T.O. 2G-T62T-43
TECHNICAL MANUAL
OVERHAUL INSTRUCTIONS
DEPOT MAINTENANCE LEVEL
ENGINE, QUICK START AUXILIARY
POWER SYSTEM (QSAS)
T-62T-40LC-2
PART NOS. 161331-135 AND 161331-135A
(ATOS-HILL)
SUNDSTRAND POWER SYSTEMS
F33657-79-C-0439
F34601-91-C-1328
DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation
without the specific authority of the Department of the Air Force of the United States, that it will be used for
military purposes only, that individual or corporate rights originating in the information, whether patented or not,
will be respected, that the recipient will report promptly to the United States, any known or suspected
compromise, and that the information will be provided substantially the same degree of security afforded it by the
Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be
downgraded or declassified without written approval of the originating United States agency.
DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors,
administrative and operational use, 15 January 1999. Refer other requests for this document to OO-ALC/417
SCMS, Hill AFB, Utah 84056-5826.
WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title
22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et
seq). Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with
provisions of DoD Directive 5230.25.
HANDLING AND DESTRUCTION NOTICE: Comply with distribution statement and destroy by any method that will
prevent disclosure of contents or reconstruction of the document.
Basic and all changes have been merged to make this a complete publication
Published under authority of the Secretary of the Air Force
15 MAY 1989
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T.O. 2G-T62T-43
TABLE OF CONTENTS
Section
Page
LIST OF ILLUSTRATIONS ....................................... ii
LIST OF TABLES ...................................................... iii
SAFETY SUMMARY ................................................ vii
INTRODUCTION..................................................... viii
I GENERAL INFORMATION ................................... 1-1
1-1
General .................................................. 1-1
1-2
Scope...................................................... 1-1
1-3
Description ............................................ 1-1
1-4
Turbine Assembly................................. 1-1
1-5
Reduction Drive Unit ........................... 1-3
1-6
Combustor Assembly ............................ 1-3
1-7
APU Accessories ................................... 1-6
1-8
Test Cell Adapter Kit ......................... 1-10
1-9
Leading Particulars ............................ 1-20
1-10
Consumable Materials ....................... 1-20
II SPECIAL TOOLS AND TEST
EQUIPMENT ........................................................... 2-1
2-1
General .................................................. 2-1
2-2
Special Tools and Test
Equipment.......................................... 2-1
III DISASSEMBLY........................................................ 3-1
3-1
General .................................................. 3-1
3-2
Unpacking ............................................. 3-1
3-3
General Disassembly
Procedures.......................................... 3-1
3-4
Disassembly of APU ............................. 3-1
3-5
Disassembly of Turbine
Assembly .......................................... 3-24
3-6
Disassembly of Reduction
Drive Unit ....................................... 3-30
3-7
Disassembly of Combustor
Assembly .......................................... 3-52
Section
Page
IV CLEANING............................................................... 4-1
4-1
General .................................................. 4-1
4-2
Solvent for General Use ....................... 4-1
4-3
Cleaning Procedures............................. 4-1
V INSPECTION, REPAIR, AND
REPLACEMENT...................................................... 5-1
5-1
GENERAL............................................. 5-1
5-2
Inspection .............................................. 5-3
5-3
Repair and Replacement .................... 5-58
VI ASSEMBLY .............................................................. 6-1
6-1
General .................................................. 6-1
6-2
General Assembly
Procedures.......................................... 6-1
6-3
Assembly of Combustor
Assembly ............................................ 6-1
6-4
Assembly of Reduction
Drive Unit ......................................... 6-2
6-5
Assembly of Turbine
Assembly .......................................... 6-21
6-6
Assembly of APU ................................ 6-49
6-7
Preservation for Shipment
and Storage ...................................... 6-61
6-8
General Part Marking....................... 6-62
6-9
UID Supplemental
Information ...................................... 6-63
VII TESTING .................................................................. 7-1
7-1
General .................................................. 7-1
7-2
Calculations .......................................... 7-1
7-3
Test Procedures .................................... 7-1
7-4
Troubleshooting
Procedures........................................ 7-30
Change 23 i
TO 2G-T62T-43
LIST OF ILLUSTRATIONS
Figure
1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
2-1
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
Title
Page
Quick Start Auxiliary Power Unit ...................x
Turbine Assembly and
Combustor Housing Assembly................... 1-2
Cutaway View of Reduction Drive
Unit ............................................................. 1-4
Lubrication System Schematic ..................... 1-5
Fuel System Schematic ................................. 1-7
QSAS -135 Auxiliary Power Unit
(APU) (-135A Not Pictured)....................... 1-8
Test Cell Adapter Kit .................................. 1-11
Load Compressor Subsystem
Schematic .................................................. 1-13
APU Thermocouple Connections
Schematic .................................................. 1-14
Hydraulic Start Subsystem
Schematic .................................................. 1-15
Water Dynamometer Subsystem
Schematic .................................................. 1-16
Vibration and Dynamometer
Load Cell Subsystem Schematic ............. 1-17
Fuel Subsystem Schematic ......................... 1-18
Lubricating Subsystem
Schematic .................................................. 1-19
Special Tools and Test
Equipment .................................................. 2-6
Removal of APU from Shipping
Container .................................................... 3-2
APU ............................................................... 3-4
Engine Hydraulic Starter, Oil
Pressure Switch, Turbine
Assembly, and Combustor Assembly ........ 3-9
Fuel Control Enclosure Base
Assembly ................................................... 3-11
Surge Control Valve, Air Flow
Sensor Assembly, and Turbine
Ignition Exciter......................................... 3-15
Inlet Housing Manifold and Air
Inlet Duct Assembly................................. 3-18
IGV Actuator................................................ 3-20
Hourmeter Junction Box
Assembly ................................................... 3-21
Hourmeter Junction Box
Assembly Wiring Diagram ...................... 3-23
Turbine Assembly........................................ 3-25
Installation of Turbine
Assembly in Rotor Fixture....................... 3-28
Reduction Drive Unit .................................. 3-31
Removal of Bevel Gear Support
and Zerol Bevel Gear ............................... 3-37
Removal of Locknut..................................... 3-38
Removal of Locknut..................................... 3-39
Removal of Carrier Assembly ..................... 3-40
Removal of Cover......................................... 3-41
Removal of Ring Gear ................................. 3-43
Removal of Housing Carrier ....................... 3-43
Removal of Locknut..................................... 3-44
ii Change 25
Figure
3-21
3-22
3-23
3-24
3-25
3-26
3-27
3-28
4-1
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-17
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
5-25.1
5-26
5-27
5-28
5-29
6-1
6-2
6-3
Title
Page
Removal of Locknut..................................... 3-45
Removal of Bearing ..................................... 3-46
Removal of Zerol Pinion.............................. 3-47
Removal of Accessory Pad Cover................ 3-48
Removal of Intermediate Gear
Shaft .......................................................... 3-49
Removal of Ball Bearings ........................... 3-50
Removal of Ball Bearing ............................. 3-51
Combustor Assembly................................... 3-53
Cleaning Combustor Liner............................ 4-6
Inspection of Bearing Aft
Carrier....................................................... 5-43
Inspection of Bearing Front
Carrier....................................................... 5-44
Inspection of Diffuser Housing ................... 5-45
Inspection of Load Compressor
Diffuser ..................................................... 5-46
Inspection of Rotor Shaft ............................ 5-47
Inspection of Seal Plate .............................. 5-47
Inspection of Turbine Nozzle ...................... 5-48
Inspection of Accessory Drive
Pinion ........................................................ 5-49
Inspection of Accessory Gear ...................... 5-49
Inspection of Carrier Assembly .................. 5-50
Inspection of Cover...................................... 5-50
Inspection of Gear Planet Set..................... 5-51
Inspection of Hub Ring Gear ...................... 5-51
Inspection of Intermediate Gear ................ 5-52
Inspection of Oil Pump Housing
Assembly ................................................... 5-53
Inspection of Pump Drive Gear .................. 5-55
Inspection of Zerol Pinion ........................... 5-55
Inspection of Combustor
Housing ..................................................... 5-56
Inspection of Combustor Liner ................... 5-57
Repair of Diamond Knurl ........................... 5-61
Blade Tuning ............................................... 5-62
Repair of Reduction Drive Unit
Housing Sleeves........................................ 5-67
Manufacture of Carrier
Assembly Sleeves ..................................... 5-68
Manufacture of Housing Liner ................... 5-70
Manufacture of Bevel Gear
Support Liners....................................... 5-70A
Repair of Bevel Gear Support
Housing ..................................................... 5-71
Inspection of Air Inlet Housing ................5-72A
Inspection of Load Compressor
Wheel Seal ............................................. 5-72B
Metal Spray Repair; Diffuser
Housing, Part No. 161625 ....................... 5-83
Oil Sump Leak Test Plate .......................... 5-84
Gear Shimming.............................................. 6-3
Determination of Shim Thickness................ 6-4
Installation of Shaft Seal .............................. 6-7
TO 2G-T62T-43
LIST OF ILLUSTRATIONS - Continued
Figure
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-13
6-14
6-15
6-16
6-17
6-18
6-19
6-20
6-21
6-22
6-23
6-24
6-25
Title
Page
Installation of Bearings on
Straight Drive Shaft .................................. 6-8
Installation of Hub Ring Gear
and Retainer ............................................. 6-10
Installation of Bearings on Zerol
Bevel Gear ................................................ 6-11
Installation of Backlash Gage .................... 6-13
Backlash and Pattern
Requirements............................................ 6-14
Installation of Adapter................................ 6-15
Installation of Shaft Seal ............................ 6-16
Installation of Bearings .............................. 6-17
Installation of Gear Planet Set
and Bearings............................................. 6-18
Oil Pump Test Setup................................... 6-20
Balancer Setup (Ref) for Legacy
Component-Balance Process.................... 6-26
Balancing Turbine Wheel ........................... 6-27
Balancing Engine Compressor
Wheel......................................................... 6-28
Balancing Load Compressor
Wheel......................................................... 6-29
Balancing Rotor Shaft................................. 6-30
Installation of Engine
Compressor Wheel.................................... 6-31
Balancing Rotor Assembly .......................... 6-32
Balancing Rotor Assembly .......................... 6-32
Clearance Limits ......................................... 6-37
Determination of Shim
Thickness .................................................. 6-40
Installation of Bridge Gage......................... 6-41
Determination of Depth .............................. 6-43
Figure
6-26
6-27
6-28
6-29
6-30
6-31
6-32
6-33
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
FO-1
Title
Page
Installation of Functional
Assembly Gage ......................................... 6-44
Determination of Spacer
Thickness .................................................. 6-48
Tolerance Specifications.............................. 6-52
QSAS Engine UID Placement
(Part Number(s): 161331-135)
(Not to Scale) ............................................ 6-64
Surge Control Valve UID
Placement (Part Number(s):
161347-1) (Not to Scale)........................... 6-65
IGV Actuator UID Placement
(Part Number(s): 161367-1)
(Not to Scale) ............................................ 6-65
Fuel Control Assembly UID
Placement (Part Number(s):
161676-203) (Not to Scale)....................... 6-66
Hydraulic Start Motor UID
Placement (Part Number(s):
161794-1) (Not to Scale)........................... 6-66
APU Installation............................................ 7-2
Test Cell Adapter Kit Test Setup................. 7-5
Test Cell Adapter Kit Controls
and Indicators........................................... 7-15
Deleted
Acceptance Run Test Data
Sheet.......................................................... 7-25
APU Acceptance Test
Performance .............................................. 7-31
APU Sequence Diagram.............................. 7-32
Decoded BITE Information ......................... 7-33
Electrical Subsystem .................................. FP-1
LIST OF TABLES
Number
1-1
1-2
1-3
2-1
5-1
5-2
5-3
Title
Page
APU Leading Particulars............................ 1-20
Test Cell Adapter Kit Leading
Particulars ................................................ 1-21
Consumable Materials ................................ 1-22
Special Tools and Test
Equipment List........................................... 2-1
General Physical Conditions ........................ 5-1
Inspection Requirements (APU)................... 5-3
Oil Pump Housing Assembly
Dimensional Limits.................................. 5-54
Number
5-4
5-5
5-6
6-1
6-2
7-1
7-2
7-3
Title
Page
Components Using Abrasive
Crocus Cloth, P-C-458.............................. 5-58
Materials Application Table ....................... 5-79
Knurled Sleeve Data .................................. 5-80
Clearance Chart .......................................... 6-33
UID Label Requirements............................ 6-64
Test Cell Adapter Kit Controls
and Indicators........................................... 7-18
Calculations ................................................. 7-27
Troubleshooting ........................................... 7-34
Change 25 iii/(iv blank)
T.O. 2G-T62T-43
SAFETY SUMMARY
DEFINITIONS. The following definitions apply to
WARNINGS, CAUTIONS, and NOTES found
throughout this publication.
warning
An operating or maintenance procedure, practice, condition, statement,
etc., which, if not strictly observed,
could result in injury or death of
personnel.
caution
An operating or maintenance procedure, practice, condition, statement,
etc. which, if not strictly observed,
could result in damage or destruction
of equipment.
NOTE
An essential operating or maintenance procedure, condition, or statement which must be highlighted.
GENERAL PRECAUTIONS. The following are gen-
eral safety precautions that are not related to any
specific procedure and therefore do not appear
elsewhere in this publication.
KEEP AWAY FROM LIVE CIRCUITS
Operating personnel shall observe all safety regulations at all times. Do not replace components
inside the equipment when potentially lethal voltages are present. Turn off system power before
making/breaking electrical connections. Regard
any exposed connector, terminal board, or circuit
board as a possible shock hazard. To prevent electrical shock, make sure no voltage is being applied
during removal or installation. If a test connection
to energize equipment is required, make the test
equipment ground connection before probing the
voltage or signal to be tested.
RESUSCITATION
Personnel working with or near high voltages or
hazardous material shall be familiar with modern
methods of resuscitation. Such information may
be obtained from the Office of Bioenvironmental
Health.
warning
Before using any of the materials
specified in this manual, be aware of
all handling, storage, and disposal
precautions recommended by the
manufacturer or supplier. Failure to
comply with manufacturer’s or supplier’s recommendations may result in
personal injury or disease.
Personnel must remain clear of dangerous areas such as intake area,
exhaust area, and rotation of turbine
blades.
Extreme care must be exercised to be
sure that all high voltage circuits are
completely discharged.
Wear eye protection when removing
lockwire. Failure to comply may
result in injury to personnel.
When using compressed air for cleaning or drying, regulate pressure not to
exceed 30 psi. Wear eye protection.
Failure to comply may result in injury
to personnel.
Voltages used can cause arcing which
may result in severe burns. Remove
watches, rings, and other jewelry.
High/dangerous voltage may cause
severe shock or death on contact during check-out of equipment. Use caution and avoid contact with energized
components.
