 28/05

Hone well 4.

D.

(11)




Remove compressor housing assembly (10), rotor (50) and engine compressor baffle (60). NOTE:

1.

Do not remove stepped pins (20, 30, 35) unless damaged.

2.

Do not remove dampers (15) unless damaged.

(b)

Remove compressor diffuser (70), spacer (80), shims (90), engine compressor deswirl (100) and shims (110).

(c)

Remove curvic ring seal (120) from turbine and compressor assembly (130).

d~lm KEY TO FIGURE 328

UP200456

10. 15. 20. 30. 35. 50. 60. 70.

COMPRESSOR HOUSINGASSY DAMPERS STEPPED PIN STEPPED PIN STEPPED PIN ROTOR COMPRESSOR BAFFLE COMPRESSOR DIFFUSER

80. 90. 100. 110. 120. 130.

SPACER SHIM ENGINE COMPRESSOR DESWlRL SHIM CURVIC RING SEAL TURBINEAND COMPRESSORASSY

49-26-49


Page 398.38 Feb 28/05

Hone3~well



40

5O

\

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\

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/ J

C .,../"

80

100

90

2O

X3800504PL157

10

UP200456



Page 398.39 Feb 28/05

HoneTwell 4.

D.

(12)




Remove bolts (10), washers (20), containment ring (30) and turbine nozzle assembly (40).

(b)

Remove turbine wheel shims (50), turbine rotor (80) using 833429-1 coupl!ng puller and back shroud shims (90) from turbine assembly (100).

~KEY

UP200456

10. 20. 30. 40.

BOLT WASHER CONTAINMENT RING TURBINE NOZZLE ASSY

TO FIGURE 329 50. TURBINE WHEEL SHIM 80. TURBINE ROTOR 90. BACK SHROUD SHIM 100. TURBINEAND COMPRESSOR ASSY

49-26-49


Page 398.40 Feb 28/05

Hone~vell



210

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_

180

\ \ 15O

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s

70

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2O

\

10

\ 3O

A3800517PL21

UP200456



Page 398.41 Feb 28/05

Hone vell 4.

D.

(13)




Remove bolts (10), bearing carrier heat shield (20), compressor seal assembly (30), seal (40), turbine seal assembly (50), seal (60) and turbine bearing shims (70).

(b)

(Pre SB 49-6883) Remove spring tension washer (80), turbine bearing spacer (90), hydraulic mount seal (100). (Post SB 49-6883) Remove spring tension washer (80) and turbine bearing spacer (90A).

(c)

Use 833092-3 bearing removal tool to remove annular ball bearing (140) and turbine seal rotor (130) from coupling half (170).

(d)

Remove retainer to carrier bolts (180), turbine back shroud retainer (190), retainer shims (200) and metal ring seal (210).

(e)

Remove back turbine wheel shroud (220), back shroud shims (230) and back shroud support ring (240) from turbine bearing carrier assembly (250).

~KEY 10. 20. 30. 40. 50. 60. 70. 80. 90. -90A. 100.

BOLT BRG CARRIER HEAT SHIELD COMPRESSOR SEAL ASSY SEAL TURBINE SEAL ASSY SEAL SHIM SPRING TENSION WASHER TURBINE BEARING SPACER TURBINE BEARING SPACER HYDRAULIC MOUNT SEAL

TO FIGURE 330 130. 140. 170. 180. 190. 200. 210. 220. 230. 240. 250.

TURBINE SEAL ROTOR ANNULAR BALL BEARING COUPLING HALF RETAINER TO CARRIER BOLT TURBINE BACK SHROUD RETAINER RETAINER SHIM METAL RING SEAL BACK TURBINE WHEEL SHROUD BACK SHROUD SHIM BACK SHROUD SUPPORT RING TURBINE BEARING CARRIER ASSY

UP200456



Page 398.42 Feb 28/05

Hone vell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] CLEANING

.

Equipment and Materials A°

NOTE:

Table 401 shows the equipment and materials necessary to clean the equipment. This section includes all the general procedures recommended by Honeywell to clean the equipment. Refer to Table 402 to find which methods are applicable to the equipment in this manual. Table 401. Equipment and Materials

Equipment/Material

UP200456

NOTE:


Equivalentequipment/material can be used.

Abrasive cloth (ANSI B74.18)

Commercially available

Alkaline cleaner (Ridoline 909) (MIL-S-5002)

Henkel Surface Technologies, 32100 Stephenson Hwy, Madison Heights, MI 48071 Phone: 800-521-6895 (248-583-9300)

Electrocleaner (FS)

Henkel Surface Technologies, 32100 Stephenson Hwy, Madison Heights, MI 48071 Phone: 800-521-6895 (248-583-9300)

Magnetic base oil (Magnaglo Carrier II)

Magnaflux, A Division of Illinois Tool Works, Inc., 3624 W. Lake Ave., Rt 27 and Vineyard Rd., Edison NJ 08818 Phone: 847-657-5300

Methyl-ethyl-ketone (MEK) (ASTM D740)


Muriatic acid (35 percent HCL, commercial grade)


Oil (MIL-PRF-7808)


Power source (0 to 7 volt DC)


Stripper, Rust Stripper (Oakite Rustripper)

Chemetall Oakite, 50 Valley Rd, Berkeley Heights, NJ 07922-2712 Phone: 800-526-4473 (908-464-6900)

Sand (120 Grit) (MIL-A-22262)


Solvent (Isopropyl alcohol, Federal Specification TT-I-735)


49-26-49 Copying,useor disclosureof informationon this pageis subjectto proprietaryrestrictions

Page 401 Feb 28/05

Hone vell 2.

.

A.

Each part must be cleaned with the procedures referred to in this section or the equivalent procedures used by an approved overhaul facility. Solutions specified must be made with the instructions in this manual or to the instructions supplied by the product manufacturer.

B.

These procedures agree with good shop procedures as used by the Honeywell overhaul facility. Clean parts are important to satisfactory overhaul and operation.

General Cleanin.q Instructions CLEAN PARTS IN AN AREA OPEN TO THE AIR, THAT HAS GOOD LIGHT AND SUFFICIENT SAFETY AND FIRE PREVENTION EQUIPMENT.

A.

Clean all metal parts to remove oil grease, rust, and dirt. Clean the flange areas and sealing surfaces to remove old gaskets and compounds.

g.

Clean painted parts but do not remove old paint if it is still serviceable.

C.

Remove carbon and combustion contamination.

D.

Heat discoloration of metal surfaces (not to include overheat due to malfunction) is permitted. Remove scale that can come loose and damage the unit.

E.

Remove all light surface corrosion from parts and treat base metal to prevent corrosion. Refer parts with heavier corrosion to inspection personnel for analysis.

CAUTION:

F.

USE THE APPROVED CAPS, PLUGS AND BARRIER MATERIALS TO PROTECT THE PART AFTER CLEANING. DO NOT USE TAPE, PLASTIC, OR RAGS TO PROTECT CLEAN PARTS. DAMAGE TO THE PARTS COULD OCCUR.

Cap, plug or seal all ports and orifices of cleaned parts. Make sure the parts are protected in storage.

Clean Dissimilar Materials CAUTION: A.

B.

AN ASSEMBLY MUST NOT BE CLEANED IN A SOLUTION THAT IS HARMFUL TO ONE OF THE PARTS IN THE ASSEMBLY.

Dissimilar materials must be cleaned one at a time. Refer to REPAIR Reference Tables.

CAUTION:

UP200456


General Cteaninq Practices

WARNING:

.


DO NOT CLEAN BRASS OR BRONZE WITH CHROMIC ACID SOLUTION.

Clean the assemblies that contain brass, bronze, steel, or cadmium with the procedures that are applicable to the base metal.

49-26-49 Copying, use or disclosure of information on this page is subject to proprietary restrictions

Page 402 Feb 28/05

Honeywell


.

C.

.

Preparation of Cleanin.q Solutions A.

Carefully clean synthetic or natural materials with a Cleaning Method that will not damage the material.

Prepare alkaline cleaner solution. WARNING:

B.

C.

.

USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURERS INSTRUCTION FOR EACH CHEMICAL.

(1)

Mix 4 to 6 ounces (113 to 170 g) of alkaline cleaner in each gallon (3,8 L) of water.

(2)

Keep the solution at 130 to 180F (54 to 82C) in an air-agitated tank.

Prepare rust remover solution. WARNING:

UP200456


USE THE CORRECT PERSONAL PROTECTION. RUST REMOVER SOLUTION FUMES CAN BE DANGEROUS. MIX THE WATER AND ADD THE RUST REMOVER SO THE SOULUTION DOES NOT BECOME TOO HOT.

(1)

Mix 3 to 5 pounds (1,4 to 2,3 kg) of rust remover in each gallon (3,8 L) of water.

(2)

Keep the solution at 160 to 200F (72 to 93C).

Prepare electrocleaner solution. (1)

Mix 9 ounces (255 g) of electrocleaner with one gallon (3,8 L) of water.

(2)

Keep the solution at 160 to 200F (72 to 93C).

Clean Component Parts A.

The material composition or physical properties of each part is listed in REPAIR.

B.

Clean the parts with the specified procedures shown in Table 402. When more than one procedure to clean a part is shown in the table, use only the procedure necessary to satisfactorily clean the part.

C.

Ball or roller bearing assemblies must be replaced or analyzed by a repair facility specializing in the repair of bearing assemblies.

49-26-49 Copying, use or disclosureof informationon this page is subjectto proprietaryrestrictions

Page 403 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 402. Cleaning Methods

IPL Figure No.

Item No.

All standard metallic hardware

X

Cleaning Methods 3 4 5

X

9

180

Igniter Plug

10

30 170 190 340 350 390

Oil Level Sensor Data Memory Module Oil Cooler Bracket Pressure Sensor Oil Sump Temp Sensor Motional Transducer

13

120

Immersion Thermocouple

14

60

Quill Shaft

15

10 190

Dipstick Cap Filter Screen

16

150 180

Gearshaft High Speed Pinion Gear

X X

17

70 90 110 300., 310 390

Starter Gearshaft Splined Shaft Assembly Clutch Large Compound Idler Gear Small Compound Idler Gear Lube Gear Assembly

X X

CAUTION:

X X X X X X X X X X X

X

X X X X

DO NOT USE 1,1,1-TRICHLOROETHANE TO CLEAN TITANIUM PARTS. HIGH TEMPERATURE OPERATION OF TITANIUM PARTS AFTER CONTACT WITH CHLORINATED CHEMICALS CAN CAUSE PART FAILURE DUE TO CRACKS.

18

210 230

Generator Idler Shaft Generator Idler Gear

20

50 90

Upper Compressor Inlet Duct Assy Lower Compressor Inlet Duct Assy

20

Compressor Inlet Temperature Sensor Nozzle Assembly Fuel Nozzle Shroud

21

8O 100

UP200456

2

Nomenclature

X X X

X

X X X


Page 404 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 402. Cleaning Methods (Cont)

IPL Figure No.

Item No.

Nomenclature

20 40

2

240

Splined Shaft Compressor Bearing Carrier Assy Coupling Seal Assy

10 50 90 200 230

Load Compressor Diffuser Compressor Rotor Compressor Scroll IGV Actuator Shaft Assy Compressor Shaft

26

110

Compressor Inlet Housing

27

10 50 140 160

Engine Compressor Housing Assy Compressor Rotor Combustion Chamber Plenum Assy

30 40

Containment Ring Turbine Nozzle Assy

24

25

28

.

Cleanin.q Methods 3 4 5 X X X X

X X X X X

X X X X X X

Cleanin,q Procedures WARNING:

USE THE CORRECT PERSONAL PROTECITON. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

CAUTION:

USE THESE PROCEDURES TO CLEAN THE PARTS. PARTS CAN BE BADLY DAMAGED BY THE USE OF THE WRONG PROCEDURE. USE ONLY THE PROCEDURE RECOMMENDED FOR THE PART.

NOTE:

Use clean, dry, filtered, compressed air at a maximum of 20 psig (138 kPa) to dry parts. METHOD 1

A.

Remove grease from parts with a spray. WARNING:

UP200456

(1)

USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

Use solvent in a booth open to the outside air.

49-26-49 Copying, use or disclosureof information on this page is subjectto proprietaryrestrictions

Page 405 Feb 28/05

Hone vell .

A.



(2)

Clean the parts until the oil and grease is removed.

(3)

Remove the caked grease or soft carbon with the use of a brush with stiff plastic fibers.

WARNING:

(4)

USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRSTREAM CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

Dry the parts with compressed air. METHOD 2

B.

Remove grease from parts with a gas. WARNING:


(1)

Use solvent in a vapor degreaser at a temperature of 165 to 170F (74 to 77C).

(2)

Put the part in a rack so the gases touch all the surfaces. The parts that do not drain completely should be arranged, if possible, to drain the liquid before they are removed from the degreaser.

(3)

Clean the parts, as necessary, to remove the heavy grease particles. Return the parts to the vapor degreaser for final cleaning.

WARNING:

(4)

USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRSTREAM CAN CAUSE CUTS DO NOT POINT IT AT YOUR SKIN.

Dry the parts with compressed air. METHOD 3

C.

Clean the aluminum alloy parts. (1)

Use of Method 1 or 2 to remove the grease from the surfaces.

WARNING:

UP200456

(2)


Put the parts in the alkaline cleaner solution for a maximum of 30 minutes.


Page 406 Feb 28/05

Honeywell 7.

C,

(2)

Clean the surfaces with a stiff fiber bristled brush until clean.

(b)

Carefully remove the old gaskets with a blade and scrape the surfaces clean.

(c)

Do the soak and clean procedure again or until the part is clean. USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRSTREAM CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

Flush the parts with water and dry with compressed air.

WARNING:


(4)

Use abrasive cloth to remove small surface corrosion on aluminum alloy parts. Use abrasive cloth and oil to remove small surface corrosion on magnesium alloy parts.

(5)

Flush the parts with water at 80 to 110F (27 to 43C). For magnesium alloy parts, flush again in hot water at 140F (60C) minimum.

WARNING:

(6)

(7)


Dry the parts with compressed air.

WARNING:


Apply touch-up solution to the exposed metal (refer to REPAIR).

WARNING:

UP200456


(a)

WARNING:

(3)


USE THE CORRECT PERSONAL PROTECTION. THE HEATED PARTS WILL CAUSE BURNS.

(8)

Dry all magnesium alloy parts and any aluminum alloy parts that have dissimilar metal inserts, crevices, or deep blind holes in an oven at 225 to 275F (107 to 135C) for a minimum of one hour. Make sure the parts are completely dry.

(9)

Keep the parts in a dry place away from gases that can cause corrosion.


Page 407 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] METHOD 4

7.

D.

Clean steel parts. (1)

Use Method 1 or 2 to remove the grease from the surfaces.

WARNING:


CAUTION:

MORE DAMAGE CAN OCCUR TO NON-STEEL PARTS IF CLEANED WITH RUST REMOVER SOLUTION.

(2)

Put the parts in a rust remover solution for 10 to 20 minutes.

CAUTION:

DO NOT DAMAGE THE HIGHLY FINISHED SURFACES. USE ONLY A BRUSH WITH STIFF PLASTIC FIBERS ON SUCH AREAS. DO NOT GLASS BEAD PEEN THE PARTS UNTIL A PENETRANT OR MAGNETIC PARTICLE INSPECTION HAS BEEN DONE.

(3)

Remove the parts from the rust remover solution. Flush the part with water, and clean with a brush with stiff plastic fibers. Remove hard carbon or scale by glass bead peening surfaces (refer to REPAIR).

WARNING:

(4)

Flush the parts in water at 80 to 110F (27 to 43C) and dry with compressed air.

(5)

Parts that need to have a magnetic particle or a penetrant inspection in eight hours can be left dry until checked. Put the parts in a clean container.

(6)

Steel parts that need a magnetic particle inspection and will be kept for more than eight hours or up to 48 hours must have a layer of magnetic base oil applied. Put the parts in a clean container.

WARNING:

(7)

UP200456



Put the steel parts that do not need a magnetic particle inspection in a dip tank of oil. Remove and let drain, then put them in a clean container and keep them away from moisture and gases that can cause corrosion.


Page 408 Feb 28/05

Honeywell 7.

D.



(8)

Stainless steel and some corrosion-resistant steel parts that are usually used where there is no oil, must be kept dry and protected from moisture that can cause corrosion.

(9)

Steel parts to be kept for more than six months or kept in humid conditions must be protected by corrosion preventive compounds. Refer to MIL-C-15074. METHOD 5

E.

Clean plumbing tubes and fittings. WARNING:

(1)

Clean the tubes and fittings externally and internally with solvent in a booth open to the outside air. Make sure that spray fluid flows freely through tubes.

WARNING:

(2)


Dry parts with compressed air.

CAUTION:

(3)


USE APPROVED CAPS, PLUGS, AND BARRIER MATERIALS TO PROTECT PART AFTER CLEANING. DO NOT USE TAPE, PLASTIC, OR RAGS TO PROTECT CLEAN PARTS, DAMAGE TO PARTS COULD OCCUR.

Install plugs or caps at each end of tubes or fittings to protect against contamination and thread damage. METHOD 6

F.

Clean electrical components.

UP200456

WARNING:


(1)

Rub parts with a clean lint free cloth dipped in methyl-ethyl-ketone or solvent.

(2)

Clean the electrical connectors with cleaning solvent. Remove oily type soil with a cotton swab dipped in solvent.

49-26-49

Copying, use or disclosureof informationon this pageis subjectto proprietaryrestrictions

Page 409 Feb 28/05

HoneTwell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] METHOD 7

.

G.

Clean the metallic filter element. (1)

Use Method 1 or 2 to remove the grease from the filter element.

UP200456

WARNING:


(2)

Soak the filter element in a rust remover solution for 30 minutes. Remove it from the solution and flush it with water.

(3)

Put the filter element in an electrocleaner solution for four to six minutes. During this time, make the filter element an anode for one to two minutes at a potential of 4 to 7 volts DC. Flush filter element in water.

(4)

Put the filter element in a solution of equal parts muriatic acid and water, by volume, at room temperature for one-half to one minute. Flush the filter element with in water.

(5)

Put the filter element in electrocleaner solution for four to six minutes. Flush the filter element with water.

(6)

Flush the filter element internally and externally with clean water under pressure.

(7)

Put the filter element in a beaker with the open end of the filter down and fill the beaker with an electrocleaner solution.

(8)

Put the beaker, with the filter element, in an ultrasonic cleaner tank and fill the tank to within three-eighths inch of the top with water.

(9)

Operate the ultrasonic cleaner tank for five minutes. Remove the filter element, discard the contaminated electrocleaner solution, and flush the filter element and the beaker with clean electrocleaner solution with the use of a plastic squeeze bottle.

(lO)

Put the filter element in a beaker and put it in an ultrasonic cleaner tank. Fill the beaker with electrocleaner solution and operate the ultrasonic cleaner for five minutes more.

(11)

Do steps (9) and (10) again until the electrocleaner solution stays clean after five minutes of operation.


Page 410 Feb 28/05

Hone)awvell WARNING:

UP200456

7.

G.



USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

(12)

Remove the filter element from the beaker and flush internally and externally with clean water under pressure. Dry the filter element with compressed air.

(13)

Do a test on the cleaned filter element for pressure drop (refer to CHECK).


Page 411/412 Feb 28/05

Hone) vell



CHECK

UP200456

.

Refer to ATA No. 49-26-51 for check procedures.


Page 501/502 Feb 28/05

Hone vell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] REPAIR

UP200456

.

Refer to ATA No. 49-26-51 for repair procedures.


Page 601/602 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] ASSEMBLY (WITH STORAGE)

.

Equipment and Materials A.

Table 701 shows the equipment and materials necessary to assemble the unit and prepare it for storage. Table 701. Equipment and Materials

Equipment/Material

UP200456

NOTE:


Equivalent equipment/material can be used for items shown.

Adhesive (RTV106)

General Electric Co., GE Silicones 260 Hudson River Rd, Waterford, NY 12188 Phone: 800-332-3390 (518-233-3330)

Barrier material (PRF-121)


Coating, high heat aluminum (DC6571-805) (Federal Specification A-A-341A Type I or II, Class A)

Griggs Paint 3635 S 16th PI, Phoenix, AZ 85040-1305 Phone: 602-243-3293

Compound (MIL-S-46163 Type I, Grade K, or Type II, Grade O)


Desiccant (MIL-D-3464E)

Commercially available.

Dry-film lubricant (Molykote 321-R)

Dow Coming Corp, 3901 S Saginaw Rd, P.O. Box 997, Midland, MI 48640

Dykem (Hi-Spot Blue No. 107)

The Dykem Co., 8501 Delport Dr., St. Louis, MO 63114-5905 Phone: 314-423-0100

Dry-ice


Liquid nitrogen (Commercial Item Description A-A- 595O3)


Lint free cloth


Lockwire (MS20995C32)


Lubricant (OS-124)

Monsanto Co., Fibers Business Unit, 800 N. Lindbergh Rd., St. Louis, MO 63167

Lubricating anti-seize (Liqui-Moly, Brand NV Thread compound) MIL-PRF-907)

Lockrey Co, Inc, Lubricants Div, 2517 Finlaw Ave, Merchantville, NJ 08109-3243 Phone: 856-665-4794

Oil (MIL-PRF-7808)


49-26-49

Copying,useor disclosureof informationonthis pageis subjectto proprietaryrestrictions

Page 701 Feb 28/05


Honeywell


Equipment/Material


Oil (MIL-PRF-23699)


pH Neutral paper (MIL-P-17667)


Primer (MIL-S-22473 Grade T)


Assembly Tools Air-oil separator support (833973-1) APU assembly stand (287750-1) Balance adapter (834166-1) Balance adapter (834248-1) Balance adapter (834249-1) Balance adapter (834250-1) Balance bearing set (833091-1)** Bearing and seal removal fixture (835550-1) Bearing and separator installer (2024021-1 ) Bearing and separator installer (834337-1) Bearing carrier support (833175-1 ) Bearing hold fixture (834157-1) Bearing installer (834336-1) Bearing set installer (833124-1) Bearing installer (833991-1) Bearing set installer (833131-1) Bearing press fixture (833096-2) Bearing press fixture (833126-1)

UP200456

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987 **Consists of: turbine balance bearing 833091-200, compressor balance bearing 833091-201


Page 702 Feb 28/05

Hone vell



Equipment/Material


Bearing press fixture (833988-1) Bearing installer (833989-1) Bearing removal fixture (833440-1) Bearing removal and replacement fixture (2024019-1 ) Carbon seal installer (2024017-1 ) Comp bearing centering fixture (833102-1) Coupling installing tool (833432-1) Coupling puller (833429-1) Cut back nut (834347-1) Dummy L/C coupling (834037-1) Gearbox housing adapter (2024003-1) Installation support (294224-1) IGV adjustment tool (834150-2) Bearing and rotor seal installer (833096-2) Lift fixture (833105-1) Lifting fixture (834334-1) Lip seal bullet (833997-1) Micrometer bridge (833424-1) Micing fixture (833449-1)

UP200456

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987


Page 703 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 701. Equipment and Materials (Cont) Description/Manufacturer

Equipment/Material Nozzle support tool (833099-1) Nut stake tool (834120-1) Pinion gear puller (833095-1) Portable engine stand assy (833565-3) Plenum puller fixture (833186-1) Protective cover (2024398-1) Rotating group bridge stand (834348-1) Rotating group cut back nut (834347-1) Runout check fixture (833097-1) Runout check fixture (833449-1) Runout indicator (833449-1) Runout test fixture (285868-1) Seal installer (834333-2) Seal press fixture (833996-1) Shaft stretch fixture (833094-1) Shim holding fixture (833871-1) Spanner wrench (2024465-1) Sprag clutch guide sleeve installer (2024392-1) Support fixture (833998-1)

*

UP200456

• Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987


Page 704 Feb 28/05

Honeywell



Equipment/Material


Support shaft installation fixture (833430-1)

*

Tie bolt arbor (834263-1/-2)

*

Turbine backshroud retainer support (834156-1)

*

Turbine rotor balance arbor (833158-1)

**

Tube installation tool (833184-1)

*

Turbine and compressor holding fixture (833093-1)

*

Turbine rotor support tool (834335-1)

*

Vacuum check tool (834149-1)

*

Vacuum check tool (834303-1)

*

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987

UP200456

**Designed for Gisholt Balance Machines only


Page 705 Feb 28/05

Hone vell .


General Assembly Instructions NOTE:

The assembly instructions are in the order of the illustration first and then the text on either the same page or facing pages where practical. All necessary information is given so the unit can be assembled without reference to another part of the manual.

A.

Remove all corrosion preventive compound and any contaminations from the parts before assembly.

B.

All nuts, bolts, and screws must be tightened to a standard torque unless torque is specified in text. Refer to FAA Manual AC65-9A, Airframe and Powerplant Mechanics General Handbook, for the standard torque.

C.

Use anti-seize compound for the assembly of all threaded parts as follows. CAUTION:

D.

USE OF TOO MUCH ANTI-SEIZE COMPOUND CAN CAUSE VENTS AND ORIFICES TO CLOG.

(1)

Apply a small quantity of anti-seize compound, to the threads of all male threaded parts.

(2)

Remove any of the compound that remains after assembly of the threaded parts.

WARNING:

UP200456



All the packings must be lubricated before installation. Use a lubricant that has been approved for the system where the packing is to be installed. For example, packings to be used in the engine oil system must be lubricated with oil (MIL-PRF-7808 or MIL-PRF-23699).

49-26-49 Copying, use or disclosureof informationon this pageis subjectto proprietaryrestrictions

Page 706 Feb 28/05


HoneTwell .


E.

Use Iockwire on all hardware (bolts, screws, plumbing, electrical connectors) with Iockwire holes. Install the Iockwire in accordance with Aerospace Standard 567 (AS567).

F.

Installation of electrical connectors. (1)

Installation of threaded connectors. (a)

Align the key of one part with the groove or keyway of the other part to find the correct position of the plug in relation to the receptacle.

(b)

Start the plug in the receptacle with a light forward pressure. Engage the threads of the coupling ring and receptacle.

CAUTION:

(c)

(2)

Carefully push in on the plug and tighten the coupling ring until the plug is seated and tight. If necessary, use connector pliers to tighten coupling rings more than finger tight.

Installation of the bayonet connector. CAUTION:

G.

.

DO NOT USE CONNECTOR PLIERS.

(a)

Align the key of one part with the groove or keyway of the other part to find the correct position of the plug in relation to the receptacle.

(b)

Start the plug in the receptacle with a light forward pressure. Engage the coupling ring and receptacle.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

H.

NEVER USE FORCE TO ENGAGE CONNECTORS TO RECEPTACLES. DO NOT HAMMER A PLUG INTO THE RECEPTACLE. DO NOT USE A TORQUE WRENCH OR PLIERS TO LOCK COUPLING RINGS.

There is no alternate screw or bolt lengths permitted for blind hole applications.

On rivet installation, if the shank of the rivet is too long or too short, use one size longer or one size shorter rivet as necessary.

Check Point Notes

UP200456

The Check Points in this section are used by Honeywell at/or after critical build operations. Use these Check Points to make sure the assembly was built correctly. Table 702 shows the Check Points.


Page 707 Feb 28/05


Hone) vell


UP200456

Table 702. Check Point Summary

Check Point

Operation

Page

10

Make sure calculations used for shims (140, 150) are correct.

716

10A

Make sure calculations used for shims (130, 140, 150) are correct.

720

20

Check gearbox for complete assembly, obvious damage and freedom of rotation.

762

20A


766

30

Make sure the shaft stretch is 0.058 to 0.062 inch (1,47 to 1,57 mm).

772

40

Make sure runout measurements are in limits.

774

50

Make sure the balance measurements are in limits.

778

60

Make sure the tie shaft stretch measurement is 0.058 to 0.062 inch (1,47 to 1,57 mm).

787

70

Make sure runout and balance measurements are in limits and rotating group is marked with dykem. Record serial numbers of turbine and compressor's impellers.

790

80

Make sure recorded Dimensions A and BB are correct.

796

90

Make sure calculations for shims (70) are correct. Verify Dim. C.

796

100

Make sure Dimension BB1 is the same as Dimension BB.

798

110

Dimension C must be the same as Dimension C1 _+0.00015 inch (0,038 mm) at each of the 4 locations.

798.4

120

Make sure the turbine rotor backshroud clearance is within limits.

798.17

130

Make sure the turbine wheel to the turbine nozzle clearance is in limits.

798.22

140

Make sure the engine compressor clearance calculations are correct.

