PW-127H Maintenance Manual Chapter 72-02

PRATT & WHITNEY CANADA MAINTENANCE MANUAL MANUAL PART NO. 3045542

LIST OF EFFECTIVE PAGES

CHAPTER SECTION

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DATE

LEP

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Contents

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72-02-00 Removal/ Installation

72-02 LEP

Page 1/2 Aug 13/2004


TABLE OF CONTENTS SUBJECT

PAGE

ENGINE MODULES - REMOVAL/INSTALLATION

72-02-00

1.

General

401

2.

Consumable Materials

401

3.

Special Tools

401

4.

Fixtures, Equipment and Supplier Tools

402

5.

Reduction Gearbox/Turbomachinery Module Replacement

402

A.

Reduction Gearbox Module

402

B.

Turbomachinery Module

403

6.

7.

Separation of Reduction Gearbox and Turbomachinery Modules

403

A.

403

Removal A.

408

Turbomachinery from Stand (PWC34200) and Associated Components

408

C.

Reduction Gearbox from Stand (PWC34300)

409

D.

Turbomachinery from Stand (PWC34300)

409

Installation

411

A.

Turbomachinery in Stand (PWC34300)

411

B.

Reduction Gearbox in Stand (PWC34200) and Associated Components

413

Turbomachinery in Stand (PWC34200) and Associated Components

413

Mating of Reduction Gearbox and Turbomachinery Modules

413

A.

413

C. 9.

408

Reduction Gearbox from Stand (PWC34200) and Associated Components

B.

8.

Procedure

Procedure

72-02 CONTENTS

Page 1/2 Aug 13/2004


ENGINE MODULES - REMOVAL/INSTALLATION 1.

General A.

This section provides instructions necessary for separation, replacement and mating of reduction gearbox and turbomachinery modules. It also covers removal and installation of modules in engine stand and individual rotating stands.

B.

When engine is separated, cover with plastic sheeting to prevent ingress of moisture and foreign material.

C.

Effective locking of self-locking nuts to studs or bolts during assembly and mating of modules requires full engagement of all nut threads.

WARNING:

WEAR GOGGLES WHEN CUTTING, INSTALLING OR REMOVING LOCKWIRE.

WARNING:

GLOVES MUST BE WORN TO PROTECT SKIN WHEN DECONTAMINATING AREAS CONTAINING GASKETS OR PACKINGS WHICH HAVE DECOMPOSED DUE TO HIGH TEMPERATURES. HYDROFLUORIC ACID IS PRODUCED WHEN THE MATERIAL DECOMPOSES. MEDICAL TREATMENT IS REQUIRED AS SOON AS POSSIBLE IF THE ACID TOUCHES BARE SKIN.

CAUTION: TO ENSURE COMPATIBILITY WITH ASSOCIATED SERVICEABLE COMPONENTS, NEW COMPONENTS MUST BE FULLY INTERCHANGEABLE WITH THOSE REPLACED. NOTE: 2.

Use engine oil (PWC03-001) to lubricate packings, threads and mating faces, unless otherwise stated.

Consumable Materials The consumable materials listed below are referred to in this section. For more data, refer to the CONSUMABLE MATERIALS section at the beginning of this manual. WARNING:

3.

READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE MATERIALS. SOME MATERIALS CAN BE DANGEROUS.

Item No.

Name

PWC03-001 PWC05-018 PWC05-018A

Oil, Engine Marker, Silver Pencil

Special Tools Special tools are identified in procedural text by part number in parentheses. Tool No.

Name

PWC32396 PWC34200 PWC34294

Jackscrews Stand Support

72-02-00 ENGINE MODULES - REMOVAL/INSTALLATION

Page 401 Aug 13/2004


4.

Tool No.

Name

PWC34300 PWC37106 PWC37107 PWC37108 PWC37109 PWC37110 PWC37650 PWC38001 PWC38114 PWC38161 PWC38212 PWC38255 PWC38307 PWC54002 PWC54212 PWC54213

Stand Support Support Support Support Adapter Adapter Adapter Support Support Adapter Sling, Reduction Gearbox Adapter Sling, Engine/Turbomachinery Adapter, Front Adapter, Rear

Fixtures, Equipment and Supplier Tools The fixtures, equipment and supplier tools listed below are referred to in procedural text. Name Hoist, 1000 lb. (453.6 kg)

5.

Reduction Gearbox/Turbomachinery Module Replacement NOTE:

A.

If a module is installed to replace one removed due to being contaminated by debris in the oil system, flush oil system (Ref. 72-00-00, SERVICING) after installation. Refer to Aircraft Maintenance Manual for additional flushing recommendations.

Reduction Gearbox Module (1)

Separate and remove reduction gearbox module from turbomachinery (Ref. Paras. 6. and 7. A.).