DO NOT SERVICE OR ADJUST ALONE
Personnel shall not under any circumstances reach
into or enter any enclosure for the purpose of servicing or adjusting the equipment without immediate presence or assistance of another person capable of rendering aid.
vii
T.O. 2G-T62T-43
INTRODUCTION
1. PURPOSE OF MANUAL (Figure 1). This manual
provides overhaul instructions for the Engine,
Quick Start Auxiliary Power Unit (QSAS), T-62T40LC-2, part number 161331-135 and 161331135A (herein referred to as APU). These instructions allow personnel to perform the various tasks
necessary so that the repaired unit will meet standards for overhauled units.
2JA3-64-3
Hydraulic Starter Overhaul
with IPB (Garrett)
33B-1-1
Nondestructive Inspection
Methods
6J3-4-112-3
Fuel Control Assembly Overhaul with IPB
2. USE OF MANUAL. A table of contents indicates
section and page numbers. Illustrations, tables,
and diagrams are located throughout the publication to supplement the text material. A list of
illustrations and tables indicates the number, title,
and page number.
6J3-8-19-3
Inlet Guide Vane Actuator
Overhaul with IPB
6J15-3-160-3
Surge Control Valve Overhaul
with IPB
3. CHANGE RECOMMENDATIONS. Recommendations proposing changes to this manual shall be
submitted per T.O. 00-5-1.
8D3-3-2-3
Electronic Sequence Control
Unit (ESCU) Overhaul
8D3-3-2-4
Electronic Sequence Control
Unit (ESCU) Illustrated
Parts Breakdown
ASTM E 1417
Standard Practice for Liquid
Penetrant Examination.
No Number
Assigned
Hydraulic Dynamometer Instruction Manual (Kahn
Companies)
4. RELATED PUBLICATIONS. The following publications are applicable to the overhaul of the APU
and its components:
List of Applicable Technical Manuals
T.O. Number
T.O. Title
00-5-1
AF Technical Order System
00-20-14
Air Force Metrology and
Calibration Program
00-25-234
General Shop Practice Requirements for the Repair, Maintenance, and Test of Electronic
Equipment
5. ABBREVIATIONS AND ACRONYMS. Abbreviations used in this manual conform to MIL-STD-12,
except for the following:
AFS
Air flow sensor
AFS. COEF
Air flow sensor coefficient
00-85-3
Corrosion Control for Packaging
AFS. COR
1-1A-1
General Manual for Structural
Repair
Air flow sensor correction
coefficient
CHP
Corrected horsepower
1-1A-8
Engineering Manual Series for
Aircraft and Missile Repair
Structural Hardware
CW. FUEL
Fuel flow corrected
ESCU
1-1A-9
Aerospace Metals-General Data
and Usage Factors
Electronic sequence control
unit
EWO
Emergency war order
1-1A-14
Installation Practices Aircraft
Electric and Electronic Wiring
P. BARO
Barometric pressure
2G-T62T-44
Engine, Quick Start Auxiliary
Power Unit System (QSAS)
Illustrated Parts Breakdown
P. EXDUCT
Exhaust duct pressure
P. EXIT
AFS total pressure
P. INLET
Inlet pressure
viii Change 24
T.O. 2G-T62T-43
SMR
Bleed air differential pressure
at AFS
Sourc, Maintenance, and
Recoverability
T. AFS
AFS bleed temperature
PB. COEF
Bleed pressure coefficient
T IN/AVG
PB. CORR
Bleed pressure corrected
Compressor inlet temperature
(average)
PCD
Pressure compressor
discharge
W FUEL
Fuel flow corrected
WB. AFS C
AFS corrected bleed flow
5. ABBREVIATIONS AND ACRONYMS - Continued
PASDIF
PEX. COEF
Pressure exhaust coefficient
PIN. COEF
Inlet pressure coefficient
Change 24 ix
T.O. 2G-T62T-43
Figure 1.
x Change 24
Quick Start Auxiliary Power Unit (Sheet 1 of 2)
T.O. 2G-T62T-43
Figure 1.
Quick Start Auxiliary Power Unit (Sheet 2 of 2)
Change 24 xi/(xii blank)
T.O. 2G-T62T-43
SECTION I
GENERAL INFORMATION
1-1. GENERAL. This manual provides overhaul
instructions for the Quick Start Auxiliary Power
Unit, T-62T-40LC-2, part number 161331-135 and
161331-135A, (hereafter referred to as APU) at the
depot maintenance level.
assembly and the aft end of the housing
mates with the diffuser housing assembly.
The air inlet duct assembly provides ducted
air into the inlet.
b.
1-3. DESCRIPTION. The APU provides compressed air and generates electrical power for starting aircraft main engines and running aircraft systems. The APU consists of three major assemblies:
turbine assembly, reduction drive unit, and combustor assembly.
Rotor Assembly. The rotor assembly is a
balanced assembly, consisting of the rotor
shaft, turbine wheel, engine compressor
wheel, load compressor wheel, bearings, and
seal plate. The engine compressor wheel
and load compressor wheel are driven by the
turbine wheel via the rotor shaft. The seal
plate prevents leakage of air between the
compressor and turbine sections of the APU.
c.
NOTE
The electronic sequence and control
unit (ESCU) is not a component of the
APU (part number 161331-135 or
161331-135A), but is required for operation of the APU.
Load Compressor Scroll. The load compressor scroll houses the load compressor wheel
assembly and load compressor diffuser. The
load compressor scroll directs compressed
air from the load compressor wheel assembly blade tips, through the air flow sensor
(AFS).
d.
Adapter Assembly. The adapter assembly is
the structural interface between the turbine
assembly and the reduction drive unit.
e.
Diffuser Housing Assembly. The circularcast diffuser housing assembly is secured to
the aft end of the inlet housing assembly.
The diffuser housing assembly is externally
flanged to permit clamping to the combustor
assembly.
f.
Load Compressor Diffuser. Mounted within
the load compressor scroll, is the load compressor diffuser, which has vanes mounted
on the forward face. The path formed
between the load compressor diffuser and
the load compressor scroll, directs the air,
compressed by the compressor wheel, into
the load compressor scroll.
g.
Pinion Assembly. The pinion assembly is
the coupling between the turbine assembly
rotor shaft and the reduction drive unit.
1-2. SCOPE. This manual enables personnel to
perform repair and overhaul operations at the depot
maintenance level.
1-4. TURBINE ASSEMBLY (FIGURE 1-1). The turbine assembly consists of a single-stage centrifugal
load compressor, joined by a common shaft with an
engine compressor wheel and turbine wheel. The
major components of the turbine assembly consist of
the inlet housing assembly, rotor assembly, load
compressor scroll, adapter assembly, diffuser housing assembly, load compressor diffuser, pinion
assembly, magnetic pickup, forward and aft bearing
carriers, manifold assembly, turbine nozzle assembly, and inlet guide vanes:
a.
Inlet Housing Assembly. The inlet housing
assembly is a contoured, cylindrical aluminum casting with dual radial inlets for air
flow to the powerhead section (turbine wheel
assembly, engine compressor wheel assembly, and combustor assembly) and to the
load compressor section (load compressor
wheel assembly, load compressor scroll, and
inlet guide vanes). The flanged forward end
of the housing mates with the adapter
Change 24 1-1
T.O. 2G-T62T-43
Figure 1-1.
1-2
Turbine Assembly and Combustor Housing Assembly
TO 2G-T62T-43
h. Magnetic Pickup. The magnetic pickup is
mounted in the adapter assembly, to provide
a speed sensing input to the ESCU.
i. Bearing Carriers (forward and aft) (not
shown). The forward bearing carrier provides an interface between the reduction
drive unit adapter assembly, the front ball
bearing, and the rotor assembly. The aft
bearing carrier provides a similar interface
for the air inlet housing, the aft ball bearing,
and the rotor assembly.
j. Manifold Assembly. The manifold assembly
is mounted on the bottom of the inlet housing assembly. The manifold assembly provides a collection point for lubricating oil supplied to the aft bearing; returns the oil to the
reduction drive unit engine oil sump; and
supplies buffer air to the labyrinth seal and
oil to the aft housing.
k. Inlet Guide Vanes. Seventeen variable inlet
guide vanes (IGV) are mounted in the inlet
housing assembly on the load compressor
side. The IGVs are modulated by the ESCU
controlled IGV actuator. This system is used
to prevent the APU exhaust gas temperature
(EGT) from exceeding specified limits.
Mounted with each IGV, is a sector gear
which meshes with the IGV drive gear assembly.
1-5. REDUCTION DRIVE UNIT (Figure 1-2). The
reduction drive unit reduces the output rotational
speed (64,643 rpm) of the rotor assembly, to the
speeds necessary to drive the APU accessories and
APU-driven equipment. The reduction drive unit
consists of the housing, engine oil sump assembly,
gears, and bearings.
a. Housing. The housing is a machined magnesium casting. The APU lubrication system
(figure 1-3), consisting of an oil pump, oil
filter, by-pass valve, and associated lubrication components, is located in the housing.
The oil filter consists of a valve housing and
an oil filter element. The by-pass valve
housing assures lubrication of the APU if the
oil filter element becomes clogged or the oil
is extremely cold. The oil filter element is a
10-micron (nominal) throwaway type element.
b. Engine Oil Sump Assembly. The engine oil
sump assembly is attached with a quick release V-clamp to an external flange on the
bottom of the reduction drive unit housing
and is sealed with an O-ring. Mounted in
the bottom of the engine oil sump assembly is
the high oil temperature switch, which is a
thermal switch that senses high oil temperature; provides an input to the ESCU; and
shuts the APU down if oil temperature exceeds 275 ±5°F. Located at the bottom of
the engine oil sump assembly is the magnetic-drain plug, which serves as a low point
drain for the lubrication system and a collection point for ferrous (iron) particles that
may be present in the lubrication system.
c. Gears. The input pinion, splined to the rotor
shaft, drives three planetary gears (gear
planet sets) mounted in the stationary carrier
assembly. The gear planet sets drive the ring
gear. The ring gear is splined to a hub ring
gear, which is keyed onto the aft end of the
main drive shaft. A Zerol bevel pinion on
the main drive shaft meshes with a Zerol
bevel gear which is secured to the accessory
drive pinion. The accessory drive pinion
drives the pump drive gear and the intermediate gear, which in turn drives the accessory
gear.
d. Bearings (not shown). All gears and shafts,
with the exception of the pump drive gear,
are supported by ball bearings. Lubrication
of the gears and bearings is by oil jets and
air-oil mist.
1-6. COMBUSTOR ASSEMBLY (Figure 1-1). The
combustor assembly consists of the combustor housing, combustor liner, and fuel system components.
1-3
TO 2G-T62T-43
Figure 1-2. Cutaway View of Reduction Drive Unit
1-4
T.O. 2G-T62T-43
Figure 1-3.
Lubrication System Schematic
Change 24 1-5
T.O. 2G-T62T-43
a.
Combustor Housing and Combustor Liner. The
combustor assembly is an annular, air atomizing type, consisting of the combustor housing and combustor liner. An external flange
at the forward end of the combustor housing
mates with an external flange on the aft end
of the diffuser housing. The combustor
assembly is secured to the diffuser housing
by a V-band clamp that fits over the flanges.
The outer wall of the combustor liner fits
over the outer aft end of the turbine nozzle.
The mating of the combustor housing inner
wall with the inner aft end of the turbine
nozzle, forms a conical exhaust duct for the
flow of exhaust gases, as they leave the
turbine portion of the rotor assembly and
flow out of the APU.
a.
Fuel Control Assembly. The fuel control
assembly, in conjunction with the ESCU,
provides automatic control of acceleration
and governing of APU fuel requirements.
The fuel control assembly is a self-contained
unit, consisting of a single-element, positivedisplacement, gear-type pump, and fuel control. The fuel control assembly includes an
electronic servovalve, which meters fuel to
the fuel manifold in direct proportion to a 0100 mA electrical input signal from the
ESCU. Two solenoid valves are installed on
the fuel control body. The fuel valve supplies
fuel to the fuel nozzle during APU starting,
while the main fuel valve supplies fuel to
the fuel manifold once the APU has achieved
5 percent rated speed.
b.
Fuel System Components (Figure 1-4).After
starting, fuel for the combustor assembly is
supplied through an external circular fuel
manifold assembly. A port located at the 6
o’clock position in the combustor housing
provides a fuel drain.
b.
Ignition Cable. The ignition cable connects
the turbine ignition exciter to the igniter
plug. The ignition cable is a shielded high
tension lead, that carries pulsating high
voltage, low amperage current from the turbine ignition exciter to the igniter plug.
c.
Turbine Ignition Exciter. The turbine ignition
exciter box is mounted at the 5 o’clock position on the combustor housing assembly,
from aft looking forward. The turbine ignition exciter box provides a high energy
spark through the igniter plug for fuel ignition. The turbine ignition exciter is a capacitive discharge type unit. Input voltage is 1430 Vdc.
(1)
Fuel Manifold Assembly (Figure 1-5).
The combustor assembly provides six
bosses for mounting the six fuel manifold nozzles, which are equally spaced at
60o intervals around the combustor
housing. The fuel manifold assembly
provides six streams of fuel into the
venturi tubes that direct fuel into the
aft end of the combustor liner.
(2)
Fuel Nozzle. The fuel nozzle is mounted
at the 2 o’clock position on the combustor housing looking aft. The fuel nozzle
provides a fine conical spray of atomized
fuel for initial APU start. Fuel to the
fuel nozzle is activated at 5 percent
rated speed and cuts off at 70 percent
rated speed.
1-7. APU ACCESSORIES (FIGURE 1-5). APU
accessories, supplied with the APU, include the fuel
control assembly, ignition cable, turbine ignition
exciter, igniter plug, junction box hourmeter assembly, oil pressure switch, fuel purge valve, air filter,
engine hydraulic starter, surge control valve, IGV
actuator, air flow sensor, and oil cooler.
1-6 Change 24
Output voltage to the turbine igniter plug is
5 kilovolts. The turbine ignition exciter has
an input connector for electrical power supply and an output connector for attaching
the ignition cable.
d.
Igniter Plug. The igniter plug is mounted at
the 10 o’clock position in the combustor
housing assembly, looking forward. The
igniter plug is a surface gap shielded type
plug, that provides for initial fuel ignition
during APU starting.
T.O. 2G-T62T-43
Figure 1-4.
Fuel System Schematic
Change 24 1-7
T.O. 2G-T62T-43
Figure 1-5.
1-8 Change 24
QSAS -135 Auxiliary Power Unit (APU) (-135A Not Pictured) (Sheet 1 of 2)
T.O. 2G-T62T-43
Figure 1-5.
QSAS -135 Auxiliary Power Unit (APU) (-135A Not Pictured) (Sheet 2 of 2)
Change 24 1-9
T.O. 2G-T62T-43
e.