798.32


Page 708 Feb 28/05

Hone vell



UP200456

Table 702. Check Point Summary (Cont)

Check Point

Operation

Page

150

Make sure load compressor tip clearance is 0.065 to 0.069 inch (0,165 to 0,175 mm).

798.59

160

Make sure calculations for spacer (150) are correct to 0.001 inch (0.025 mm).

798.68

170

Make sure the shaft stretch (RSL) measurement is correct.

798.71

180

Make sure the runout on surfaces A and B are in limits.

798.73

190

Make sure that a gearbox cavity inspection is accomplished before installing the gearbox.

798.89

49-26-49 Copying,use or disclosureof informationon this page is subjectto proprietaryrestrictions

Page 709 Feb 28/05


Hone~veil

430 \


4404~,~

45~~~

1'~

160~~~

120 140 ,L~

LUBEGEARASSY

GEI~ERATORGEARASSY

3.

10\ 8,

HIGHSPEEDPINIONASSY

30 10 GENERATORIDLERGEARASSY X3800504AY55

UP200456

Assemble the Bearings and Gears (Gearbox Part No. 3863019) (Code A) Figure 701

49-26-49 Copying, use or disclosureof informationon this page is subject to proprietaryrestrictions

Page 710 Feb 28/05

Honeywell .



Assembly Procedures A.

Assemble the Gearbox Assembly. (1)

(Part No. 3863019) Assemble the bearings and gears. (Refer to Figure 701 .) (a)

Use the 833131-1 bearing press fixture to push lube pump ball bearings (450) on lubrication pump gear assembly (430). Install expansion plug (440) if necessary.

(b)

Use the 834336-1 bearing press fixture to push generator roller bearings (120) on generator gear assembly (150). Make sure that OUTER THRUST side of bearings faces away from large gear. Install insert (140) and plug (160) into generator gear assembly (150) if necessary.

(c)

Use 833976-2 bearing press fixture and 833973-1 support fixture to push pinion gear bearings (330) on pinion gear (340). Make sure OUTER THRUST side of bearings faces away from gear. Install retaining ring (320).

(d)

Install inner spacer (40) and outer spacer (30) into generator idler gear (50).

(e)

Use 833986-1 bearing installation fixture and 833987-1 support fixture to install roller bearings (20) into idler gear (50). Make sure OUTER THRUST side of bearing faces toward gear.

(f)

Install retaining rings (10).

~KEY RETAINING RING (IPC FIG. 40) ROLLER BEARING OUTER SPACER INNER SPACER IDLER GEAR GENERATOR ROLLER BEARING (IPC FIG. 17) 140. INSERT

UP200456

10. 20. 30. 40. 50. 120.

TO FIGURE 701 150. 160. 320. 330. 340. 430. 440. 450.

GENERATOR GEAR ASSY PLUG RETAINING RING (IPC FIG. 19) PINION GEAR BEARING PINION GEAR LUBE GEAR ASSY EXPANSION PLUG LUBE PUMP BALL BEARING

49-26-49 Copying, use or disclosure of informationon this pageis subjectto proprietaryrestrictions

Page 711 Feb 28/05


Honeywell


170

150

160

120 140 ~ w

~

ss

150

GENERATORGEARASSY

14o

30,

1 20 HIGHSPEEDPINIONASSY

10

GENERATORIDLERGEARASSY X3800504AY56

UP200456

Assemble the Bearings and Gears (Gearbox Part No. 3863136) (Code B) Figure 701A


Page 712 Feb 28/05

Hone vell 4.

A.

(2)



(Part No. 3863136) Assemble the bearings and gears. (Refer to Figure 701A.)

(a)

Use the 833131-1 bearing press fixture to push lube pump ball bearings (330) on lube gear assembly (350). Install expansion plug (340) if necessary. Position lube gear assembly in gearbox cavity before installing air-oil separator assembly.

(b)

Use the 834336-1 bearing press fixture to push bearings (120, 170) on generator gear assembly (150). Make sure that OUTER THRUST side of bearings faces away from large gear. Install insert (140) and plug (160) into generator gear assembly (150) if necessary.

(c)

Use 833976-2 bearing press fixture and 833973-1 support fixture to push pinion roller bearings (130) on pinion gear (140). Make sure OUTER THRUST side of bearings faces away from gear. Install retaining rings (120,150).

(d)

Use 2024019-1 bearing installation fixture to install roller bearing (20) into generator idler gear (30). Make sure OUTER THRUST side of bearing faces away from gear on opposite side from retaining ring (10).

(e)

Install retaining ring (10).

41~ KEY TO FIGURE 701A RETAINING RING (IPC FIG. 40A) ROLLER BEARING IDLER GEAR GENERATOR ROLLER BEARING (IPC FIG. 17A) 120. RETAINING RING (IPC FIG. 19A) 130. PINION ROLLER BEARING 140. PINION GEAR

UP200456

10. 20. 30. 120.

140. 150. 150. 160. 170. 330.

INSERT (IPC FIG. 17A) GENERATOR GEARASSY RETAINING RING (IPC FIG. 19A) PLUG (IPC FIG. 17A) GENERATOR BALL BEARING LUBE PUMP BALL BEARING (IPC FIG. 19A) 340. EXPANSION PLUG 350. LUBE GEARASSY

49-26-49

Copying,use or disclosureof informationon this pageis subjectto proprietaryrestrictions

Page 713 Feb 28/05

Hone~vell



SO

.~'y\

| ViEWA

140

ViEWD

150

' l0

;

I~

1

DFTAll X

DETAIl.Y

ViEWB

~

... ' " ~ . .

70

90

SO

VIEW C

X~O~l~Y14

5O

UP200456

Assemble the Starter Clutch Components (Gearbox Part No. 3863019) (Code A) Figure 702


Page 714 Feb 28/05

Honeywell 4.

A.

(3)



(Part No. 3863019) Assemble the starter clutch components. (Refer to Figure 702.) (a)

Use 833124-1 bearing installer and push starter bearings (60) on gearshaft (70) as shown in View A, with THRUST marking away from gear. NOTE:

Make sure all drain holes on shaft assembly (90) are not blocked.

(b)

Use 833991-1 bearing installer and 833998-1 support fixture and push one ball bearing (80) on shaft assembly (90).

(c)

Install clutch (110) on shaft assembly (90). NOTE:

Make sure clutch direction arrow is in the counterclockwise position when looked at from the splined end of shaft (90) as shown in View B.

(d)

Use 833991-1 bearing installer and 833998-1 support fixture and push the remaining ball bearings (80) on shaft assembly (90).

(e)

Install retaining ring (50) in gearshaft (70). Use 2024392-2 sprag clutch guide sleeve and install shaft assembly (90) with assembled items in gearshaft (70) with splines down as shown in View C.

(f)

Use a depth micrometer to measure from the top of gearshaft (70) to the outer race of ball bearing (80). Write the measurement as Dimension A. Refer to Detail X.

(g)

Measure the thickness of retaining ring (50) and write the measurement as Dimension B. Install retaining ring (50) in gearshaft (70). Refer to View D.

(h)

Measure from the top of gearshaft (70) to the top of retaining ring (50). Write the measurement as Dimension C. Refer to Detail Y.

~KEY

UP200456

50. 60. 70. 80. 90.

RETAINING RING (IPC FIG. 18) STARTER BEARING GEARSHAFT BALL BEARING SHAFT ASSY

TO FIGURE 702 110. 130. 140. 150.

CLUTCH SPRING WASHER SHIM SHIM

49-26-49

Copying, use or disclosureof informationon this page is subjectto proprietaryrestrictions

Page 715 Feb 28/05

Honeywell 4.

A.

(3)

(i)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Use this formula to calculate the necessary thickness of shims (140, 150). Formula A - B - C - 0.031 to 0.035 inch (0,8 to 0,9 mm) = the necessary thickness of shims (140, 150). Dimension A _ _ inch ( . _ _ mm) Dimension B - _ _ inch ( . _ _ mm) Dimension C - _ _ inch ( _ _ _ mm) minus 0.031 to 0.035 inch (0,8 to 0,9 mm) = necessary thickness of shims (140, 150) to get +_0.002 (+_0,5 mm) tolerance.

UP200456

Check Point 10:

Make sure calculations used for shims (140, 150) are correct.

(.i)

Remove retaining ring (50) from gearshaft (70).

(k)

Install spring washer (130), calculated amount of shims (140, 150) and retaining ring (50) as shown in View E.


Page 716 Feb 28/05

Hone~vell



UP200456



Page 717 Feb 28/05

Hone~vell


COMPONENTMAINTENANCEMANUAL GTCP36-280[D]

~_ ___:/_

Y~,

/

~EWA

140

VIEW O

150

' S.O

,09

CLUTCHDIRECTION

;

t 0.031TO0.035IN. I" 7 (0,8TO0,9MM) ~. _1 BUILDDIMENSION

'°-'~ o2

m

ViEWE m

t,

i

""'120 [J,,d"~ .a~.jl r",,,$O

f DIM. A

DIM. C

DETAILX

/.f"

9o

,0

~ /l

"

DETAILY

X\

")

~

"J 140

I

/

100VIEW 60C

t "

- . < "/"~~....-<"~'~''/~ O0 ~

.

120

X3800516AY15

UP200456

Assemblethe StarterClutchComponents(GearboxPart No. 3863136) (Code B) Figure702A


Page718 Feb 28/05

Honeywell 4.

A.

(4)



(Part No. 3863136) Assemble the starter clutch components. (Refer to Figure 702A.) (a)

Use 833124-1 bearing installer and push starter bearings (70) on gearshaft (80) as shown in View A, with THRUST marking away from gear. .NOTE:

Make sure all drain holes on shaft (100) are not blocked.

(b)

Use 833991-1 bearing installer and 833998-1 support fixture and push one ball bearing (90) on shaft (100).

(c)

Install clutch (120) on shaft assembly (100). NOTE:

Make sure clutch direction arrow is in the counterclockwise position when looked at from the splined end of shaft (100) as shown in View B.

(d)

Use 833991-1 bearing installer and 833998-1 support fixture and push the remaining ball bearings (90) on shaft (100).

(e)

Install retaining ring (60) in gearshaft (80). Use 2024392-2 sprag clutch guide sleeve and install shaft (100) with assembled items in gearshaft (80) with splines down as shown in View C.

(f)

Use a depth micrometer to measure from the top of gearshaft (80) to the outer race of ball bearing (90). Write the measurement as Dimension A. Refer to Detail X.

(g)

Measure the thickness of retaining ring (60) and write the measurement as Dimension B. Install retaining ring (60) in gearshaft (80). Refer to View D.

(h)

Measure from the top of gearshaft (80) to the top of retaining ring (60). Write the measurement as Dimension C. Refer to Detail Y.


UP200456

60. 70. 80. 90. 100.

RETAINING RING (IPC FIG. 18A) STARTER BEARING GEARSHAFT BALL BEARING SHAFT

120. 130. 140. 150. 160.

CLUTCH SHIM SHIM SHIM SPRING WASHER


Page 719 Feb 28/05


Hone vell 4.

A.

(4)

(i)

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Use this formula to calculate the necessary thickness of shims (130, 140, 150). Formula A - B - C - 0.031 to 0.035 inch (0,8 to 0,9 mm) = the necessary thickness of shims (130, 140, 150). Dimension A _ _ inch ( _ _ mm) Dimension B - _ _ inch ( . _ _ mm) Dimension C - _ _ inch ( . _ _ mm) minus 0.031 to 0.035 inch (0,8 to 0,9 mm) = necessary thickness of shims (130, 140, 150) to get +0.002 (+_0,5 mm) tolerance.

UP200456

Check Point 10A:

Make sure calculations used for shims (130, 140, 150) are correct.

(J)

Remove retaining ring (60) from gearshaft (80).

(k)

Install spring washer (160), calculated amount of shims (130, 140, 150) and retaining ring (60) as shown in View E.

49-26-49 Copying, use or disclosure of information on this page is subject to proprietaryrestrictions

Page 720 Feb 28/05


Hone~vell


UP200456



Page 721 Feb 28/05


Hone vell


420 400 380,~ 410 360

#

¢

DIM. A

X3800504AY57

350. ROLLER BEARING (IPC FIG. 19) 360. AIR-OILSEPARATOR 380. PIN

400. IDLERASSY 410. GEARSHAFTASSY 420. PLUG

UP200456

Assemble the Air-Oil Separator and Idler Assembly (Gearbox Part No. 3863019) (Code A) Figure 703


Page 722 Feb 28/05


Hone weU 4.

A.

(5)


(Part No. 3863019) Assemble air-oil separator and idler assembly. (Refer to Figure 703.) (a)

Measure Dimension A on idler assembly (400). Write down the result.

(b)

Measure Dimension B on air-oil separator (360). Write down the result. Subtract Dimension A from Dimension B, this equals Dimension C1. Write down the result.

UP200456

CAUTION:

MAKE SURE TO ALIGN HOLES IN AIR-OIL SEPARATOR (360) WITH PINS ON IDLER ASSEMBLY (400).

(c)

Use 834337-1 bearing press fixture and 833973-1 support to push air-oil separator (360) with plug (420) and gearshaft assembly (410) on idler assembly (400).

(d)

Measure Dimension C and write down the result.

(e)

Dimension C must equal Dimension C1. If they are not equal, disassemble and reassemble air-oil separator.

(f)

Push roller bearings (350) on air-oil separator assembly using 2024301-1 press fixture.


Page 723 Feb 28/05


Honeywell


320 310 29O 270 300

240

BN.C

f

DIM. A

m

DIM. B

X3800504AY5

240. ROLLER BEARING (IPC FIG. 19A) 250. AIR-OILSEPARATOR 270. PIN 290. IDLER ASSY

300. 310. 320.

GEARSHAFTASSY PLUG ROLLER BEARING

UP200456

Assemble the Air-Oil Separator and Idler Assembly (Gearbox Part No. 3863136) (Code B) Figure 703A


Page 724 Feb 28/05


Hone vell 4.

A.

(6)


(Part No. 3863136) Assemble air-oil separator and idler assembly. (Refer to Figure 703A.) (a)

Measure Dimension A on idler assembly (290). Write down the result.

(b)

Measure Dimension B on air-oil separator (250). Write down the result. Subtract Dimension A from Dimension B, this equals Dimension C1. Write down the result.

UP200456

CAUTION:

MAKE SURE TO ALIGN HOLES IN AIR-OIL SEPARATOR (250) WITH PINS ON IDLER ASSEMBLY (290).

(c)

Use 2024021-1 bearing press fixture and 833973-1 support to push air-oil separator (250) with plug (310) and gearshaft assembly (300) on idler assembly (290).

(d)

Measure Dimension C and write down the result.

(e)

Dimension C must equal Dimension C1. If they are not equal, disassemble and reassemble air-oil separator.

(f)

Push roller bearings (240, 320) on air-oil separator assembly using 2024301-1 press fixture.


Page 725 Feb 28/05


Hone vell


250

\

90

/

f

X3800504AY59

70. 80.

SCREW (IPC FIG. 19) PINION JET

90. 250.

PACKING GEARBOX HOUSING

UP200456

Install High Speed Pinion Jet (Gearbox Part No. 3863019) (Code A) Figure 704

49-26-49 Copying,use or disclosureof informationon this pageis subjectto proprietaryrestrictions

Page 726 Feb 28/05

Honeywell 4.

A.

(7)


(Part No. 3863019) Install the pinion jet. (Refer to Figure 704.) (a)

UP200456


Install pinion jet (80) with packing (90) in gearbox housing (250). Attach in place with screws (70).


Page 727 Feb 28/05

Honeywell



360

",F---400

250

\

33O 34O

180 160 . ~ E

170

J

Z/ I

~ ~ 3 7 0 361)

X3800504AY60

UP200456

Install the Restrictor and Gear Assemblies (Gearbox Part No. 3863019) (Code A) Figure 705

49-26-49


Page 728 Feb 28/05


Hone) well 4.

A.

(8)


(Part No. 3863019) Install the restrictor and gear assemblies. (Refer to Figure 705.) (a)

Install restrictor (170).

(b)

Use 834333-2 seal installer to install lip seal (180) in gearbox housing.

(c)


(d)

Install lube gear assembly (430) in gearbox housing. NOTE:

Do not put lube gear assembly in aft bearing liner at this time. Let the lube gear assembly rest in the gearbox housing below the aft liner.

(e)

Install air-oil separator (360) and idler assembly (400) in gearbox housing (250).

(f)

Place lube gear assembly (430) in its aft bearing liner. The lube gear mates with the small gear on the air-oil separator.

(g)

Install packing (360) and retaining ring (370) in cover assembly (350).

(h)

Install cover assembly (350) in gearbox housing. Attach in place with washers (340) and bolts (330).

~KEY

UP200456

160. 170. 180. 250. 330. 340. 350.

RETAINING RING (IPC FIG. 18) RESTRICTOR LIP SEAL GEARBOX ASSY (IPC FIG. 19) BOLT (IPC FIG. 18) WASHER COVER ASSY

TO FIGURE 705 360. PACKING 370. RETAINING RING 360. AIR-OIL SEPARATOR (IPC FIG. 19) 400. IDLER ASSY 430. LUBE GEARASSY

49-26-49

Copying, use or disclosure of informationon this pageis subjectto proprietaryrestrictions

Page 729 Feb 28/05


Hone)~vell


so

/

" /

300 310

(

,o

X3800504AY61

UP200456

Install the Restrictor and Gear Assemblies (Gearbox Part No. 3863136) (Code B) Figure 705A


Page 730 Feb 28/05

Hone vell 4.

A.

(9)



(Part No. 3863136) Install the restrictor and gear assemblies. (Refer to Figure 705A.) (a)

Install restrictor (190).

(b)


(c)

Install lube gear assembly (350) in gearbox housing. NOTE:

Do not put lube gear assembly in aft bearing liner at this time. Let the lube gear assembly rest in the gearbox housing below the aft liner.

(d)

Install air-oil separator (250) and idler assembly (290) in gearbox housing (38O).

(e)

Place lube gear assembly (350) in its aft bearing liner. The lube gear mates with the small gear on the air-oil separator.

(f)

Install packing (330) and retaining ring (340) in cover assembly (320).

(g)

Install cover assembly (320) in gearbox assembly (380). Attach in place with washers (310) and bolts (300).

~KEY

UP200456

60. RETAINING RING (IPC FIG. 18A) 190. RESTRICTOR 250. AIR-OILSEPARATOR (IPC FIG. 19A) 290. IDLERASSY 300. BOLT (IPC FIG. 18A) 310. WASHER

TO FIGURE 705A 320. COVERASSY(IPC FIG. 18A) 330. PACKING 340. RETAINING RING 350. LUBE GEARASSY (IPC FIG. 19A) 380. GEARBOXASSY


Page 731 Feb 28/05


Hone) well


f f

200

J

J J

f

J

'230 210

190 220

,

230

&.. X3800516AY20

UP200456

(Pre SB 49-7596) Install the Adapter and Lip Seal (Gearbox Part No. 3863019) (Code A) Figure 706 (Sheet I of 3)


Page 732 Feb 28/05


Hone vell


41~ KEY TO FIGURE 706 (SHEET 1) 190. 200. 210. 220. 4.

BOLT (IPC FIG. 18) WASHER ADAPTER INSERT A.

(10)

230. LIP SEAL 240. PACKING 410. GEARBOX ASSY

(Part No. 3863019) (Pre SB 49-7596) Install the adapter and lip seal. (Refer to Figure 706, Sheet 1.) (a)

Use 833996-1 seal press fixture to push lip seal (230) on adapter (210). Install insert (220) if necessary.

CAUTION:

UP200456

(b)

USE 833997-1 LIP SEAL BULLET TO DEFORM LIP SEAL (230) PRIOR TO INSTALLATION OF ADAPTER (210) IN GEARBOX HOUSING. USE LIP SEAL BULLET WHEN ASSEMBLED ITEMS ARE INSTALLED IN GEARBOX HOUSING.

Install adapter (210) with packing (240) in gearbox assembly (410). Attach in place with washers (200) and bolts (190).

49-26-49 Copying,use or disclosure of informationon this pageis subjectto proprietaryrestrictions

Page 733 Feb 28/05


Honeywell


410

./ ./ 200 T6-~M 1 238 234 190

~,. 220

210A

X3800516AY215

UP200456

(Post SB 49-7596) Install the Adapter and Carbon Face Seal (Gearbox Part No. 3863019) (Code A) Figure 706 (Sheet 2)


Page 734 Feb 28/05


Honeywell


~lm KEY TO FIGURE 706 (SHEET 2) 190. 200. 210A. 220. 230A.

232. 234. 236. 238. 240. 410.

BOLT WASHER ADAPTER INSERT CARBON SEAL

(11)

(Part No. 3863019) (Post SB 49-7596) Install adapter and carbon seal. (Refer to Figure 706, Sheet 2 and 3) (a)

Measure Dimensions A and B.

(b)

Use the following formula to calculate the necessary thickness of shims: FORMULA: Dimension A Dimension B

A + B - .450 in. (11,43 mm) in. or + in. or -.450

Calculated Thickness

UP200456

PACKING SHIM SHIM SHIM PACKING GEARBOX ASSY

in. or

11,43

mm mm mm

in. or mm = thickness of shims necessary 0.002 in. (0,0508 mm) =

(c)

Install packing (232) and shims (234, 236, 238) into adapter, use 2024017-1 carbon seal installer to push carbon seal (230A) into adapter (210A).

(d)

Install assembled adapter/seal on gearbox assembly (410). Attach in place with washers (200) and bolts (190).


Page 735 Feb 28/05


COMPONENT MAINTENANCE MANUAL

Honeywell

GTCP36-280[D]

\ --~

"xl

.=----DIMA

,J

I i

\ I

I

~J

_r]DIM. B - -

-LL --! !

/

H

I i

I

I X3800516AY217

UP200456

(Post SB 49-7596) Install the Adapter and Carbon Seal (Gearbox Part No. 3863019) (Shimming Dimensions) (Code A) Figure 706 (Sheet 3)


Page 736 Feb 28/05

Honeywell



UP200456


49-26-49 Copying, use or disclosure of information on this page is subjectto proprietary restrictions

Page 737 Feb 28/05

Honeywell



-% -

22o,,J

,

\ 250 240 230

270

\

290

DIM.A - - ~ _ j~-DIM.C

280~,,

380

\

~ DIM. B DIM. D

X3800516AY21

UP200456

Install the Adapter and Carbon face Seal (Gearbox Part No. 3863136) (Code B) Figure 706A

49-26-49

Copying, use or disclosureof informationon this page is subject to proprietaryrestrictions

Page 738 Feb 28/05

Hone vell 4.

A.

(11)



(Part No. 3863136) Install the adapter and carbon face seal. (Refer to Figure 706A.) (a)

Measure Dimensions A and B to establish gear end play.

(b)

Use the formula that follows to calculate the necessary thickness of shims (350, 360, 370). FORMULA: Dimension A Dimension B Calculated Thickness

A - B + 007 in. (0,1778 mm) in. or in. or + .007 in. or 0,1778

in. or mm = thickness of SHIM 1 (350, 360, 370) necessary _+0.002 in. (0,0508 mm) =

The gear end play must be shimmed before the carbon face seal operating height shim pack is determined.

NOTE:

(c)

Measure Dimensions C and D to establish operating height of carbon face seal (280).

(d)

Use the formula that follows to calculate the necessary thickness of shims (250, 260, 270). FORMULA: Dimension C Dimension D Calculated Thickness SHIM 1

C + D + SHIM 1 in. + in. + in.

-.450 Calculated thickness

4~KEY

UP200456

200. 210. 220. 230. 240. 250. 260.

mm mm mm

BOLT (IPC FIG. 18A) WASHER ADAPTER INSERT PACKING SHIM SHIM

.450 in. (11,43 mm) or mm or mm or mm

in. or

11,43

mm

= in. or mm = thickness of SHIM 2 (250, 260, 270) necessary _0.002 in. (0,0508 mm)

TO FIGURE 706A

27O. 280. 29O. 35O. 360. 370. 380.

SHIM CARBON FACE SEAL PACKING SHIM SHIM SHIM GEARBOX ASSY


Page 739 Feb 28/05

Hone vell

UP200456

4.

A.

(11)



(e)

Install packing (240) and SHIM 2 (250, 260, 270) into adapter. Use 2024017-1 carbon seal installer to push carbon face seal (280) into adapter (220). Install insert (230) if necessary.

(f)

Install adapter (220), packing (290) and SHIM 1 (350,360,370) on gearbox assembly (380). Attach in place with washers (210) and bolts (200).

49-26-49 Copying,use or disclosure of informationon this page is subjectto proprietaryrestrictions

Page 740 Feb 28/05

Hone3~well



UP200456



Page 741 Feb 28/05


Hone~vell


22O

250

270 260~ ( ~

210.

"~

.-

"Y

I I

180 170

.,

160,~

lO0

60

!

I

10 3O

/

105

,

"~,

"

!

300 I k ;Z90

'/

~'k

'

i

, L;o ,o 230

190 X3800504AY62

UP200456

Install the Generator Idler Gear Assembly and Bearing Carrier (Gearbox Part No. 3863019) (Code A) Figure 707


Page 742 Feb 28/05

Honeywell 4.

A.

(12)



(Part No. 3863019) Install generator idler gear assembly and bearing carrier. (Refer to Figure 707.) (a)

Install packings (160, 180) on idler shaft (170).

(b)

Install idler gear assembly (190) and spacer (200) in gearbox housing (250).

(c)

Install idler shaft (170) with packings (160, 180) through the gearbox and through idler gear assembly (190) and spacer (200).

(d)

Install bolt (150) through idler shaft (170) and assembled parts. Install washer (210) and nut (220). NOTE:

The air-oil separator may have to be lifted up to allow for installation of the pinion gear.

(e)

Install packing (140) on transfer tube assembly (110). Install support (130) if necessary.

(f)

Install high speed pinion gear assembly (340) in gearbox (250).

(g)

Install transfer tube assembly (110), bearing carrier (100) with insert (105) and bearing retainer (40) in gearbox housing (250). NOTE:

Protruding bracket on transfer tube assembly (110) must be located on top of retainer bearing (40).


UP200456

10. 20. 30. 40. 50. 60. 100. 105. 110. 130. 140. 150. 160. 170. 180. 190.

BOLT (IPC FIG. 19) WASHER SCREW BEARING RETAINER BOLT WASHER BEARING CARRIER INSERT TRANSFER TUBE ASSY SUPPORT PACKING BOLT PACKING IDLER SHAFT PACKING IDLER GEARASSY

200. 210. 220. 230. 235. 240. 245. 250. 260. 270. 280. 290. 300. 310. 340.

SPACER WASHER NUT BOLT WASHER PLUG PACKING GEARBOX HOUSING PLUG PACKING BOLT WASHER COVER PACKING HS PINION GEAR

49-26-49

Copying, use or disclosureof informationon this pageis subjectto proprietaryrestrictions

Page 743 Feb 28/05

Hone vell

UP200456

4.

A.

(12)



((h)

Install washers (60, 20) and bolts (50, 10) and screws (30). Tighten bolts (10, 50) and screws (30) to a torque value of 50 in-lb (5,7 Nm).

(i)

Install packing (245), plug (240), washer (235) and bolt (230) on gearbox housing (250).

d)

Install packing (310), cover (300), washer (290) and bolt (280).

(k)

Install packing (270) and plug (260) on gearbox housing (250).

49-26-49

Copying, use or disclosure of information on this page is subject to proprietary restrictions

Page 744 Feb 28/05

Honeywell



UP200456



Page 745 Feb 28/05


HoneTwell


160

2zo~ 380

280 ~

\

340

330

25O 310 320

33O

I/ 210 220

~I~ "~

10

•

~

8o.i/

-'~"P"

I

"~

,,~4"x ,-",,J_

~

120

130

X3800504PL124

UP200456

Install the Generator Idler Gear Assembly and Bearing Carrier (Gearbox Part No. 3863136) (Code B) Figure 707A (Sheet I of 2)


Page 746 Feb 28/05


Hone)well 4.

A.

(13)


(Part No. 3863136) Install generator idler gear assembly, bearing carrier, and oil jets. (Refer to Figure 707A, Sheet 1) (a)

Install packings (200, 220) on idler shaft (210).

(b)

Install idler gear assembly (190) and spacer (180) in gearbox housing (380).

(c)

Install idler shaft (210) with packings (200, 220) through the gearbox housing (380) and through idler gear assembly (190) and spacer (180).

(d)

Install bolt (230) through idler shaft (210) and assembled parts. Install washer (20) and nut (160). NOTE:

The air-oil separator may have to be lifted up to allow for installation of the pinion gear.

(e)

Install packing (50) on transfer tube assembly (40).