(2)

Remove characterization plugs from EEC and AFU (Ref. 72-01-10). NOTE:

(3)

The plugs are matched to and must remain with the reduction gearbox.

Install replacement reduction gearbox module on turbomachinery (Ref. Paras. 8. and 9.).


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(4)

Check characterization plug classes are the same as those called up on the reduction gearbox identification plate. NOTE: 1. Plug classes are determined during test of reduction gearbox. NOTE: 2. Values on EEC characterization plug decal, R3xxxx and R4xxxx must be identical to those on RGB identification plate Q2Bxxxx (offset) and Q2Gxxxx (gain), respectively. NOTE: 3. The characterization plug classes of AFU are recorded on RGB identification plate as follows: CLxxxx, where first two digits are offset value, last two digits, gain value.

(5) B.

Install characterization plugs on EEC and AFU (Ref. 72-01-10).

Turbomachinery Module (1)

Separate and remove turbomachinery module from reduction gearbox (Ref. Paras. 6. and 7. A.).

(2)

Remove characterization plugs from EEC and AFU (Ref. 72-01-10) and retain with reduction gearbox.

(3)

Install replacement turbomachinery module (Ref. Paras. 8. and 9.).

(4)

Check characterization plug classes are the same as those called up on the reduction gearbox identification data plate. NOTE: 1. Values on EEC characterization plug decal, R3xxxx and R4xxxx must be identical to those on RGB identification plate Q2Bxxx (offset) and Q2Gxxx (gain), respectively. NOTE: 2. The characterization plug classes of AFU are recorded on RGB identification plate as follows: CLxxxx, where first two digits are offset value, last two digits, gain value.

(5) 6.

Install characterization plugs on EEC and AFU (Ref. 72-01-10).

Separation of Reduction Gearbox and Turbomachinery Modules (Ref. Fig. 401) A.

Procedure (1)

Drain oil (Ref. 72-00-00, SERVICING).

(2)

Disconnect overspeed governor pressure sensing tube (Ref. 72-01-30).

(3)

Disconnect fuel (Ref. 72-01-40) and oil tubes to fuel-cooled oil cooler (Ref. 72-01-50).


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5

1

6

2 3 4 16

17

8

12

14 7 8

18 20 19

15

20 21 8 13

C38976 Stand PWC34200 - Separation/Mating of Modules Figure 401 (Sheet 1 of 3)


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Key to Figure 401 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Bolt Packing with Retainer Cover Packing Bolt Keywasher Nut Washer Bracket Bracket Bracket Bolt Bolt Jackscrew Support Support Nut Coupling Shaft Transfer Tube Packing Packing Adapter Sling Bolt Ball Lockpin Support Bolt Adapter Stand Support Bracket Bracket Bracket Bracket


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31

8

7

B

A

13

7

8

13

8 7

11 A

B

B

A 10 A

7

7

8

7

8

12

12

8

7 7

8

13

13

8

7

8

34 D 19o 7

A

8

8

7

SCHEMATIC REAR VIEW OF FLANGE

9

11

9

32 33

31 10 8 7

8

D

12 13

8

13 VIEW AT A B

7

SECTION A−A 33

12 13

32

7 TYPICAL INSTALLATION SECTION B−B

SECTION D−D

C63380 Stand PWC34200 - Separation/Mating of Modules Figure 401 (Sheet 2)


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23

22

28

24 27

30 26 25

29

C14953B Stand PWC34200 - Separation/Mating of Modules Figure 401 (Sheet 3)


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7.

(4)

Disconnect P7 and P9 electrical harness connectors and remove nuts, bolts and wiring harness clamp assemblies as required (Ref. 72-01-10, REMOVAL/ INSTALLATION).

(5)

Disconnect RGB scavenge tube (Ref. 72-01-50).

(6)

Remove bolts (1, Fig. 401), packing with retainer (2), cover (3) and packing (4) from front inlet case. Discard packing.

(7)

Remove bolts (5) and keywashers (6) from coupling shaft flange. Discard keywashers.

(8)

Remove nuts (7), washers (8), brackets (9, 10, 11, 31, 32, 33, 34) and bolts (12, 13).

(9)

Install jackscrews (PWC32396) (14) and separate reduction gearbox from turbomachinery.

(10)

Roll reduction gearbox clear of turbomachinery and install support (PWC38114) (15) on front inlet case flange and support (PWC38161) (16) on coupling shaft (18). Secure support (16) with two nuts (17).

(11)

Remove transfer tube (19) and packings (20). Discard packings.

(12)

Remove and discard packing (21).

Removal A.

Reduction Gearbox from Stand (PWC34200) and Associated Components (Ref. Fig. 401) (1)

If required, separate RGB from turbomachinery (Ref. Para. 6.).

(2)

Install sling (PWC38255) (23) and adapters (PWC37650) (22) on RGB.