Junction Box Hourmeter Assembly. The junction box hourmeter assembly is mounted on
the right side of the fuel enclosure base
assembly looking aft. The junction box contains two hourmeters (normal APU operating hours and emergency war order (EWO)
operating hours), an events counter (APU
starts), two terminal boards, and an electrical connector.
f.
Oil Pressure Switch. The oil pressure switch
senses low APU oil pressure. It provides an
input to the ESCU, which shuts the APU
down if oil pressure drops below 6 (±1) psig
after the APU reaches 65 percent rpm, or if
the switch is closed (shorted) on start.
g.
Fuel Purge Valve. The fuel purge valve is an
electrically operated solenoid valve. The fuel
purge valve, in conjunction with the purge
restrictor tee assembly, is connected via
tube assembly to the fuel control assembly,
fuel nozzle, and the fuel manifold assembly.
When an APU stop is initiated, a signal from
the ESCU opens the fuel purge valve, which
allows pressure compressor discharge to
purge fuel from the fuel manifold assembly.
The purge restrictor tee assembly allows
purging of the fuel nozzle after fuel shutoff.
h.
Air Filter. The 20-micron air filter is located
on the left side of the APU looking aft. The
air filter removes particulate matter from
the control air used to operate the IGV actuator and surge control valve.
i.
Engine Hydraulic Starter. The engine hydraulic starter is mounted on the right side of the
reduction drive unit looking aft. The engine
hydraulic starter provides cranking torque
for initial rotation of the APU. The engine
hydraulic starter incorporates an overrun
clutch to disengage the engine hydraulic
starter, when APU rotational speed exceeds
engine hydraulic starter rotational speed.
The clutch case is internally drained, but
maintained at 30 (±5) psig by means of a
self-contained pressurizing valve. A drain
port in the bottom of the case allows fluid to
drain to the enclosure reservoir. A fill port
on the top of the case is used to service the
starter after installation.
j.
Surge Control Valve. The surge control valve
is located above the right side of the combustor assembly looking aft. The valve is pneumatically actuated and electronically controlled. The surge control valve is activated
1-10 Change 24
by a 30-80 psi air supply, from the
powerhead compressor and controlled by an
electronic signal from the ESCU. The surge
control valve prevents the APU from surging when no aircraft demand is present. The
valve will open with loss of signal and/or loss
of supply pressure.
k.
IGV Actuator. The IGV actuator is located on
the load compressor scroll and is a pneumatically actuated, electronically controlled servomotor. The IGV actuator controls the
opening and closing of the load compressor
inlet guide vanes. The IGV actuator is powered by a 30-80 psi air supply from the
powerhead compressor and controlled by an
electronic signal from the ESCU. The IGV
actuator is connected to the inlet guide
vanes through a link which drives a ring
gear. As the IGV actuator shaft extends, the
ring gear rotates closing the inlet guide
vanes. When the IGV actuator shaft is fully
retracted, the inlet guide vanes are open.
l.
Air Flow Sensor. The Air Flow Sensor (AFS)
is mounted on the outlet side of the load
compressor scroll. Two pneumatic probes, P
EXIT and P NOZZLE, are installed in the
AFS housing. These probes provide pneumatic pressure to the P EXIT and P NOZZLE transducer on the ESCU. A remote
temperature sensor, installed in the AFS,
measures bleed air temperature and provides a signal to the ESCU.
m.
Oil Cooler. The oil cooler is mounted to the
accessory drive housing and is used to eliminate ‘‘hot oil’’ shutdowns.
1-8. TEST CELL ADAPTER KIT (FIGURE 1-6). The
Test Cell Adapter Kit (hereafter called adapter kit),
part number 164650-100, consists of those components necessary to facilitate starting, controlling,
and monitoring the APU, when testing is being
accomplished in the test cell facility. The adapter
kit consists of the APU cart and the following subsystems: load compressor subsystem, engine subsystem, exhaust subsystem, hydraulic start subsystem, dyna-
TO 2G-T62T-43
Figure 1-6. Test Cell Adapter Kit
1-11
TO 2G-T62T-43
mometer subsystem, electrical subsystem, vibration
measurement subsystem, fuel system subsystem, and
lubricating subsystem. For installation procedures of
the adapter kit, refer to Section VII - Testing.
a. Load Compressor Subsystem (figure 1-7).
The load compressor subsystem provides a
means of exhausting the output air generated
from the APU's load compressor section.
There are two separate paths. One path exhausts bypass air when the by-pass valve is
open. The adapter connects to the outlet
port of the by-pass valve to the depot exhaust duct. The other path routes load compressor air to the facility ducting.
The
adapter simulates aircraft ducting volume and
attaches to the APU duct assembly. The
load compressor subsystem consists of four
hose and transducer assemblies. Two assemblies mate the air flow sensor (AFS) at the P
exit and P nozzle ports, to the transducer
ports on the ESCU, located inside the cart.
The pressure transducer on the P exit port
has an operating range of 0-100 psig. The
other pressure transducer on the P nozzle
port has an operating range of 0-15 psid.
The other two assemblies measure APU duct
inlet and exit pressures. An accumulator
tank (approximately 10 cubic feet volume)
simulates aircraft pneumatic system volume.
b. Engine Subsystem. The engine subsystem
contains drain containers, container receptacles, and hardware to collect combustor, fuel
control, hydraulic starter, and gearbox spent
fluids. The subsystem also contains a 500 ml
graduated cone to measure oil leakage or oil
expended from the reduction drive unit vent.
c. Exhaust Subsystem. The engine exhaust subsystem consists of the following four sections
clamped together:
(1) Adapter section mates with the APU
combustor assembly.
(2) Exhaust gas temperature (EGT) thermocouple assembly (figure 1-8) containing six individually read chromealumel EGT probes with connectors.
1-12
(3) Bellows assembly between the adapter
and tailpipe sections to compensate for
thermal expansion.
(4) Tailpipe section connects to the exhaust stack.
d. Hydraulic Start Subsystem (figure 1-9). The
hydraulic start subsystem controls hydraulic
fluid to the engine hydraulic starter.
e. Dynamometer Subsystem (figure 1-10). The
dynamometer subsystem is used to apply a
shaft load to the APU reduction drive unit
being tested. The dynamometer bolts to the
output pad on the reduction drive unit and is
required to absorb 0-50 hp. Facility water is
provided to this subsystem at 50 ±2 psig.
f. Electrical Subsystem (FO-1). The electrical
subsystem contains an ESCU, three wiring
harnesses, and junction box with annunciator
indicators. The electrical subsystem interfaces with other subsystems.
g. Vibration Subsystem (figure 1-11). The vibration subsystem provides for independent
measurement of the vibration of the APU
and of the reduction drive unit. The vibration subsystem consists of an engine accelerometer, gearbox accelerometer and mounts,
and individual coaxial cables for connecting
the accelerometers to the fluid panel connection point.
h. Fuel Subsystem (figure 1-12). The fuel subsystem provides for switching from JP-4 type
fuel to preservation oil, to facilitate APU
preservation upon completion of testing.
JP-4 type fuel is regulated by the facility to
5-40 psig and preservation oil is gravity fed
from the wall mounted preservation oil box.
i.
Lubricating Subsystem (figure 1-13). The
lubricating subsystem consists of a reduction
drive unit temperature probe, which measures the APU oil sump temperature. An oil
to water heat exchanger is provided for cooling the oil using facility cooling water.
TO 2G-T62T-43
Figure 1-7. Load Compressor Subsystem Schematic
1-13
TO 2G-T62T-43
Figure 1-8. APU Thermocouple Connections Schematic
1-14
TO 2G-T62T-43
Figure 1-9. Hydraulic Start Subsystem Schematic
1-15
TO 2G-T62T-43
Figure 1-10. Water Dynamometer Subsystem Schematic
1-16
TO 2G-T62T-43
Figure 1-11.
Vibration and Dynamometer Load Cell Subsystem Schematic
1-17
TO 2G-T62T-43
Figure 1-12. Fuel Subsystem Schematic
1-18
TO 2G-T62T-43
Figure 1-13. Lubricating Subsystem Schematic
1-19
TO 2G-T62T-43
1-9. LEADING PARTICULARS.
Leading particulars for the APU are listed in Table 1-1. Leading
particulars for the test cell adapter kit are listed in Table 1-2.
1-10. CONSUMABLE MATERIALS.
Consumable
materials required to accomplish prescribed maintenance are listed in table 1-3.
c-
Table
1-1.
APU Leading
Particulars
Dimensions:
38.77 in.
24.00 in.
27.90 in.
Length ..................................................
Width ..................................................
Height .................................................
Weight,
.........,...,........,...,..,....... .,..,
maximum
Maximum
64,643 rpm
.........................................
Rated engine speed
.................................
shaft output power
190.0 lbsdry)
198.0 Ibs (wet)
40 Hp
Rated axial output shaft speed .................................
8,080. rpm
Fuel
MIL-T-5624,
......................................................
fuels
.............................................
Lubricating
oil
..............................................
Lubrication
system filtration
Alternate
Standard
operating
Operating
Air delivery
Maximum
[59°F,
day
.............. ...... ...,....
Maximum specific fuel consumption
for standard day conditions
Speed variation
at constant
Speed variation
during on/off
load
.......... ....... .......
....,.................. .......
load transients
Vibration at rotor frequency operating
under pneumatic load and/or shaft load
1-20
10 micron
disposable
(nominal)
type filter
14.696 psia (sea level)]:
........................................
EGT for standard
JP-5
JP-7
JP-8
MIL-L-7808
........ ,....................,....
temperatures
rates
MIL-T-5624L,
MIL-T-38219,
MIL-T-83133,
...................................
conditions
JP-4
....................
................... .....
-40 to 120°F
42.5 lb/min. at 57.5 psia
(ap 0.098 minimum)
P
Less than 1320°F for
more than 10 sec.
252 lb/hr. rrected
to sea level. 59°F
Less than ±0.5%
Less than ±2%
Less than 5 Gs
T.O. 2G-T62T-43
Table 1-1.
APU Leading Particulars - Continued
Vibration at rotor frequency when operating under no pneumatic
load (IGV’s closed) no shaft load .........................................................
Less than 10Gs
Oil pressure at 100% rotor speed........................................................
Greater than 18 psig
Engine oil sump temperature..............................................................
Not to exceed 275oF
Exhaust gas temperature ....................................................................
Not to exceed 1375 (±12)oF
APU oil consumption (measured at reduction drive unit oil vent
by 500 ml graduated cylinder) ............................................................
Less than 20 cc/hr
Compressor discharge pressure ..........................................................
45 psig (nominal)
Table 1-2.
Test Cell Adapter Kit Leading Particulars
Hydraulic fluid .....................................................................................
MIL-H-5606
Filtration:
High pressure .................................................................................
Non-bypass, 3 micron, Beta (β) 3
filter = 200
Low pressure ..................................................................................
Non-bypass, 3 micron, Beta (β) 2
filter = 200
Breather ................................................................................................
3 Micron
Hydraulic supply ..................................................................................
3000 +150, -300 psig
Hydraulic pressure transducer (hydraulic and nitrogen) .................
0-3000 psig
Hydraulic accumulator, nitrogen precharge (no hydraulic charge)
500 (±5) psig
AFS pressure transducer (differential)...............................................
0-15 psid
AFS pressure transducer (total)..........................................................
0-100 psig
Dynamometer:
Water supply ..................................................................................
Minimum flow rate 350 gal/hr at
50 (±2) psig
Seal cooling water ..........................................................................
Minimum flow rate to 0.1 gal/
min at 50 (±2) psig
Load cell output..............................................................................
0-300 pounds-force
Fuel .......................................................................................................
MIL-T-5624, JP-4
MIL-DTL-83133, JP-8
Fuel boost pressure ..............................................................................
5-40 psig
Fuel flow rate capacity ........................................................................
Minimum 350 pound/hr
Preservation oil ....................................................................................
MIL-L-6081, grade 1010
Oil cooler supply water ........................................................................
Minimum flow rate 20 (±10)
psig, 7 gal/min
Change 22
1-21
T.O. 2G-T62T-43
Table 1-3.
Consumable Materials
Specification/
Manufacturer
Nomenclature
Use
Acetone
O-A-51
Cleaning braze repair
Adhesive
MIL-A-46106
Attach gaskets
Adhesive
MIL-A-46146, type III
Attach ID plate
Adhesive/sealant
RTV-3145
Attach silicone pads
Adhesive, silicone
GE P/N PSA529/SRC18 or equiv
(NSN 8040-00-097-6524
Adhesive, structural
EC-1386
Install housing liner
Alcohol, ethyl
O-E-760, type III
Freeze gear planet set
Alloy, brazing
AWS A5.8-62T BAU4
Repair fuel manifold
Aluminum oxide, coarse-grit
Metrolite, type C (FSCM 39918)
Dry blasting
Aqueous cleaner
MIL-C-87937
Ultrasonic cleaning tank
Bead, glass
MIL-G-9954
Vapor blasting
Blast medium
MB-3, type IV, class 2, MIL-A21380B
Vapor blasting
Brush, soft-bristle
MIL-B-15319, type I, class 2
Clean titanium and aluminum
alloy parts
Caps and plugs
MS90376-8R, -10R, -12R, -14R,
-16R, -16Y, -18Y, -20R, -20Y,
-22R, -22Y, -24R, -24Y, -28Y
Protect against dust and
moisture
Caps
1/8 SC, FSCM 95760
Protect fuel manifold tips
Cheesecloth
CCC-C-440
Clean aluminum parts
Cleaner, alkaline
TT-C-490C
Clean steel parts
Cleaner, alkaline
MIL-C-87936
Clean titanium parts
Cleaner, solvent
P-D-680, type II or III
Degrease turbine nozzle, seal
plate, turbine wheel
Cloth, abrasive crocus
P-C-458
Remove nicks, burrs, scratches,
surface blemishes, and scoring
Cloth, lint-free
MIL-C-85043, type II
Dry components
Coating, black oxide
MIL-C-13924, class I
Coat replacement sleeves
Coating, chemical conversion
MIL-C-81706, type III
Treat exposed surfaces
1-22 Change 22
T.O. 2G-T62T-43
Table 1-3.
Consumable Materials - Continued
Specification/
Manufacturer
Nomenclature
Use
Compound, aircraft surface
cleaning
MIL-C-43616
Clean steel parts
Compound, alkaline cleaning
P-C-436
Clean aluminum alloy parts
Compound, antiseize
MIL-A-907
Apply on components
Compound, corrosion
preventive
MIL-C-16173, grade 4
Preserve steel parts
Compound, gear marking
No. 89 or Dykem Blue
Mark teeth of accessory drive
pinion
Compound, sealing
MIL-S-45180
Coat magnetic pickup threads
Compound, thread-locking
MIL-S-46163A
Apply to screw threads
Corrosion inhibitor
Rustlick 606
Corrosion prevention of rotor
assembly
Cushioning, cellulosic
PPP-C-843
Wrap APU
Desiccant
MIL-D-3464
Absorb moisture in container
Fluid, assembly
RT-403A, No. 1 (FSCM 77988)
Lubricate parts
Change 22
1-23
T.O. 2G-T62T-43
Table 1-3.