(f)

Install high speed pinion gear assembly (140) in gearbox housing (380). Install oil jets in gearbox housing. (See Figure 707A, Sheet 2) Refer to 49-2645 except as follows: WARNING:

(g)

USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT, IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN

1

Apply lubricant MIL-PRF-7808 or equivalent to packings (149, 150).

2

Put packings (140, 150) on jet (130)

3

Install oil jet (130) with packings (140, 150) into gearbox housing.

4

Secure the oil jet into the gearbox housing boss with retainer (160).

Install transfer tube assembly (40) and bearing carrier (30) in gearbox housing

UP200456

(380). (h)

Install washers (20) and bolts (10). Tighten bolts (10) to a torque value of 50 in-lb (5,7 Nm).

(i)

Install packing (90), plug (80), washer (70) and bolt (60) on gearbox housing (380).

49-26-49


Page 747 Feb 28/05


Hone well


~lm KEY TO FIGURE 707A (SHEET 1)

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 140.

UP200456

.

BOLT (IPC FIG. 19A) WASHER BEARING CARRIER TRANSFER TUBE ASSY PACKING BOLT WASHER PLUG PACKING TRANSFER TUBE PACKING HS PINION GEAR ASSY A.

(13)

150. PACKING 160. NUT 170. BOLT 180. SPACER 190. IDLER GEARASSY 200. PACKING 210. IDLER SHAFT 220. PACKING 230. BOLT 360. COVER 370. PACKING 380. GEARBOX HOUSING

(J)

Install packing (370), cover (360), washer (20) and bolt (170).

(k)

Install packing (110) and transfer tube (100) on gearbox housing (380).

49-26-49 Copying, use or disclosureof information on this pageis subjectto proprietaryrestrictions

Page 748 Feb 28/05


Hone vell


KEY TO FIGURE 707A (SHEET 2)

UP200456

130. OIL JET 140. PACKING (IPC FIG. 33A)

150. 160.

PACKING RETAINER (IPC FIG. 33A)


Page 749 Feb 28/05

Hone vell



. ~ "~~150 ~ 130 140 160

A X3800504PL221

(Post

SB49-7598)Install Oil Jets (Gearbox Part No.3863136)

UP200456

(Code B) Figure 707A (Sheet 2)


Page 750 Feb 28/05


Honeywell


UP200456



Page 751 Feb 28/05

Hone~vell



200

,/~8o90\ /~ 65 6O\ 30

\ .

/->

"10

~

_/

~~ ASSEMBLY

X3800504AY222

UP200456

Install the GeneratorGearAssemblyand Adapter(GearboxPart No. 3863019) (CodeA) Figure708


Page752 Feb 28/05


Honeywell 4.

A.

(14)


(Part No. 3863019) Install generator gear assembly and adapter. (Refer to Figure 708, 708A, and 708B.)

(a)

(Pre 49-6940) Install tetra seal (110) in rotor seal (100). Install rotor seal (100) on shaft of generator gear assembly (150).

(b)

(Post 49-6940) Install shaft spacer (135A) and rotor seal (100A) on generator gear assembly (150). (Refer to Figure 708A.)

CAUTION:

Rotor seal (100B) is packed in engine oil. Use a lint-free cloth soaked in isopropyl alcohol to clean the etched face of the rotor seal (100B). Do not touch the etched face with anything other than a clean lint-free cloth.

NOTE:

(c)

TAKE CARE TO AVOID CONTAMINATING THE ETCHED SURFACE OF THE ROTOR SEAL (100B).

(Post SB 49-7760) Lubricate packing per MIL-C-11796 (Braycote 248) or equivalent. Assemble rotor seal (100B) and drive ring (100C) with packing (IOOD).

NOTE:

Make sure the two tangs on the rotor seal (100B) engage the two slots on the rear flange of the drive ring (100C).

(d)

Install assembled rotor seal and drive ring on generator gear assembly with etched surface of rotor seal (100B) facing forward.

(e)

(Post SB 49-6840/7660) Install nut locking tab (220) and nut (210) on generator gear assembly (150).

(f)

(Post SB 49-6940/7660) Tighten nut (210) with spanner wrench (2024465-1) to torque value of 475 to 525 in-lb (53,7 to 59,3 Nm). Bend tab of nut locking tab (220) over one of the flats of nut (210).

(g)

Install generator gear assembly (150).

(h)

Install packing (70) in generator adapter (80).

(i)

Install generator adapter (80) with packing (90) in gear box housing (200) and secure with Hi-torque screws (85).

(J)

(Pre SB 49-6805) Install flanged seal assembly (60) in generator adapter (80). Attach in place with washers (50) and bolts (40). Tighten bolts (40) to a torque of 50 in-lb (5,7 Nm).

(k)

(Post SB 49-6805/7660) Determine shims (65) required to set rotor seal (100) or (100B) operating height (Dimension A). (Refer to Figure 708B.) 1

Use a depth micrometer to measure from seal mounting flange surface of generator adapter (80) to polished portion of rotor seal face (100) or (100B). This measurement must be taken with shaft of generator gear assembly (150) pushed aft. Record Dimension A.

UP200456

Dimension A =

inch (mm).


Page 753 Feb 28/05


Honeywell .

A.

(14)

(k)

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] _2

Calculate shim thickness (65) required for rotor seal (100) or (100B) to set operating height at maximum. Subtract maximum seal cavity height (Dimension A) from 0.547 inch (13,89 mm). Rotor seal shim thickness = 0.547 inch (13,89 mm) - Dimension A = inch (mm) shims. NOTE:

The thickness may be rounded down to nearest 0.005 inch (0,13 mm) increment.

Select shims (65) equal to number calculated in Step (14)(k)(2) within 0.005 inch (0,13 mm). 4

Install flanged seal assembly (60) and shims (65) in generator adapter (80). Attach in place with washers (50) and bolts (40). Tighten bolts (40) to torque value of 50 in-lb (5,7 Nm).

(i)

Install generator cover pad (30) on gearbox housing (200). Attach in place with washers (20) and nuts (10).

(m)

Install spring washer (120) in gearbox housing (200).

(n)

Install clutch assembly in gearbox housing (200) with splined end of shaft facing out of gearbox housing (200).

(o)

Install packing (40) on starter cover (30).

(p)

Install starter cover (30) on gearbox housing (200). Attach in place with washers (20) and bolts (10, 15).

~KEY 10. 10. 15. 20. 20. 30.

UP200456

30. 40. 40. 50. 60. 65. 70. 80.

NUT(IPC FIG. 17) BOLT (IPC FIG. 18) BOLT WASHER (IPL FIG. 17) WASHER (IPC FIG. 18) GENERATORCOVER PAD (IPC FIG. 17) STARTERCOVER (IPC FIG. 18) BOLT (IPC FIG. 17) PACKING (IPC FIG. 18) WASHER FLANGEDSEALASSY SHIM (POST SB 49-6805/-7660) PACKING GENERATOR ADAPTER

TO FIGURE 708 85. 90. 100. 100A. 100B. 100C. 100D. 110. 120. 135A. 150. 200. 210.

SCREW PACKING ROTOR SEAL ROTOR SEAL (POST SB 49-6940) ROTOR SEAL (POST SB 49-7660) DRIVE RING (POST 49-7660) PACKING (POST SB 49-7660) TETRA SEAL SPRING WASHER (IPC FIG. 18) SPACER (POST SB 49-6940) GENERATOR GEAR ASSY GEARBOX HOUSING RETAINING NUT (POST SB 49-6940/-7660) 220. LOCKING TAB (POST SB 49-6940/-7660)


Page 754 Feb 28/05


Hone~vell


UP200456



Page 755 Feb 28/05


Hone vell


SEALROTORPART MARKING THISSIDE

100A

200

\

/

150

\ 135A X3800504AY182

100A. 135A.

ROTOR SEAL (IPC, FIG. 17) SPACER

150. 210. 220.

GEARSHAFT RETAINING NUT LOCKING TAB

UP200456

(Pre SB 49-7660) Assemble the Generator Gear Assembly Figure 708A


Page 756 Feb 28/05

Hone~vell



i

UP200456



Page 757 Feb 28/05


Hone) vell


GEARPUSHEDAFT

X3800504AY192

80. 100.

GENERATOR ADAPTER ROTOR SEAL

120. 130.

BEARING GEARSHAFT

UP200456

(Post SB 49-6940/-7760) Gearbox Assembly Shim Calculations Figure 708B


Page 758 Feb 28/05


Hone) well


UP200456



Page 759 Feb 28/05


Honeywell


/

180

oo:O,Z 50

40 30 2O

10

\

J"

~

~

1,0

l

,,

i~~'~. [,.,.."

I

CLUTCH ASSEMBLY

4O

10 X3800504AY227

UP200456

(Post SB 49-7660) Install the Generator Gear Assembly and Adapter (Gearbox Part No. 3863136) (Code B) Figure 708C


Page 760 Feb 28/05


Honeywell 4.

A.

(15)


(Pre SB 49-6805) (Post SB 49-6940) (Part No. 3863136) Install generator gear assembly and adapter. (Refer to Figure 708C.) (a)

(Pre SB 49-6940) Install tetra seal (110) in rotor seal (100A). Install rotor seal (100A) on shaft of generator gear assembly (150). (Post SB 49-6940) Install spacer (105) and rotor seal (100B) on shaft of generator gear assembly (150). (Refer to Figure 708D.) 1

Install nut locking tab (200) and nut (190) on the generator gear assembly (150).

2

Tighten nut (190) with spanner wrench (2024465-1) to a torque value of 475 to 525 in-lb (53,7 to 59,3 Nm). Bend a tab of the locking tab (200) over one of the flats on nut (190).

(b)


(c)

Install packing (70) in generator adapter (50). NOTE_:

Make sure that anti-rotation pin and groove are aligned forward and aft on outer bearing races.

(d)

Install generator adapter (50) with packing (70) in gearbox housing (180) and secure with hi-torque screws (75).

(e)

Install retaining ring (80) in generator adapter (50) with packing (40), seal assy (30), and retaining ring (10). NOTE:

Make sure that the seal assembly (30) is pushed forward against the retaining ring (10).

~KEY

UP200456

10. RETAINING RING (IPC FIG. 17A) 10. BOLT (IPC FIG. 18A) 20. SHIM (IPC FIG. 17A) (POST SB 49-6805) 20. WASHER (IPC FIG. 18A) 30. SEALASSY (IPC FIG. 17A) 30. STARTERCOVER (IPC FIG. 18A) 40. PACKING (IPC FIG. 17A) 40. PACKING(IPC FIG. 18A) 50. GENERATORADAPTOR (IPC FIG. 17A) 70. PACKING 75. SCREW 80. RETAINING RING 90. SHIMS (POST SB 49-6805/-7660)

TO FIGURE 708C 100A. 100B. 100C. 100D. 100E. 105. 110. 150. 170. 180. 180. 190.

ROTOR SEAL ROTOR SEAL (POST SB 49-6940) ROTOR SEAL (POST SB 49-7660) DRIVE RING (POST SB 49-7660) PACKING (POST 49-7660) SPACER (POST SB 49-6940) TETRA SEAL GENERATOR GEAR ASSY SPACER (IPC FIG. 18A) GEARBOX (IPC FIG. 18A) HOUSING SPRING WASHER (IPC FIG. 17A) RETAINING NUT (POST SB 49-6940/-7660) (POST SB 49-6940/-7660) 200. LOCKING TAB (POST SB 49-6940/-7660)

49-26-49 Copying,useor disclosureof informationon thispageis subjectto proprietaryrestrictions

Page 761 Feb 28/05


Honeywell 4.

A.

(15)


(f)

Install spring washer (180) and spacer (170) in gearbox housing (180).

(g)

Install clutch assembly in gearbox housing with splined end of shaft facing out of gearbox housing (180).

(h)


(i)

Install starter cover (30) on gearbox housing (180). Attach in place with washers (20) and bolts (10).

200

100~

SEAL ROTORPART MARKINGTHIS SIDE

150

o/ \ 105 X3800504AY173

100B.

ROTOR SEAL (IPL, FIGURE 17A) 105. SPACER 150. GEARSHAFT

190. RETAINING NUT 200. LOCKING TAB

UP200456

Assemble the Generator Gear Assembly (Post SB 49-6940/-7660) Figure 708D (Sheet 1)


Page 762 Feb 28/05

Hone~vell



UP200456



Page 763 Feb 28/05

Honeywell



DIM_ B -

E~

X3800504SB198

UP200456

Measuring Dimension B Figure 708D (Sheet 2)


Page 764 Feb 28/05

Honeywell



UP200456



Page 765 Feb 28/05

Honeywell



D,M.C PUSH GEARSHAFT

JL X3800504SB199

10. RETAININGRING

30. SEAL

UP200456

Measuring Dimension C Figure 708D (Sheet 3)


Page 766 Feb 28/05

,Hone3~vell



UP200456



Page 767 Feb 28/05


Hone~well

20


40

80

"'i SEENOTE NOTE: MEASUREDIM.X BEFORE SHIM(20)IS INSTALLED

IOOA

~

"" ~ !

X3800504AY193

UP200456

Gearbox Assembly Shim Calculations Figure 708E


Page 768 Feb 28/05


HoneTwell 4.

A.

(16)


(Post SB 49-6805) (Pre SB 49-6940) (Part No. 3863136) Install generator gear assembly and adapter. (Refer to Figure 708C and 708E.) NOTE: (a)

Check gearshaft of generator gear assembly (150) to make sure antirotation pin is correctly engaged. Measure gearshaft (150) end play as follows. !

Install generator gear assembly (150) in gearbox housing (180). (Refer to Figure 708C.)

2

Install generator adapter (50) with retaining ring (80) and packing (70) on gearbox housing (180) to determine gearshaft (150) axial travel.

3

Mount a dial indicator across the adapter (50) flange of gearshaft (150). Push and pull on the gearshaft (150) through the full range of axial travel and record the axial play. (Record as Dimension W.) (Refer to Figure 708E.) Dimension W =

4

inch (mm).

Remove generator adapter (50), retaining ring (80) and packing (70) and determine shims (90) required to reduce the gearshaft (150) maximum axial travel, Dimension W, to 0.006 to 0.016 inch (0,15 to 0,41 mm). The shims (90) are installed between the gear bearing (120) and the retainer ring (80). Actual shims required = Dimension W - 0.006 to 0.016 inch (0,15 to 0,41 mm) = inch (mm). NOTE:

(b)

Install tetraseal (110) and seal rotor (100A) on the gearshaft (150).

(c)

Measure the rotor seal drop dimension from the gearshaft (150) to the polished face of the rotor seal (100A). Record as Dimension Y. Dimension Y =

~KEY

UP200456

10. 20. 30. 40. 50. 80.

Do not use shims thinner than 0.010 inch (0,25 mm) next to the bearing.

RETAINING RING SHIM SEALASSY PACKING GENERATOR ADAPTOR RETAINING RING

inch (mm).

TO FIGURE 708E 90. 100A. 110. 120. 150.

SHIM ROTOR SEAL TETRASEAL BEARING GEARSHAFT

49-26-49


Page 769 Feb 28/05

Hone well



CAUTION:

4.

A.

(16)

(d)

USE CAUTION WHEN YOU INSTALL SEAL ASSEMBLY (30). MAKE SURE THAT PACKING (40) IS NOT DAMAGED DURING ASSEMBLY.

Install packing (40), seal assembly (30) and retaining rings (10, 80) into adapter (50), insert shims (90) aft of retaining ring (80) and install adapter (50) over gearshaft of generator gear assembly (150) with screws (75) (refer to Figure 708C). NOTE:

Make sure that seal assembly (30) is forward against retaining ring

(lO). Check gearshaft of generator gear assembly(150) to make sure anti-rotation pin is correctly engaged. (e)

Use a depth micrometer with gearshaft of generator gear assembly (150) pushed aft (towards APU tailpipe) to measure the seal assembly (30) drop dimension from end of gearshaft of generator gear assembly (150) to the back of the seal assembly (30). Record as Dimension X. (Refer to Figure 708E.) Dimension X =

inch (ram).

(f)

Dimension X should be in the range of 0.240 +_.0.013 inch (6,10 ___0,33 mm). A reading greater than this indicates aft bearing anti-rotation pin may be disengaged.

(g)

If measurement indicates anti-rotation pin is improperly engaged remove the generator gear assembly (150). Make sure the anti-rotation pin is engaged.

(h)

Install generator gear assembly (150), rotor seal (100A) and retainer rings (10, 80) (refer to Figure 708C).

(i)

Repeat measurement of drop Dimension X to make sure anti-rotation pin is engaged into slot on the end face of the bearing.

(J)

Calculate required shims (20) as follows: Shim stack required = DIM. Y - [DIM. X + 0.587 inch (14,91 mm)] = _ _ shims. NOTE:

CAUTION: NOTE:

UP200456

(k)

This number may be rounded up to nearest 0.005 inch (0,13 mm) increment. TAKE CARE TO AVOID CONTAMINATING THE ETCHED SURFACE OF THE ROTOR SEAL (100C). Rotor seal (100C) is packed in engine oil. Use a lint-free cloth soaked in isopropyl alcohol to clean the etched face of the rotor seal (100C). Do not touch the etched face with anything other than a clean lint-free cloth.

(Post SB 49-7760) Lubricate packing per MiI-C-11796 (Braycote 248) or equivalent. Assemble rotor seal (100C) and drive ring (100D) with packing (100E). (Refer to Figure 708C.)

49-26-49


Page 770 Feb 28/05


Hone) well

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] NOTE: 1

2

Make sure the two tangs on the rotor seal (100C) engage the two slots on the rear flange of the drive ring (100D). Install assembled rotor seal and drive ring on generator gear assembly (150) with etched surface of rotor seal (100C) facing forward. Install nut locking tab (200) and nut (190) on generator gear assembly

(150). 3

Tighten nut (190) with spanner wrench (2024465-1) to torque value of 475 to 525 in-lb (53,7 to 59,3 Nm). Bend tab of nut locking (200) over one of the flats of nut (190).

4


5

Install packing (70) in generator adapter (50).

6

Determine shims (90) required to set rotor seal (100C) to maximum operating height. a

Measure Dimension B from end of gearshaft to face of rotor seal (100C). (Refer to Figure 708D, Sheet 2.) Record Dimension B. Dimension B = ~

b

Install retaining ring (10) and seal assembly (30). (Refer to Figure 708E.)

c

With gearshaft pushed in the direction of arrow, measure Dimension C from end of gearshaft to back of seal housing. (Refer to Figure 708D, Sheet 3.) Record Dimension C. Dimension C = ~

UP200456

inch (mm).

inch (ram).

d

Calculate Dimension B - Dimension C - 0.587 inch (14,91 mm) = thickness of shims to achieve maximum rotor seal operating height.

e

Select shims (20) equal to number calculated in Step ~ within 0.005 inch (0,13 mm).

(i)

Remove retaining ring (10) and install required shims (20) and retaining ring (10). Make sure seal assembly (30) is firmly seated against the shims/retainer.

(m)

Install spring washer (180) and spacer (170) in gearbox housing (180). (Refer to Figure 708C.)

(n)

Install clutch assembly in gearbox housing with splined end of shaft facing out of gearbox housing (180).

(o)


(p)

Install starter cover (30) on gearbox housing (180). Attach in place with washers (20) and bolts (10).


Page 771 Feb 28/05

Hone vell



10A

Q

20

\ SO 130 330

\ 230

~t~tf'~"~ ~

~ ~ - " - 210 4..,,___200

/ 150

| 1SO 165

'~

4u"~%

/ 140

; 110 170

/ 100

1SO X3800504PL18

UP200456

Install the Plugs and Sight Glass Housing (Gearbox Part No. 3863019) (Code A) Figure 709


Page 772 Feb 28/05

Honeywell 4.

A.

(17)



(Part No. 3863019) Install the plugs and sight glass housing. (Refer to Figure 709.) (a)

Install plug (300), magnetic plug (280) with packings (290, 310) in gearbox housing (330). Tighten magnetic drain plug to a torque value of 68 in-lb (7,7 Nm).

(b)

Install plug (170) with packing (180) in gearbox housing (330). Tighten plug to a torque value of 68 in-lb (7,7 Nm).

(c)

Install oil tube assembly (240) with packing (260) and filter (250) in gearbox housing (330). Install retaining ring (230).

(d)

Install sump cover (210) with packing (220) in gearbox housing (330). Attach in place with washers (200) and bolts (190). Tighten bolts to a torque value of 25 in-lb (2,8 Nm).

(e)

Install scupper oil fill housing (90) with packing (80) on gearbox housing (330). Attach in place with washers (70) and bolts (60). Tighten bolts (60) to a torque value of 25 in-lb (2,8 Nm).

(f)

Install packing (50) on sight glass (40).

(g)

Install sight glass (40) on gearbox housing (330). Attach in place with washers (30) and bolts (20). Tighten bolt to a torque value of 25 in-lb (2,8 Nm).


UP200456

10. 15. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160.

OIL FILLCAP (IPC FIG. 16) RING BOLT WASHER SIGHT GLASS PACKING BOLT WASHER PACKING SCUPPER OIL FILL HOUSING SCREW OIL COVER PLATE PACKING PACKING BOLT WASHER TEMP SENSOR ADAPTER

165. 170. 180. 190. 200. 210. 220. 230. 240. 250. 260. 280. 290. 300. 310. 320. 330.

PACKING PLUG PACKING BOLT WASHER SUMPCOVER PACKING RETAINING RING OIL TUBE ASSY FILTER PACKING MAGNETIC PLUG PACKING PLUG PACKING ID PLATE GEARBOX HOUSING

49-26-49


Page 773 Feb 28/05

Honeywell 4.

A.

(17)



(h)

Install ring (15) and oil fill cap (10).

(i)

Install identification plate (320) if necessary.

(J)

Install temperature sensor adapter (160) with packing (165). Attach in place with washers (150) and bolts (140).

(k)

Install packings (120, 130) and oil cover plate (110) with screws (100).

UP200456

Check Point 20:



Page 774 Feb 28/05

Hone~mtell



UP200456



Page 775 Feb 28/05


Hone~vell


10

@ 4O

50

\

80<

20' 160 60 70

300

~ o

270

26o ~~p/

/

"

290 280

~

t

/ f

/ f

t

i

!

.%

%

oo

~

200 ~

/4 190

I~I170 180

210

~

X3800504PL19

UP200456

Install the Plugs and Sight Glass Housing (Gearbox Part No. 3863136) (Code B) Figure 709A


Page 776 Feb 28/05

Honeywell 4.

A.

(18)



(Part No. 3863136) Install the plugs and sight glass housing. (Refer to Figure 709A.) (a)

Install magnetic drain plug assembly (280) with packing (290) in gearbox housing (300). Tighten magnetic drain plug to a torque value of 68 in-lb (7,7 Nm).

(b)

Install metal plug (210) with packing (220) in gearbox housing (300). Tighten metal plug to a torque value of 68 in-lb (7,7 Nm).

(c)

Install filter screen (270) in gearbox housing (300). Install retaining ring (260).

(d)

Install sump cover (240) with packing (250) in gearbox housing (300). Attach in place with retaining ring (230).

(e)

Install temperature sensor adapter (190) with packing (200) on gearbox housing (300). Attach in place with washers (180) and bolts (170). Tighten bolts to a torque value of 25 in-lb (2,8 Nm).

(f)

Install packings (150, 160) and oil cover plate (140) on gearbox housing (300) with screws (130).

(g)

Install scupper oil fill housing (90) with packing (80) on gearbox housing (300). Attach in place with washers (70) and bolts (60). Tighten bolt to a torque value of 25 in-lb (2,8 Nm).

~1~ KEY TO FIGURE 709A

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 130. 140. 150. 160. 170.

OILFILLCAP (IPC FIG. 16A) BOLT WASHER SIGHT GLASS PACKING BOLT WASHER PACKING SCUPPER OIL FILL HOUSING SCREW OILCOVER PLATE PACKING PACKING BOLT

180. 190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300.

WASHER TEMP SENSOR ADAPTER PACKING METAL PLUG PACKING RETAINING RING SUMPCOVER PACKING RETAINING RING FILTER SCREEN MAGNETIC DRAIN PLUG PACKING GEARBOX HOUSING


Page 777 Feb 28/05

HoneTwell .

A.

(18)



(h)

Install packing (50) and sight glass (40). Attach in place with washers (30) and bolts (20).

(i)

Install oil fill cap (10).

UP200456

Check Point 20A:



Page 778 Feb 28/05

Honeywell



UP200456



Page 779 Feb 28/05


Hone) well 4.

go


Assemble Turbine Rotor Balance Assembly (1)

Assemble the turbine rotor seal and coupling half. (Refer to Figure 710.) WARNING:

USE THE CORRECT PERSONAL PROTECTION. DRY ICE WILL CAUSE BURNS. CARBON DIOXIDE REMOVES THE OXYGEN FROM THE AIR. THIS CAN CAUSE ASPHYXIATION.

(a)

Put shaft coupling half (170) into dry ice for 10 minutes.

(b)

Measure thickness of 833091-200 turbine balance bearing and record as dimension TD. This will be used later during shaft stretch calculation. Measure to nearest 0.0001 inch (0,003 mm) WARNING:


(c)

Put 833091-200 turbine balance bearing and turbine rotor seal (130) into an oven set at 350F (177C) for 10 minutes.

(d)

Apply dry lubricant (Molykote 321 -R) to areas shown.

(e)

Install 833091-200 turbine balance bearing and turbine rotor seal (130) on shaft coupling half (170). If necessary, use 833096-2 bearing and rotor seal installer to seat balance bearing and turbine rotor seal.

130

BALANCE BEARING

=~

kk~

DIM.TD

/

170

170

\

~" f f ,~'~J

fJ.~

; 1 _ /f / .f / /f

DRYLUBE /////I /////1 '/////1

"/////1 "/ // // // // ~ /I

X3800278AY267

130. TURBINE ROTOR SEAL (IPC, FIG. 30)

170. SHAFT COUPLING HALF

UP200456

Assembly of the Turbine Rotor Seal and Coupling Half Figure 710


Page 780 Feb 28/05

Honeywell



UP200456



Page 781 Feb 28/05

Honeywell



----~SHAFT STRETCHNUT

E \ \ \ \ \ \ \ \ \ \ X \

-j

BALANCEARBOR

SHAFT STRECH

LUBRICANT . ~/APPLY BEFODRY RA ESS EMBLY '

TURBINEROTORSEAL ~

~

m

~

- j T U RBINT~III~LDCOMPRESSOR HOLDINGFIXTURE

m

[

1

X3800504AY44

UP200456

Installation of the Coupling Half Figure 711


Page 782 Feb 28/05


Hone vell 4.

B.

(2)


Install the coupling half. (Refer to Figure 711 .) (a)

Install the turbine rotor into 833093-1 turbine and compressor holding fixture.

(b)

Refer to CLEANING and clean the curvic area of the turbine rotor and 833158-1 turbine rotor balance arbor.

(c)

Apply dry lubricant (Molykote 321-R) to the turbine rotor surface as shown.

WARNING:

(d)

Heat the coupling half with the balance bearing and turbine seal rotor to a temperature of 350F (177C) for 10 minutes.

(e)

Install the assembled coupling half on the turbine rotor.

(f)

Install 833158-1 turbine rotor balance arbor and make sure the coupling is aligned.

(g)

Install 834347-1 shaft stretch nut and 834155-1 shaft stretching spacer on the turbine rotor shaft.

(h)

Install 833094-1 shaft stretch fixture on the turbine rotor shaft.

(i)

Apply 1000 psig (6900 kPa) tool pressure to seat the coupling half on the turbine rotor.

(j)

Reduce the tool pressure to zero and remove 833094-1 shaft stretch fixture.

(k)

Loosen 834347-1 shaft stretch nut then torque to 50 in-lb (5,7 Nm).

(I)

Use 834348-1 micrometer bridge and measure the free length of the shaft. Write this measurement.

CAUTION:

UP200456

USE THE CORRECT PERSONAL PROTECTION. HEATED PARTS WILL CAUSE BURNS.

DO NOT EXCEED A RAM PRESSURE OF 3900 PSIG (26910 KPA).

(m)

Install 833094-1 shaft stretching fixture and apply 3750 to 3850 psig (25875 to 26565 kPa) of shaft stretch. Hand tighten 834347-1 shaft stretch nut.

(n)

Measure and write the stretch shaft length.

49-26-49


Page 783 Feb 28/05

Honeywell 4.

B.