(3)

Attach sling to hoist and apply enough tension to sling to allow removal of bolts (24) and ball lockpin (25).

CAUTION: DO NOT ATTEMPT TO RAISE A GEARBOX THAT IS ATTACHED TO THE STAND.

B.

(4)

Lower support (26) and raise RGB clear of stand (PWC34200) (29).

(5)

Remove bolts (27) and adapters (28).

(6)

Install shipping closures and plugs if RGB is to be shipped.

Turbomachinery from Stand (PWC34200) and Associated Components (Ref. Fig. 402) (1)

If required, drain oil (Ref. 72-00-00, SERVICING) and separate RGB from turbomachinery (Ref. Para. 6.).


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(2)

If turbomachinery is to be shipped, remove support (PWC38161) (1) and install shipping cap (Ref. 72-00-00, SERVICING).

(3)

Remove ball lockpin (12) and roll support (PWC38114) (11) clear.

(4)

Install sling (PWC54002) (2) with front adapter (PWC54212) (13) and rear adapter (PWC54213) (14).

(5)

Attach sling to hoist and apply enough tension to sling to allow removal of nuts (3), bolts (4) and ball lockpins (5).

CAUTION: DO NOT ATTEMPT TO RAISE A TURBOMACHINERY THAT IS ATTACHED TO THE STAND.

C.

(6)

Lower support (6) and raise turbomachinery clear of stand (PWC34200) (9).

(7)

Remove bolts (7) and adapters (8).

Reduction Gearbox from Stand (PWC34300) (Ref. Fig. 404) NOTE:

Steps (1), (2) and (3)must be done just prior to mating RGB to turbomachinery.

(1)

While RGB is still in stand (PWC34300), measure Dim. A (Ref. Fig. 403). It must be 1.807 in. (45.898 mm).

(2)

If less than required, tilt RGB rear downward and rotate propeller shaft until 1.807 in. (45.898 mm) is achieved.

(3)

If more than required, tilt RGB rear upward and rotate propeller shaft until 1.807 in. (45.898 mm) is achieved.

(4)

Install adapter (PWC37650) and sling (PWC38255) (1, Fig. 404) on RGB.

CAUTION: DO NOT ATTEMPT TO RAISE A GEARBOX THAT IS ATTACHED TO THE STAND.

D.

(5)

Attach sling to hoist and apply enough tension to sling to allow removal of nuts (8) and bolts (7). Adjust eye on sling to ensure a level lift.

(6)

Raise RGB (4) from stand (PWC34300) (5) and move stand away.

(7)

Remove bolts (2) and adapters (PWC38001) (3).

(8)

Store bolts (2) in bolt holes of adapters (3).

Turbomachinery from Stand (PWC34300) (Ref. Fig. 405) CAUTION: DO NOT ATTEMPT TO LIFT TURBOMACHINERY THAT IS STILL ATTACHED TO THE STAND. (1)

Attach sling (PWC54002) (1), front adapter (PWC54212) (9) and rear adapter (PWC54213) (10) on turbomachinery (4).


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2 13 14

1

3

4 7

8

10

6 5 12 9

11

15

C11976D Stand PWC34200 - Turbomachinery Removal/Installation Figure 402


Page 410 Aug 13/2004


Key to Figure 402 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. (2)

Support Sling Nut Bolt Ball Lockpin Support Bolt Adapter Stand Support Support Ball Lockpin Adapter, Front Adapter, Rear

Attach sling to hoist (adjust eye of sling to ensure a level lift) and apply enough tension to sling to allow removal of nuts (8) and bolts (7).

CAUTION: DO NOT ATTEMPT TO LIFT TURBOMACHINERY THAT IS STILL ATTACHED TO STAND.

8.

(3)

Raise turbomachinery (4) out of stand (PWC34300) (5) and move stand away.

(4)

Remove bolts (2) and adapters (PWC37110) (3).

(5)

Store bolts (2) in bolt holes of adapters (3).

Installation A.

Turbomachinery in Stand (PWC34300) (Ref. Fig. 405) NOTE:

Turbomachinery is suspended on sling (PWC54002) (1) with front adapter (PWC54212) (9), rear adapter (PWC54213) (10) and hoist.

(1)

Remove bolts (2) from bolt storage holes of adapters (PWC37110) (3).

(2)

Install adapters on turbomachinery (4) with bolts (2). Torque bolts 290 to 325 lb.in. (32.77-36.73 Nm).

(3)

Position stand (PWC34300) (5) under turbomachinery.

(4)

Lower turbomachinery and align adapters (3) with shear pads (6).

(5)

Secure adapters to shear pads using bolts (7) and nuts (8).

(6)

Remove sling (PWC54002) (1), front adapter (PWC54212) (9), rear adapter (PWC54213) (10) and hoist.