Consumable Materials - Continued
Specification/
Manufacturer
Nomenclature
Use
Fluid, calibrating
MIL-C-7024, type II
Test fuel nozzle and fuel
manifold
Fluid, hydraulic
MIL-H-5606
Precharge accumulator
Fuel
MIL-T-5624, JP-4,
MIL-T-5624L, JP-5,
MIL-T-38219, JP-7,
MIL-T-8133, JP-8,
Operate APU
Gloves, thermally insulated
MIL-G-440, type II
(HH-G-450D)
Handle components
Grain, sof t abrasive
MIL-G-5634
Vapor blasting
Ice, dry
BB-C-104
Freeze components
Indicator, humidity
MIL-I-8835A6
Check humidity in shipping
container
Lockwire
MS20995C20, MS20995C32
Safety wire components
Lubricant, solid
MIL-L-8937
Coat threads of shaf t
Mat, non-metallic
MIL-A-9962
Clean aluminum alloy parts
Material, barrier
MIL-B-131, class III
Wrap APU
Material, braze f iller
BNI-2, AMS 4777
Cover braze cracks
Material, titanium bar
6A1-4V, AMS 4996-84
Manufacture sleeve
Nitrogen, liquid
MIL-P-27401
Freeze components
Nitrogen, technical
BB-N-411, type I, class 1,
grade B
Precharge accumulator
Oil
Grade S 150
Flow test oil jet cartridges
Oil, lubricating
MIL-L-7808, MIL-L-23699
Lubricate components
Oil, non-carbon penetrating
VV-P-216
Loosen igniter plug grommet
Oil, preservation
MIL-L-6081, grade 1010
(NSN 9150-00-273-2388)
Test and preserve components
Paint, epoxy polyamide
MIL-C-22750, class I, type I
Paint component
Powder, welding
Metco 601 NS (FSCM 78253)
Apply abradable coat and plasma
spray
Powder, welding
Metco 450
Apply abradable coat and plasma
spray.
Primer, epoxy
MIL-P-23377, type I, class C or N
Restore f inish
Primer, water borne epoxy
MIL-P-85582, type I, class 2
Restore f inish
Rod, welding
MIL-R-5031, class 7
Weld cracks or holes
1-24
Change 16
T.O. 2G-T62T-43
Table 1-3.
Consumable Materials - Continued
Specification/
Manufacturer
Nomenclature
Use
Sealant
MIL-C-81733, type III
(NSN 9Q8030-00-008-7196)
Treat repair areas
Sealant
MIL-S-22473, grade A
Apply to sleeve
Shot
AB
Glass shot peening
Soap, silicate
MIL-M-7752
(NSN 8520-00-228-0598)
Clean aluminum and magnesium parts
Solder
QQ-S-571, type Sn63
Solder/unsolder wires
Stone, abrasive
SS-S-736
Polish surface
Stop-off
Nicrobraze green
Prevent excess flow of braze
material
Tape, masking
MIL-T-21595
Mask surfaces for vapor blasting
Tape, pressure sensitive
MIL-T-22085, type II
Mask ports, outlets, and fittings
Water, deionized
Local purchase
Mix alkaline cleaning solution
Water, distilled
Local purchase
Mix alkaline cleaning solution
Tape, Tesa
Tesa Secure 6973 PV6
Change 23 1-25/(1-26 Blank)
TO 2G-T62T-43
SECTION II
SPECIAL TOOLS AND TEST EQUIPMENT
2-1. GENERAL. Special tools and test equipment required for maintenance of the APU are presented in
this section. Equivalent items may be used if the recommended tool/test equipment is not available.
2-2. SPECIAL TOOLS AND TEST EQUIPMENT.
Special tools and test equipment required for maintenance of the APU are listed in table 2-1 and illustrated in figure 2-1.
Table 2-1. Special Tools and Test Equipment List
Tool/Equipment
Figure/Index
Number
Number
FD-100
2-1-1
Nomenclature
Use and Application
Eddy current tester
Detect flaws in components
HBH-003
-2
Balancer
Balance rotor assembly
M93
-3
Accelerometer
Used with vibration analysis tool,
ST63939 (see index no. 13)
APU service cart
Mount APU build stand
MIL-T-16549G
Not illus.
SD340
-4
Spectrum analyzer
Used with vibration analysis tool,
ST63939 (see index, no. 13)
ST60051
-5
Bridge gage
Measure dimension
ST60811
-6
Backlash gage
Check backlash gears
ST60880
-7
Wire gage
Measure load compressor wheel
ST61186-06
-8
Ring gage
Check clearance between diffuser
and engine compressor wheel
ST61404
-9
Inspection fixture
Inspect and qualify final assembly
of combustor assembly
ST62880
-10
Inspection fixture
Check alignment and critical
details
ST63929
-11
Assembly function gage
Determine shim thickness
ST63931
-12
Functional gage assembly
Pre-gage stacking height of load
compressor wheel
ST63939
-13
Vibration analysis tool
Blade tuning
ST64016
-14
Rotor assembly
inspection fixture
Inspect run-out of rotor assembly
ST64037
-15
Eddy current holder
Hold component
2-1
TO 2G-T62T-43
Table 2-1. Special Tools and Test Equipment List - Continued
Tool/Equipment
Number
Figure/Index
Number
Nomenclature
Use and Application
ST64038 or
LKG 05
-16
Tension tester
Test movement of gears
ST70137
-17
Rotor fixture
Hold turbine assembly
ST70170
-18
Puller
Removal of support and gear
ST70234
-19
Puller
Removal of accessory pad cover
ST70235
-20
Puller
Removal of shaft
ST70236
-21
Arbor plate
Installation/removal of
components
ST70237
-22
Bushing
Removal of pinion and ring
ST70238
-23
Bushing
Removal of bearings
ST70241
-24
Spanner wrench
Installation/removal of locknuts
ST70242
-25
Adapter
Torquing nuts
ST70243
-26
Spanner wrench
Torquing
ST70254
-27
Holding bar
Used with backlash gage,
ST6081 1
ST70266
-28
Holding fixture
Hold component to torque
ST70267
-29
Holding fixture
Hold gear to torque
ST70277
-30
Bearing remover holder
Removal of bearings
ST70278
-31
Holding fixture
Support reduction drive unit
housing
ST70281
-32
Driver
Installation of bearings
ST70282
-33
Driver
installation of bearings
ST70283
-34
Driver
installation of hub
ST70284
-35
Disassembling tool
Compress retaining ring
ST70286
-36
Arbor plate and driver
Installation/removal of bearings
ST70370
-37
Assembly fixture
Hold reduction drive unit for
assembly
2-2
T.O. 2G-T62T-43
Table 2-1.
Tool/Equipment
Number
Special Tools and Test Equipment List - Continued
Figure/Index
Number
Nomenclature
Use and Application
ST70414
-38
Driver set
Installation of bearings
ST70433
-39
Oil filter cap assembly fixture
Installation of spring and pin
ST71078
-40
Stretch tool
Stretch shaft
ST71186
-41
Turbine wheel puller
Remove turbine wheel
ST71191
-42
Wrench
Torquing
ST71201
-43
Combustor puller
Installation/removal of combustor assembly
ST71206
-44
Assembly build stand
Hold APU for assembly/disassembly
ST71207
-45
Arbor press guide
Installation/removal of labyrinth seal
ST71209
-46
Pinion installation and disassembly tool
Installation/removal of pinion
ST71214
-47
Assembly check gage plate
Check dimensions
ST71217
-48
Assembly check gage plate
Use with bridge gage,
ST60051
ST71219
-49
Load compressor rotor assembly
tooling
Press load compressor wheel
onto rotor shaft
ST71231
-50
Bearing bevel gear removal tool
Remove bearings
ST71232 or local
manufacture
-51
Containment ring
Hold dry ice
ST71234
-52
Rotor assembly tool
Assist in rotor assembly
ST71235
-53
Assembly clearance gage
Measure dimensions
ST71236
-54
Load compressor wheel assembly
Support load compressor to
shoulder
-55
Turbine stud torque wrench
Remove and torque stud
18D8325-1 (Alt to
ST71236)
ST71238
Change 22 2-3
TO
2G-T62T-43
Table 2-1.
Tool/Equipment
Special
Tools and Test Equipment
List - Continued
-.
Figure/Index
Number
Nomenclature
ST71 240
or TM 70017
-56
Bearing installation
ST80043
-57
Balancing
ST8021 1
-58
Oil filter cap removal tool
Remove by-pass
ST80472
-59
Balancing
Hold rotor shaft for balancing
ST80608
-60
Balance arbor
Assist in balancing
parts
ST8061 6
-61
Balance arbor
Assist in balancing
parts
ST8061 7
-62
Balance arbor
Assist in balancing
parts
ST90030
or TM 90027
-63
Adapter
Installation of oil pump on
flow bench
ST901 33
-64
Driver
Press bearing on gear planet set
ST90 142
-65
Driver
Installation of bearing and gear
planet set
ST90288
-66
Puller
Removal of carrier assembly
cover
ST94270
-67
Support fixture
Balance rotor assembly
ST90671
-68
Bearing assembly
ST90682
-69
Mounting
ST90684
-70
Retaining plate
Removal of carrier assembly
cover
ST90889-01
-71
Guide tool set
Installation
of shaft seals
ST90889-04
-72
Guide tool set
Installation
of shaft seals
ST91 061
-73
Bearing puller
Provide pressure surface for
removal of bearings from shaft
Number
Use and Application
tool
of pinion
Used with balancing
ST80472
cradle
tool cradle
block
Installation
tool
Installation
tool cradle,
housing valve
of bearings
Hold shim
ST9 1064
-74
Flaring fixture
Flaring igniter plug grommet
ST92300
-75
Flow check fixture
Check spray flow of fuel nozzle
2-4
-.
w
TO
Table 2-1.
Tool/Equipment
Number
Figure/lndex
Number
Special
Tools
and Test Equipment
2G-T62T-43
List - Continued
Use and Application
Nomenclature
Remove shaft seal
ST93057
-76
Seal puller
ST93950
-77
Load compressor
tool
clearance
Check for axial load compressor
to scroll clearance
ST93951 -04
-78
Load compressor
restrainer
wheel
Hold load compressor
ST93975
-79
Spanner
ST94276
-80
Balancing
support
Support part while balancing
ST9428 1
-81
Balancing
support
Support balancing
ST94409
-82
Lifting fixture
ST94426
-83
Carrier bearing
163000
-84
Eddy current
master
inspection
Detect flaws in components
164101-100
-85
Fuel manifold
flow bench
Test fuel nozzle and fuel manifold
164650-l
7-2
Test cell adapter
166471-100
-86
Shipping
166819-100
-87
Engine support
167147-l
-88
APU cart
Hold engine in test cell
Local manufacture
or ST78602
-89
Driver
Press seal on load compressor
wheel
Local manufacture
or ST78603
-90
Holder
Hold load compressor wheel
during seal installation
Local manufacture
-91
Bushing
Support rotor shaft during
balancing
Layout table
Making measurements
00
00
No part no.
Not illus.
wheel
Torquing
wrench
Lift APU engine
puller
kit
container
kit
Remove bearing
Test APU in test cell
Store or ship APU
Install APU on test cell cart
on APU
2-5
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 1 of 16)
2-6
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 2 of 16)
2-7
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 3 of 16)
2-8
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 4 of 16)
2-9
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 5 of 16)
2-10
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 6 of 16)
2-11
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 7 of 16)
2-12
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 8 of 16)
2-13
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 9 of 16)
2-14
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 10 of 16)
2-15
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 11 of 16)
2-16
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 12 of 16)
2-17
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 13 of 16)
2-18
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 14 of 16)
2-19
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 15 of 16)
2-20
TO 2G-T62T-43
Figure 2-1. Special Tools and Test Equipment (Sheet 16 of 16)
2-21/(2-22 blank)
T.O. 2G-T62T-43
SECTION III
DISASSEMBLY
3-1. GENERAL. This section contains information necessary to disassemble the APU, including
the turbine assembly, the reduction drive unit, and
the combustor assembly. The extent of disassembly
should be determined by preliminary visual inspection and test. No part should be disassembled
unless it requires servicing, or unless it must be
removed to allow access to other parts requiring
replacement or servicing.
3-2. UNPACKING. This section contains procedures for removing the APU from the shipping
container, SPI NO. F01-345-3402 (86, Figure 2-1).
Unless otherwise indicated, index numbers refer to
Figure 3-1.
WARNING
Two maintenance personnel are
required to remove APU from shipping
container. Failure to comply could
result in injury to personnel.
a.
Remove lag screws (1) and washers (2)
securing cover (3) to skid (4).
b.
Remove cover (3) from skid (4).
c.
Remove masking tape and cellulosic cushioning from around APU.
d.
Remove barrier material from around APU.
e.
Install lifting fixture, ST94409 (82, Figure 21), in forward and aft eye bolts on APU.
f.
Hook suitable hoist (minimum 2,000 lbs lifting capacity) to lifting fixture, ST94409 (82,
Figure 2-1), and take up slack.
g.
Remove bolts (5, Figure 3-1), nuts (6), and
washers (7) securing APU to supports on
skid (4).
h.
Lift APU from skid (4).
3-3. GENERAL DISASSEMBLY PROCEDURES. The
following general disassembly procedures shall be
observed during disassembly.
a.
Clean all parts per Section IV - Cleaning.
b.
Place all parts in order of disassembly on a
flat, clean surface to avoid loss or disarrangement. Place small parts in suitable
containers.
c.
Carefully observe any specific instructions
given.
d.
Never apply force during removal and
installation of parts. If a part is not easily
removed, investigate the cause (i.e. alignment or some attaching part being
overlooked).
e.
Always use the proper tool for an operation.
f.
Do not mix parts from several APUs.
3-4. DISASSEMBLY OF APU. This section contains procedures for removal of accessory parts,
tubing, and wiring mounted on the APU. It also
covers breaking down the APU into three main
subassemblies for individual disassembly outlined
in following paragraphs.
a.
Place assembly build stand, ST71206 (44,
Figure 2-1), on APU service cart, Specification MIL-T-16549G.
b.
Install APU in assembly build stand,
ST71206 (44, Figure 2-1), then remove lifting fixture, ST94409 (82).
.
.
NOTE
If APU is not being completely disassembled, perform only those steps necessary to accomplish the required
maintenance.
With the APU mounted on assembly
build stand fixture, the APU can be
rotated to either the vertical or horizontal position. To facilitate disassembly, rotate APU whenever necessary.
c.
Tilt APU into a vertical position and remove
lockwire from magnetic-drain plug (1, Figure 3-2, detail G). Return APU to horizontal
position.
d.
Place suitable container under fuel lines and
oil lines to catch oil and spilled fluid.
Change 24 3-1
T.O. 2G-T62T-43
Figure 3-1.