(2)

(o)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Use the formula that follows to make sure shaft stretch is correct. Free Length Stretched Length

in. or in. or

mm. mm. =

The necessary stretch of 0.058 to 0.062 in (1,47 to 1,57 mm). NOTE:

If the stretch measurement is incorrect, repeat steps (m) through (o) and adjust the ram pressure accordingly.

UP200456

Check Point 30:

Make sure the shaft stretch is 0.058 to 0.062 inch (1,47 to 1,57 mm).

(P)

Write the ram pressure which provides the proper shaft stretch.

(q)

Release pressure and remove 833094-1 shaft stretching fixture.


Page 784 Feb 28/05

Honeywell



UP200456



Page 785 Feb 28/05

Hone vell 4.

B.



Do a runout check of the turbine rotor assembly. (Refer to Figure 712.)

(3)

(a)

Set turbine rotor assembly on 833097-1 runout checking fixture.

(b)

Measure runout at surface A. Runout must not be more than 0.0004 inch (0,0102 mm).

(c)

Measure runout at surface B. Runout must not be more than 0.0004 inch (0,0102 mm).

(d)

Measure runout at surface C. Runout must not be more than 0.0015 inch (0,0381 mm).

(e)

Rotate parts as necessary to bring the runout in limits NOTE:

Make sure runout are in limits before balancing the turbine rotor assembly.

Check Point 40:

Make sure runout measurements are in limits.

TURBINE ROTOR AS EMBLY SURFACE B

SURFACE A

N \xx\\\\\\\xx\\\',/

SURFACE C

I

RUNOU]" FIXIURE

A3800504AY138

UP200456

Runout Check of the Turbine Rotor Assembly Figure 712


Page 786 Feb 28/05

Hone vell



DIM.B ---b PLANEM-,..~.I

I

PLANEN ~ DIM.C----~

DIAA

W~I I I ~ " - " ' ' - - / T x / / / / , ~

\&\\\\\\\\\\\\\\e

~.

i

~rT-~//./tLE_~\\\\\\\\'Xl

7' I

;

~~ / i N~_~.~.J

DIM. D

SHAFTSTRETCHNUT

BALANCEA R B O R

S 1 AND2

/ OTES 1 AND2

TURBINE ROTOR ASSEMBLY

" ~ I~-'D M. E X3800504AY66

NOTE

.

2.

Material can be removed from these areas for balancing. Areas where material is removed must have a surface roughness of 63 microinches (1,60 micrometers) or better. REPAIRED LIMITS

UP200456

DIA A DIM. B DIM. C DIM. D DIM. E DIM. F

4.820 in. (122,43 mm) max. 0.650 in. (16,51 mm) max. 1.110 in. (28,19 mm) max. 0.11 in. (2,79 mm) min. 0.080 in. (2,03 mm) max. 0.120 in. (3,05 mm) max.

Balance of the Turbine Rotor Assembly Figure 713 (Sheet I of 2)


Page 787 Feb 28/05

HoneTwell



\

SMOOTHTRANSITIONAL RADIU80050(~MM) MIN

/ \

DIM. F ~

"="--

VIEW A- A

DIM. F - ~ D =

NOTE:

4-~

6,94 MM 4.596 IN. (116,74 MM)

A3800278AY296

All areas where material has been removed for balancing must blend and have a surface finish of 63 microinches (1,60 micrometers) or better. Resultant fillet must have a radius of 0.050 inch (1,27 mm).

UP200456

Balance of the Turbine Rotor Assembly Figure 713 (Sheet 2)


Page 788 Feb 28/05

Honeywell

UP200456

4.

B.

(4)



Balance the turbine rotor assembly. (Refer to Figure 713.)

(a)

Install turbine rotor assembly on balancing machine (Model HBS-35), or equivalent with the supports set at the same locations used to measure runout (Refer to Figure 712). Index mark the balance arbor with respect to the turbine assembly.

(b)

Apply controlled shop air to the turbine rotor vanes or belt drive to the balance arbor to get the necessary balance speed of 1800 to 2000 rpm.

(c)

Balance the turbine rotor assembly to an accuracy of not less than 0.005 ounce-inch (0,0353 Nm) in Plane N and 0.012 ounce-inch (0,0847 Nm) in Plane M. (Refer to Figure 712 and 713.)

(d)

Write the balance results.

(e)

Install the turbine rotor assembly into 833093-1 turbine and compressor holding fixture (Figure 711).

(f)

Install 833094-1 shaft stretching fixture and apply the same pressure applied in ASSEMBLY, paragraph 4.B.(2)(m) and loosen 834347-1 shaft stretch nut.

(g)

Release the pressure from 833094-1 shaft stretching fixture.

(h)

Use the same amount of ram pressure applied in 4.B.(2)(m) to restretch the tie shaft.

(i)

Do steps (a) through (d) again. Make sure that the index marks are aligned.

(J)

If the difference between the two measurements (amplitude and angle) in the either plane is greater than the first balance measurement of step (d), unstretch the tie shaft, clean the curvics, and examine the balance set-up.

(k)

Do steps (d) through (j) again until balance measurements repeat.

(D

Do steps (e) and (f).

(m)

Turn the balance arbor and make sure the index marks are 180 degrees apart.

(n)

Do step (h).

(o)

Do steps (b) through (d).


Page 789 Feb 28/05

Honeywell 4.

B.

(4)

(p)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Use the balancing machine calculator and find the residual tooling imbalance. Check Point 50:

(q)

If the balance measurements are correct, use Dykem Hi-Spot Blue No. 107 to make alignment marks at each mating surface.

CAUTION:

UP200456

(r)

Make sure the balance measurements are in limits.

DO NOT EXCEED A RAM PRESSURE OF 3900 PSIG (26910 KPA).

Apply pressure to 833094-1 shaft stretch fixture and loosen 834347-1 shaft stretch nut. Remove shaft stretch nut and balance arbor from the turbine rotor assembly.


Page 790 Feb 28/05

Hone~vell



UP200456



Page 791 Feb 28/05

Honeywell



27O

DRYLUBRICANT X3800504AY223

UP200456

20.

SPLINED SHAFT (IPC, FIG. 25)

270. 370.

COUPLING COMPRESSOR SEAL ROTOR

Installation of the Balance Bearing Compressor Rotor Seal and Coupling Figure 714


Page 792 Feb 28/05

Hone3 vell .

C.



Rotating Group Assembly (1)

Install the balance bearing, compressor seal rotor and coupling onto the splined shaft (20). (Refer to Figure 714.) WARNING:

(a)

Apply a coat of lubricant (Molykote 321) in the area shown and put splined shaft (20) into dry ice for 10 minutes.

(b)

Measure thickness of 833091-201 compressor balance bearing and record as dimension CD. This will be used later during shaft stretch calculation. Measure to nearest 0.0001 inch (0,003 mm).

WARNING:

UP200456



(c)

Put 833091-201 compressor balance bearing, coupling (270) and compressor seal rotor (370) into an oven set at 250 to 300F (121 to 149C) for 10 minutes.

(d)

Use 833096-1 bearing and rotor installer and push the 833091-201 compressor balance bearing, compressor seal rotor (370) and coupling (270) on splined shaft (20).


Page 793 Feb 28/05


Honeywell


20

240,

TURBINE ROTOR ASSEMBLY

\

-TURBINE AND COMPRESSOR HOLDINGFIXTURE

X3800504AY174

UP200456

Assembly of the Rotating Group Assembly Figure 715


Page 794 Feb 28/05

Honeywell 4.

C.

(2)



Assemble the rotating group. (Refer to Figure 715.) CAUTION: (a)

Set turbine rotor assembly onto 833093-1 turbine and compressor holding fixture. NOTE:

(b)

Make sure parts with the etch mark are positioned so etch marks are 180 degrees apart.

Clean curvic couplings. Install compressor rotor (50) on the turbine rotor assembly.

WARNING:

(c)

KEEP THE PROTECTIVE SLEEVE ON THE TURBINE ROTOR ASSEMBLY SHAFT, UNTIL READY FOR INSTALLATION.


(Pre SB 49-A6653) Put compressor shaft (230) into an oven set at 250 to 300F (121 to 149C) for 10 minutes.

WARNING:


(d)

(Pre SB 49-A6653) Put turbine shaft support (60, 240, 260) into dry ice for 10 minutes.

(e)

(Pre SB 49-A6653) Install turbine shaft support (240) into compressor shaft (230).

(f)

(Pre SB 49-A6653) Install retaining ring (250).

(g)

(Pre SB 49-A6653) Install turbine shaft support (60, 260), into compressor shaft (230).

~KEY

UP200456

10. ROUND NUT (IPC, FIG. 25) 20. SPLINED SHAFT 50. COMPRESSOR ROTOR (IPC FIG. 28) 50. COMPRESSOR ROTOR (IPC, FIG. 26)

TO FIGURE 715 60. 230. 230A. 240. 250. 260. 280.

TURBINE SHAFT SUPPORT COMPRESSOR SHAFT COMPRESSOR SHAFT TURBINE SHAFT SUPPORT RETAINING RING TURBINE SHAFT SUPPORT CURVIC SEAL GASKET


Page 795 Feb 28/05

Hone vell

UP200456

4.

C.

(2)



(h)

(Pre SB 49-A6653) Clean curvic couplings and install compressor shaft (230) on turbine rotor assembly.

(i)

(Post SB 49-A6653 and 49-7307) Clean curvic couplings and install curvic seal gasket (280) on compressor shaft (230A). Install compressor shaft (230A) and compressor rotor (50) on turbine rotor assembly.

(j)

Install splined shaft (20) with assembled items.

(k)

Apply lubrication (Liqui-Moly, Brand NV) to the threads of the turbine rotor assembly shaft and round nut (10).

(I)

Install round nut (10) and tighten hand tight.


Page 796 Feb 28/05


HoneTwell


UP200456



Page 797 Feb 28/05

Hone) well



I

AFL*

NOTE: FORAFLAND ASLMEASUREMENT~ TIESHAFTIS STRETCHED USINGTOOLINGTO 3700TO3850P$1G RAMPRESSURE

AFL

A~ L

F

'

I ~

~

i~\

~,, \

Ir

' INSPECTIONPLATEl TABL'&.\'%. * MEASUREMENTSTAKENWHEN USINGTHEMICROMETERBRIDGE

.

A3800278AY589

MICROMETER BRIDGE

UP200456

Shaft Stretch and Calculation Figure 716


Page 798 Feb 28/05

Honeywell 4.

C.

(3)



Rotating group shaft stretch and calculation. (Refer to Figure 716.) (a)

Make sure all curvic connections are properly engaged and are not stacked.

(b)

Tighten round nut to a torque value of 50 in-lb (5,7 Nm).

(c)

Measure and write dimension RFL (Reference Free Length) as shown.

(d)

Install 834348-1 micrometer bridge (1) over rotating group. Measure and write dimension AFL (Assembly Free Length) as shown. Remove micrometer bridge.

(e)

Install 833094-1 shaft stretch fixture on the rotating group.

CAUTION:

DO NOT EXCEED 3900 PSIG (26910 KPA) TOOL PRESSURE.

(f)

Apply a ram pressure of 3750 psig (25875 kPa) to the rotating group and tighten round nut finger-tight. Reduce ram pressure to zero psig and remove 833094-1 shaft stretch fixture.

(g)

Install 834348-1 micrometer bridge over rotating group. Measure and write dimension ASL (Assembly Stretch Length) as shown.

(h)

Calculate tie shaft stretch. FORMULA: AFL inch or ASL inch or = tie shaft stretch.

mm mm

Tie shaft stretch must be 0.058 to 0.062 inch (1,47 to 1,57 mm). Check Point 60:

CAUTION:

UP200456

NOTE:

Make sure the tie shaft stretch measurement is 0.058 to 0.062 inch (1,47 to 1,57 mm).

DO NOT EXCEED 3900 PSIG (26910 KPA) TOOL PRESSURE.

If tie shaft stretch is not in limits, restretch shaft until limits are met.

(i)

Write the final ram pressure used to satisfy the tie shaft stretch limits.

(J)

Measure and write the dimension RSL (Reference Stretch Length) which corresponds to the final ASL dimension.

49-26-49 Copying,use or disclosureof informationon this pageis subject to proprietaryrestrictions

Page 798.1 Feb 28/05



Honeywell 4.

C.

Do a runout and balance check of the rotating group assembly. (Refer to Figure 717.)

(4)

(a)

Install the rotating group assembly on the 833097-1 runout checking fixture, on surfaces A and B.

(b)

Measure runout at locations shown. The maximum permitted runout on both surfaces is 0.002 in. (0,05 mm). NOTE:

(c)

If there is too much runout, turn the part closest to the excessive runout. Do not turn a part more than 3 curvic teeth at a time. If a part is turned more than 90 degrees and runout is still excessive, the part must be replaced.

Install the rotating group assembly on the balancing machine (Model HBS-35 or equivalent) on surfaces A and B.

/ 1002c0,04A I B I

I/1~

SURFACEA

1004 A I

PLANEC SURFACEB A3800278AY109

UP200456

Runout and Balance Check of the Rotating Group Assembly Figure 717


Page 798.2 Feb 28/05

Honeywell 4.

C.

(4)

(d)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Make sure imbalance is not more than 0.026 ounce-inch (184 Nm), for plane C or 0.045 ounce-inch (317,7 Nm) for plane D. NOTE:

(e)

If either plane is found to be out of balance, do not remove metal. Realign parts in relationship to each other to bring the rotating assembly in limits. Do not realign turbine balance assembly parts since these parts have been balanced. If parts are realigned for balance requirement, do step (b) again to make sure that the run outs are still acceptable.

Use Dykem (Hi-Spot Blue No. 107) and make alignment marks at each coupling mating surface for realignment during assembly procedures.

UP200456

Check Point 70:

Make sure runout and balance measurements are in limits and rotating group is marked with dykem. Record serial numbers of turbine and compressor's impellers.

49-26-49 Copying,use or disclosureof information on this page is subjectto proprietaryrestrictions

Page 798.3 Feb 28/05


Hone vell


COMPRESSOR BALANCEBEARING~_....~

.,,.1~~370

10 I

20

TURBINE BALANCEBEARING

270

I

~47fl

80 DETAILA

TURBINEANDCOMPRESSOR HOLDINGFIXTURE

X3800504AY224

UP200456

Disassemble the Rotating Group Assembly Figure 718


Page 798.4 Feb 28/05

Hone) vell 4.

C.

(5)



Disassembly of the rotating group assembly. (Refer to Figure 718.) (a)

Set the rotating group assembly on the 833093-1 turbine and compressor holding fixture.

(b)

Use marking compound (Dykem Hi-Spot Blue) to apply an alignment mark between the staking indent of turbine rotor assembly (80) shaft and splined shaft (20).

(c)

Install 833094-1 shaft stretching fixture and apply the final ram pressure applied to the tie shaft in paragraph 4.C.(3)(i) to turbine rotor assembly (80) tie shaft.

(d)

Removeround nut (10).

(e)

Remove assembled items (20), (370), (270) and 833091-201 compressor balance bearing.

(f)

Use marking compound (Dykem Hi-Spot Blue) to apply an alignment mark to coupling seal assembly (270) and splined shaft (20).

(g)

Removecompressor rotor (50).

(h)

(Pre SB 49-A6653) Remove assembled items (230), (60), (270), (260), and

(25o). (i)

(Post SB 49-A6653) Remove compressor shaft (230A).

(J)

Use marking compound (Dykem Hi-Spot Blue) to apply an alignment mark on shaft of turbine rotor assembly (80) and compressor rotor (50).

~ 10. ROUND NUT (IPC FIG. 25) 20. SPLINEDSHAFT 50. COMPRESSOR ROTOR (IPC, FIG. 28) 50. COMPRESSOR ROTOR (IPC, FIG. 26) 60. TURBINE SHAFT SUPPORT 80. TURBINE ROTORASSY (IPC, FIG. 29)

KEYTO FIGURE 718 130. TURBINE SEAL ROTOR (IPC, FIG. 30) 170. COUPLING HALF (IPC, FIG. 30) 230. COMPRESSOR SHAFT (IPC, FIG. 26) -230A. COMPRESSOR SHAFT 240. TURBINE SHAFT SUPPORT 250. RETAINING RING 260. TURBINE SHAFT SUPPORT 270. COUPLING SEALASSY (IPC FIG 25) 370. COMPRESSOR SEAL ROTOR

UP200456

ITEM NOT ILLUSTRATED

49-26-49 Copying,useor disclosureof informationon this pageis subjectto proprietaryrestrictions

Page 798.5 Feb 28/05

Hone vell

UP200456

4.

C.

(5)



(k)

Remove compressor rotor (50).

O)

Use marking compound (Dykem Hi-Spot Blue) to apply an alignment mark on shaft of turbine rotor assembly (80) and coupling half (170).

(m)

Use 833429-1 coupling puller to remove assembled items (170), and (130) from turbine rotor assembly (80).

(n)

Use 833440-1 bearing removal fixture and remove compressor seal rotor (370), coupling seal assembly (270), and 833091-1 balance bearing from splined shaft (20).

(o)

Use marking compound to apply an alignment mark on the inside diameter of coupling half (170) and turbine seal rotor (130).

(P)

Use 835550-1 bearing and seal rotor removal fixture to remove turbine seal rotor (130) and 833091-200 turbine balance bearing from coupling half (170).


Page 798.6 Feb 28/05

HoneTwell



UP200456



Page 798.7 Feb 28/05

Hone3 well



#;

250 25O

90

-

. , 1 4 0

c

DETAIL A

250

____DIM.BB

I

THRUST X3800278AY3

UP200456

Installation of the Bearing and Spacer Figure 719


Page 798.8 Feb 28/05

Honeywell .

D.



Assemble Turbine and Compressor Assembly (1)

Install the bearing and spacer. (Refer to Figure 719.) (a)

Install turbine bearing carrier assembly (250) on 835586-1 power section build cart.

(b)

Measure thickness of bearing (140) inner race and record as Dimension TB. This will be used later during shaft stretch calculation.

(c)

Install bearing (140) into turbine bearing carrier assembly (250) with bearing thrust as shown. Align anti-rotation pin in turbine bearing carrier assembly (250) with slot in bearing.

(d)

Install 833665-1 micrometer bridge. Measure and write dimension BB. Remove micrometer bridge.

(e)

Install spacer (90) with shoulder face up.

(f)

Install 833665-1 micrometer bridge. Measure from the turbine bearing carrier assembly (250) to shoulder of spacer (90). Write down the result as Dimension A. Remove micrometer bridge.

(g)

Remove spacer (90). Check Point 80:

(h)

Make sure recorded Dimensions A and BB are correct.

Calculate for shims (70, Figure 721 ). FORMULA: Dimension A

Check Point 90:

inch or mm - 0.003 inch or 0,08 mm = necessary thickness of shims _+0.001 (0,03 mm). Make sure calculations for shims (70) are correct. Verify Dim. C.


UP200456

90. SPACER (IPC, FIG. 30) 100. SEAL

140. BEARING 250. TURBINE BEARING CARRIERASSY


Page 798.9 Feb 28/05


Honeywell


170

250

/

130

250

DIM. BB1

170

A3800278AY579

130.

TURBINE SEAL ROTOR (IPC, FIG. 30)

170. SHAFT COUPLING HALF 250. TURBINE BEARING CARRIERASSY

UP200456

Installation of the Shaft Coupling Half and Turbine Seal Rotor Figure 720

49-26-49


Page 798.10 Feb 28/05

Honeywell 4.

D.

(2)



Install shaft coupling half and turbine seal rotor. (Refer to Figure 720.) WARNING:

(a)

USE THE CORRECT PERSONAL PROTECTION. DRY ICE WILL CAUSE BURNS. CARBON DIOXIDE REMOVES THE OXYGEN FROM THE AIR, THIS CAN CAUSE ASPHYXIATION.

Put shaft coupling half (170) in dry ice for 10 minutes.

WARNING:


(b)

Heat turbine seal rotor (130) to 250 to 300 F (121 to 149C) for 10 minutes.

(c)

Use 834157-1 coupling installer fixture to install shaft coupling half (170) on turbine bearing carrier assembly (250).

(d)

Align balance index marks and install turbine seal rotor (130) on shaft coupling half (170). Use 833096-2 bearing and rotor installer to fully seat turbine rotor seal on shaft coupling half.

(e)

Remove spacer (90, Figure 719) from turbine bearing carrier assembly (250, Figure 720).

(f)

Install 833665-1 micrometer bridge. Measure and write dimension BBI. Dimension BB1 must be the same as Dimension BB measured in step 4.D.(1)(c). Remove micrometer bridge. Check Point 100:

(g)

If Dimension BB1 is not the same as Dimension BB, do steps 1through 4 1

Remove turbine seal rotor (130), coupling shaft half (170), and bearing (140, Figure 719) from turbine bearing carrier assembly (250, Figure 720).

2

Look at condition of the anti-rotation pin located in turbine bearing carrier assembly (250).

3

If damage to the anti-rotation pin is found, replace pin (refer to ATA No. 49-26-51 for repair) and assemble the turbine bearing, shaft coupling half (170) and turbine seal rotor (130) in turbine bearing carrier assembly (250). (Refer to step 4.D.(1).) Do step 4.D.(2) again.

m

UP200456

Make sure Dimension BB1 is the same as Dimension BB.

49-26-49 Copying, use or disclosure of informationon this page is subjectto proprietaryrestrictions

Page 798.11 Feb 28/05


Hone vell

UP200456

4.

D.

(2)

(g)

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] 4

If no damage to the anti-rotation pin is found, assemble bearing (140, Figure 719), shaft coupling half (170, Figure 720), and turbine seal rotor (130) in turbine bearing carrier assembly (250). (Refer to step 4.D.(1).) Do step 4.D.(2) again.

49-26-49 Copying,use or disclosure of informationon this page is subjectto proprietaryrestrictions

Page 798.12 Feb 28/05

Hone3~vell



UP200456



Page 798.13 Feb 28/05

Honeywell



10

-,.-,

p

C

100

90

80

J

DIM. C

70

250

_\

t

20. 6o"

!

-"~

,,

,J

.

-

50

\

\

X3800278AY4

UP200456

Assembly of the Turbine Bearing Carrier Assembly Figure 721


Page 798.14 Feb 28/05

Honeywell 4.

D.

(3)



Assemble the turbine bearing carrier assembly. (Refer to Figure 721.) (a)

Install turbine seal assembly (50) on turbine bearing carrier assembly (250). Measure and write Dimension C in 4 locations, 90 degrees apart. Write the location of the measurement. Remove seal assembly.

(b)

(Pre SB 49-6883) Install seal (100) around bearing (140) in the gap formed between the bearing and turbine bearing carrier assembly (250).

(c)

(Pre SB 49-6883) Install spacer (90). (Post SB 49-6883) Install spacer (90A). NOTE:

SB 49-6883 replaces spacer (90) and seal (100) with spacer (90A).

(d)

Install spring tension washer (80).

(e)

Install shims (70) calculated in step 4.D.(1)(g) in turbine bearing carrier assembly (250).

(f)

Install air-oil seal (60) in slot of turbine seal assembly (50).

(g)

Install air-oil seal (40) in slot of compressor seal assembly (30).

(h)

Install two guide pins in turbine seal assembly (50). Install turbine seal assembly on turbine bearing carrier assembly (250) NOTE:

Make sure shims (70) between turbine bearing carrier (250) and turbine seal assembly (50) are not pinched.

~lm KEY TO FIGURE 721 10. 20. 30. 40. 50. 60.

BOLT (IPC, FIG. 30) BEARING CARRIER HEAT SHIELD COMPRESSOR SEAL ASSEMBLY AIR-OIL SEAL TURBINE SEALASSEMBLY AIR-OIL SEAL

70. 80. 90. -90A. 100. 140. 250.

SHIM SPRING TENSION WASHER SPACER SPACER SEAL BEARING TURBINE BEARING CARRIER ASSY

UP200456



Page 798.15 Feb 28/05

Hone vell 4.

D.

(3)

(i)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Place turbine bearing carrier assembly (250) so turbine seal assembly (50) is under turbine bearing carrier assembly. NOTE:

(J)

Install compressor seal assembly (30) and bearing carrier heat shield (20) over the guide pins. Remove guide pins and install bolts (10). NOTE:

(k)

Make sure shims (70) between turbine bearing carrier assembly (250) and turbine seal assembly (50) are not pinched.

Make sure shims (70) between turbine bearing carrier assembly (250) and turbine seal assembly (50) are not pinched.

Measure Dimension C in each location noted in step (a). Write as Dimension C1. Dimension C1 must be the same as Dimension C _+0.0015 inch (0.038 mm). If Dimension C1 is not the same as Dimension C, remove bolts (10) and turbine seal assembly (50). See if shims (70) are pinched. Check Point 110:

(i)

Dimension C must be the same as Dimension C1 _0.0015 inch (0,038 mm) at each of the 4 locations.

Do a vacuum test. Install 834303-1 vacuum check fixture on turbine bearing carrier assembly (250). 2

Assemble the vacuum test setup shown in Figure 722. NOTE:

The location and accuracy of the test equipment must be as described in Figure 722.

Turn on the vacuum pump. Adjust the shutoff valve to get a vacuum of -5 to -15 inches (-12,7 to 38,1 cm) Hg as read on the pressure gage.(20). Write the pressure. Write the airflow on the rotameter (50).

UP200456

Refer to Figure 723. Take the pressure and airflow readings from steps 3 and 4 and apply them to the graph to find the intersect point. The intersect point must be in the shaded area of the graph. Do not continue assembly if the leakage is too much.


Page 798.16 Feb 28/05

Honeywell



UP200456



Page 798.17 Feb 28/05


HoneTwell


2O

/ /

50

/

10

TOTURBINE BEARING CARRIBR

NOTE:

41)

30

A3800278AY581

Install pressure gage as close to vacuum check tube as possible.

10. VACUUM CHECKTUBE (834303-1) 20. PRESSURE GAGE (0TO 17 IN. (43,2 CM) HGG)

30. 40. 50.

SHUTOFF VALVE VACUUM PUMP ROTAMETER

UP200456

Turbine Bearing Carrier Vacuum Test Setup Figure 722


Page 798.18 Feb 28/05


Hone~vell


UP200456



Page 798.19 Feb 28/05

Honeywell



.10 .09 .O8 .07 .06

o, .05 LL

BBMmMmE mm UmEZ /EWm mz wmm/m /mm E mMm

.03

.01 0

-3

-4

-5

-6

-7

-8

-9

-10

-11

-12

-13

-14

DAUGEPRESSURE(IN.HgG)

-15

-16

A3800278AY580

UP200456

Turbine Bearing Carrier Seal Leakage Accept Criteria Figure 723


Page 798.20 Feb 28/05

Hone) vell

UP200456

4.

D.

(3)

(k)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] If necessary to examine for damage, remove compressor seal assembly (30, Figure 721), turbine seal assembly (50), turbine seal rotor (130, Figure 720), and shaft coupling half (170).


Page 798.21 Feb 28/05

HoneTwell



190

\ 250

'% ; 190

DIM AH

-...~~ DIM CA

250

X3800278AY5

UP200456

Measure Dimensions AH and CA Figure 724


Page 798.22 Feb 28/05

Honeywell 4.

D.

(5)



Measure Dimension AH and CA. (Refer to Figure 724.) (a)

Install turbine wheel shroud (220) on turbine backshroud retainer (190) and measure as shown. Write the result as Dimension AH.

(b)

Install turbine ring support (240) on turbine bearing carrier assembly (250) and measure as shown. Write the result as Dimension CA.

4 ] ~ KEY TO FIGURE 724

TURBINE BACKSHROUD RETAINER (IPC, FIG. 30) 220. TURBINE WHEEL SHROUD

UP200456

190.

240. TURBINE RING SUPPORT 250. TURBINE BEARING CARRIER ASSY


Page 798.23 Feb 28/05

Honeywell



,,\

210

23O

\ J

/ /

f

/

180

19~200 2 0

~40

A3800278AY541

UP200456

Installation of the Turbine Wheel Shroud and Turbine BackshroudRetainer Figure 725


Page 798.24 Feb 28/05

HoneTwell 4.

D.

(6)



Install turbine wheel shroud and turbine backshroud retainer. (Refer to Figure 725.)

(a)

Calculate for shims (230). NOTE:

Dimension AH was measured in step 4.D.(5)(a). Dimension CA was measured in step 4.D.(5)(b).

FORMULA: Dimension AH Dimension CA Calculated Thickness (200)Trial thickness

=

inch or inch or

mm mm

inch or

mm

+ 0.024 inch or 0,61 mm = thickness of shims (230) necessary _+0.001 inch (0,025 ram)

(b)

Install thickness of shims (230) on turbine bearing carrier assembly (250).