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1.807 IN. (45.898 mm)

A

CLOSE TORLERANCE BOLT HOLES

VIEW

A

C17226B Reduction Gearbox Input Shaft Coupling Assembly - Dimension Check Figure 403


Page 412 Aug 13/2004


B.

C.

9.

Reduction Gearbox in Stand (PWC34200) and Associated Components (Ref. Fig. 401) (1)

With reduction gearbox suspended on sling (PWC38255) (23), adapters (PWC37650) (22) and hoist, install adapters (PWC38307) (28) and bolts (27). Torque bolts 720 to 800 lb.in. (81.36-90.40 Nm).

(2)

Position stand (PWC34200) (29) under gearbox and apply stand brake.

(3)

Lower gearbox onto stand and align front support (PWC37107) (30) with adapter (28).

(4)

Install bolts (24).

(5)

Raise front support (PWC37106) (26).

(6)

Align support with adapter and install bolt (24) and ball lockpin (25).

(7)

Remove sling, adapters, hoist and shipping closures.

Turbomachinery in Stand (PWC34200) and Associated Components (Ref. Fig. 402) (1)

With turbomachinery suspended on sling (PWC54002) (2), front adapter (PWC54212) (13), rear adapter (PWC54213) (14) and hoist, install adapters (PWC38212) (8) and bolts (7); torque bolts 290 to 325 lb.in. (32.77-36.73 Nm).

(2)

Position stand (PWC34200) (9) under turbomachinery and apply stand brake.

(3)

Lower turbomachinery onto stand and align adapter (8) with support (PWC37109) (10).

(4)

Install bolt (4) and nut (3).

(5)

Raise support (PWC37108) (6).

(6)

Align support with adapter and install bolt (4), nut (3) and ball lockpin (5).

(7)

Remove sling with adapters and hoist.

(8)

Install support (PWC38114) (11) and ball lockpin (12).

Mating of Reduction Gearbox and Turbomachinery Modules (Ref. Fig. 401) A.

Procedure NOTE:

Both RGB and turbomachinery are assumed to be in stand (PWC34200) (Ref. Para. 8. B. and C., respectively).

(1)

Lubricate with engine oil (PWC03-001) and install packing (21).

(2)

Lubricate packings (20) with oil (PWC03-001) and install on transfer tube (19). Install tube.


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4 1

7 3 8 5

2 6

C14122C Stand PWC34300 - Reduction Gearbox Removal/Installation Figure 404


Page 414 Aug 13/2004


Key to Figure 404 1. 2. 3. 4. 5. 6. 7. 8.

Sling Bolt Adapter RGB Stand Shear Pad Bolt Nut

(3)

If required, use a marker (PWC05-018) to identify the three close tolerance bolt holes in the RGB coupling shaft flange.

(4)

Remove nuts (17) and support (PWC38161) (16), securing RGB coupling shaft (18) and roll gearbox to mate with turbomachinery.

(5)

Remove support (PWC38114) (15).

(6)

Install bolts (12, 13), washers (8), brackets (9, 10, 11, 31, 32, 33, 34) and nuts (7). Torque nuts 85 to 95 lb.in. (9.61-10.74 Nm).

CAUTION: ENSURE INPUT SHAFT TO FLANGE B (DIMENSION A, REF. FIG. 403) IS 1.807 in. (45.898 mm) (REF. PARA. 7. C.). (7)

Turn propeller shaft to centralize gearbox components. Check dimension from input case to coupling shaft is 1.807 in. (45.898 mm).

(8)

Install keywashers (6) and bolts (5) in the three marked close tolerance bolt holes in the RGB coupling shaft flange. Install the three remaining keywashers (6) and bolts (5). Torque bolts 85 to 95 lb.in. (9.61-10.74 Nm) and lock keywashers. NOTE:

(9)

Rotating propeller shaft to centralize bearings and locate couplings will make mating operation easier.

Lubricate packing (4) with engine oil (PWC03-001) and install on cover (3).

(10)

Install cover, packing with retainer (2) and bolts (1). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).

(11)

Connect RGB scavenge tube (Ref. 72-01-50).

(12)

Connect P7 and P9 electrical harness connectors and secure harness branches with clamps assemblies (Ref. 72-01-10).

(13)

Install fuel and oil tubes on fuel-cooled oil cooler (Ref. 72-01-40 and 72-01-50).

(14)

Connect overspeed governor pressure sensing tube (Ref. 72-01-30).

(15)

Fill engine with oil (Ref. 72-00-00, SERVICING).


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1

9

10

4

7

8 3 2 6

5

C14120A Stand PWC34300 - Turbomachinery Removal/Installation Figure 405


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Key to Figure 405 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Sling Bolt Adapter Turbomachinery Stand Shear Pad Bolt Nut Front Adapter Rear Adapter


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PW-127H Maintenance Manual Chapter 72-02

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