3-2 Change 24
Removal of APU from Shipping Container
T.O. 2G-T62T-43
e.
e1.
f.
Remove magnetic-drain plug (1) and selfclosing valve (2), and drain oil from engine
oil sump assembly (71). Reinstall self-closing valve (2) and magnetic-drain plug (1).
assembly (75, Figure 3-2, detail B).
Remove support clamps (7).
(5)
Remove bolt (1, Figure 3-5, detail A),
nut (2), and washer (3), securing support clamps (4) to ignition cable (27) and
thermocouple harness (40). Remove
support clamps (4).
(6)
Remove bolts (3, Figure 3-2, detail C),
nuts (4), and washers (5), securing support clamps (6 and 8) to engine control
harness (13, Figure 3-2, detail B), and
thermocouple harness (14). Remove two
sets of support clamps (6 and 8, Figure
3-2, detail C).
(7)
Remove bolts (3), nuts (4), and washers
(5), securing support clamps (6 and 9) to
start fuel control to tee tube assembly
(16, Figure 3-2, detail B) and purge
valve to fuel manifold tube assembly
(19) and to engine control harness (13).
Remove support clamps (6 and 9, Figure
3-2, detail C).
(8)
Remove bolts (10, Figure 3-2, detail C),
nuts (4), washers (5), and spacers (11),
securing support clamps (6 and 7) to
engine control harness (13, Figure 3-2,
detail B), purge valve to fuel manifold
tube assembly (19), and APU. Remove
support clamps (6 and 7).
(9)
Remove bolts (3, Figure 3-2, detail H),
nuts (4), and washers (5), securing support clamps (6) to tee to gearbox adapter
tube assembly (54, Figure 3-2, detail G),
oil pressure manifold housing to reduction drive tube assembly (66), and
engine control harness (13). Remove six
sets of support clamps (6, Figure 3-2,
detail H).
(10)
Remove bolts (3), nuts (4), and washers
(5), securing support clamps (6) to filter
to tee PCD air tube assembly (36, Figure 3-2, detail F) and engine control
harness (13). Remove support clamps (6,
Figure 3-2, detail H).
If applicable (-135A APU) remove oil cooler
(76, Figure 3-2, detail I), as follows:
(1)
Disconnect hose assembly, (82, Figure
3-2, detail I), from the ‘‘oil in’’ fitting of
the oil cooler.
(2)
Disconnect hose assembly, (81, Figure
3-2, detail I), from the ‘‘oil out’’ fitting of
the oil cooler.
(3)
Disconnect hose assembly, (82, Figure
3-2, detail I), from the ‘‘oil out’’ fitting of
the APU gearbox.
(4)
Disconnect hose assembly, (81, Figure
3-2, detail I), from the ‘‘oil in’’ fitting on
the APU gearbox.
(5)
Remove left bracket, (86, Figure 3-2,
detail I), (cooler end) by removing nut,
(92, Figure 3-2, index 1) and bolt (91,
Figure 3-2, detail I), and nut (gearbox
end) (93, Figure 3-2, index 1).
(6)
Remove right bracket (85, Figure 3-2,
detail I), (cooler end) by removing bolt
(91, Figure 3-2, detail I), and nut (92,
Figure 3-2, detail I), and nut (gearbox
end) (93, Figure 3-2, detail I).
(7)
Remove top bracket (84, Figure 3-2,
detail I) by removing two bolts (90, Figure 3-2, detail I) from oil breather pad of
APU gearbox.
Remove support clamps as follows:
(1)
(2)
(3)
(4)
Remove bolts (3, Figure 3-2, detail H),
nuts (4), and washers (5), securing support clamps (6) to purge valve to fuel
manifold tube assembly (19, Figure 3-2,
detail B) and engine control harness
(13). Remove support clamps (6).
Remove bolts (3, Figure 3-2, detail H),
nuts (4), and washers (5) securing support clamps (6) to purge valve to tee
tube assembly (24, Figure 3-2, detail B)
and thermocouple harness (14). Remove
support clamps (6).
Remove bolts (3, Figure 3-2, detail E),
nuts (4), and washers (5), securing support clamps (6) to fuel manifold to purge
valve tube assembly (20, Figure 3-2,
detail B), thermocouple harness (14)
and ignition cable (67, Figure 3-2, detail
E). Remove support clamps (6).
Remove bolts (3, Figure 3-2, detail D),
nuts (4), and washers (5), securing support clamps (7) to engine control harness (13) at fuel control enclosure base
g.
Remove bolt (1, Figure 3-3), self-locking nut
(2), and washer (3), securing support clamp
(4) to connector mounting bracket (23) and
engine control harness. Remove support
clamp (4).
h.
Remove bolts (5, Figure 3-3), nuts (6), and
washers (7), securing connector mounting
bracket (23) to engine control harness (13,
Figure 3-2, detail A).
i.
Remove tiedown strap (12) from engine control harness (13).
Change 24 3-3
T.O. 2G-T62T-43
Figure 3-2.
3-4 Change 24
APU (Sheet 1 of 5)
T.O. 2G-T62T-43
Figure 3-2.
APU (Sheet 2 of 5)
Change 24 3-5
T.O. 2G-T62T-43
Figure 3-2.
3-6 Change 24
APU (Sheet 3 of 5)
T.O. 2G-T62T-43
Figure 3-2.
APU (Sheet 4 of 5)
Change 24 3-7
T.O. 2G-T62T-43
Figure 3-2.
3-8 Change 24
APU (Sheet 5 of 5)
T.O. 2G-T62T-43
j.
Remove lockwire from all connectors and
disconnect connectors on engine control harness (13) and thermocouple harnesses (14
and 15) as follows:
(1)
Connector mounting bracket, J1.
(2)
Fuel control enclosure spacer, P2.
(3)
Hourmeter junction box, P3.
(4)
Fuel purge valve, P4.
(5)
Turbine ignition exciter, P302.
(6)
Low oil pressure switch, P303.
(7)
Magnetic pickup, P304.
(8)
High-oil temperature switch, P305.
(9)
Surge control valve, P306.
(10)
Ambient temperature, P307.
(11)
IGV actuator, P308.
(12)
Air flow sensor, P309.
k.
Remove engine control harness (13) and
thermocouple harnesses (14 and 15).
l.
Separate thermocouple harnesses (14 and
15) from engine control harness (13) at connectors P8 and P9.
m.
Install protective plugs on all fuel oil lines
and caps on all electrical connectors on
engine control harness (13).
n.
Remove fuel control enclosure base (44, Figure 3-4) and fuel electronic control assembly
(33) as follows:
(1)
Loosen studs (1), springs (2), and washers (3 and 4) securing fuel control enclosure cover (5) to enclosure spacer
assembly (18). Remove fuel control
enclosure cover.
NOTE
Do not remove gasket (6) unless loose
or damaged.
(2)
If necessary, remove gasket (6) from
fuel control enclosure cover (5).
(3)
Remove screws (7), self-locking nuts (8),
and washers (9), securing fuel electronic
harness (16) and gasket (17) to enclosure spacer assembly (18).
(4)
Remove bolt (10), washer (11), and nut
(12), securing support clamp (13) and
bracket (14) to fuel electronic harness
(16). Remove clamp (13) and bracket
(14).
(5)
Remove tiedown straps (15) from fuel
electronic harness (16).
(6)
Disconnect connectors of fuel electronic
harness (16) from fuel electronic control
assembly (33).
(7)
Remove fuel electronic harness (16) and
gasket (17) from enclosure spacer
assembly (18).
(8)
Install protective caps on all connectors
of fuel electronic harness (16).
(9)
Loosen studs securing enclosure spacer
assembly (18) to fuel control enclosure
base (44). Remove enclosure spacer
assembly (18) and hourmeter junction
box (18, Figure 3-8) as an assembled
unit.
NOTE
Do not remove gasket (19) unless loose
or damaged.
(10)
If necessary, remove gasket (19, Figure
3-4) from enclosure spacer assembly
(18) and discard.
(11)
Remove bolts (20), nuts (21), and washers (22), securing support clamps (23) to
enclosure elbow to fuel pump tube
assembly (24). Remove support clamps
(23).
(12)
Remove enclosure elbow to fuel pump
tube assembly (24) from elbows (25 and
41).
(13)
Remove elbow (25) and O-ring (26) from
fuel electronic control assembly (33).
Discard O-ring (26). Install protective
cap.
(14)
Remove tube elbow (27) and main fuel
control to elbow tube assembly (28) from
nipple (29) in fuel electronic control
assembly (33). Install protective caps on
main fuel control to elbow tube assembly (28).
Change 24 3-8A/(3-8B blank)
TO 2G-T62T-43
Figure 3-3. Engine Hydraulic Starter, Oil Pressure Switch, Turbine Assembly, and
Combustor Assembly (Sheet 1 of 2)
3-9
TO 2G-T62T-43
Legend for figure 3-3:
1. Bolt
2. Self-locking nut
3. Washer
4. Support clamp
5. Bolt (4)
6. Nut
7. Washer (4)
8. Self-locking nut (6)
9. Washer (6)
10. Engine hydraulic starter
11. Gasket
12. Nipple
13. O-ring
14. Self-locking nut (6)
15. Washer (6)
16. Reduction drive cover
17. Gasket
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Oil pressure switch
O-ring
Eye bolt
Bolt (4)
Washer (4)
Connector mounting bracket
Clamp
Check valve (-114 only)
O-ring (-114 only)
Combustor assembly
Seal ring
Bolt (6)
Turbine assembly
O-ring
Adapter gasket
Reduction drive unit
Figure 3-3. Engine Hydraulic Starter, Oil Pressure Switch, Turbine Assembly, and
Combustor Assembly (Sheet 2 of 2)
3-10
TO 2G-T62T-43
Figure 3-4. Fuel Control Enclosure Base Assembly (Sheet 1 of 2)
3-11
TO 2G-T62T-43
Legend for figure 3-4:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24. Enclosure elbow to fuel pump tube assembly
25. Elbow
Stud (22)
Spring (22)
Washer (22)
Washer (22)
Fuel control enclosure cover
Gasket
Screw (4)
Self-locking nut (4)
Washer (4)
Bolt (2)
Washer (2)
Nut (2)
Support clamp
Bracket
Tiedown strap (4)
Fuel electronic harness
Gasket
Enclosure spacer assembly
Gasket
Bolt
Nut
Washer
Support clamp
Figure 3-4.
3-12
26,
27.
28.
29.
30.
31,
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Fuel Control
Enclosure
O-ring
Tube elbow
Main fuel control to elbow tube assembly
Nipple
O-ring
Bolt (4)
Washer (4)
Fuel electronic control assembly
Engine accessory drive gasket
Locknut
Elbow
O-ring
Locknut
Washer (2)
Washer
Elbow
Bolt (4)
Washer (4)
Fuel control enclosure base
Gasket
Base Assembly
(Sheet 2 of 2)
TO 2G-T62T-43
(15) Remove nipple (29) and O-ring (30)
from fuel electronic control assembly
(33). Discard O-ring (30). Install protective cap.
(16) Disconnect start fuel control to tee
tube assembly (16, figure 3-2, detail
B) from elbow (36, figure 3-4).
(17) Remove bolts (31, figure 3-4) and
washers (32) securing fuel electronic
control assembly (33) to fuel control
enclosure base (44) and reduction
drive unit (33, figure 3-3). Remove
fuel electronic control assembly (33,
figure 3-4). Install protective plugs on
fuel electronic control assembly (33)
and spline-shaft protective cover (part
number 164416, TO 6J3-4-112-3) on
fuel pump spline.
(18) Remove engine accessory drive gasket
(34) and discard.
(19) Loosen locknut (35) and remove elbow
(36) and O-ring (37) from fuel electronic control assembly (33). Discard
O-ring (37).
(20) Remove locknut (38) and washers (39
and 40) securing elbow (41) to fuel
control enclosure base (44). Remove
elbow (41).
caution
Start fuel control to tee tube assembly (16)
and purge valve to fuel manifold tube assembly (19, figure 3-2, detail B) are held
tightly in enclosure base (44, figure 3-4).
Be careful to avoid damaging when removing.
(23) Remove O-ring (17) from purge valve
to fuel manifold tube assembly (19)
and discard.
(24) Remove O-ring (18) from start fuel
control to tee tube assembly (16) and
discard.
NOTE
Do not remove gasket (45) unless loose or
damaged.
(25) Remove bolts (42) and washers (43)
securing fuel control enclosure base
(44) and gasket (45) to reduction drive
unit (33, figure 3-3). Remove fuel
control enclosure base (44, figure 3-4)
and if necessary, gasket (45). Discard
gasket (45) if removed.
(26) Temporarily install bolts (42) and
washers (43) into reduction drive unit
(33, figure 3-3).
(27) Install protective cover on accessory
pad cover (108, figure 3-12) and secure.
o. Remove fuel purge valve and tubing as follows:
(1) Remove fuel manifold to purge valve
tube assembly (20, figure 3-2, detail
B), connecting tee (28) on fuel purge
valve (25) and fuel manifold on combustor assembly (74). Install protective
caps.
(2) Remove start fuel to start nozzle fuel
tube assembly (21) from fuel nozzle
(22) and bulkhead tee (35). Install
protective caps.
NOTE
Do not remove fuel nozzle (22) and fitting
(23) from combustor assembly (74) at this
time.
(21) Remove start fuel control to tee tube
assembly (16, figure 3-2, detail B)
from bulkhead tee (35).
(3)
Remove purge valve to tee tube assembly (24), connecting fuel purge valve
(25) to tee tube (30). Remove fuel
purge valve (25).
(22) Remove purge valve to fuel manifold
tube assembly (19) from tee (28). Install protective caps.
(4) Remove straight adapter (26) and Oring (27) from fuel purge valve (25).
Discard O-ring (27).
3-13
TO 2G-T62T-43
Remove tee (28) and O-ring (29) from
fuel purge valve (25). Discard O-ring
(29).
reduction drive unit (73) to elbow (59) on
inlet housing manifold (72). Install protective plugs.
(6) Remove tee tube (30) from orifice jet
restrictor (31).
z. Remove elbow (55) and O-ring (56) from
reduction drive unit (73), Discard O-ring
(56).
aa. Remove lockwire, then remove high-oil temperature switch (57), and O-ring (58) from
engine oil sump assembly (71). Discard Oring (58). Install protective cap.
(5)
(7) Remove orifice jet restrictor (31) and
O-ring (32). Discard O-ring (32).
(8)
Remove locknut (33), washer (34) and
bulkhead tee (35).
p.
Remove filter to tee PCD air tube assembly
(36, figure 3-2, detail F) from air filter (37)
and tee (45) on IGV actuator (70). Remove
air filter (37). Install protective caps on air
filter (37), and plugs on filter to tee PCD air
tube assembly (36).
q.
Remove diffuser to filter PCD air tube assembly (38) from elbow (39). Install protective
plugs.
r.