(c)

Calculate for shims (200). FORMULA: Thickness of shims (230) necessary Calculated (230) thickness

~KEY

UP200456

180. BOLT (IPC, FIG. 30) 190. TURBINE BACKSHROUD RETAINER 200. SHIM 210. SEAL RING

inch or

mm

inch or mm = inch or mm -0.001 inch or 0,025 mm = thickness of shims (200) necessary _ 0.001 inch (0,025 mm).

TO FIGURE 725

220. TURBINE WHEEL BACK SHROUD 230. SHIM 240. TURBINE RING SUPPORT 250. TURBINE BEARING CARRIER ASSY


Page 798.25 Feb 28/05

Hone) well 4.

D.

(6)

(7)



(d)

Install seal ring (210) into slot of turbine wheel backshroud (220).

(e)

Install turbine wheel backshroud (220) and calculated shims (200).

(f)

Install turbine backshroud retainer (190).

(g)

Install bolts (180). Torque bolts to 145 in-lb (16,4 Nm).

Measure Dimension AA1. (Refer to Figure 726)

(a)

Install turbine nozzle assembly (40) on the turbine rotor assembly.

(b)

Measure Dimension AA1 in three places. Average Dimension AA1.

(c)

Remove turbine nozzle assembly (40) from the turbine rotor assembly.

TURBINE ROTOR ASSY

DIMIAA1

I~ ! / I /

X3800278AY6

40.

TURBINE NOZZLE ASSY (IPC, FIG. 29)

UP200456

Measure Dimension AA1 Figure 726

49-26-49

Copying,useordisclosureofinformatioon n thispageissubjecttoproprietaryrestrictions

Page 798.26 Feb 28/05

Honeywell



UP200456



Page 798.27 Feb 28/05

Hone) well



100

/

,

t.

"a

THRUST 80

APPLYDRYLUBRICANT BEFOREASSEMBLY

BUILDDIM.

t \ TURBINEWHEEL SHROUD

X3800278AY7

UP200456

Adjustment of the Turbine Rotor Clearance Figure 727


Page 798.28 Feb 28/05

Honeywell 4.

D.

(8)



Adjust turbine rotor backshroud clearance. (Refer to Figure 727.)

(a)

Apply dry lubricant (Molykote 321-R) to the mating surface of turbine rotor (80) as shown.

(b)

Install turbine and compressor assembly (100) over turbine rotor (80) and align balance index marks.

(c)

Install 834165-1 turbine wheel arbor and 834347-1 shaft stretch nut on shaft of turbine rotor (80).

(d)

Install 833094-1 shaft stretching tool and apply 2000 psig (13,800 kPa) tool pressure to seat turbine rotor (80) curvic coupling.

(e)

Apply a thrust load to turbine rotor (80) in the direction shown. Measure the build dimension of two blades 180 degrees apart at the same time. .NOTE:

(f)

Due to differences in blade dimensions, measure the build dimension from the two turbine rotor blades which are closest to the turbine backshroud.

The build dimension must be 0.026 to 0.028 inch (0,66 to 0,71 mm). If the build dimension is not in limits, adjust shims (230, Figure 725) equally. Check Point 120:

Make sure the turbine rotor backshroud clearance is within limits.

(g

If shim adjustment is necessary, do steps (b) through (h) again until you get a build dimension of 0.026 to 0.028 inch (0,66 to 0,71 mm).

(h)

Decrease pressure to zero.

(i)

Remove 833094-1 shaft stretching tool.


UP200456

80. TURBINE ROTOR (IPC, FIG. 29)

100.

TURBINE AND COMPRESSOR ASSY


Page 798.29 Feb 28/05


Hone~vell


DIMBH

DIMBA

J

411

L

g_,__,

t TURBINEWHEEL SHROUD

DIMCD

X

TURBINEBEARING CARRIERASSE~VBLY

40.

X3800278AY8

TURBINE NOZZLE ASSY (IPC FIG. 29)

UP200456

Measurement of Dimensions BA, BH and CD Figure 728


Page 798.30 Feb 28/05

Honeywell

UP200456

4.

D.

(9)



Measure Dimension BA, BH and CD. (Refer to Figure 728.) (a)

Use 833098-2 micing bridge to measure the turbine nozzle assembly (40) as shown and write the results as Dimension BA and BH for later use.

(b)

Measure from the turbine wheel shroud to the turbine bearing carrier assembly and write the result as Dimension CD for later use.


Page 798.31 Feb 28/05

RELEASED FOR THE EXCLUSIVE USE BY: ASERCA AIRLINES COMPONENT MAINTENANCE M A N U A L

Hone) well

GTCP36-280[D]

•

/ t

/ ~

J i

'f'

,

.c, ~

r

, t . .* , ,

iw•t

~"

/

""';"'

¢u~2

6"\ 10~"'2o TURBINE . ROTORASSY

1

50

\\

i

~

\ ( LJ, /

~ /SUPPORT

TURBINEBEARING CARRIERASSY X3800504AY183

UP200456

Installation of the Turbine Nozzle Assembly Figure 729


Page 798.32 Feb 28/05

Hone vell 4.

D.

(10)



Install the turbine nozzle assembly and containment ring. (Refer to Figure 729.) (a)

Calculate Dimension BG. NOTE:

Dimensions BA, BH and CD were measured in Figure 7 2 8 .

Dimension BH Dimension BA Dimension BG (b)

in. or in. or in. or

=

mm. mm. mm.

Calculate for shims (90). FORMULA: Dimension BG Dimension CD Calculated (90) thickness Trial (90) thickness

(c)

=

inch or inch or

mm mm

inch or

mm

+ 0.034 inch or 0,86 mm = thickness of shims (90) necessary _ 0.001 (0,025 mm).

Calculate for shims (50). FORMULA: Actual thickness of shims (90) used from step (b)

inch or

Calculated thickness of shims (90) from step (b) = - 0.003 = thickness inch (0.025

4~KEY

UP200456

10. BOLT (IPC, FIG. 29) 20. WASHER 30. CONTAINMENT RING

mm

inch or mm inch or mm inch or 0,076 mm of shims (50) necessary_+0.001 mm).

TO FIGURE 729

40. 50. 90.

TURBINE NOZZLEASSY SHIM SHIM


Page 798.33 Feb 28/05

Hone vell 4.

D.

(10)



(d)

Remove turbine nozzle assembly(40).

(e)

Install shims (90) calculated in step (b).

(f)

Install shims (50) calculated in step (c).

(g)

Install turbine nozzle assembly (40) and slave bolts and washers. Tighten slave bolts to a torque value of 60 in-lb (6,8 Nm).

(h)

Measure dimension AA2 and subtract from dimension AAI. NOTE:

(i)

Dimension AA1 was calculated in Figure 726.

Calculate turbine wheel to turbine nozzle clearance. FORMULA: Dimension AA2 Dimension AA1

Check Point 130:

(J)

Make sure the turbine wheel to the turbine nozzle clearance is in limits.

If turbine wheel to turbine nozzle clearance is not 0.027 to 0.029 inch (0,68 to 0,73 mm), equally remove or add shims (50, 90) to get satisfactory turbine nozzle clearance. 1

Remove slave bolts, washers and turbine nozzle assembly (40).

2

Install correct thickness of shims (50) and (90).

3

Install containment ring (30).

4

Install turbine nozzle assembly (40).

5

Install slave bolts and washers. Tighten slave bolts to a torque value of 60 in-lb (6,8 Nm).

(k)

Do steps (h) through (j) as necessary until turbine wheel clearance is 0.027 to 0.029 inch (0,68 to 0,73 mm).

(J)

Loosen slave bolts one-quarter turn. Measure between the bearing carrier and the turbine nozzle. The gap must be 0.002 to 0.004 inch (0,05 to 0,10 mm). NOTE:

UP200456

inch or mm inch or mm = turbine wheel/nozzle clearance (0.027 to 0.029 inch (0,68 to 0,73 mm)). -

Containment ring (30) should be free to rotate but must not move axially.


Page 798.34 Feb 28/05

Hone3well

UP200456

4.

D.

(10)



(m)

Remove slave bolts and washers.

(n)

Install bolts (10) and washers (20). Tighten the bolts to a torque value of 60 in-lb (6,8 Nm).

(o)

Install 833094-1 shaft stretch fixture.

(p)

Apply 2000 psi (13,800 kPa) tool pressure to loosen 834347-1 shaft stretch nut.

(q)

Reduce 833094-1 shaft stretch fixture pressure to zero. Remove shaft stretch fixture.

(r)

Remove 834347-1 shaft stretch nut and 834165-1 turbine wheel arbor assembly.


Page 798.35 Feb 28/05


Hone~well


tl!l Illl I II \

IliJf

J

II

5O 5O

~,%

DIM°

AF:

4 X3800516AY31

UP200456

Measurement of Dimensions AD and AF Figure 730


Page 798.36 Feb 28/05

Hone vell 4.

D.

(11)



Measure Dimensions AD and AF. (Refer to Figure 730.)

(a)

Set compressor rotor (50) on a flat surface. Install curvic protectors on rotor impeller backface curvics.

(b)

Set engine compressor housing (10) on compressor rotor (50).

(c)

Install 833871-1 micing fixture on engine compressor housing (10). Attach with at least 4 equally spaced slave bolts.

(d)

Measure and write Dimension AD.

(e)

Remove the micing fixture and turn the engine compressor housing and compressor rotor over.

(f)

Use a thickness gauge and simultaneously measure the tip clearance 180 degrees apart. Write the results as Dimension AF for later use. NOTE:

It is permitted for Dimension AF to be zero.


UP200456

10. ENGINE COMPRESSOR HOUSING (IPC, FIG. 28)

50.

COMPRESSOR ROTOR


Page 798.37 Feb 28/05

Hone~vell



8O DIM. MA

DIM. MB

--~=~

~"~"

100

130-~ - ~ ~ t

DIM. MC

X3800516AY32

UP200456

Measurementof DimensionsMA, MB and MC Figure731


798.38

Page Feb 28/05

Honeywell 4.

D.

(12)



Measure Dimensions MA, MB and MC. (Refer to Figure 731.)

(a)

Measure spacer (80) and write the result as Dimension MA.

(b)

Measure turbine bearing carrier assembly (130) and write the result as Dimension MC.

(c)

Measure compressor deswirl (100) and write the result as Dimension MB.

4~KEY

UP200456

80. SPACER (IPC, FIG. 28) 100. COMPRESSOR DESWlRL

TO FIGURE 731

130. TURBINE BEARING CARRIERASSY

49-26-49


Page 798.39 Feb 28/05

Hone~vell



11 100

90 80 70

60

\

5O t0

\

\ TURBINE BEARING CARRIER ASSEMBLY

J

CtM.AE

/

50

MICING

70

NOZZLE SUPPORT FIXTURE

~,~ 110 THRUST

BEARING CARRIER ASSEMBLY

IO0

X3800516AY33

UP200456

Measurement of Dimension AE Figure 732


Page 798.40 Feb 28/05

Honeywell 4.

D.

(13)



Measure Dimension AE. (Refer to Figure 732.) (a)

Install a trial thickness 0.040 inch (1,02 ram) of shims (110) on the turbine bearing carrier assembly.

(b)


Dimensions MB, MC, and MA were measured in step 4.D.(12).

FORMULA: Dimension MB Dimension MC *shim (110) thickness Dimension MA

+ =

inch or inch or inch or

mm mm mm

+ =

inch or mm inch or mm inch or mm = inch or mm + 0.002 inch or 0,05 mm = thickness of shims necessary +_0.001 inch (0,025 mm)

*Initial calculation (before adjusting shim thickness, as necessary) should use trial shim (110) thickness used in step (a).

(c)

Install shims (90) on turbine bearing carrier assembly.

(d)

Install spacer (80) on turbine bearing carrier assembly.

(e)

Install compressor deswirl (100).

(f)

Install compressor diffuser (70).

(g)

Install compressor baffle (60). Make sure slot engages pin in engine compressor housing (10).

~KEY

ENGINE COMPRESSOR HOUSING ASSY(IPC, FIG. 28) 50. COMPRESSOR ROTOR 60. COMPRESSOR BAFFLE 70. COMPRESSOR DIFFUSER

UP200456

10.

TO FIGURE 732

80. 90. 100. 110.

SPACER SHIM COMPRESSOR DESWlRL SHIM


Page 798.41 Feb 28/05

Honeywell



.•flo APPLY HIGH HE A T ~ - - ~ ~ ALUMINUM IN THIS AREA

'~

f

X3800516TR1

UP200456

(Optional) Application of Adhesive in Cavity Location of Compressor Housing Figure 732A

49-26-49

Copying,use or disclosureof informationon this page is subjectto proprietaryrestrictions

Page 798.42 Feb 28/05

Honeywell .

D.

(13)

(h)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] (Optional) Apply adhesive to compressor housing assembly (10) and baffle (60). 1

If required, mating surfaces may be lightly abraded with abrasive paper (320 grit).

WARNING:

ACETONE IS FLAMMABLE AND CAN CAUSE SKIN, EYES AND RESPIRATORY TRACT PROBLEMS. USE IN A WELLVENTILATED AREA. DO NOT BREATHE VAPORS. DO NOT PERMIT CHEMICAL TO TOUCH EYES OR SKIN. KEEP AWAY FROM SPARKS AND FLAMES. USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL.

2

Clean mating surfaces with acetone and let dry. Make sure all residues and fingerprints are removed from mating surfaces.

3

Apply High Heat Aluminum Coating (Griggs DC6571-805) to the compressor housing assembly (10), as shown in Figure 732A. Do not let the aluminum coated surface set more than 5 minutes prior to assembly.

_4

Put the baffle (60) on the compressor housing assembly (100), align the anti-rotation slot on the baffle (60) with the anti-rotation pin in the compressor housing assembly (10). Apply and maintain pressure on the baffle (6) to make good contact with the compressor housing assembly (10). Refer to Figure 732A.

5

Let the bonded assembly sit undisturbed for 24 hours to cure the adhesive.


UP200456

10.

ENGINE COMPRESSOR HOUSING ASSY (IPC, FIG. 28)

60.

COMPRESSOR BAFFLE


Page 798.43 Feb 28/05


Honeywell 4.

D.

(13)


(i)

Install compressor rotor (50).

(J)

Install engine compressor housing assembly (10).

(k)

Install 833871-1 shim holding fixture. Attach with 19 slave bolts. Tighten slave bolts to a torque value of 60 in-lb (6,8 Nm).

(l)

Apply thrust in the direction shown and measure Dimension AE.

(m)

Use the formula that follows to calculate the engine compressor clearance. NOTE:

Dimensions AD and AF were found in Figure 730.

Dimension AD Dimension AE Dimension AF

in. or mm. in. or mm. = in. or mm. + in. or mm. = required engine compressor clearance

Engine compressor clearance must be 0.022 to 0.026 inch (0,56 to 0,66 mm). If engine compressor clearance is not 0.022 to 0.026 inch (0,56 to 0,66 mm), remove or add shims (110) as necessary and do step (I).

UP200456

Check Point 140:

Make sure the engine compressor clearance calculations are correct.


Page 798.44 Feb 28/05


Honeywell


UP200456



Page 798.45 Feb 28/05

Hone~well



\ 130

\ 120

X3800516AY34

UP200456

Installation of the Compressor Rotor Components Figure 733


Page 798.46 Feb 28/05


Honeywell 4.

D.

(14)


Install compressor rotor components. (Refer to Figure 733.) (a)

Install curvic ring seal (120) on shaft of turbine and compressor assembly (130).

(b)

Install compressor rotor (50). Make sure index marks are aligned.

(c)

Apply a coat of aluminum paint (DC6571-805) on engine compressor housing assembly (10) and turbine compressor assembly (130) mating surfaces.

(d)

Install engine compressor housing assembly (10). NOTE:

Make sure that compressor baffle (60) is locked onto engine compressor housing assembly (10). The guide pin from engine compressor housing assembly (10) must be between the fourth and fifth hole clockwise from the top of the turbine bearing carrier vent hole.


UP200456

10. ENGINE COMPRESSOR HOUSING ASSY (IPC, FIG. 28) 50. COMPRESSOR ROTOR 60. COMPRESSOR BAFFLE

120. CURVIC RING SEAL 130. TURBINEAND COMPRESSOR ASSY


Page 798.47 Feb 28/05

Honeywell



40-~...~

50

---~..~ 20

\

ViEWA CUTOikETINEOFF

A TOP

BOTTOM SECTIONA-A BOTTOM

A3800278AY583

VIEWB

UP200456

Inlet Guide Vane Housing Assembly Figure 734


Page 798.48 Feb 28/05

Honeywell 4.

D.

(15)



Assemble the Inlet Guide Vane Assembly. (Refer to Figure 734, View A.) (a)

Install face gear (70) on inlet housing (50).

(b)

Install inlet guide vane (60) through inlet housing (50). Use 833194-1 position fixture to preset the vanes.

(c)

Install spring washer (40) and gear (30). NOTE:

(d)

Make sure to position gear 'V' mark to face gear (70) teeth.

Install pin (20) through gear (30) and inlet guide vane (60). NOTE:

Make sure face gear (70) is in the close stop position. The inlet guide vane (60) angle should be approximately 15 degrees more than the closed (flat) position.

(e)

Install cotter pin (10) through pin (20) and secure as shown in Figure 734 (View B) with the eye of cotter pin (10) towards face gear (70).

(f)

Remove 833194-1 position fixture.

(g)

Cut one of cotter pin (10) tines flush. Bend the other tine outboard (away from the vanes) and trim the excess, as shown in View B (Section A-A).


UP200456

10. 20. 30. 40.

COTTER PIN (IPC FIG. 39) PIN GEAR SPRING WASHER

50. INLET HOUSING 60. INLET GUIDE VANE 70. FACE GEAR


Page 798.49 Feb 28/05


Hone~vell

~ ~

\.


~'~~120! 1

150

-1/////

\ 1,0~ "-..

140 .~

"

100

(

\

lg) 180 DETA,.A

110 120

,~

B•APPLY RTV

DETAIL B

90

170

130

X3800504AY69

UP200456

InstallationoftheCompressorScrolland InletGuideVanes Figure735


Page798.50 Feb28/05

Hone vell 4.

D.

(16)



Install the compressor scroll and inlet guide vanes. (Refer to Figure 735.) (a)

Apply a 0.0625 inch (1,59 mm) bead of adhesive (RTV106) to flange of scroll liner (100) as shown in Detail B.

(b)

Install scroll liner (100) into compressor scroll (90). Make sure pin in compressor scroll is aligned with slot of scroll liner.

(c)

Install packings (150, 160) on compressor shroud (130) and install compressor shroud on compressor scroll (90).

(d)

Install actuator shaft assembly (200) and attach with spring pin (190) and cotter pin (180).

(e)

Install inlet guide vane assembly (170), into compressor scroll (90), and attach with washers (120) and screws (110). Tighten screw to 7 in-lb (0,79 Nm) over running torque.


UP200456

90. COMPRESSOR SCROLL (IPC, FIG. 26) 100. SCROLL LINER 110. SCREW 120. WASHER 130. COMPRESSOR SHROUD

150. PACKING 160. PACKING 170. INLET GUIDE VANEASSY 180. COTTER PIN 190. SPRING PIN 200. ACTUATOR SHAFTASSY


Page 798.51 Feb 28/05

Honeywell



90

/ 160 /

IOOB

/F,%

0/

Z~

/

/

140

120 , /

\

110

100

150

9/> 8O

X3800504AY70

UP200456

Installation of the IGV Actuator Figure 736


Page 798.52 Feb 28/05

Hone vell 4.

D.

(17)



Install the IGV actuator. (Refer to Figure 736.) (a)

Install packings (150, 160) on tube assembly (140).

(b)

Install tube assembly (140) into assembled compressor scroll (90).

(c)

Install nut (130) on screw (120).

(d)

Turn screw into the actuator shaft assembly. Use 834150-2 adjustment fixture to adjust the vanes. Tighten nut (130).

(e)

Adjust screw (120) until vanes are closed (flat). Tighten nut (130) to a torque value of 45 in-lb (5 Nm). Remove 834150-2 adjustment fixture.

(f)

Install clevis (110) on the IGV actuator assembly shaft (100, IPC FIG. 15) and push the shaft into the IGV actuator assembly housing until it stops.

(g)

Pull the actuator shaft assembly from the compressor scroll (90) until it stops.

(h)

Slide clevis (110) on screw (120). Make sure clevis stays on actuator screw and carefully push IGV actuator assembly (100) on compressor scroll (90). Attach with washers (90) and bolts (80). Tighten bolts to a torque value of 120 in-lb (13,6 Nm).


UP200456

90. COMPRESSOR SCROLL (IPC FIG. 26) 80. BOLT (IPC FIG. 15) 90. WASHER 100. IGV ACTUATOR ASSY 100B. IGV ACTUATOR ASSY (POST SB 49-6658)

110. 120. 130. 140. 150. 160.

CLEVIS (IPC FIG. 22) SCREW NUT TUBEASSY PACKING PACKING


Page 798.53 Feb 28/05

Honeywell 4.

D.

(17)

(i)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Look at IGV vanes. All IGV vanes should be in the closed (flat) position. vanes are open (not flat), do steps 1through 5. Remove bolts (80), and washers (90). Remove IGV actuator assembly (100). Adjust IGV actuator screw (120) a small amount as necessary. Install IGV actuator assembly (100), washers (90), and bolts (80). Tighten bolts to a torque value of 120 in-lb (13,6 Nm). 5

Look at IGV vanes. The vanes must be in the closed (flat) position.

UP200456

Do steps I through 5 again as necessary.

49-26-49 Copying, use or disclosure of information on this page is subjectto proprietaryrestrictions

Page 798.54 Feb 28/05

Hone~vell



UP200456



Page 798.55 Feb 28/05


Honeywell


./

\

/

100

210

~"~214 "212 90

~J

\

\

\.

8! 70

. • -=.~. ~' ~

,~ ~

50

CENTERINGFIXTURE

Dill.

DIM.AG

R

I

I

9O

i

COMPRESSOR SHROUD

X3800504AY225

UP200456

Measurement of Dimensions AG and R Figure 737


Page 798.56 Feb 28/05

Honeywell 4.

D.

(18)



Measure Dimension AG and R. (Refer to Figure 737.) (a)

Install IGV cover (210) and compressor inlet housing (100) on scroll (90). Attach with washers (80), and nuts (70). Tighten nuts to a torque value of 50 in-lb (5,7 Nm). (Post SB 49-7454) 1

Clean interfacing flanges of IGV Assembly (170, Figure 735)

WARNING:

USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL.

Apply a thin bead of fluorosilicone RTV (Don Coming 730 or equivalent to both surfaces (less than 0.05 inch (1,3 mm)( total thickness for both beads). 3

Install IGV Housing Cover Seal (212) and Backup Ring (214) or scroll (90). Install IGV Cover (210) on scroll (90). Wipe off excess RTV with solvent-soaked cloth. Install compressor inlet housing (120) on scroll (90) and attach with washers (80) and nuts (70). Tighten nuts to a torque value of 50inchpounds (5,7 Nm).

NOTE:

Make sure the word 'TOP" on the compressor inlet housing (100) is at the 12 o'clock position.

(b)

Put compressor rotor (50) in the compressor shroud.

(c)

Measure the space between compressor rotor (50) blade tips and scroll (90). Write as dimension AG. NOTE:

It is permitted for Dimension AG to be zero.

(d)

Install 833102-1 compressor centering fixture on scroll (90). Attach with slave nuts.

(e)

Measure and write Dimension R as shown.

(f)

Remove 833102-1 compressor centering fixture and compressor rotor (50).

~ll~ KEY TO FIGURE 737

UP200456

50. COMPRESSOR ROTOR (IPC, FIG. 26) 7O. NUT 8O. WASHER 90. SCROLL

100. COMPRESSOR INLET HOUSING (IPC, FIG. 27) 210. IGV COVER (IPC FIG. 26) 212. IGV HOUSING COVER SEAL 214. BACKUP RING


Page 798.57 Feb 28/05

Honeywell 4.

D.

(19)



(Pre SB 49-A6642) Assembly Compressor Shaft Assembly. (Refer to Figure 738.) (a)

Install turbine shaft support (240) and retaining ring (250) in compressor shaft (230).

(b)

Install shaft support (60) and turbine shaft support (260) on compressor shaft (230).

288

24o 2so \ oo

..~ ~ ~ L ~ ' ~ ' ~

60. SHAFT SUPPORT (IPC, FIG. 25) 230. COMPRESSOR SHAFT 240. TURBINE SHAFT SUPPORT

A3800278AY584

250. RETAINING RING 260. TURBINE SHAFT SUPPORT

UP200456

Assemble Compressor Shaft (Pre SB 49-A6642) Figure 738


Page 798.58 Feb 28/05

Hone)~vell



UP200456



Page 798.59 Feb 28/05

Honeywell



TURBINE COMPRESSOR ASSEMBLY

230A

150 - - - - ~

~

J

50

8o 90 110

1 10

\

SLAVE BOLT SCROLLINLETASSEMBLY

X3800504AY72

UP200456

(Pre SB 49-7307) Preliminary Load Compressor Component Installation Figure 739


Page 7 9 8 . 6 0 Feb 28/05

Hone vell 4.

D.

(20)



Preliminary Load Compressor Component Installation. (Refer to Figure 7.39.) (a)

Make sure the curvic couplings are clean (refer to CLEANING). Install the compressor shaft assembly on the turbine/compressor assembly. Make sure to align balance index marks.

(b)

Install packing (150) on the turbine/compressor assembly.

(c)

Install 0.060 inch (1,52 mm) preliminary thickness of shims (110).

(d)

Install inlet adapter (80), plenum inlet seal (90) and the scroll/inlet assembly on turbine/compressor assembly. Install 2024398-1 protective cover to prevent foreign objects from entering the compressor. Attach with slave bolts and washers.

(e)

Make sure curvics are clean and align balance index marks. Install compressor rotor (50) and 834037-1 dummy coupling on scroll/inlet assembly.

(f)

Apply lubricant (Liqui-Moly, Brand NV) to turbine/compressor assembly shaft threads.

(g)

Install round nut (10).

(h)

Look at all curvics for proper engagement. Tighten round nut (10) to a torque value of 50 in-lb (5,7 Nm). Measure and write Dimension RFL (refer to 4.C.(3)(c), Figure 716). Dimension RFL must be the same as originally measured in step 4.C.(3)(c) _0.004 inch (1,0 ram). Look for damaged or incorrect engagement of curvics if dimension cannot be met.

~KEY DUMMY COUPLING (834037-1) ROUND NUT (IPC, FIG. 25) SPLINED SHAFT COMPRESSOR ROTOR (IPC, FIG. 26) 80. INLET ADAPTER (IPC FIG. 27)

UP200456

1. 10. 20. 50.

TO FIGURE 739 90. 110. 150. 230A.

PLENUM INLET SEAL SHIM PACKING COMPRESSOR SHAFT (IPC FIG. 26)


Page 798.61 Feb 28/05

Honeywell



CAUTION:

UP200456

4.

D.

(20)

DO NOT EXCEED 3900 PSIG (26890 KPA) RAM PRESSURE.

(i)

Install 833094-1 shaft stretching fixture and apply approximately the same pressure as applied in 4.C.(3)(i). Tighten round nut (10).

(j)

Deleted.


Page 798.62 Feb 28/05

Honeywell



UP200456



Page 798.63 Feb 28/05


Hone~vell


UP200456

DELETED Figure 739A


Page 798.64 Feb 28/05


Honeywell

UP200456

I

4.

D.

(21)


Deleted.


Page 798.65 Feb 28/05

Hone vell



ROUND

t

DIM. T

LOAD

X3800278AY11

UP200456

Measurement of Dimension T Figure 740


Page 798.66 Feb 28/05

Hone vell

UP200456

4.

D.

(22)



Measurement of Dimension T. (Refer to Figure 740.) (a)

Load the rotating group as shown in Figure 740 and measure Dimension T.

(b)

Remove 833102-1 compressor bearing centering fixture.


Page 798.67 Feb 28/05


Hone} vell


TURBINE COMPRESSOR ASSEMBLY

235

J~ 80 9O 5O

"'~. ~.

10

\

~

~> J

~

SCROLL INLET ASSEMBLY

10

X3800504AY226

UP200456

Calculation of CompressorShims Figure 741


Page798.68 Feb 28/05


Hone) vell 4.

D.

(23)


Calculation of Compressor Shims. (Refer to Figure 741.)

(a)

Install 833094-1 shaft stretch fixture on turbine/compressor assembly shaft.

(b)

Apply the same ram pressure as that applied in 4.C.(3)(i) and remove round nut (10). Remove 833094-1 shaft stretch fixture.