Remove elbow (39) from straight adapter
(40) on PCD air outlet on turbine assembly
(68, figure 3-2, detail G).
ab. Remove surge control valve (9, figure 3-5)
as follows:
(1) Remove V-band clamp (5), securing
duct assembly (6) to duct assembly
(17).
(2) Remove duct assembly (6) and O-ring
(7). Discard O-ring (7).
(3)
(4)
s.
Remove straight adapter (40, figure 3-2, detail F) and O-ring (41). Discard O-ring
(41).
t.
Remove tee to surge valve PCD air tube assembly (42). connecting PCD air to surge
control valve (69) and tee (45) on IGV actuator (70). Install protective plugs.
u.
Remove reducer (43) and O-ring (44) from
surge control valve (69). Discard O-ring
(44).
(2)
v.
Remove tee (45), reducer (43). and O-ring
(46) from IGV actuator (70). Discard Oring (46).
(3)
w. Remove oil hose assembly (47, figure 3-2,
detail G), connecting engine oil sump assembly (71) to straight adapter (63) on inlet
housing manifold (72). Install protective
plugs on oil hose assembly (47).
x.
y.
3-14
Remove straight adapter (48) and O-ring
(49) from engine oil sump assembly (7.1).
Discard O-ring (49). Install protective cap
in engine oil sump assembly (71).
Remove oil pressure-manifold housing to reduction drive tube assembly (54), connecting
(5)
Remove V-band clamp (8), securing
surge control valve (9) to duct assembly
(17).
Remove surge control valve (9) and Oring (10). Discard O-ring (10).
Loosen band clamp (11), but do not
remove.
ac. Remove air flow sensor (25) as follows:
(1) Remove nuts (13), washers (14), and
bolts (15). securing duct support
bracket (16) to containment ring (37).
Remove duct support bracket (16).
(4)
(5)
(6)
(7)
(8)
Remove V-band clamp (12), securing
duct assembly (17) to air flow sensor
(25).
Remove duct assembly (17) and O-ring
(18). Discard O-ring (18).
Remove temperature sensor (19) and
O-ring (20) from air flow sensor (25).
Discard O-ring (20).
Remove bolt (21), securing fitting assembly (22) to air flow sensor (25).
Remove fitting (22) and O-rings (23).
Discard O-rings (23).
Remove V-band clamp (24) from air
flow sensor (25).
Remove air flow sensor (25) and Oring (26) from load compressor scroll
(38). Discard O-ring (26).
T.O. 2G-T62T-43
Figure 3-5.
Surge Control Valve, Air Flow Sensor Assembly, and Turbine Ignition Exciter (Sheet 1 of 2)
Change 20
3-15
T.O. 2G-T62T-43
Legend or figure 3-5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Bolt
Nut
Washer
Support clamp (2)
V-band clamp
Duct assembly
O-ring
V-band clamp
Surge control valve
O-ring
Band clamp
V-band clamp
Nut (2)
Washer (2)
Bolt
Duct support bracket
Duct assembly
O-ring
Temperature sensor
O-ring
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Bolt (2)
Fitting
O-ring (2)
V band clamp
Air flow sensor
O-ring
Ignition cable
Nut (4)
Bolt (4)
Washer (4)
Turbine ignition exciter
Bolt (2)
Bushing
Engine mounting adapter (2)
Locking ring (2)
Identification plate (2)
Containment ring
Load compressor scroll
Igniter plug
Thermocouple harness
P9100234
Figure 3-5. Surge Control Valve, Air Flow Sensor Assembly, and Turbine Ignition Exciter (Sheet 2 of 2)
3-16
Change 1
TO 2G-T62T-43
ad. Remove turbine ignition exciter (31, figure
3-5) as follows:
warning
NOTE
Do not remove spring pin (7) unless loose
or damaged.
(6)
Remove O-rings (5, 6, and 15, figure
3-6) and if necessary, spring pin (7)
from inlet manifold assembly (3) and
manifold assembly (4). Discard Orings (5, 6, and 15).
(7)
Remove elbow (59, figure 3-2, detail
G) and O-ring (60) from inlet housing
manifold (72). Discard O-ring (60).
(8)
Remove orifice fitting (61) and O-ring
(62) from inlet housing manifold (72).
Discard O-ring (62).
(9)
Remove straight adapter (63) and Oring (64) from inlet housing manifold
(72). Discard O-ring (64).
Be sure ignition cable and turbine ignition exciter are cool before handling.
Do not touch end of turbine ignition
cable when removing cable. Always remove cable from igniter plug end. Ground
end of ignition cable to combustor to discharge turbine ignition exciter. Failure to
do so could cause injury.
(1)
(2)
Remove lockwire, disconnect, and remove ignition cable (27) from igniter
plug (39) end and turbine ignition exciter (31). Do not remove igniter plug
(39) at this time. Install protective
caps.
Remove nuts (28), bolts (29), washers
(30) and turbine ignition exciter (31)
from containment ring (37). Install
protective caps.
ae. Remove inlet housing manifold (3, figure
3-6) as follows:
af. Remove air inlet duct (13, figure 3-6) as follows:
(1) Remove lockwire from straps (8).
(2) Loosen nuts (16) and separate straps
(8).
(3) Remove temperature sensor (14) from
air inlet duct (13).
(4)
Remove top half of air inlet duct (13).
(1)
Remove tee to gearbox adapter tube assembly (66, figure 3-2, detail G), connecting orifice fitting (61) on inlet
housing manifold (72). Install protective plugs.
(5)
Remove diffuser to tee PCD air tube assembly (65, figure 3-2, detail G), connecting combustor assembly (74) to orifice fitting (61) on inlet housing manifold (72).
(2)
Remove straight adapter (52) and Oring (53) from turbine assembly (68).
Discard O-ring (53).
(6)
Remove bottom half of air inlet duct
(13, figure 3-6) and O-ring (15). Discard O-ring (15).
(3)
Disconnect diffuser to tee PCD air tube
assembly (65) from orifice fitting (61).
(4)
Remove bolts (1, figure 3-6) and washers (2), securing inlet housing manifold
(3) to manifold assembly (4).
(5)
Remove inlet housing manifold (3)
from manifold assembly (4).
NOTE
Top and bottom half of air inlet duct (13)
should be kept together as a matched set,
per serial number.
(7)
Assemble top and bottom half of air inlet duct (13) and secure with straps (8).
3-17
TO 2G-T62T-43
Figure 3-6. Inlet Housing Manifold and Air Inlet Duct Assembly
3-18
TO 2G-T62T-43
NOTE
Do not remove straps (8) unless damaged.
(8) If straps (8) are damaged, remove nuts
(9), washers (10), bolts (11), and
bushings (12), securing straps (8) to air
inlet duct (13).
ag. Remove IGV actuator (6, figure 3-7) as follows:
(1) Remove nut (1) securing IGV drive
link (8) to turbine assembly.
(2) Remove self-locking nuts (2), bolts
(3), washers (4), and insulation actuator bushings (5), securing IGV actuator
(6) to turbine assembly. Remove IGV
actuator (6).
(3)
Remove nut (1) and bolt (7) securing
IGV drive link (8) to IGV actuator (6).
Remove IGV drive link (8).
(4) Remove IGV actuator stop (9) from
IGV actuator (6).
ah. Remove and disassemble hourmeter junction box (18, figure 3-8) as follows:
(1) Remove screws (1), lockwashers (2),
washers (3), cover (4), and gasket (5)
from hourmeter junction box (18).
(2) Disconnect terminal lugs (6 and 7)
from hourmeters (11).
(3) Remove screws (8), nuts (9), and lockwashers (10), securing hourmeters (11)
Remove hourmeters
to cover (4).
(11).
warning
Soldering fumes are toxic. Do not breathe
fumes. Solder in well-ventilated area. Wear
eye protection.
(5)
Remove screws (12), self-locking nuts
(13), and washers (14) from event
counter ( 15). Remove event counter
(15.
(6)
Remove screws (16) and washers (17),
securing hourmeter junction box (18)
to enclosure spacer assembly (31). Remove hourmeter junction box (18).
(7)
Remove screws (19), nuts (20), and
washers (21) securing connector (22)
to hourmeter junction box (18). Remove connector (22).
(8)
Remove screws (23), nuts (24), and
lockwashers (25), securing terminal
boards (26) and terminal board strips
(27) to hourmeter junction box (18).
Remove terminal boards (26) and terminal board strips (27).
NOTE
Wiring will be labeled according to its termination.
(9)
(10) Remove nuts (28, figure 3-8), lockwashers (29), and washers (30), securing terminal lugs (7) to studs on terminal boards (26). Remove terminal lugs
(7) from terminal boards (26).
ai. Remove engine hydraulic starter (10, figure
3-3) as follows:
(1)
Remove self-locking nuts (8) and
washers (9), securing engine hydraulic
starter (10) to reduction drive unit
(33). Remove engine hydraulic starter
(10).
(2)
Remove gasket (11) and discard.
(3)
Remove nipple (12) and O-ring (13)
from engine hydraulic starter (10).
Discard O-ring ( 13).
caution
Be careful not to break wires on event
counter.
Use a minimum of heat when unsoldering components. Use a heat sink to prevent
damage.
(4)
Unsolder wires from event counter
(15).
Tag and disconnect wiring from components to be replaced (see figure 3-9 for
wiring diagram).
3-19
TO 2G-T62T-43
Figure 3-7. IGV Actuator
3-20
TO 2G-T62T-43
Figure 3-8. Hourmeter Junction Box Assembly (Sheet 1 of 2)
3-21
TO 2G-T62T-43
Legend for figure 3-8:
1,
2,
3,
Screw (4)
Lockwasher (4)
Washer (4)
17, Washer (3)
18. Hourmeter junction box
19. Screw (4)
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
cover
Gasket
Terminal lug (14)
Terminal lug (4)
Screw (6)
Nut (6)
Lockwasher (6)
Hourmeter (2)
Screw (2)
Self-locking
nut (2)
Washer (2)
Event counter
Screw (3)
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Nut (4)
Washer (4)
Connector
Screw (4)
Nut (4)
Lockwasher (4)
Terminal board (2)
Terminal board strip (2)
Nut (8)
Lockwasher (8)
Washer (6)
Enclosure spacer assembly
C”-
Figure 3-8.
3-22
Hourmeter
Junction
Box Assembly
(Sheet 2 of 2)
T.O. 2G-T62T-43
Figure 3-9.
Hourmeter Junction Box Assembly Wiring Diagram
3-23
T.O. 2G-T62T-43
aj.
Remove self-locking nuts (14) and washers
(15), securing cover (16) to reduction drive
unit (33). Remove cover (16).
(4) Using combustor puller, ST71201 (43,
figure 2-1), remove combustor assembly
(27, figure 3-3).
ak. Remove gasket (17).
al.
Remove oil pressure switch (18) as follows:
(1)
(2)
Record information on identification
plate before removing.
Remove lockwire from oil pressure
switch (18).
ap.
Remove oil pressure switch (18) and Oring (19) from reduction drive unit (33).
Discard O-ring (19). Install protective
cap on oil pressure switch (18).
If damaged, remove identification plate (36,
figure 3-5) from containment ring (37).
aq.
ar.
Remove containment ring (37).
as.
Remove turbine assembly (30, figure 3-3) as
follows:
am.
Remove eye bolt (20).
an.
Remove bolts (21) and washers (22) securing
connector mounting bracket (23) to reduction drive unit (33). Remove connector
mounting bracket (23).
ao.
NOTE
Remove combustor assembly (27) as follows:
(1)
Remove lockwire, bolts (32, figure 3-5),
and bushing (33) from containment ring
(37).
NOTE
Do not remove engine mounting
adapter (34) on right hand side looking
from aft end unless removing diffuser
housing.
(2)
Unstake locking ring (35) and, using
spanner wrench, ST93975 (79, figure
2-1), remove engine mounting adapter
(34, figure 3-5) and locking ring (35)
from left side of containment ring (37)
looking from aft end. If necessary,
remove engine mounting adapter (34)
and locking ring (35) from right side.
(3) Remove clamp (24, figure 3-3) from
combustor assembly (27).
3-24 Change 9
(1)
Remove seal ring (28) and discard.
(2)
Remove lockwire, loosen bolts (1, figure
3-10), and remove turbine nozzle (2).
(3)
Remove bolts (29) securing turbine
assembly (30) to reduction drive unit
(33).
(4) Separate turbine assembly (30) from
reduction drive unit (33).
caution
Locking ring (35, figure 3-5) is staked.
Be sure to unstake prior to removing
engine mounting adapter (34) to prevent damage to adapters or special
tools.
Remove elbow (50, figure 3-2, detail G) and
O-ring (51) from turbine assembly (74). Discard O-ring (51).
(5)
3-5.
Remove O-ring (31) and adapter gasket
(32) from reduction drive unit (33). Discard O-ring (31).
DISASSEMBLY OF TURBINE ASSEMBLY.
This section contains procedures for disassembly of
the turbine assembly after it has been removed
from the APU. Unless otherwise indicated, index
numbers refer to figure 3-10.
NOTE
Make sure slots in turbine fit into slots
of rotor fixture, ST70137 (figure 3-11).
a.
Install turbine assembly (turbine end) in
rotor fixture, ST70137 (figure 3-11).
b.
Remove lockwire from magnetic pickup (3),
then remove magnetic pickup.
TO 2G-T62T-43
Figure 3-10. Turbine Assembly (Sheet 1 of 3)
3-25
TO 2G-T62T-43
Figure 3-10. Turbine Assembly (Sheet 2 of 3)
3-26
TO 2G-T62T-43
Legend for figure 3-10:
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.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Bolt (6)
Turbine nozzle
Magnetic pickup
Nut
Pinion assembly
Steel ball (3)
Bearing front carrier
Spring (6)
Spacer (A/R)
O-ring. (3)
Forward bearing
Pin’
Nut (19)
Washer (40)
Stud
Bolt (18)
Adapter assembly
Load compressor diffuser
O-ring
Load compressor wheel
Load compressor seal
Rotor assembly
Load compressor scroll
Shim (AIR)
Bolt (17)
Lockring (19)
Insert (19)
Pin (2)
Pin
Support housing
Inlet housing
Figure
54.
55.
56.
57.
58.
59.
60.
61.
3-10.
Turbine
Assembly
Bolt (2)
Pin-drive flange
IGV drive gear
IGV drive gear bearing
Insert (2)
Locknut (17)
IGV sector gear (17)
Inlet guide vane (17)
IGV bushing (34)
Diffuser
O-ring (2)
Bolt (12)
Washer (12)
Diffuser housing
Lockring (18)
Insert (12)
Lockring (4)
Insert (4)
Insert (6)
Shim (A/R)
Labyrinth seal
Bearing aft carrier
Nut
Turbine wheel
Pin (3)
Seal plate
Stud
Rotor shaft
Engine compressor
Aft bearing
(Sheet
3 of 3)
3-27
TO 2G-T62T-43
Figure 3-11.
3-28
Installation of Turbine Assembly in Rotor Fixture
T.O. 2G-T62T-43
c. Install pinion installation and disassembly
tool, ST71209 (Figure 3-11), on to top of adapter
assembly (Figure 3-10, 17). Tighten screws on tool
and press down on toggle clamps until it is secure
on bearing aft carrier (53).
d. Using wrench, ST71191 (Figure 2-1, 42),
remove nut (Figure 3-10, 4), pinion assembly (5),
and steel balls (6). Discard steel balls (6).
n. Install turbine assembly in load compressor
wheel restrainer, ST 93951-04 (Figure 2-1, 78) and
place in hydraulic press.
o. Using an assembly aid (4 inches long x 0.437
inches diameter steel dowel), press off load compressor wheel (Figure 3-10, 20) and rotor assembly
(22) from turbine assembly.
NOTE
Do not remove load compressor seal
(21) unless loose or damaged.
WARNING
Ensure nut (4) is reinstalled and
clamps loosened slowly to prevent personnel injury when releasing compressed bearing aft carrier (53).
e.
Reinstall nut (4) finger tight.
f. Slowly loosen toggle clamps of pinion installation and disassembly tool, ST71209 (Figure 3-11),
and back off nut (Figure 3-10, 4) until pre-load on
bearing aft carrier (53) is removed. Remove pinion
installation and disassembly tool, ST71209 and nut
(4) using wrench, ST71191 (Figure 2-1, 42).
p. If necessary, remove load compressor seal
(21) by machining off from load compressor wheel
(20).
q. Remove load compressor scroll (23) with
rubber mallet.
r.
Remove shim (24) from inlet housing (31).
s. Remove bolts (25) and washers (14) securing
support housing (30) to inlet housing (31).
g. Using carrier bearing puller, ST94426 (Figure 2-1, 83), lift and remove bearing front carrier
(Figure 3-10, 7).
NOTE
Do not remove lockrings (26), inserts
(27 and 36), and pins (28 and 29)
unless loose or damaged. If necessary
to remove, refer to Section V for
procedure.
h. Remove springs (8), O-rings (10), and spacer
(9). Discard O-rings (10).
t. Separate support housing (30) from inlet
housing (31).
i. Remove forward bearing (11) from bearing
front carrier (7) and discard.
u. Remove bolts (32), pin drive-flange (33), IGV
drive gear (34), and IGV drive gear bearing (35).
Discard IGV drive gear bearing (35).
NOTE
Do not remove pin (12) from bearing
front carrier (7) unless loose or damaged. If necessary to remove, refer to
Section V for procedure.
v. Remove locknuts (37) securing IGV sector
gears (38) to inlet guide vanes (39).
w. Remove IGV sector gears (38) from inlet
guide vanes (39).
j. Remove nut (13), washers (14), and stud (15)
from adapter assembly (17).
x. Remove inlet guide vanes (39) and IGV
bushings (40).
k. Remove bolts (16), washers (14), and nuts
(13), securing adapter assembly (17) to load compressor scroll (23).
NOTE
Support housing and inlet housing are
a matched set and must be kept
together.
l. Using puller, ST70170 (Figure 2-1, 18),
remove adapter assembly (Figure 3-10, 17).
m. Remove load compressor diffuser (18) and Oring (19). Discard O-ring (19).
y. Reinstall support housing (30) on inlet housing (31) and secure loosely with four bolts (25).
Change 22
3-29
T.O. 2G-T62T-43
WARNING
WARNING
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable Material Safety Data Sheet
(MSDS) and local Occupational Safety
and Health (OSH) regulations for additional information.
When handling titanium parts, be sure
to wear clean, white, cotton gloves.
ah. Remove turbine wheel (55) using turbine
wheel puller, ST71186 (Figure 2-1, 41).
NOTE
Do not remove pins (Figure 3-10, 56)
unless loose or damaged. If necessary
to remove, refer to Section V for
procedure.
z. Remove diffuser (Figure 3-10, 41) from diffuser housing (45) by first heating the assembly to
400-450oF. Remove from oven. Install containment
ring, ST71232 (Figure 2-1, 51), or local manufacture, in diffuser (41) and place dry ice, CGA-G6.2,
in containment ring.
aj. Install turbine wheel (55) in rotor fixture,
ST70137 (Figure 2-1, 17), and using turbine stud
torque wrench, ST71238 (55), or equivalent, remove
stud (Figure 3-10, 58).
aa.
(45).
Remove diffuser (41) from diffuser housing
ak. Remove engine compressor wheel (60) from
rotor shaft (59) as follows:
ab. Remove O-rings (42) from inlet housing (31)
and discard.
(1) If engine compressor wheel (60) is to be
reused, match-mark engine compressor wheel (60)
to rotor assembly (22).
ac. Remove bolts (43) and washers (44), securing diffuser housing (45) to inlet housing (31).
ad. Place diffuser housing (45) in arbor press
with locally manufactured wooden ring, and press
off diffuser housing (45) from inlet housing (31).
NOTE
Do not remove inserts (47, 49, and 50)
or lockrings (46 and 48) unless loose or
damaged. If necessary to remove, refer
to Section V for procedure.
ae.
Remove shim (51).
af. Using arbor press guide, ST71207 (Figure 21, 45), and arbor press, remove labyrinth seal (Figure 3-10, 52) and bearing aft carrier (53).
ag. Install rotor assembly (22) in load compressor rotor assembly tooling, ST71219 (Figure 2-1,
49), and using stretch tool, ST71078 (40), remove
nut (Figure 3-10, 54).
3-30 Change 22
ai.
Remove seal plate (57).
(2) Using load compressor rotor assembly
tooling, ST71219 (Figure 2-1, 49), and hydraulic
press, press rotor shaft (Figure 3-10, 59) away from
engine compressor wheel (60).
al. Remove aft bearing (61) using load compressor rotor assembly tooling, ST71219 (Figure 2-1,
49), an assembly aid, and hydraulic press. Discard
aft bearing (61).
3-6. DISASSEMBLY OF REDUCTION DRIVE UNIT.
This section contains procedures for disassembly of
the reduction drive unit after it has been removed
from the APU. Unless otherwise indicated, index
numbers refer to Figure 3-12.
a.
Remove engine oil sump (22) as follows:
(1) Place suitable container under engine
oil sump drain to catch any excess oil.
T.O. 2G-T62T-43
Figure 3-12. Reduction Drive Unit (Sheet 1 of 5)
Change 4 3-31
T.O. 2G-T62T-43
Figure 3-12. Reduction Drive Unit (Sheet 2 of 5)
3-32 Change 4
TO 2G-T62T-43
Figure 3-12. Reduction Drive Unit (Sheet 3 of 5)
3-33
to 2g-t62t-43
legend for figure 3-12
44. Insert (5)
45. Zerol bevel gear
46. Shim
47. O-ring
48. Screw (5)
49. Retainer
50. Locknut
51. Locknut
52. Accessory drive pinion
53. Ball (2)
54. Ball bearing
55. Ball bearing
56. Spacer
57. Shaft seal
58. Bolt (8)
59. Washer (8)
60. Carrier assembly
61. Bolt (3)
62. Washer (3)
63. Cover
64. Bearing (6)
65. Gear planet set
66. Retaining ring (3)
67. Dowel (3)
68. Retaining ring
69. Ring gear
70. Gasket
71. Lube oil elbow
72. Insert (9)
73. Sleeve (3)
74. Sleeve (3)
75. Oil jet cartridge
pin
76. Spring-slotted
77. Housing carrier
78. Straight drive shaft
79. O-ring
80. O-ring
81. Pipe plug (2)
82 Cover
83. Locknut
84. Retainer
85. Hub ring gear
86. Screw (3)
1. Caplug
2. Plug (3)
3. O-ring (3)
4. Nameplate
5. Retaining ring
6. By-pass valve housing
7. O-ring
8. Spring pin
9. Valve spring
10. Bali bearing (2)
11. Oil filter element
12. Bolt
13. Accessory pad cover
14. Accessory drive gasket
plug
15. Magnetic-drain
16. O-ring
valve
17. Self-closing
O-ring
18.
19. Caplug
20. Clamp
21. O-ring
22. Engine oil sump
23. Screw
24. Screw
25. Dowel pin
26. Oil pump housing
27. Gasket
28. Cap screw
29. Oil suction tube
30. O-ring
nut
31. Self-locking
32. Washer
33. Pump drive gear
34. Dowel pin (3)
35. Cover
36. Pump element gear (2)
37. Driver shaft
38. Driven shaft
39. Cap screw (2)
40. Bevel gear support
41. Pin
42. Liner
43. Liner
Figure
3-34
3-12.
Reduction
Drive Unit (Sheet 4
of 5)
TO 2G-T62T-43
Legend for figure 3-12 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.
Continued:
117.
118.
119.
120.
121,
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
Lockwasher (3)
Shim
Locknut
Bearing
Zerol pinion
Bearing
Retainer bearing ring
Key
Key
Housing liner
Shaft seal
Insert (4)
Screw (2)
Washer (2)
Washer (6)
Vent plate
Valve housing
Bail
Relief valve spring
Screw (4)
Washer (4)
Accessory pad cover
O-ring
Lockring
Insert (4)
Retaining ring
Intermediate gear shaft
O-ring
O-ring
Bearing spacer
Figure 3-12.
Reduction
Intermediate gear
Ball bearing
Oil shield
Accessory gear
Oil/air separator
Oil/air separator
Ball bearing (2)
Plug
Dowel pin
Shaft seal
Retaining ring (2)
Insert
Insert (12)
Insert (8)
Insert (4)
Lockring (12)
Stud (5)
Stud
Stud (6)
Pin
Sleeve
Lockring
Insert
Oil/air separator sleeve
Spring-slotted
pin (2)
Housing
Drive Unit (Sheet 5 of 5)
3-35
TO 2G-T62T-43
(2)
(3)
Remove magnetic-drain plug (15) and
O-ring (16) from self-closing valve
(17). Discard O-ring (16).
Remove self-closing valve (17) and Oring (18) from engine oil sump (22).
Discard O-ring (18).
(4)
Unscrew caplug (19).
(5)
Remove clamp (20) and O-ring (21)
from engine oil sump (22). Discard Oring (21).
(6)
Remove engine oil sump (22).
(7)
Remove cap screw (28), oil suction
tube (29), and O-ring (30). Discard
O-ring (30).
b. Remove oil pump housing (26) as follows:
NOTE
NOTE
Record information on nameplate before removing.
f.
g. Remove oil filter element (11) as follows:
Remove screws (23 and 24), oil pump
housing (26), and gasket (27). Discard
gasket (27).
(2)
Remove self-locking
washer (32).
(3)
Remove pump drive gear (33) from
driver shaft (27). Remove one dowel
pin (34).
(4)
Separate oil pump housing (26) from
cover (35).
nut
(31) and
(5)
Remove pump element gears (36) from
driver shaft (37) and driven shaft (38).
(6)
Remove remaining dowel pins (34)
from driver shaft (37) and driven shaft
(38).
c. Remove reduction drive unit from assembly
build stand, ST71206 (44, figure 2-1), and
place on assembly fixture, ST70370 (37, figure 2-1).
(1)
Remove retaining ring (5).
(2)
Place suitable container under by-pass
valve housing (6) to catch oil.
(3)
Using oil filter cap removal tool,
ST80211 (58, figure 2-1), remove bypass valve housing (6, figure 3-12)
from housing (142).
NOTE
Do not remove spring pin (8). valve spring
(9), or ball bearings (19) from by-pass valve
housing (6).
Do not remove dowel pin (25) unless loose
or damaged. If necessary to remove, refer
to Section V for procedure.
(1)
If damaged, remove nameplate (4).
(4)
Remove and discard O-ring (7).
(5)
Remove oil filter element (11).
card oil filter element.
h. Remove bolts (12), accessory pad cover
(13), and accessory drive gasket (14) from
housing (142).
i.
Remove bevel gear support (40) and Zerol
bevel gear (45) as follows:
(1)
3-36
Remove cap screws (39) attaching
bevel gear support (40) to housing
(142).
NOTE
Do not remove pin (41), liners (42 and 43).
or inserts (44) unless loose or damaged. If
necessary to remove inserts (44), refer to
Section V for procedure.
(2)
If necessary, remove pin (41) and liners (42 and 43).
(3)
Using puller, ST70170 (figure 3-13),
remove bevel gear support (40) and
Zerol bevel gear (45, figure 3-12) as
an assembled unit from housing (142).
(4)
Remove shim (46) and O-ring (47).
Discard O-ring (47).
(5)
Remove screws (48)
(49).
d. Remove caplug (1, figure 3-12).
e. Cut lockwire and remove plugs (2) and Orings (3). Discard O-rings (3).
Dis-
from retainer
TO 2G-T62T-43
Figure 3-13. Removal of Bevel Gear Support and Zerol Bevel Gear
(6)
Remove retainer (49) and Zerol bevel
gear (45) as an assembled unit.
(10) Using common gear puller, remove accessory drive pinion (52, figure 3-12)
and balls (53).
(7)
Install holding fixture, ST70267 (figure
3-14), on face of Zerol bevel gear
(45).
(8)
Using spanner wrench, ST70243 (figure 3-14), remove locknut (50).
(11) Using arbor plate, ST70236 (21, figure
2-1), bushing, ST70238 (23), and
bearing bevel gear removal tool,
ST71231 (50), remove ball bearings
(54 and 55, figure 3-12) and spacer
(56) from Zerol bevel gear (45). Discard ball bearings (54 and 55).
(9)
Using holding fixture, ST70267, and
spanner wrench, ST70241 (figure
3-15). remove locknut (51).
(12) Using sealer puller, ST93057 (76, figure 2-1), remove shaft seal (57, figure
3-12) from bevel gear support (40).
3-37
TO 2G-T62T-43
.
Figure 3-14. Removal of Locknut
3-38
TO 2G-T62T-43
Figure 3-15. Removal of Locknut
j. Remove carrier assembly (60) as follows:
(1)
(2)
Remove bolts (58) and washers (59)
securing carrier assembly (60) to housing (142).
(6)
Using puller, ST70170 (figure 3-16),
remove carrier assembly (60) from
housing (142).
Remove bearings (64, figure 3-12) and
gear planet set (65) as an assembled
unit from carrier assembly (60).
(7)
Using bearing puller, ST91061 (73, figure 2-1), and an arbor press, push gear
planet set (65, figure 3-12) off bearings
(64). Discard bearings (64).
(3)
Remove lube oil elbow (71) from carrier assembly (60) and discard.
(4)
Remove bolts (61) and washers (62)
securing cover (63) to carrier assembly
(60).
(5)
puller until cover (63) is free from carrier assembly. Remove retaining plate,
ST90684, from carrier assembly (60).
Using retaining plate, ST90684, and
puller, ST90288 (figure 3-17), place
three fingers of puller around edge of
cover (63). With three guide pins on
flange of carrier assembly (60), rotate
NOTE
Carrier assembly and cover are a
matched set and must remain together.