(c)

Remove 834037-1 dummy coupling (1).

(d)

Remove slave bolts and washers and remove the scroll/inlet assembly.

(e)


Dimension R and AG were measured in step 4.D.(18). Dimension T was measured in step 4.D.(21 ).

FORMULA: Dimension R Dimension T

= Dimension AG + = - 0.067 = thickness (0,05 mm))

(f)

Adjust thickness of shims (110) to agree with necessary thickness calculated in step (d).

~KEY

UP200456

1. 10. 10. 20. 30. 40. 45. 50.

inch or mm inch or mm inch or mm inch or mm inch or mm inch or 1,7 mm of shims (110) necessary (_+0.002 in.

DUMMY COUPLING (834037-1) BOLT (IPC, FIG. 27) ROUND NUT (IPC, FIG. 25) WASHER (IPC, FIG 27) BOLT CONTAINMENT SHIELD SEGMENT BOLT CONTAINMENT SHIELD SEGMENT

TO FIGURE 741

55. 60. 70. 80. 90. 100. 110. 130. 235.

BOLT NUT WASHER INLET ADAPTER PLENUM INLETSEAL COMPRESSOR INLET HOUSING SHIM TURBINEAND COMPRESSORASSY CURVIC SEALGASKET (POST SB 49-7307)


Page 798.69 Feb 28/05

Hone) well 4.

D.

(23)

(g)



(Pre SB 49-6608) Install the scroll/inlet assembly, containment shield segments (40, 50), washers (20, 70), and bolts (10, 30, 45, 55), inlet adapter (80) and plenum inlet seal (90) on the turbine/compressor assembly(130). Tighten bolts (30) to a torque value of 50 in-lb (5,7 Nm). (Post SB49-6608) Install the scroll/inlet assembly, containment shield segments (40, 50), Iockwashers, Part No. MS9581-09, and nuts (60), Part No. MS210436C3 inlet adapter (80) and plenum inlet seal (90) on the turbine/compressor assembly (130). Tighten nuts to a torque value of 25 in-lb (2,9 Nm). Bend the tab of each lock washer against the flat of the nut.

(h)

Make sure all curvics are clean and align balance index marks. Install 834037-1 dummy coupling (1) and round nut (10). (Post SB 49-7307) Make sure curvics are clean and align balance index marks. Install the curvic seal gasket (235) over the forward end of the compressor shaft bumper against the flange. Install the compressor rotor assembly (50) and the 834037-1 dummy coupling on the scroll inlet assembly. NOTE:

The dimension from the top of the load compressor bumper shaft scaling shoulder to the top of the curvic tooth must not be more than 0.018 inch (0,457 mm). If the dimension is more than 0.018 inch (0,457 mm), do not install the gasket.

(i)

(Post SB 49-7307) Move the inlet guide vane assembly to the open position and visually inspect for proper curvic engagement at the load compresor aft end.

(J)

Look at all curvics for proper engagement. Tighten round nut (10) to a torque value of 50 in-lb (5,7 Nm). Measure and write Dimension RFL (refer to 4.C.(3)(c), Figure 716). Dimension RFL must be the same as originally measured in step 4.C.(3)(c) _0.004 inch (1,0 mm). Look for damaged or incorrect engagement of curvics if dimension cannot be met.

CAUTION:

MAKE SURE YOU PROPERLY SEAT THE CURVIC SEAL GASKET (235). IMPROPER SEATING OF THE GASKET CAN CAUSE CURVIC MISALIGNMENT.

(Post SB 49-7307) Look at all curvics for proper engagement. Tighten round nut (10) to a torque value of 100 pound-inches (11,4 Nm) to properly seat curvic seal gasket (235). Measure and write Dimension RFL (refer to 4.C.(3) (c), Figure 716). Dimension RFL must be the same as Dimension RFL measured in step 4.C.(3)(c) +_0.04 inch (1,0 mm). Look for damaged or incorrect engagement of curvics if dimension cannot be met.

UP200456

CAUTION:


(k)

Install 833094-1 shaft stretching fixture and apply approximately the same pressure as applied in 4.C.(3)(i). Tighten round nut (10).

(I)

Remove 833094-1 shaft stretching fixture.

(m)

Install 833102-1 compressor bearing centering fixture and 833099-1 turbine nozzle support fixture.


Page 798.70 Feb 28/05


HoneTwell 4.

D.

(23)

(n)

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Load the rotating group as shown in Figure 742 and measure the load compressor rotor tip clearance at two locations, 180 degrees apart with a wire gage and average the measurements. Rotor tip clearance must be 0.065 to 0.069 inch (1,65 to 1,75 mm). Add or remove shims (110, Figure 741) as necessary.

UP200456

Check Point 150:

Make sure load compressor tip clearance is 0.065 to 0.069 inch (0,165 to 0,175 mm).

(o)

Install 833094-1 shaft stretching fixture and apply the same ram pressure as in step 4.C.(3)(i). Make round nut (10) loose. Remove shaft stretching fixture.

(p)

Remove round nut (10) and 834037-1 dummy coupling.


Page 798.71 Feb 28/05


Honeywell


ROUI~

BLADETIP CLEA~CE

THRUST

X3800278AY12

UP200456

Measurement of Blade Tip Clearance Figure 742


Page 798.72 Feb 28/05


Hone~well


UP200456



Page 798.73 Feb 28/05


Hone)~well


.) SLAVE BOLT

DIM. V

DIM. U

I

F~ja_~.///~/~:~A V!/ItI~I,///IIIIt/II/ I~1

160

I

r/////

SLAVE BOLTAND NUT

40

i

I

I

/,

I

390(OUTERFACE)

I

I

DIM. W I

t

25O

X3800504AY74

UP200456

Measurement of Dimensions U, V and W Figure 743


Page 798.74 Feb 28/05


Honeywell 4.

D.

(24)


Measure Dimension U, V and W. (Refer to Figure 743.) WARNING:


(a)

Heat compressor bearing carrier assembly (40) to 350 F (177 C) for 10 minutes.

(b)

Install compressor bearing carrier assembly (40) on bearing carrier (70) and attach with slave bolts and nuts. NOTE:

(c)

Use guide pins to assist in the installation of bearing carrier assembly (40).

Install outer race of bearing (390) in compressor bearing carrier assembly

(40).

(d)

Install spacer (160) and housing (250) in compressor bearing carrier assembly

(40). (e)

Measureand write Dimensions U, V, and W.

(f)

Removethe slave bolts and nuts.

~KEY

UP200456

40. COMPRESSOR BEARING CARRIERASSY (IPC, FIG. 25) 70. BEARING CARRIER

TO FIGURE 743 160. SPACER 250. HOUSING 390. BEARING


Page 798.75 Feb 28/05

Hone)~ell



X3800504AY75

UP200456

Assemble Seal Assembly Figure 744


Page 798.76 Feb 28/05

Hone) veil 4.

D.

(25)



Assemble Seal Assembly. (Refer to Figure 744.) (a)

Install in sequence, wavespring washer (240), washer (230), wavespring washer (240), and washer (230) in housing (250).

(b)

Carefully install seal (220) and carbon ring (210) in housing (250). Lock in place with retainer (200). NOTE:

(c)

Use care when you handle the carbon ring (210). The carbon ring seal ability can decrease if worked or touched too much.

Test assembled seal assembly. 1

Install assembled seal assembly in 833423-1 leak test fixture.

2

Apply 55 psia (284,4 cm Hg abs). Leakage must not exceed 0.010 Ibs/min (4,5 g/min).

I 1 ~ KEY TO FIGURE 744

UP200456

200. RETAINER (IPC, FIG. 25) 210. CARBON RING 220. SEAL

230. WASHER 240 WAVESPRING WASHER 250. HOUSING


Page 798.77 Feb 28/05

Honeywell



270

2,0 \ ~ J 170

180

3°\

"~,,.,'=-"~

39

\I,,--/~,-~? ,

4o

\

20

.-

5O 30

20

390,

160 50 60

,,0

30

40

ul

17o

'/li/ 10

350

340 330

270

310

300

X3800504AY76

UP200456

Assembly of the Bearing Carrier Area Figure 745


Page 798.78 Feb 28/05

Honeywell 4.

D.

(26)



Assemble the bearing carrier. (Refer to Figure 745.) WARNING:

(a)

USE THE CORRECT PERSONAL PROTECTION. DRY ICE WILL CAUSE BURNS. CARBON DIOXIDE REMOVES THE OXYGEN FROM THE AIR, THIS CAN CAUSE ASPHYXIATION.

Cool splined shaft (20) in dry ice for 10 minutes.

WARNING:


(b)

Heat compressor rotor seal (380) and coupling seal assembly (270) to 250 to 300 F (121 to 149 C) for 10 minutes.

(c)

Measure thickness of inner race of roller bearing (410) and record as Dimension CB.

(d)

Align balance index marks and use 833096-2 bearing and rotor seal installer to push inner race of bearing (390), and compressor rotor seal (380) on splined shaft (20).

CAUTION:

MAKE SURE TO INSTALL FLAT SIDE OF COMPRESSOR SEAL ROTOR FACE AWAY FROM BEARING.

(e)

Install coupling seal assembly (270) and the seal assembly on 833432-1 coupling installation fixture.

(f)

Align all balance index marks and install splined shaft (20) in coupling seal assembly (270).

(g)

Install packings (330, 340, 350) on housing assembly (310)

~ l n KEYTO FIGURE 745 '

UP200456

10. LOAD COMPRESSOR DIFFUSER (IPC, FIG. 26) 20. SPLINED SHAFT (IPC, FIG. 25) 30. SPECIAL BOLT (IPC, FIG. 26) 30. BOLT (IPC, FIG. 25) 40. BEARING CARRIERASSY 50. NUT 60. WASHER 70. BEARING CARRIER 150. PACKING 160. SPACER

170. 180. 250. 270. 300. 310. 330. 340. 350. 380. 390.

COMPRESSOR SPRING SPACER HOUSING COUPLING SEALASSY LOAD COMPRESSOR BACKFACE INSULATOR HOUSINGASSY PACKING PACKING PACKING COMPRESSOR ROTOR SEAL BEARING


Page 798.79 Feb 28/05

Hone ell 4.

D.

(26)

(h)


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Look at Figure 745. Install load compressor backface insulator (300) on housing assembly (310). NOTE:

(i)

Make sure compressor backface insulator is installed correctly.

Calculate for thickness of spacer (180). NOTE:

Dimensions U, V, and W were measured in step 4.D.(23).

FORMULA: Dimension U Dimension V Dimension W

inch or mm inch or mm = inch or mrn inch or mm = inch or mm -0.079 inch or 2,01 mm = thickness of spacer (180) necessary =--0.006 inch (0,15 mm).

UP200456

Check Point 160:

Make sure calculations for spacer are accurate to 0.001 inch (0,025 mm).

(J)

Remove spacer (160), and bearing (outer race) (390) from bearing carrier assembly (40).

(k)

Install one spacer (180), compressor spring (170), and spacer (160) on the housing (250). Install outer race on bearing (390).

(D

Install assembled splined shaft (20) in seal housing (310).

(m)

Install at least two guide pins on housing assembly (310).

(n)

Carefully install bearing carrier (70) with bearing carrier assembly (40) on assembled splined shaft (20), the seal assembly, and housing assembly (310).

WARNING:

USE EYE PROTECTION WHEN YOU CUT THE LOCKWlRE. WHEN YOU CUT THE LOCKWlRE, PIECES THAT BREAK OFF CAN HIT YOUR EYES AND CAUSE INJURY.

CAUTION:

MAKE SURE LOAD COMPRESSOR BACKFACE INSULATOR (300) IS NOT PINCHED UNDER SEAL HOUSING (310).

(o)

Remove guide pins from housing assembly (310). Install bolts (30) and tighten to a torque value of 50 in-lb (5,7 Nm). Lockwire bolts per AS567.

(P)

Install special bolts (30) in slots of load compressor diffuser (10).

49-26-49 Copying, use or disclosure of information on this ,page is subject to proprietary restrictions

Page 798.80 Feb 28/05

Hone vell

UP200456

.

D.

(26)



(q)

Install assembled bearing carrier (70) on load compressor diffuser (10). Install washers (60) and nuts (50). Tighten nuts to a torque value of 20 in-lb (2,3 Nm) then loosen 1 turn to provide sufficient float of diffuser on bearing carrier.

(r)

Install packings (150) on bearing carrier (70).


Page 798.81 Feb 28/05

Hone) well



SCROLL ASSEMBLY

370

10

j

SPLINEDSHAFT

10 "~"60

370

ROTAT,NO~ROUP-._...._~

X3800504AY77

UP200456

Installation of the Assembled Bearing Carrier Figure 746


Page 798.82 Feb 28/05

Honeywell 4.

D.

(27)



Install the assembled bearing carrier. (Refer to Figure 746.) (a)

Make sure exposed curvics are clean.

(b)

Install curvic ring seal (370) on the scroll assembly shaft.

(c)

Install the assembled bearing carrier (70) on the scroll assembly with nuts

(50). (d)

Tighten nuts (50) to a torque value of 20 in-lb (2,3 Nm).

(e)

Align balance index marks and install round nut (10).

(f)

Look at all curvics for proper engagement. Tighten round nut to a torque value of 50 in-lb (5,7 Nm). Measure and write Dimension RFL (refer to 4.C.(3)(c), Figure 716). Dimension RFL must be the same as originally measured in step 4.C.(3)(c) ___0.04inch (1,0 mm). Look for damaged or incorrect engagement of curvics if dimension cannot be met.

CAUTION:


(g)

Install 833094-1 shaft stretching fixture and apply approximately the same pressure as applied in 4.C.(3)(I). Tighten round nut (60). Reduce ram pressure to zero and remove 833094-1 shaft stretching fixture.

(h)

Use Dimensions TB,TD,CB,and CD previously measured to calculate A RSL (RSL correction factor): TB +CB -TD -CD = A RSL

(i)

Measure and write Dimension RSL (refer to 4.C.(3)(i), Figure 716). Dimension RSL must be the same as originally measured in step 4.C.(3)(j) after correcting for thickness of actual turbine and compressor bearings. Adjust the ram pressure until the following formula is met within a tolerance of _+.0005: RSL (just measured) = RSL (measured in step 4.C.(3)(j)) + A RSL. Check Point 170:

Make sure the shaft stretch (RSL) measurement is correct.

(j)

Install 834149-1 vacuum check tool on bearing carrier (70) and apply vacuum. A vacuum of at least 25 inches (635 mm) Hg is necessary. No leakage is allowed.

(k)

Use 834120-1 nut staking fixture to stake round nut (10) collar at the axial groove of the tieshaft threads.


UP200456

10. ROUND NUT (IPC, FIG. 25) 50. NUT 60. WASHER

70. 370.

BEARING CARRIER CURVIC RING SEAL


Page 798.83 Feb 28/05

Honeywell



GRAVITYLOAD

SURFACEA ~

\ ENGINE COMPRESSOR ASSEMBLY

BEARING CARRIER

SURFACEB A3800279AY200

UP200456

Runout Check of the Turbine and Compressor Assy Figure 747


Page 798.84 Feb 28/05

Honeywell 4.

D.

(28)



Do a runout check of the turbine and compressor assembly. (Refer to Figure 747.) (a)

Install 833105-1 lift fixture minus hoist ring onto the engine compressor assembly.

(b)

Turn the turbine and compressor assembly so that it is standing on the 833105-1 lift fixture.

(c)

Attach 833449-1 micing fixture onto either the engine compressor housing assembly or bearing carrier as needed to do the necessary runout checks.

(d)

Do a runout check on Surfaces A and B.

(e)

The runout must not be more than 0.002 inch (0,05 mm).

UP200456

Check Point 180:

Make sure the runout on Surfaces A and B are in limits.


Page 798.85 Feb 28/05


Hone) well


20D

\

20B

\

3O

/

\ \

20C 20F

\ 20E X3800504PL26

UP200456

Install the Turbine Plenum Blanket Figure 748


Page 798.86 Feb 28/05

Honeywell 4.

D.

(29)



Install the turbine plenum blanket. (Refer to Figure 748.) (a)

Install turbine plenum blankets (20B through 20F) on turbine and compressor assembly (30). Use Iockwire to attach blankets.


UP200456

20B. 20C. 20D.

SIDE BLANKET (IPC FIG. 20) FLANGE BLANKET FLANGE BLANKET ASSY

20E. SIDE BLANKET 20F. UPPER BLANKET 30. TURBINE AND COMPRESSOR


Page 798.87 Feb 28/05


Honeywell


5O

110

/

20

100N ~

20 I0,,~

y

6O 10 20 .80

<

" 2 ./^-

10.20~

\

\

120 130

\

140

A3800504AY158

UP200456

Installation of the Combustor, Turbine Plenum Assy and Mounting Hardware Figure 749


Page 798.88 Feb 28/05


Honeywell 4.

D.

(30)


Install the combustor, turbine plenum assembly and mounting hardware. (Refer to Figure 749.) (a)

Install combustion chamber (120) on turbine nozzle assembly.

CAUTION:

MAKE SURE THAT THE LARGE DIAMETER OF TURBINE SHROUD SEAL FACES AFT.

(b)

Install turbine seal (130) in turbine plenum assembly (110). Make sure that the wide side of turbine seal (130) is facing the exhaust end of the APU.

(c)

Install turbine plenum assembly (110) on turbine and compressor assembly (140).

CAUTION:

MAKE SURE THAT THE TURBINE HOUSING IS ALIGNED TO ENGAGE ENGINE COMPRESSOR SHROUD ALIGNMENT PIN.

(d)

Use 833186-1 plenum puller fixture to remove turbine plenum assembly if not properly aligned.

(e)

Install left engine mount (90) and right engine mount (100). Attach with bolts (60, 70), spacers (80), washers (20) and nuts (10).

(f)

Install hoist mount (50). Attach with bolts (30, 40), washers (20) and nuts

(10). (g)

Install bolts (30, 40) and washers (20) and nuts (10) in remaining holes of turbine plenum assembly (110) and turbine and compressor assembly (140).

(h)

Tighten bolts (60, 40) to a torque value of 60 in-lb (6,8 Nm).

(i)

Use 833105-1 power section lift fixture to place power section on 835332-1 maintenance stand with 2024008-1 fixture assembly to secure power section.

~ll

UP200456

10. 20. 30. 40. 50. 60. 70.

NUT (IPC FIG. 24) WASHER BOLT BOLT HOIST MOUNT BOLT BOLT

KEY TO FIGURE 749 80. 90. 100. 110. 120. 130. 140.

SPACER LEFT ENGINE MOUNT RIGHT ENGINE MOUNT TURBINE PLENUMASSY COMBUSTION CHAMBER TURBINE SEAL TURBINEAND COMPRESSORASSY


Page 798.89 Feb 28/05


Honeywell


~A

¢/ 42

30

120

60

\

SO

K//11o

70

t 0 " " b 90 X3800504PL190

UP200456

Install the Pressure and Scavenge Tubes Figure 750


Page 798.90 Feb 28/05


Hone) well 4,

D.

(30)


Install pressure and scavenge tubes. (Refer to Figure 750.) (a)

Install 834303-1 vacuum check tubes and do a vacuum check. A minimum of 10 inches Hg (69,0 psi) vacuum is necessary.

(b)

Remove 834303-1 vacuum check tubes.

(c)

Install packings (110) on oil pressure tube (100).

(d)

Use 833184-1 tube installation tool to install lower oil scavenge tube (70) in turbine ball bearing carrier. Tighten oil scavenge tube (70) to a torque value of 60 in-lb (6,8 Nm).

(e)

Insert oil pressure tube (100) in oil scavenge tube (70).

(f)

Remove 833184-1 tube installation tool.

(g)

Install tube shield (60) and gasket (50) over oil scavenge tube (70).

(h)

Install packing (40) on lube adapter assembly (80). Install lube adapter assembly (80) with gasket (40). Attach in place with washers (20) and bolts (10). Tighten bolts (10) to a torque value of 25 in-lb (2,8 Nm).

(i)

(Pre SB 49-6840) Install upper oil scavenge tube (70) in the APU. Use 833184-1 tube installation tool to tighten oil scavenge tube (70). Tighten oil scavenge tube to a torque value of 60 in-lb (6,8 Nm). (Post SB 49-6840) Install upper oil scavenge tube (75) in the APU. Use 833184-1 tube installation tool to tighten oil scavenge tube (75). Tighten oil scavenge tube to a torque of 60 in-lb (6,8 Nm).

(J)

Remove 833184-1 tube installation tool.

(k)

Install lower gasket (50) and tube shield (60).

0)

Install packings (40 or 41 and 42) on vent fitting (30 or 30A).

(m)

Install vent fitting (30 or 30A) with upper gasket (50). Attach in place with washers (20) and bolts (10). Tighten bolts to a torque value of 25 in-lb (2,8 Nm).


UP200456

10. 20. 30. 30A. 40. 41. 42. 50.

BOLT (IPC FIG. 23) WASHER VENT FITTING VENT FITTING (POST SB 49-6840) PACKING PACKING (POST SB 49-6840) PACKING (POST SB 49-6840) GASKET

60. TUBE SHIELD 70. OIL SCAVENGE TUBE 75. OIL SCAVENGE TUBE (POST SB 496840) 80. LUBEADAPTERASSY 90. INSERT 100. OIL PRESSURE TUBE 110. PACKING 120. TURBINE PLENUMASSY


Page 798.91 Feb 28/05


Honeywell


170

7O 6O

I\\

4O 3O

20

\

10

A~O~O~YI~

UP200456

Install the Fuel Nozzle Assembly and Temperature Sensor Figure 751


Page 798.92 Feb 28/05


Honeywell 4.

D.

(31)


Install the fuel nozzle assembly and temperature sensor. (Refer to Figure 751 .) (a)

Rotate the APU and clamp the turbine plenum in 287750-1 APU assembly stand.

(b)

Install preformed packing (90) and fuel nozzle shroud (100) on fuel nozzle assembly (80).

(c)

Install fuel nozzle assembly (80) in turbine plenum. Attach in place with bolts (70). Tighten bolts to a torque value of 60 in-lb (6,8 Nm).

NOTE:

Make sure to align pin on fuel nozzle assembly with slot on shroud.

(d)

Install locking plate (60) and lock pins (50).

(e)

Install packings (30, 40) on temperaturesensor (20).

(f)

Install temperature sensor (20) with packings (30, 40) in the APU. Attach in place with bolts (10). Tighten bolts (10) to a torque value of 50 in-lb (5,7 Nm).

~KEY

UP200456

10. 20. 30. 40. 50.

BOLT (IPC FIG. 22) TEMPERATURE SENSOR PACKING PACKING LOCK PIN

TO FIGURE 751 60. LOCKING PLATE 70. BOLT 80. FUEL NOZZLE ASSY 90. PREFORMED PACKING 100. FUEL NOZZLE SHROUD

49-26-49


Page 798.93 Feb 28/05


Hone~vell


~--i..

i

!

...". ~,,':?-

" .-,.-:-,4"~,,",',,.m. i,~.. [.... "~'1,fl

'°"-

.....1 7 , ~ ; l!:

A

A

//7

30

"

110 (REF)

~

i/"

J .......

___.~- ---,a~,~,

I',

IO0

[ ,/r-- .... t

9O (REF)

40 -.

e~.Z)

-,~

,,

50 X3800504PL156

UP200456

(Post SB 49-7473 Pre SB 49-7587) Install Load Compressor Containment Shield Figure 751A


Page 798.94 Feb 28/05


Hone) well I

4.

D.

(32)


(Post SB 49-7473 Pre SB 49-7587) Install the load compressor containment shield. (Refer to Figure 751A). (a)

Install containment shields (20, 30, 40), flange (50), and bracket (60) with bolts (70, 80, 90, 100, 110) to a torque valve of 60 in-lb (6,78 Nm).


UP200456

20. TOP CONTAINMENT SHIELD SEGMENT (IPC, 49-26-45, FIGURE 26A) 30. SIDE CONTAINMENT SHIELD SEGMENT 40. BOTTOM CONTAINMENT SHIELD FLANGE 50. CONTAINMENT SHIELD FLANGE

60. 70. 80. 90. 100. 110.

CONTAINMENT SHIELD BRACKET BOLT BOLT BOLT BOLT BOLT


Page 798.95 Feb 28/05


Hone) vell


10

L3o /

6O

A3800504AY162

UP200456

Install the Compressor Inlet Screens and Inlet Ducts Figure 752


Page 798.96 Feb 28/05

Honeywell 4.

D.

(33)



Install the compressor inlet screens and inlet ducts. (Refer to Figure 752.) (a)

Install packing (105) on data memory module (100).

(b)

Install data memory module (100) inside inlet duct assembly (10). Attach in place with bolts (90), washers (80) and nuts (70).

(c)

Install inlet compressor screens (120) with attached parts on inlet duct assembly (10). Attach in place with screws (110).

(d)

Install seal (40), inlet duct assembly (10) with attached parts, quick coupler strap assembly (20) and T-bolt strap assembly (30) to turbine and compressor assembly (150).

4~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 80.

INLET DUCTASSY (IPC FIG. 21) QUICK COUPLER STRAPASSY T-BOLT STRAP ASSY SEAL RIVET NUTPLATE NUT BOLT

TO FIGURE 752 90. 100. 105. 110. 120. 130. 140. 150.

WASHER DATAMEMORY MODULE PACKING SCREW COMPRESSOR INLETSCREEN RIVET NUTPLATE TURBINEAND COMPRESSORASSY


Page 798.97 Feb 28/05

Honeywell



110

\

'

\ 3O \ 40"50

60

70

\

10 20 A3800504AYIB3

UP200456

Install the Quill Shaft Figure 753


Page 798.98 Feb 28/05

Hone ell .

E.



Assemble Turbine and Compressor Assembly. (Refer to Figure 753.) (1)

Install quill shaft.

(a)

Install packings (50, 70) on quill shaft (60).

(b)

Install quill shaft (60) in turbine and compressor assembly (110).

(c)

Attach quill shaft (60) in place with spacer (40) and retaining ring (30).

(d)

Install packing (20) in groove of bearing carrier on turbine and compressor assembly (110).

(e)

Install packing (10) in turbine and compressor assembly.


UP200456

10. PACKING (IPC FIG. 15) 20. PACKING 30. RETAINING RING 40. SPACER

50. 60. 70. 110.

PACKING QUILLSHAFT PACKING TURBINEAND COMPRESSORASSY


Page 798.99 Feb 28/05

Honeywell



f

q

I

•

A3B00504AY28

UP200456

Install the Gearbox Assembly Figure 754


Page 798.100 Feb 28/05


Hone) well 4.

E.

(2)


Install gearbox assembly. (Refer to Figure 754.) (a)

Install packing (40) on oil transfer tube in gearbox assembly (30).

Check point 190:

Make sure that a gearbox cavity inspection is accomplished before installing the gearbox.

(b)

Install gearbox assembly (30) on power section.

(c)

Attach in place with washer (20) and nuts (10). Tighten nuts to a torque value of 100 in-lb (11,3 Nm).

(d)

Remove engine from 287750-1 maintenance stand and remove 833426-1 maintenance stand adapters.

(e)

Install 834389-1,834390-2 and 834119-2 stand assembly support adapters on engine and install engine in 833565-3 portable gas turbine engine stand.

~KEY

UP200456

10. NUT (IPC FIG. 13) 20. WASHER

TO FIGURE 754 30. 40.

GEARBOX ASSY PACKING

49-26-49


Page 798.101 Feb 28/05

Hone~vell



7O

. 90

,/ ~

80

110

\ 230 '

\

V

-

p ~ \ 2oo 411

160

X3800504PL48

UP200456

Assemble the Lube Pump and Fuel Control Figure 755


Page 798.102 Feb 28/05

Hone) vell 4.

E.

(3)



Assemble the lube pump and fuel control. (Refer to Figure 755.)

(a)

Install packings (210) on transfer tube (200).

(b)

Install packing (190) on transfer tube (180).

(c)

Install packing (220) on gearbox.

(d)

Install lube pump (170) with transfer tube assemblies (180, 200) and packings (190, 210) on the gearbox assembly (230).

(e)

Attach lube pump (170) on gearbox assembly (230). Attach in place with washers (150) and bolts (140, 160).

(f)

Install tube nut (100) and packing (130) on adapter (110).

(g)

Install tube nut (60) and packing (90) on adapter (70).

(h)

Install adapter (70, 110) with assembled items in lube pump (170).

(i)

Install packing (50) on plug (40). Install plug (40) with packing (50) in lube pump (170).

(J)

Install packing (30) on lube pump (170).

(k)

Install fuel control assembly (20) on lube pLUmp(170).

(I)

Attach in place with coupling clamp (10). Tighten coupling clamp to a torque value of 50 in-lb (5,7 Nm).

i'


UP200456

10. 20. 30. 40. 50. 60. 70. 90. 100. 110.

COUPLING CLAMP (IPC FIG. 12) FUEL CONTROLASSY PACKING PLUG PACKING TUBE NUT ADAPTER PACKING TUBE NUT ADAPTER

130. 140. 150. 160. 170. 180. 190. 200. 210. 220. 230.

PACKING BOLT WASHER BOLT LUBE PUMP TRANSFER TUBE PACKING TRANSFER TUBE PACKING PACKING GEARBOX ASSY


Page 798.103 Feb 28/05


Honeywell


1

b.. j

70 80'X% f

J

J

\

110 100

gO

X3800504AY78

UP200456

Install the Fan Assembly Figure 756


Page 798.104 Feb 28/05


Hone) well 4.

E.

(4)


Install the fan assembly. (Refer to Figure 756.)

(a)

Install packings (100, 110) on fan assembly (90).

(b)

Install fan assembly (90) on gearbox assembly (190).

(c)

Attach fan assembly (90) in place with washers (80) and bolts (70).


UP200456

70. BOLT (IPC FIG. 9) 80. WASHER 90. FAN ASSY

100. PACKING 110. PACKING 190. GEARBOX ASSY


Page 798.105 Feb 28/05


Honeywell


I/

A 20

80

\

\ 2O

A A3800504AY26

UP200456

Install the Starter Motor and Oil Temperature Regulator (Oil Cooler) Figure 757


Page 798.106 Feb 28/05

Hone vell 4.

E.

(5)



Install the starter motor and oil temperature regulator (oil cooler). (Refer to Figure 757.) NOTE:

Connect oil scavenge line to oil pump before installing starter motor.

(a)

Install starter motor (70) with packing (80) on gearbox assembly (230). Attach in place with coupling clamp (60).

(b)

Install bracket (50) to the gearbox assembly (230). Attach in place with bolts

(c)

Install oil temperature regulator (30) on bracket (50). Attach in place with washers (20) and bolts (10).

(40, 45).


UP200456

10. 20. 30. 40. 45.

BOLT (IPC FIG. 11) WASHER OIL TEMPERATURE REGULATOR BOLT BOLT

50. 60. 70. 80. 230.

BRACKET COUPLING CLAMP STARTER MOTOR PACKING GEARBOX ASSY


Page 798.107 Feb 28/05


Honeywell


120 130 140

170 180

\

/A

290

\

f

/_.

170 180

nee

~.

i@ 0

'~"

120 130 140

150 160

100 220

110

110 120 130

X3800504AY79

UP200456

(Pre SB 49-6658,6699) Install the Transducer Assy, Engine Hoist Assy, Oil Sump Temperature Sensor and Pressure Sensor (Code A) Figure 758 (Sheet 1 of 2)


Page 798.108 Feb 28/05

Honeywell



120 110

I ' I I" . ~

,o\\

\,oo

~100

A X3800504AY86

UP200456

(Pre SB 49-6658/-6699) Install the Transducer Assy, Engine Hoist Assy, Oil Sump Temperature Sensor and Pressure Sensor (Code A) Figure 758 (Sheet 2)


Page 798.109 Feb 28/05

Hone)well 4.

E.

(6)



(Pre SB 49-6658,6699) Install the transducer assembly, engine hoist assembly, oil sump temperature sensor and pressure sensor. (Refer to Figure 758.) (a)

Attach transducer assembly (130) with gasket (140) to bleed duct (110) with bolts (120).

(b)

Install packing (100) and bleed duct (110) with attaching hardware. Attach to engine assembly (290) with bolts (220).

(c)

Install packing (130) nut (110) and PCD tee (120) on engine assembly (290).

(d)

Install sensor bracket (160), with bolts (150).

(e)

Install pressure sensor (140) with bolts (130) and nuts (120).

(f)

Install oil temperature sensor (170) with packing (180).

(g)

Install pressure sensor tube (180) with bolts (170).

(h)

~nstall engine hoist assembly (140B) on engine assembly (290). Attach with bolts (100, 120), washers (110, 130) and nut (90).


UP200456

90. 100. 100. 110. 110. 110. 120. 120. 120. 130. 130. 13'0. 130. 140.

NUT (IPC FIG. (11, 11A) BOLT PACKING (IPC FIG. 10) BLEED DUCT WASHER (IPC FIG. (11, 11A) NUT (IPC FIG. 14) PCD TEE BOLT (IPC FIG. 11, 11A) NUT (IPC FIG. 9) BOLT TRANSDUCERASSY (IPC FIG 10) PACKING(IPC FIG 14) WASHER (IPC FIG. 11, 11A) PRESSURESENSOR (IPC FIG. 9)

140. 140B. 145. 146. 147. 150. 160. 170. 170, 180. 180. 220. 290.

GASKET (IPC FIG. 10) HOIST BRIDGE (IPC FIG. 11, 11A) BOLT (IPC FIG. 11) HOIST RING INSERT BOLT (IPC FIG. 9) BRACKET BOLT (IPC FIG. 10) TEMPERATURE SENSOR PRESSURE SENSOR TUBE PACKING (IPC FIG. 9) BOLT (IPC FIG. 10) ENGINE ASSEMBLY


Page 798.110 Feb 28/05



Hone3~vell

120 130 300

160 170

\ -\

A 170 180

190 200 210 220 23O 24O

90 100

~so

\ 110

B

/ 110 120 130

X3B00504AYB0

UP200456

(Post SB 49-6658, 6699) Install the Transducer Assy, Engine Hoist Assy, Oil Sump Temperature Sensor and Pressure Sensor (Code B) Figure 758A (Sheet 1 of 2)


Page 798.111 Feb 28/05

Honeywell



250 ~ ( ~

~

"

270

A 146"--~;'....

"'

110

i]r

.~

B X3800504AY87

UP200456

(Post SB 49-6658, 6699) Install the Transducer Assy, Engine Hoist Assy, Oil Sump Temperature Sensor and Pressure Sensor (Code B) Figure 758A (Sheet 2)


Page 798.112 Feb 28/05

Hone) vell 4.

E.

(7)



(Post SB 49-6658, 6699) Install the transducer assembly, engine hoist assembly, oil sump temperature sensor and pressure sensor. (Refer to Figure 758A.) (a)

Attach transducer assembly (200) and bracket (240) to gearbox with bolts (210, 220, 230).

(b)

Install packing (100) and bleed duct (110) with attaching hardware. Attach to engine assembly (360) with bolts (90).

(c)

Attach flow assembly (300) and gasket (130) to bleed duct (110) with bolts (120).

(d)

Install packing (130) nut (110) and PCD tee (120) on engine assembly (360).

(e)

Attach pressure sensor (260) and bracket (270) to gearbox with bolts (10,

25o). (f)

Install oil temperature sensor (170) with packing (180).

(g)

Install pressure sensor tube (170) with bolts (160).

(h)

Install engine hoist assembly (140B) on engine assembly (360). Attach with bolts (100, 120), washers (110, 130) and nut (90).


UP200456

10. 90. 90. 100. 100. 110. 110. 110. 120. 120. 120. 130. 130. 130. 140. 40B. 145. 146.

BOLT (IPC FIG. 11A) NUT (IPC FIG. 11, 11A) BOLT (IPC FIG. 10A) PACKING BOLT (IPC FIG. 11, 11A) WASHER BLEED DUCT (IPC FIG. 10A) NUT (IPC FIG. 14A) PCD TEE BOLT (IPC FIG. 11, 11A) BOLT (IPC I=IG. 10A) GASKET PACKING (IPC FIG 14) WASHER (IPC FIG. 11, 11A) HOIST BRIDGE ENGINE HOIST BRIDGE ASSY BOLT (IPC FIG. 11) HOIST RING

147. 160. 170. 170. 180. 190. 200. 210. 220. 230. 240. 250. 260. 270. 300. 360.

INSERT BOLT (IPC FIG. 10A) PRESSURE SENSOR TUBE OIL TEMPERATURE SENSOR (IPC FIG. 9A) PACKING BOLT TRANSDUCER ASSY BOLT BOLT BOLT BRACKET BOLT (IPC FIG. 11A) PRESSURE SENSOR BRACKET FLOW ASSY (IPC FIG 10A) ENGINE ASSEMBLY


Page 798.113 Feb 28/05

Hone~vell



140

\

150

°o°J

0

0

-ti .,ql~. A

80

260

90 230 240

180

~

190 200 210

160 170 180 t90

SO

ROTATED

A

A3800504AY164

UP200456

Install the Immersion Thermocouple and Ignition Exciter Figure 759

49-26-49


Page 798.114 Feb 28/05


Hone) well 4.

E.

(8)


Install the immersion thermocouple and ignition exciter. (Refer to Figure 759.) (a)

Install ignition box bracket (260), insulator spacer (240) and ignition exciter (230) with bolts (90).

(b)

Install gaskets (210) and immersion thermocouples (200) with bolts (190).

(c)

Attach ecology drain tank (150) to plenum drain line and tailpipe with nuts (160, 180) and sleeves (170, 190).

(d)

Install secondary fuel manifold (150) and primary fuel manifold (140) to fuel nozzleessembly (80) on engine assembly (280).

(e)

Install flow divider valve assembly (70). Attach in place with washers (60) and bolts (50).

(f)

Install packings (80, 90) on unions (100, 110).

~1~ KEY TO FIGURE 759 BOLT (IPC FIG. 3) WASHER FLOW DIVIDER VALVE ASSY FUEL NOZZLE (IPC FIG. 22) PACKING (IPC FIG. 13) PACKING BOLT (IPC FIG. 10) UNION (IPC FIG. 13) UNION PRIMARY FUEL MANIFOLD (IPC FIG. 14) 150. SECONDARY FUEL MANIFOLD

UP200456

50. 60. 70. 80. 80. 90. 90. 100. 110. 140.

150. 160. 170. 180. 190. 190. 200. 210. 230. 240. 260. 280.

ECOLOGY DRAIN TANK (IPC FIG. 13) NUT SLEEVE NUT SLEEVE BOLT (IPC FIG. 10) IMMERSION THERMOCOUPLE GASKET IGNITION EXCITER INSULATOR SPACER IGNITION BOX BRACKET ENGINEASSY


Page 798.115 Feb 28/05


Honeywell


~-A - - J

80

10

7/

• 50

30 40

A X3800504AY81

UP200456

(Pre SB 49-6634) Install the Bleed Duct Elbow and Load Control Valve (Code A) Figure 760


Page 798.116 Feb 28/05

Honeywell 4.

E.

(9)



(Pre SB 49-6634) Install the bleed duct elbow and load control valve. (Refer to Figure 760.)

(a)

Attach brackets (50, 80) to engine assembly (290) and bleed duct with bolts (40) and nuts (30).

(b)

Install coupling clamps (10) on bleed duct.

(c)

Tighten coupling clamps (10) to a torque value of 90 to 100 in-lb (10,2 to 11,3 Nm).

(d)

Install bleed duct elbow (60) with load control valve (70).


UP200456

10. 30. 40. 50.

COUPLING CLAMP (IPC FIG. 10) NUT BOLT BRACKET

60. 70. 80. 290.

BLEED DUCT ELBOW LOAD CONTROLVALVE BRACKET ENGINE ASSY

49-26-49


Page 798.117 Feb 28/05



Hone)~vell

-,----,--i

~-A T--

-7 10

-it

50

3O

,o

A X3800504AY82

UP200456

(Post SB 49-6634) Install the Bleed Duct Elbow and Load Control Valve (Code B) Figure 760A

49-26-49


Page 798.118 Feb 28/05

Honeywell 4.

E.

(10)



(Post SB 49-6634) Install the bleed duct elbow and load control valve. (Refer to Figure 760A.) (a)

Attach strut supports (50, 80) to engine assembly (360) and bleed duct with bolts (40) and nuts (30).

(b)

Install coupling clamps (10) on bleed duct.

(c)

Tighten coupling clamps (10) to a torque value of 90 to 100 in-lb (10,2 to 11,3 Nm).

(d)

Install bleed duct elbow (60) with load control valve (70).

~ l n KEY TO FIGURE 760A

UP200456

10. 30. 40. 50.

COUPLING CLAMP (IPC FIG. 10A) NUT BOLT STRUT SUPPORT

60. BLEED DUCT ELBOW 70. LOAD CONTROL VALVE 80. STRUT SUPPORT 360. ENGINEASSY


Page 798.119 Feb 28/05


Hone~weU


180

130 10

30

40

o©o

A

O

O

10

50

120

/

20

20

A X3800504AY83

UP200456

(Pre SB 49-6634, 6775) Install the Surge Control Valve, Igniter Plug and Igniter Lead (Code A) Figure 761

49-26-49 Copying, use or disclosure of informationon this page is subject to proprietaryrestrictions

Page 798.120 Feb 28/05

Honeywell 4.

E.

(11)



(Pre SB 49-6634, 6775) Install the surge control valve, igniter plug and igniter lead. (Refer to Figure 761.)

(a)

Install gasket (140), igniter plug (130), and igniter lead (120) into engine assembly (180).

(b)

Tighten igniter plug (130) to a torque value of 180 in-lb (20,3 Nm).

(c)

Install exhaust surge duct (40) and surge control valve (50) with coupling clamps (10, 30).

(d)

Install surge duct (20) with coupling clamp (30).


UP200456

10. 20. 20. 30. 40.

CLAMP (IPC FIG, 14A) SURGE DUCT COUPLING CLAMP (IPC FIG. 10) COUPLING CLAMP (IPC FIG. 14A) EXHAUST SURGE DUCT

50. 120. 130. 140. 180.

SURGE CONTROL VALVE IGNITER LEAD (IPC FIG. 13) IGNITER PLUG GASKET ENGINEASSY

49-26-49


Page 798.121 Feb 28/05


Hone)~vell


220

130 10

30

A

'

I

50

TURBINE

PLENUM ~~

210

I

'

'

120

20

!0 (REF~ 40 (REF)

~_, ~

2OO

A

X3800504AY84

UP200456

(Post SB 49-6634, 6775) Install the Surge Control Valve, Igniter Plug and Igniter Lead (Code B) Figure 761A

49-26-49

Copying,useordisclosureofinformationonthispageissubjecttoproprietaryrestrictions

Page 798.122 Feb 28/05

Hone well 4.

E.

(12)



(Post SB 49-6634, 6775) Install the surge control valve, igniter plug and igniter lead. (Refer to Figure 761A.) (a)

Install gasket (140), igniter plug (130), and igniter lead (120) on engine assembly (220).

(b)

Tighten igniter plug (130) to a torque value of 180 in-lb (20,3 Nm).

(c)

Install exhaust surge duct (40) and surge control valve (50) with coupling clamps (10, 30).

(d)

Attach exhaust surge duct (40) with stiffener (200), bracket (210), bolts (190), washer (180) and nut (60).

(e)

Install surge duct (20) with coupling clamp (30).


UP200456

10. 20. 20. 30. 40. 50. 60. 120.

CLAMP (IPC FIG. 14) SURGE DUCT COUPLING CLAMP (IPC FIG. 10) COUPLING CLAMP (IPC FIG. 14) EXHAUST SURGE DUCT SURGE CONTROL VALVE NUT IGNITER LEAD (IPC FIG. 13)

130. 140. 180. 190. 200. 210. 220.

IGNITER PLUG GASKET WASHER (IPC FIG 14) BOLT STIFFENER BRACKET ENGINE ASSY


Page 798.123 Feb 28/05


Hone) well


'I 60

f--

10

i L1

~ " " _~__r-

j

/

i

' / i~'-7"

! i

i ~

L" 1.

X3800504AY85

UP200456

Install the Fan Inlet Duct, Fan Exit Duct and Oil Cooler Duct Figure 762


Page 798.124 Feb 28/05

Honeywell 4.

E.

(13)



Install the fan inlet duct, fan exit duct and oil cooler duct. (Refer to Figure 762.)

(a)

Install fan exit duct (60) with clamp (50).

(b)

Install oil cooler duct (40) with clamps (30).

(c)

Install fan inlet duct (20) with bolts (10).

(d)

Tighten clamps (30, 50) to a torque value of 20 to 25 in-lb (2,3 to 2,8 Nm).


UP200456

10. BOLT (IPC FIG. 9) 20. FAN INLET DUCT 30. CLAMP

40. OIL COOLER DUCT 50. CLAMP 60. FAN EXIT DUCT


Page 798.125 Feb 28/05

Honeywell

7°.,,.



10 4O

t

A

_

|

II II

)i !

A3800504PL106

UP200456

Plumbing and Electrical Installation (Part No. 3615682) (Code A) (Partial Breakdown) Figure 763


Page 798.126 Feb 28/05


Honeywell .

F.


Plumbing and Electrical Installation. (Refer to Figure 763.) WARNING:

NOTE:


All packings are to be installed using a lubricant compatible with the system in which the packing is used. (i.e. Packings used in oil systems are to have oil (MIL-PRF7808 or MIL-PRF-23699) applied)). An approved alternate method is to use lubricant (OS-124) on all packings before installation. (Refer to Figures 763 through 769B.) Apply thread compound (Liqui-Moly) to all fittings, unions, and tees before installation.

(1)

Assemble plumbing and electrical installation. (a)

Assembly of the plumbing and electrical installation must be done when possible during the installation of external components.

(b)

Install new packings and gaskets during assembly.


UP200456

10. 20. 30. 40.

NUT (IPC FIG. 8) BOLT CLAMP CLAMP

50. BOLT 60. SPACER 70. WIRING HARNESS


Page 798.127 Feb 28/05


Hone vell


10 3O 4O 5O

100 110 120

"~-'~ \

120 130

\

;/

10 20 5O 9O

8O

70

60

10 30 40 50

220

200 210 A3800504PL195

UP200456

Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 763A


Page 798.128 Feb 28/05

Honeywell 4.

F.

(2)



Install electrical connectors. (a)

Threaded connector installation. 1

m

Find the correct position of the plug in relation to the receptacle by aligning the key of one part with the groove keyway of the other part.

CAUTION:

2

DO NOT USE FORCE TO ENGAGE CONNECTORS TO RECEPTACLES. DO NOT HAMMER A PLUG INTO ITS RECEPTACLE. DO NOT USE A TORQUE WRENCH OR PLIERS TO LOCK COUPLING RINGS.

Start the plug into the receptacle with a light forward pressure and engage the threads of the coupling ring and receptacle. NOTE:

Use connectors pliers to tighten coupling rings more than finger tight if space around the connector is too small to get a good finger grip.

Alternately push in plug and tighten the coupling ring until the plug is completely installed.

~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110.

NUT (IPC FIG. 8A) BOLT BOLT SPACER CLAMP TUBE ASSY VALVE ASSY TUBE ASSY CLAMP NUT ELBOW

TO FIGURE 763A 120. 130. 140. 150. 160. 170. 180. 190. 200. 210. 220.

PACKING UNION BOLT BRACKET CLAMP TUBE ASSY TEETUBE CLAMP UNION PACKING TUBE ASSY


Page 798.129 Feb 28/05

Hone vell



10 20 ,50

10 20 50 230

10 30 40

10 20 50 90

80

100 110 1:t0

70

80

120 130

10 30 40 50

220

200 210

A3800504PI.201

UP200456

Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 763B


Page 798.130 Feb 28/05

Hone well 4.

F.

(2)


(b)

COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Bayonet connector installation.

CAUTION:

1

DO NOT USE CONNECTOR PLIERS. Find the correct position of the plug in relation to the receptacle by aligning the key of one part with the groove or keyway of the other part. Start the plug into the receptacle with a light forward pressure and engage the coupling ring and receptacle.

3

To complete the installation turn coupling ring clockwise until an audible sound (click) is heard.

_4

Coupling is installed correctly when visual examination shows: Three axial stripes on the coupling ring aligned with three corresponding stripes on the receptacle, or coupling pins on the receptacle are visible through holes in the coupling ring.

~1~ KEY TO FIGURE 763B

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110.

NUT (IPC FIG. 8B) BOLT BOLT SPACER CLAMP TUBE ASSY VALVE ASSY TUBE ASSY CLAMP NUT ELBOW

120. 130. 140. 150. 160. 170. 180. 190. 2OO. 210. 220. 230.

PACKING UNION BOLT BRACKET CLAMP TUBE ASSY TEETUBE CLAMP UNION PACKING TUBE ASSY BRACKET


Page 798.131 Feb 28/05

Hone)~vell



..~ \, "-'~~~'\ ,

~

",

~ ~~ ;t f ~ - "

\ ~//'" k~';_, i/." ~:

!\ ,,,-/-

,

10 20

/..1 ~ "_2 30

/

-,~

-..

A

A

~.i_------._..~ _.,

X3800504PLI~

UP200456



Page 798.132 Feb 28/05

HoneTwell



~ 1 ~ KEY TO FIGURE 764

UP200456

10. 20.

NUT (IPC FIG. 7) BOLT

30. 40.

CLAMP BRACKET


Page 798.133 Feb 28/05

Honeywell



30 40 120

11o~ |

I I

t

®

I

t

80 90 100

10 20 60

!

!

30 40 50

70 A3800504PL194

UP200456



Page 798.134 Feb 28/05

Hone vell



'~KEY

UP200456

10. 20. 30. 40. 50. 60.

NUT (IPC FIG. 7A) BOLT SPACER CLAMP BOLT CLAMP

TO FIGURE 764A 7O. 80. 90. 100. 110. 120.



Page 798.135 Feb 28/05


Hone~vell


30 40 120

11o~ I

;

I

f

i

!

® ~H

!

80 90 100

10 20 60 70

30 40 50

A3800504PL194

UP200456



Page 798.136 Feb 28/05


Hone vell


41~ KEY TO FIGURE 764B

UP200456

10. 20. 30. 4O. 50. 60.

NUT (IPC FIG. 7B) BOLT SPACER CLAMP BOLT CLAMP

70. 80. 90. 100. 110. 120.

BRACKET NUT PACKING ELBOW HOSEASSY BOLT


Page 798.137 Feb 28/05

Honeywell

10 20 40 60



20 200 240

10 30 4O 70 25O

1~)

10 40 60 70 250 /

1~)

10 20 40 5/0

90 I

\

10 20 40 80

140

\

I

l

,t

1

/

100 110

/ 220 230

'

210

/ 170 180

170

u - \ . \150

J' / 190

160 170

250 260

10 3O 70 X3800504PL147

UP200456



Page 798.138 Feb 28/05

Honeywell



~111 KEY TO FIGURE 765

UP200456

10. 20. 30. 40. 50. 60. 70. 8O. 90. 100. 110. 120. 130.

NUT (IPC FIG. 6) BOLT CLAMP CLAMP CLAMP CLAMP SPACER CLAMP DE-OIL SOLENOID REDUCER PACKING TUBE ASSY TUBEASSY

140. 150. 160. 170. 180. 190. 200. 210. 220. 230. 24O. 250. 260.

TUBEASSY TEE REDUCER PACKING REDUCER LOP SWITCH RETAINER TUBEASSY UNION PACKING PACKING BOLT RETAINER

49-26-49 Copying,use or disclosureof informationon this pageis subject to proprietaryrestrictions

Page 798.139 Feb 28/05

Hone) vell



10 90 110 120 190

10 120 200 210 220

40

260

240

250

10 10 90 20 110 280 120

300 310

20 170 180 160 140 140 150 10 20 120 130

10 90 100 110

80

70

60

40 50

30 40

10 20 120 130

10 20 130

10 90 110 190 280

320 360 330 370 350 380 390

320 330 340 350

A~300504F'LI93

UP200456



Page 798.140 Feb 28/05

Hone vell




UP200456

10. 20. 30. 4O. 50. 60. 7O. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180. 190. 200.

NUT (IPC FIG. 6A) BOLT REDUCER PACKING LOP SWITCH TEE UNION TUBE ASSY BOLT CLAMP SPACER CLAMP CLAMP UNION PACKING UNION RETAINER PACKING CLAMP BOLT

210. 220. 230. 240. 25O. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360. 370. 380. 390.



Page 798.141 Feb 28/05

Honeywell



10 90 110 120 190

10 120 200 210 22O

40 230

240

250

10 20 280

260 270

10 9O 110 120

;° J

20 170 180

310

11

160 140 140 150

10 ~ 20 120 130

/ 10 IO0 110

80

70

60

40 50

30 40

10 20 120 130

10 20 130

10 90 110 190 280

320 330 3,50 390

320 330 340 350

360 370 380

A3800504PL200

UP200456



Page 798.142 Feb 28/05


Hone vell


~KEY

UP200456

10. 20. 30. 40. 50. 60. 7O. 8O. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180. 190. 200.

NUT (IPC FIG. 6B) BOLT REDUCER PACKING LOP SWITCH TEE UNION TUBE ASSY BOLT CLAMP SPACER CLAMP CLAMP UNION PACKING UNION RETAINER PACKING CLAMP BOLT

TO FIGURE 765B

210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360. 370. 380. 390.



Page 798.143 Feb 28/05



Honeywell

10 20 40 60

~cck/,~/;

/ //

10 40 180 220 230

10 20 30 40

10 20\

10 20 180

70 "~'~-~

~

4o ~ / / i "~/~ ~

22o / .~,:

170

19o

t'~__~ ~--~'~ ~ '

\\

I.o ~)'~: '~b,,/g\ .

20

20 40 100

,:-...

~;

..

20 40 190

~ ,

i ~. . . . it..

180

A 10

B

90

110 120 200

,w

\.

\

\ !J.s,,'vj."j~m.

"f~ /10 .: ': f,~ 20 "~" 170 180

BI

\

I,ii I )11 l {

./()i

10-~---

'°

170 180

)

210

i l t L! k! I

., -

A

140

80

X3800504PL145

UP200456



Page 798.144 Feb 28/05


Honeywell


~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 8O. 90. 100. 110.

NUT (IPC FIG. 5) BOLT CLAMP CLAMP DELETED CLAMP TUBE ASSY TUBE ASSY BRACKET CLAMP ELBOW

TO FIGURE 766

120. 130. 140. 150. 160. 170. 180. 190. 2O0. 210. 220. 230.

NUT CLAMP TEE REDUCER PACKING CLAMP CLAMP CLAMP PACKING UNION SPACER BOLT


Page 798.145 Feb 28/05


Hone~vell


UP200456



Page 798.146 Feb 28/05


Honeywell


10 20 70

\

!

L~ i 50

GO

|

t ' ' rI

=,

I

/ I

_/'1'

,t

10 70 110 120 130

10 20 8O 100

7O 8O

A

A3800504F'L191

UP200456

Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 766A (Sheet 1 of 2)


Page 798.147 Feb 28/05


Hone vell

10 20 80 100


140 150

150 160 170

50 180

A

I0 70 80 110 120

10 20 70 100

I0 20 70

I0 20 70 100

I0 20 190 200

120

A A3800504PL192

UP200456

Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 766A (Sheet 2)


Page 798.148 Feb 28/05

Honeywell




UP200456

10. 20. 30. 40. 5O. 60. 70. 80. 90. 100.

NUT (IPC FIG. 5A) BOLT TUBE ASSY ELBOW PACKING NUT CLAMP CLAMP TUBE ASSY CLAMP

110. BOLT 120. SPACER 130. CLAMP 140. PLUG 150. PACKING 160. NUT 170. ELBOW 180. UNION 190. BRACKET 200. CLAMP


Page 798.149 Feb 28/05


Honeywell


170A 170B 210A

160

/

zlo

17o

10 20 70

/" i, li

\

b

\

40 50 60

It i 14

/ #

/i

10 70 110 120 130

10 20 80 100

90

10 2O

~A

70 80 X3800504PL189

UP200456

Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 766B (Sheet 1 of 2)


Page 798.150 Feb 28/05

Hone~vell



UP200456



Page 798.151 Feb 28/05


Hone~vell


10 20 80

140 1.50

150 160 170

50

I

A %%

; ~i,,

" '

10 70 80 110 120

10 20 70 100

10 20 70

10 20 70 100

10 20 190 200

A

t

A

A3800504PL199

UP200456

Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 766B (Sheet 2)


Page 798.152 Feb 28/05

HoneTwell



4~KEY TO FIGURE766B

UP200456

10. 20. 30. 40. 5O. 60. 70. 80. 90. 100. 110. 120.

NUT (IPC FIG. 5B) BOLT TUBE ASSY ELBOW PACKING NUT CLAMP CLAMP TUBE ASSY CLAMP BOLT SPACER

130. 140. 150. 160. 170. 170A. 170B. 180. 190. 200. 210. 210A.

CLAMP PLUG PACKING NUT ELBOW UNION (POST SB 49-7578) SWIVEL FITTING (POST SB 49-7578) UNION BRACKET CLAMP PACKING SEAL (POST SB 49-7578)

49-26-49


Page 798.153 Feb 28/05

Honeywell :300- - . . . ~



~___----,

3 340

~"

160 10 30 330 340

27O 280

A

B 170 170 180 2OO 190 29O

100 130 310,

'-~ \1

10 21) 4O

210

~

|l

II

llllhl

11

20 250 280

,IilII~ E

260 :300

/ 10 40 330 340

/ 10 / 20 60 40 250

110 120 X380~'--~4PL142

UP200456



Page 798.154 Feb 28/05

Hone vell




UP200456

10. 20. 30. 4O. 50. 60. 7O. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170.

NUT (IPC FIG. 4) BOLT CLAMP CLAMP HOSEASSY TUBE ASSY NUT ELBOW PACKING PACKING CHECK VALVE TEETUBE NUT NUT PACKING ELBOW SCREW

180. 190. 200. 210. 220. 230. 240. 250. 260. 27O. 280. 290. 300. 310. 320. 330. 340.

RETAINER PACKING RETAINER TUBE ASSY TUBE ASSY UNION TUBE ASSY CLAMP PACKING CLAMP BRACKET PACKING REDUCER ELBOW CLAMP SPACER BOLT


Page 798.155 Feb 28/05


Honeywell


10 ., 20

~

(

C

i~_~.__~: _sr-"--

d

AI

lO,OlOlO 40 50 70

70 80

30

30 60

10 170 180

-~, ..-L~/~

,

20

.-

,

~..~~/I

1.~ 13o

"-i

/

':

~

~.,,, C-,'

-

210

='-'-'-'-'-'-'-'-'-~= lOO

7~tI ~r'-/v.~ i

,

,kJ ~! '~U/

11o .

X3800504PL143

UP200456

Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 767A (Sheet 1 of 2)


Page 798.156 Feb 28/05

Honeywell



UP200456



Page 798.157 Feb 28/05


Honeywell


17o ------~'~7 250 .j ~

%

.

"~ /@_

260 ~

/

--"

360

270~ . . x 280

"~

29o

-M~

310 350

,'4~.

/ju

30O 310

310 340

330

310 320

_B

m

10 2O 7O

10 20 3O 0

10 2O 3O 140

~ --~-,~_/~

A3800504PL190

UP200456

Plumbing and Electrical Installation (Part No. 3616215) (Code B) (Partial Breakdown) Figure 767A (Sheet 2)


Page 798.158 Feb 28/05


Honeywell


~ll

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180.

NUT (IPC FIG. 4A) BOLT CLAMP SPACER BOLT CLAMP CLAMP BRACKET NUT PACKING ELBOW BRACKET CLAMP CLAMP REDUCER PACKING BOLT CLAMP

KEY TO FIGURE 767A 190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 350. 360.

BRACKET BRACKET CLAMP TUBE ASSY REDUCER PACKING RETAINER BOLT NUT ELBOW PACKING UNION PACKING REDUCER TEE UNION NUT REDUCER


Page 798.159 Feb 28/05


gone well


10

,o C 3O

t•

t"--c

I I

A""

10 30 40 50 70

10 20 70 80

10 20 30

10 20 3O 60

10 170 180

190

150~ I

"~'," /\

200

.__..~. 210

~ 10 i-f'-- :-%~//

20 ~

120 1~-"--- ~ 130 "

~'

~ !

100

T~-~ 11o ' X3800504PL143

UP200456

Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 767B (Sheet 1 of 2)


Page 798.160 Feb 28/05


HoneTwell


UP200456



Page 798.161 Feb 28/05


Honeywell


170 250 260 360 270 280 290

310 350

300 310

310 340 330

310 320

10 20 70

B 10 20 30

10 20 30

A3800504PL190

UP200456

Plumbing and Electrical Installation (Part No. 3616519) (Code B) (Partial Breakdown) Figure 767B (Sheet 2)


Page 798.162 Feb 28/05


Honeywell


4~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180.

NUT (IPC FIG. 4B) BOLT CLAMP SPACER BOLT CLAMP CLAMP BRACKET NUT PACKING ELBOW BRACKET CLAMP CLAMP REDUCER PACKING BOLT CLAMP

TO FIGURE 767B

190. 200. 210. 220. 230. 240. 250. 260. 27O. 280. 290. 300. 310. 320. 330. 34O. 350. 360.

BRACKET BRACKET CLAMP TUBE ASSY REDUCER PACKING RETAINER BOLT NUT ELBOW PACKING NIPPLE PACKING REDUCER TEE UNION NUT REDUCER


Page 798.163 Feb 28/05


Honeywell


10 20 30 50 I

10 20 40 130

./"

,i

/

J

J

\ ~

)

li!

90 100

"\

//; ,

/,I

•/:]//

0

:: /

// 0

10 20 30 120

10 20 30 120

L____..__/ 10 20 70 110

110

X3800504PL141

UP200456



Page 798.164 Feb 28/05


Hone vell



UP200456

10. NUT (IPC FIG. 3) 20. BOLT 30. CLAMP 40. CLAMP 50. CLAMP 60. DELETED

70. 8O. 9O. 100. 110. 120. 130.

BRACKET PACKING ELBOW NUT CLAMP CLAMP BRACKET


Page 798.165 Feb 28/05


Honeywell

20 60


40 30 70 80

100

10

10 20 50 110

20 110 120

4) I

J

J

,f

~I~ "

/ 180

130 160 170

130 140 150

10 20 110 120 A3800504PL188

UP200456



Page 798.166 Feb 28/05


Hone3 vell



UP200456

10. 20. 30. 40. 5O. 6O. 7O. 80. 90.

NUT (IPC FIG. 3A) BOLT PACKING PACKING CLAMP TUBE ASSY TUBE ASSY TUBE ASSY" TUBE ASSY

100. 110. 120. 130. 140. 150. 160. 170. 180.

UNION CLAMP BRACKET SCREW TUBE RETAINER PACKING TUBE RETAINER PACKING TUBEASSY


Page 798.167 Feb 28/05


Honeywell

20

40 70


30 8O

100

SO

I// ~~

~,/~,------.

',,-. ~

I

, :',

,

N.

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.."

I .:'/+!!

f

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/

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,'-r--

~:"

"l~I ~

.'

o,

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.:

120

i;

, ' -T-F---t

10 20 110

:.

~

I ,,c~

I

~,-!

,

-,:, , -" ~

[

i! _

180

UP200456

.,';,

"-

.i

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'

~-._#~,~'T~----~-~,;

",,

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~- - - i ~ / , : .

~.~..,,~-~L~_-"--~"

~',

",

"y - :

::>~'=L~'.Z---~__~~

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L_

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=t~ E ~ I L ' I ~ I ~ L . E

ff~ddl

10 20 50 110

~

200 190 130 160 170

-.

210

130 140 150

10 20 110 120

A3801To04PL197



Page 798.168 Feb 28/05


Hone vell


~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 8O. 90. 100. 110.

NUT (IPC FIG. 3B) BOLT PACKING PACKING CLAMP TUBE ASSY TUBE ASSY TUBE ASSY" TUBE ASSY UNION CLAMP

TO FIGURE 768B

120. 130. 140. 150. 160. 170. 180. 190. 200. 210.

BRACKET SCREW TUBE RETAINER PACKING TUBE RETAINER PACKING TUBEASSY TEE TUBE ASSY TUBEASSY


Page 798.169 Feb 28/05


Honeywell


250__~N--'T7 430 ~ 260 230"~L~-~ ,_~/430

.o

(BEHIND FILTER)

70 140 330

80 140 340

10

20

110 410

I E~I

220 - ~ ' ~ L 240--'w~i~ 430

10

20

•/!~

350

110 ~I0.,

~,o

A 10 20 110 450

90 120 400

20 100 370 380

B130 60 360 \

~L.

40 390 280 _ ~

320

3O " ¢ ~ 25O

310~,

A'}~

ql

/ 10 50 190 200

10

20

300

10 20 180

420

10 l 10 270 20 170 20 280 150 t50 290 210 420

~ 160

10 20 150

10 20 150

420

420

10 20 150 410

180

420 X3800504PL140

UP200456



Page 798.170 Feb 28/05

Honeywell




UP200456

10. 20. 30. 40. 50. 60. 7O. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170. 180. 190. 200. 210. 220. 230.

NUT (IPC FIG. 2) BOLT ELBOW TUBE ASSY BOLT TUBE ASSY TUBE ASSY TUBE ASSY TUBE ASSY TUBE ASSY CLAMP PACKING TUBEASSY BOLT CLAMP TUBEASSY TUBE ASSY CLAMP CLAMP SPACER CLAMP TEE UNION

240. 250. 260. 270. 280. 290. 300. 310. 320. 330. 340. 35O. 360. 370. 380. 390. 400. 410. 420. 43O. 440. 450. 460.

REDUCER NUT UNION ELBOW REDUCER PACKING NUT TUBE ASSY PACKING UNION PACKING PACKING UNION PACKING RETAINER PACKING PACKING BOLT CLAMP CLAMP PACKING REDUCER CLAMP TUBE ASSY


Page 798.171 Feb 28/05


Hone~vell

230

240


250 260

10 100 110 310

270 270 280 290 280 300

A\\

\ ~

210 220 200

170 180 190

20 150 160

~

140

20 120 130

10 90 100 110

10 20 70 80

60 50

10

30

~

10 20 310

330

.... ~ :-~~// A A3800504PL187

UP200456



Page 798.172 Feb 28/05

Honeywell




UP200456

10. 20. 30. 40. 50. 60. 70. 8O. 90. 100. 110. 120. 130. 140. 150. 160. 170.

NUT (IPC FIG. 2A) BOLT TUBE ASSY CLAMP WIRE HARNESS REDUCER CLAMP CLAMP CLAMP SPACER BOLT TUBE ASSY PACKING TUBE ASSY TUBEASSY PACKING ELBOW

180. 190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 32O. 330.

PACKING NUT TUBE ASSY UNION PACKING TUBE ASSY TUBE ASSY TUBE ASSY PACKING REDUCER PACKING DE-OIL SOLENOID VALVE TUBE ASSY CLAMP CLAMP CLAMP

49-26-49


Page 798.173 Feb 28/05


Hone)~vell

230

210

200


270 270 280 290 280 300

250 260

240

10 100 110 310

~ : "~~ :~.~-~7--:-4:-:: ~ -

----~'~

170 190

.

/

150 160

/

/

/

i

/

14o

/ 120 130 340

/

10 9O 100 110

/

/

10 20 70 80

60

50

10 20 40

30

i

10

A A3800504PL196

UP200456



Page 798.174 Feb 28/05

Hone) vvell



~KEY

UP200456

10. 20. 30. 40. 50. 60. 70. 80. 90. 100. 110. 120. 130. 140. 150. 160. 170.

NUT (IPC FIG. 2B) BOLT TUBE ASSY CLAMP WIRE HARNESS REDUCER CLAMP CLAMP CLAMP SPACER BOLT TUBE ASSY PACKING TUBE ASSY TUBE ASSY PACKING ELBOW

TO FIGURE 769B

180. 190. 200. 210. 220. 230. 240. 250. 260. 270. 280. 290. 300. 310. 320. 33O. 340.

PACKING NUT TUBE ASSY UNION PACKING TUBE ASSY TUBE ASSY TUBE ASSY PACKING REDUCER PACKING DE-OIL SOLENOID VALVE TUBE ASSY CLAMP CLAMP CLAMP BOLT


Page 798.175 Feb 28/05

Honeywell .



Storaqe Instructions A.

General

(i)

Most parts made today do not need age control. Age control does not apply to assemblies, silicon rubber, fluorocarbon rubber, fuel tank synthetics, or static seals used with fasteners.

(2)

Age Controls of Age-Sensitive Elastomeric Material for Aerospace Applications is specified in SAE AS 1933. Refer to this standard for all military and commercial use. Assemblies that contain age-sensitive material in this specification are limited by failure rates, in service use, and system life estimated by the user.

(3)

Bad weather conditions can cause damage to parts. Such conditions are, but not limited to: Moisture High temperature (over 125F (52C)) Fuel or solvents that have expanded Fumes that can cause corrosion Mechanical stresses Ultraviolet light

(4) B.

UP200456

C.

Parts that have been in bad weather conditions must be examined for damage and replaced as necessary.

Prepare unit for storage. (1)

Clean the external surfaces with a clean, lint-free cloth.

(2)

Cap all ports.

(3)

Wrap the unit in pH neutral paper.

(4)

Put cushions at the sharp corners to prevent damage to the barrier material and pack with Desiccant (MIL-D-3464E). Put the part in the applicable size barrier material.

Monitor storage conditions.

(i)

Keep the unit in an area away from high temperatures, dust, moisture and corrosive fumes.

(2)

The recommended storage temperature is less than 100F (38C) and must not be more than 125F (52C).

(3)

Control the humidity to prevent moisture on the unit.

(4)

If the time in storage is more than 12 months, refer to TESTING and test the unit before it is put back in service.


Page 798.176 Feb 28/05

Hone vell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] FITS AND CLEARANCES

.

Fits and Clearances A.

Table 801 shows the fits and clearances that can be found in REPAIR and/or ASSEMBLY. Table 801. Fits and Clearances

UP200456

Nomenclature (Item and Figure No.) Description

Requirement/Dimension

Shims (140, 150, Figure 702) thickness of shims

0.031 to 0.035 inch (0,8 to 0,9 mm)

Shims (130, 140, 150, Figure 702A) thickness of shims

0.031 to 0.035 inch (0,8 to 0,9 mm)

Runout at surface A & B (Figure 712)

0.0004 inch (Max) (0,0102 mm)

Runout at surface C (Figure 712)

0.0015 inch (0,0381 mm)

Rotating group assembly (Figure 716) shaft stretch

0.058 to 0.062 inch (1,47 to 1,57 mm)

Rotating group assembly (Figure 717) balance

0.045 ounce-inch (Max) (317,7 Nm) 0.026 ounce-inch (Max) (184 Nm)

Maximum permitted rotating group assembly runout (Figure 717)

0.002 inch (Max) (0,05 mm)

Engine compressor clearance (Figure 725)

0,022 to 0.026 inch (0,56 to 0,66 mm)

Rotating group assembly build dimension (Figure 727)

0.026 to 0.028 inch (0,66 to 0,71 mm)

Turbine wheel to turbine nozzle shims (Figure 729)

0.027 to 0.029 inch (0,068 to 0,073 mm)

Shims (50, Figure 729) thickness of shims

_0.001 inch (+_0,025 mm)

49-26-49

Copying,use or disclosureof informationonthis pageis subjectto proprietaryrestrictions

Page 801 Feb 28/05

Hone vell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 801. Fits and Clearances (Cont)

Nomenclature (Item and Figure No.) Description Engine compressor clearance (Figure 732)

0,022 to 0.026 inch (0,56 to 0,66 mm)

Shims (110, Figure 741 ) thickness of shims

+_0.002 inch (___0,05mm)

Tip clearance (Figure 741)

0.065 to 0.069 inch (1,65 to 1,75 mm)

Spacer (160, Figure 745) thickness

_+0.006 inch (0,15 mm)

Runout (Figure 747)

0.002 inch (Max) (0,05 mm)

2.

UP200456

Requirement/Dimension

Torque Values A.

Tighten nuts, bolts, screws, and tube fittings to the standard torque unless specified differently. Refer to FAA Manual AC65-9A, Airframe and Powerplant Mechanics General Handbook, for standard torque.

B.

Tighten fasteners installed through non-elastic boundaries to remove visible clearance between the parts. Monitorthe rundown torque necessary just before the fastener becomes tight. Then tighten to the final torque (refer to Table A for the correct thread size) and add the rundown torque. This procedure is sufficient for all fasteners not shown under torque values below. Table B shows procedures for final torque.

C.

Tighten fasteners installed through elastic boundaries (sealed by means of a diaphragm or similar elastomeric gasket) equally to get a pressure tight seal.


Page 802 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table A. Torque in-lb (Nm)

Thread Size

Aluminum Fastener

6 8 10 1/4 (6,350 mm) 5/16 (7,937 mm) 3/8 (9,525 mm)

CRES Fastener

5 (0,565) 10 (1,13) 15 (1,694) 45 (5,085) 80 (9,04) 140 (15,82)

10 (1,13) 20 (2,26) 35 (3,955) 75 (8,475) 160 (18,08) 275 (31,070)

Table B. Thread Size

Approximate Turn After Run-Down

6-32 8-32 10-24 1/4-20 (6,350 mm) 5/16-18 (7,937 mm) 3/8-24 (9,525 mm) .

45 deg 60 deg 40 deg 40 deg 40 deg 60 deg

Nonstandard Torque Values. A.

Table 802 gives information necessary to tighten fasteners to non-standard torque. Values shown do not include frictional torque caused by self-locking devices or rundown resistance. Frictional torque values must be added to the specified torque.

UP200456

Table 802. Nonstandard Torque Figure No.

Item No.

Nomenclature

Torque Ib-in. (Nm)

707

10, 50 30

Bolt Screw

50 (5,7) 50 (5,7)

707A

10

Bolt

50 (5,7)

708

40

Bolt

50 (5,7)

709

170, 280 20, 60, 190

Metal Plug and Magnetic Plug Bolt

68 (7,7) 25 (2,8)

709A

210, 280 60, 170

Metal Plug and Magnetic Plug Bolt

68 (7,7) 25 (2,8)


Page 803 Feb 28/05

Honeywell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] Table 802. Nonstandard Torque (Cont)

Figure No.

Item No.

Nomenclature

Torque Ib-in. (Nm)

711

Shaft Stretch Nut

50 (5,7)

716

Round Nut

50 (5,7)

Slave Bolt Bolt

60 (6,8) 60 (6,8)

Slave Bolt

60 (6,8)

729 10

UP200456

732 735

110

Screws

7 (0,79)

736

80, 120 130

Bolt Nut

120 (13,6) 45 (5,0)

737

70

Nut

50 (5,7)

739

10

Round Nut

50 (5,7)

741

10 30 60

Round Nut Bolt Nut

50 (5,7) 50 (5,7) 25 (2,9)

745

30 50

Bolt Nut

50 (5,7) 20 (2,3)

746

10

Round Nut

50 (5,7)

749

40, 60

Bolt

60 (6,8)

750

70 10

Oil Scavenge Tube Bolt

60 (6.8) 25 (2,8)

751

70 10

Bolt Bolt

60 (6,8) 50 (5,7)

754

10

Nut

100 (11,3)

755

10

Coupling Clamps

50 (5,7)

760

10

Coupling Clamps

90 to 100(10,2 to 11,3)


Page 804 Feb 28/05

Hone vell



UP200456

Table 802. Nonstandard Torque (Cont) Figure No.

Item No.

Nomenclature

760A

10

Coupling Clamps

90 to 100 (10,2 to 11,3)

761

130

Igniter Plug

180 (20,3)

761A

130

Igniter Plug

180 (20,3)

762

30,50

Clamps

20 to 25 (2,3 to 2,8)

764

270

Coupling Clamp

90 to 100 (10,2 to 11,3)

Torque Ib-in. (Nm)

49-26-49


Page 805/806 Feb 28/05

Hone vell


COMPONENT MAINTENANCE MANUAL GTCP36-280[D] SPECIAL TOOLS, FIXTURES AND EQUIPMENT

.

General Information Procedures shown in this publication, that need special tools, fixtures and equipment, can be done with the use of the special tools, fixtures and equipment shown in Table 901. The items can be purchased from *Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix Drive, South Bend, IN 46628-1000, Telephone: 574-231-3987 Table 901. Special Tools, Fixtures and Equipment

Nomenclature

UP200456

NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Gearbox Housing Adapter

Used to position gearbox during assembly.

2024003-1

Gearbox Housing Adapter

Used to position gearbox during assembly.

2024008-1

Bearing Removal Fixture

Used to remove air-oil separator from idler gear.

2024014-1

Carbon Seal Installer

Used to install seal in adapter.

2024017-1

Carbon Seal Removal Fixture

Used to remove carbon seal from adapter.

2024018-1

Bearing Removal and Installation Fixture

Used to remove and install idler gear bearing.

2024019-1

Bearing Removal Fixture Replacement Fixture

Used to remove bearing from gearshaft.

2024020-1

Air-oil Separator Installer

Used with 833973-1 support to install air-oil separator.

2024021-1

Idler Shaft Puller

Used to pull generator idler shaft from gearbox.

2024080-1

Tube puller

Used to remove oil pressure tube.

2024228-1

Diffuser Puller

Used to remove diffuser from load compressor.

2024230-1

Oil pickup Tube Puller

Used to remove oil pickup tube from gearbox.

2024084-1

Press Fixture

Used to install roller bearings on air-oil separator.

2024301-1

Surge Valve Positioning Sensor

Used to measure surge valve position during testing.

2024323-1

Sprag Clutch Guide Sleeve

Used to install sprag clutch assy on starter gearshaft.

2024392-1

49-26-49

Copying,use or disclosureof information on this page is subjectto proprietaryrestrictions

Page 901 Feb 28/05


Hone vell


UP200456

Table 901. Special Tools, Fixtures and Equipment (Cont) Nomenclature

Use

Part No.

Sprag Clutch Guide Sleeve

Used to install sprag clutch assy on starter gearshaft.

2024392-2

Protective Cover

Used to prevent FOD in compressor section.

2024398-1

Spanner Wrench

Used to remove/install retaining nut on gearshaft.

2024465-1

Runout Test Fixture

Used for rotating group.

285868-1

APU Assembly Stand

Used with turbine and compressor assembly.

287750-1

Micing Fixture

Used to measure the free length of the shaft.

298212-1

Installation Support

Used to install compressor seal rotor and coupling onto splined shaft.

294224-1

Bearing Removal Plate

Used to remove bearings from gear shaft.

833985-2


Used to remove bushings from gear shaft.

833985-3

Balance Bearing Set

Simulate turbine bearing.

833091-1

Turbine and Compressor Fixture

Buildup stand for turbine and compressor.

833093-1

Shaft Stretch Fixture

Used to apply shaft stretch.

833094-1

Pinion Gear Puller

Used to remove gear from shaft.

833095-1

Bearing and Rotor Seal Installer

Used to install turbine rotor seal and bearing on coupling shaft.

833096-1

Bearing and Rotor Seal Installer

Used to install turbine rotor seal and bearing on coupling half.

833096-2

Runout Check Fixture

Used to do runout checks.

833097-1

Micing Bridge

Used to measure dimensions BA and BH.

833098-2

Nozzle Support Tool

Used for turbine nozzle assembly.

833099-1

Compressor Centering Fixture

Used in assembly of rotating group.

833102-1

Power Section Fixture Assy

Used to attach power section to lift fixture.

833104-1


Page 902 Feb 28/05


Honeywell


UP200456


Use

Part No.

Power Section Lift Fixture

Used to hoist power section during assembly.

833105-1

Bearing Puller Plate Set

Used to remove various bearings.

833123-102

Bearing puller plate assy

Use to remove bearing from starter gearshaft.

833123-105

Bearing Installer

Used to push bearings on starter gearshaft.

833124-1

Bearing Press Fixture

Used to push bearings on high speed pinion gear.

833126-1

Bearing Removal Adapter

Used to remove bearings from starter gearshaft.

833130-200


Used to press bearing on gear assembly.

833131-1


Used with 833123-102.

833134-203


Used with 834826-1 adapter plate.

833135-2O3


Used with 833123-102.

833135-204

Balance Arbor

Used for balancing the turbine rotor assembly.

833158-1

Bearing Carrier Support

Used for bearing carrier assembly.

833175-1

Tube Installation Fixture

Used to install and torque scavenge tubes.

833184-1

Plenum Puller Fixture

Use puller to remove plenum assembly.

833186-2

Inlet Guide Vane Position Fixture

Used to preset the vanes during assembly.

833194-1

Micing Bridge

Used for shim calculation.

833424-1

Coupling Puller

Used to remove the coupling.

833429-1

Support Shaft Installation

Used to install the support shaft.

833430-1

Power Section Lift Fixture

Used to remove/install compressor scroll.

833431-1

Coupling Install Tool

Used to install turbine coupling.

833432-1

Bearing Removal Tool

Used to remove bearing.

833440-1

49-26-49


Page 903 Feb 28/05


Hone well


UP200456


Use

Part No.

Micing Plate and Runout Indicator

Used to make shim measurements.

833449-1

Stand Assembly Support Adapters

Used with the maintenance stand.

833493-1

Portable Stand Assembly

Used for APU test and maintenance.

833565-3

Micrometer Bridge

Used to measure dimensions A, BB, and BB1.

833665-1

Shim Holding Fixture

Used to make shim measurements.

833871-1

Air-oil Separator Support

Used with 2024021-1 air-oil separator installer.

833973-1


Used to remove lube pump bearings.

833974-1


Used to install pinion gear bearing on pinion gear.

833976-2


Used with 833985-2 bearing puller plate.

833978-1


Used to remove pinion gear bearings.

833978-2

Bearing and Puller Plate Set

Used to remove bearings from gearshaft.

833980-9


Used to remove bearing from gearshaft.

833984-1


Used to remove bearings from gearshaft.

833985-2#3

Bearing Removal and Installation Fixture

Used to remove and install bearings.

833986-1

Support Fixture

Used with 833986-1 bearing removal and installation fixture.

833987-1

Bearing Support Fixture

Used to press bearing and assembled parts.

833988-1

Bearing Installer

Used to push bearings on starter gearshaft.

833989-1

Bearing Installer

Used to push bearings on splined starter shaft.

833991-1

Seal Press Fixture

Used to press lip seal into adapter.

833996-1

Lip Seal Bullet

Used to deform lip seal prior to installation.

833997-1

49-26-49 Copying,use or disclosureof information on this pageis subjectto proprietaryrestrictions

Page 904 Feb 28/05

Honeywell



UP200456


Use

Part No.

Support Fixture

Used to push bearing on shaft assembly.

833998-1


Used with 834826-1 adapter plate.

833999-1

Dummy L/C Coupling

Used to install compressor shaft.

834037-1

Engine Stand Mount

Used on 833565-3 stand.

834117-1

Engine Stand Mount


834118-2

Engine Stand Mount


834119-1

Nut Stake Tool

Used to stake round nut.

834120-1

Inlet Duct Assembly

Used to measure inlet air temperature.

834130-1

Exhaust Gas Temperature Duct

Used to test exhaust gas.

834133-1

Vacuum Check Tool

Used to check bearing carrier.

834149-1

IGV Adjustment Tool

Used to adjust IGV.

834150-2

Shaft Stretching Tool

Used during shaft stretching.

834155-1

Micing Tool

Used to obtain measurements.

834156-1

Bearing Hold Fixture

Used to hold bearing carrier assembly.

834157-1

Turbine Wheel Arbor

Used to provide support during stretching of turbine shaft.

834165-1

Vacuum Check Tool

Used to perform a vacuum check.

834303-1

Seal Installer

Used to install lip seal in gearbox housing.

834333-2

Lifting Fixture

Used with compressor housing.

834334-1

Turbine Rotor Support Tool

Used for turbine nozzle and bearing carrier assembly.

834335-1


Used to press bearing on generator gear.

834336-1


Press air-oil separator on idler assembly.

834337-1


Page 905 Feb 28/05


Hone) well


UP200456


Use

Part No.

Shaft Stretch Nut

Used with 833094-1 shaft stretch fixture.

834347-1

Micrometer Bridge

Can be used to measure dimensions AFL and ASL.

834348-1

Starter Clutch Puller

Used to pull LRU starter clutch and cover from gearbox after starter has been removed.

834397-1

Water Brake Adapter

Used as an alternate method of applying shaft load during test.

834429-1


Remove bearings from starter splined shaft

834622-9

Instrumented Bleed Duct

Used to measure bleed air flow.

834662-1


Used to remove bearings from starter splined shaft.

834826-1

Build Stand Adapter

Used with build stand.

835332-1

Bearing Removal Tool

Used in disassembly of bearing and turbine rotor seal.

835550-1

Balance Adapter

Used to balance compressor shaft.

835582-1

Balance Adapter

Used to balance compressor shaft.

835583-1

Power Section Build Cart

Used to assemble turbine and compressor assembly.

835586-1

Seal Removal Fixture

Used to remove seal from compound idler adapter in gearbox.

835607-1

Medium Duty Proto Puller

Used to adapt various removal tools.

Model No. 4020C


Page 906 Feb 28/05

Honeywell CMM GTCP36-280D

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