(8)
Reinstall cover (63) on carrier assembly
(60) and secure loosely with bolts (61).
(9)
Remove retaining ring (66) from carrier
assembly (60).
3-39
TO 2G-T62T-43
Figure 3-16. Removal of Carrier Assembly
3-40
TO 2G-T62T-43
Figure 3-17. Removal of Cover
3-41
TO 2G-T62T-43
Remove O-rings (79 and 80) from
housing carrier (77) and discard.
NOTE
Do not remove dowels (67) unless loose or
damaged. If necessary to remove, refer to
Section V for procedure.
k. Remove ring gear (69) as follows:
(1)
Remove cover (82) from housing carrier (77).
(2) Install disassembling tool, ST70284
(figure 3-18); inserting each leg of tool
in equally spaced access slots inside
ring gear (69, figure 3-12) [the slots
are recessed around edge of teeth that
mate with splines on hub ring gear
(85)]. Turn knurled knob of tool and
compress retaining ring (68) into
groove on hub ring gear (85).
(3)
Tip ring gear (69) to hold retaining ring
(68) in place, and continue working retaining ring into groove until ring gear
slips forward. Remove and discard retaining ring (68).
(4)
Remove ring gear (69) from carrier assembly (60).
(5)
Remove and discard gasket (70).
NOTE
Do not remove inserts (72), sleeves (73
and 74), oil jet cartridge (75). and springslotted pin (76) unless loose or damaged.
If necessary to remove inserts or sleeves,
refer to Section V for procedure.
(6) If necessary, remove oil jet cartridge
(75) by grinding around spring-slotted
pin (76) sufficiently to grasp springslotted pin (76) with small needle-nose
pliers. Remove and discard springslotted pin (76) and oil jet cartridge
(75).
l. Remove housing carrier (77) and straight
drive shaft (78) as follows:
(1) Using adapter, ST70242 (figure 3-19),
and rubber mallet, remove housing carrier (77) and straight drive shaft (78,
figure 3-12) as an assembled unit from
housing (142).
3-42
NOTE
Do not remove pipe plugs (81) unless
loose or damaged. If necessary to remove,
refer to Section V for procedure.
(3)
Using holding fixture, ST70266, and
wrench, ST70243 (figure
3-20), remove locknut (83) from
straight drive shaft (78, figure 3-12).
spanner
(4)
Remove retainer (84).
(5)
Using common gear puller, remove hub
ring gear (85) from straight drive shaft
(78).
(6)
Straighten tab on lockwashers (87);
then remove screws (86) and lockwashers (87).
(7)
Separate housing carrier (77) from
straight drive shaft (78).
(8)
Remove shim (88) and tie to housing
carrier (77) to prevent loss.
(9)
Using holding fixture, ST70266, and
spanner wrench, ST70241 (figure
3-21), remove locknut (89) from
straight drive shaft (78).
(10) Using arbor plate, ST70236, bushing,
ST70238, and an arbor press (figure
3-22), remove bearing (90) from
straight drive shaft (78). Discard bearing (90).
(11) Using arbor plate, ST70236, bushing,
ST70237, and an arbor press (figure
3-23), remove Zerol pinion (91), bearing (92), retainer bearing ring (93),
and key (94, figure 3-12) as an assembled unit from straight drive shaft (78).
NOTE
Do not remove key (95) or housing liner
(96) unless loose or damaged. If necessary to remove, refer to Section V for procedure.
(12) Remove shaft seal (97, figure 3-12)
from housing (142).
TO 2G-T62T-43
Figure 3-18. Removal of Ring Gear
Figure 3-19. Removal of Housing Carrier
3-43
TO 2G-T62T-43
Figure 3-20. Removal of Locknut
3-44
TO 2G-T62T-43
Figure 3-21.
Removal of Locknut
3-45
TO 2G-T62T-43
Figure 3-22. Removal of Bearing
3-46
TO 2G-T62T-43
Figure 3-23. Removal of Zerol Pinion
3-47
TO 2G-T62T-43
NOTE
Do not remove inserts (98) unless loose or
damaged. If necessary to remove, refer to
Section V for procedure.
m. Remove valve housing (103) as follows:
(1)
Remove screws (99) and washers (100
and 101) securing valve housing (103)
and vent plate (102) to housing (142).
(2) Remove vent plate (102).
(3)
Remove valve housing (103), ball
(104), and relief valve spring (105)
from housing (142).
n. Remove intermediate gear (117) and accessory gear (120) as follows:
(1)
Remove screws (106) and washers
(107) securing accessory pad cover
(108) to housing (142).
(2)
Using puller, ST70234 (figure 3-24),
remove accessory pad cover (108).
(3)
Remove O-ring (109, figure 3-12)
from accessory pad cover (108) and
discard.
(4)
Remove accessory gear (120), oil/air
separators (121 and 122), ball bearings
(123), plug (124), and dowel pin (125)
from housing (142) as an assembled
unit.
Figure 3-24. Removal of Accessory Pad Cover
3-48
TO 2G-T62T-43
remove intermediate gear shaft (113)
from housing (142).
NOTE
Do not remove lockrings (110) or inserts
(111) unless loose or damaged. If necessary to remove, refer to Section V for procedure.
(5) Remove retaining ring (112) securing
intermediate gear shaft (113) to housing (142).
(7)
Remove O-rings (114 and 115) from
intermediate gear shaft (113) and discard.
(8)
Remove bearing spacer (116), intermediate gear (117), ball bearing (118), oil
shield (119), and retaining rings (127)
from housing (142).
(9)
holder,
removal
bearing
Using
ST70277, a piece of brass stock
(0.467 in. approximately), and arbor
press (figure 3-26), remove ball bearings (123, figure 3-12) from accessory
gear (120). Discard ball bearings
(123).
caution
To prevent damage, support intermediate
gear (117) during removal of intermediate
gear shaft (113). Do not allow intermediate gear to drop.
(6) Using puller, ST70235 (figure 3-25),
Figure 3-25. Removal of Intermediate Gear Shaft
3-49
TO 2G-T62T-43
Figure 3-26. Removal of Ball Bearings
3-50
TO 2G-T62T-43
(10) Remove oil/air separators (121 and
122) from accessory gear (120).
NOTE
Do not remove plug (124) and dowel pin
(125) unless loose or damaged. If necessary to remove dowel pin (124), refer to
Section V for procedure.
(11) Using arbor press and a piece of brass
stock (0.725-0.750 in.), remove shaft
seal (126) from accessory pad cover
(108).
(12) Remove retaining rings (127) securing
ball bearing (118) in intermediate gear
(117).
(13) Using arbor plate and driver, ST70286
(figure 3-27). remove ball bearing
(118, figure 3-12) from intermediate
gear (117). Discard ball bearing (118).
Figure 3-27. Removal of Ball Bearing
3-51
TO 2G-T62T-43
fold from tube fittings on combustor
housing (17).
NOTE
Do not remove pin (136), sleeve (137),
oil/air separator sleeve (140), or springslotted pins (141) unless loose, damaged
on inside diameter surface, or not in
proper position. If necessary to remove,
refer to Section V for procedure.
Do not remove inserts (128, 129, 130,
131, or 139), lockrings (132 or 138), or
studs (133, 134, or 135) unless loose or
damaged. If necessary to remove, refer to
Section V for procedure.
3-7. DISASSEMBLY OF COMBUSTOR ASSEMBLY.
This section contains procedures for disassembly of
the combustor assembly after it has been removed
from the APU. Unless otherwise indicated, index
numbers refer to figure 3-28.
a. Remove igniter plug (1) from combustor
housing ( 17).
b. Remove fuel nozzle (3) and fitting (2) from
combustor housing ( 17).
c. Remove fuel manifold (9) as follows:
(1)
(2)
Remove filter fitting (4) and O-ring (5)
from fuel manifold (9). Discard Oring (5).
Remove bolts (6), nuts (7), and washers (8) securing fuel manifold (9) to
combustor housing (17).
(4) Install protective caps on tips of fuel
manifold (9).
d. If necessary, remove bolts (10), nuts (11),
and washers (8) securing loop clamps (12)
and loop clamp cushions (13) to fuel manifold (9).
e. Remove lockwire and pins (14) from combustor housing ( 17).
f. Remove combustor liner assembly (15) from
combustor housing (17).
g. Remove O-rings (16) from atomizer fittings
in combustor liner (15). Discard O-rings
(16).
NOTE
Do not remove igniter plug grommet (18),
washers (19), and spring (20) unless loose
or damaged.
h. If necessary, remove igniter plug grommet
(18) as follows:
(1)
If igniter plug grommet (18) is frozen,
apply a few drops of non-carbon penetrating oil, VV-P-216, to igniter plug
grommet and remove.
(2)
If igniter plug grommet (18) still remains frozen, use a pair of pliers, or
equivalent tool, and collapse igniter
plug grommet.
(3)
Using a soft-ended drift (copper or
wood), carefully remove igniter plug
grommet (18) from liner assembly
(16). Discard igniter plug grommet
(18), washers (19), and spring (20).
caution
To prevent damage to fuel outlet tips of
fuel manifold (9), do not bend tubes during removal of fuel manifold.
(3)
3-52
Loosen six coupling nuts on fuel manifold (9) and carefully slide fuel mani-
TO 2G-T62T-43
Figure 3-28. Combustor Assembly (Sheet 1 of 2)
3-53
TO 2G-T62T-43
Legend for figure 3-28:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Igniter plug
Fitting
Fuel nozzle
Filter fitting
O-ring
Bolt (2)
Nut (2)
Washer (4)
Fuel manifold
Bolt (2)
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Nut (2)
Loop clamp (2)
Loop clamp cushion (4)
Pin (4)
Combustor liner
O-ring (6)
Combustor housing
Igniter plug grommet
Washer (2)
Spring
Figure 3-28. Combustor Assembly (Sheet 2 of 2)
3-54
T.O. 2G-T62T-43
SECTION IV
CLEANING
4-1. GENERAL. Cleaning instructions for the
APU are provided in this section. To ensure satisfactory results, each cleaning procedure must be
performed exactly as described. All dust, dirt, corrosion, rust, and moisture must be removed, as
these destructive agents will eventually cause operational failure.
4-2. SOLVENT FOR GENERAL USE. Only the solvent specified in this section should be used for
cleaning purposes. Any part not specifically mentioned in the text should be cleaned in the same
general manner as a similar part. Whenever refinishing is required, adherence to the procedure given
in this section or in Section V - Inspection, Repair,
and Replacement will ensure satisfactory results.
4-3. CLEANING PROCEDURES. This section con-
tains cleaning procedures for the APU and its
components.
a.
Solvent Cleaning of Painted Aluminum
Alloy Parts.
b.
Aqueous Cleaning of Aluminum Alloy Parts.
warning
compound,
Alkaline
cleaning
PP-C-436, is toxic, irritating to the
skin, and harmful to the eyes. Do not
breathe vapors. Use in well-ventilated
area. Wear eye protection and gloves.
caution
Aluminum alloy parts having protective coatings, either anodized or chemical film treatment, must be cleaned
using non-etching alkaline cleaner,
unless otherwise specified.
(1)
Prepare cleaning solution using 6-10 oz.
of non-etching alkaline cleaning compound, P-C-436, per gallon of water,
maintained at a temperature of 160-180
°F.
(2)
Immerse parts in cleaning solution for
5-15 minutes.
(3)
Remove parts from cleaning solution
and immerse in clear, agitated water
within 15 seconds. Leave component in
water for 1-2 minutes.
(4)
Remove parts and spray rinse with
fresh water.
warning
Cleaning solvent, P-D-680, type II, is
toxic and flammable. Do not breathe
vapors. Use in well-ventilated area.
Wear goggles and solvent-resistant
gloves.
caution
Aluminum alloy parts having protective coating, either anodized or chemical film treatment, must be cleaned
using non-etching alkaline cleaner,
unless otherwise specified.
(1)
Wipe parts with clean, cheesecloth,
CCC-C-440, saturated with cleaning solvent, P-D-680, type II or III.
(2) Scrub parts with abrasive crocus cloth,
P-C-458, or non-metallic mat,
MIL-A-9962.
(3) Wipe parts again with clean, cheesecloth, CCC-C-440, saturated with cleaning solvent, P-D-680, type II or III.
(4)
(5) Allow parts to air dry.
c.
Cleaning of Steel and Corrosion-Resistant
Alloy Parts.
warning
Alkaline cleaner, TT-C-490, and aircraft surface cleaning compound,
MIL-C-43616, are toxic, irritating to
the skin, and harmful to the eyes. Do
not breathe vapors. Use in well-ventilated area. Wear eye protection and
gloves.
Allow parts to air dry.
Change 10 4-1
T.O. 2G-T62T-43
13. Blasting shall be to the extent
required to remove foreign material and
oxidation, but not to the extent to distort or remove metal, and shall be followed by thorough cleaning of blasting
debris from blasting area. Surface treat
part by Type VIII chromate treatment
per MIL-M-3171.
CAUTION
Steel-plated parts having protective
coatings, either cadmium, chromium,
nickel, or zinc, must be cleaned using
alkaline cleaner solution only.
d.
(1)
Prepare alkaline cleaning solution using
6-8 oz. of alkaline cleaner, TT-C-490C,
per nine gallons of water.
(2)
As an alternate solution, use one part
aircraf t surface cleaning compound,
MIL-C-43616, per nine parts of water.
Maintain solution at a temperature of
160-180oF.
(3)
Immerse parts in cleaning solution for
5-20 minutes.
(4)
Remove parts from cleaning solution
and immerse in clear, agitated water
within 15 seconds or spray rinse with
fresh water.
(5)
Pressure-wash parts with fresh water.
(6)
Dry parts with clean, lint-free cloth,
MIL-C-85043, type II.
(7)
If part is a low-alloy steel, preserve
immediately af ter rinsing as follows:
(a)
Dip or spray with corrosion preventive compound, MIL-C-16173, grade
4.
(b)
Allow parts to air dry.
Cleaning Magnesium Parts.
(1)
Soak parts in silicate soap solution,
MIL-M-7752, maintained at 190-200 oF
for 10-15 minutes,
(2)
Rinse parts
water.
(3)
Dry parts with clean, lint-free cloth,
MIL-C-85043, type II.
thoroughly
with
fresh
e.
Cleaning Titanium Parts.
WARNING
Methyl-ethyl-ketone, TT-M-261, and
cleaning solvent, P-D-680, type II, are
toxic and f lammable. Do not breathe
vapors. Use in well-ventilated area.
Wear eye protection and gloves.
CAUTION
Titanium parts must not come in contact with chlorinated solvents, chloride
salts (including perspiration), methyl
alcohol, silver and silver compounds,
and cadmium.
(1)
WARNING
Alkaline cleaner, MIL-C-87936, is
toxic, irritating to the skin, and harmful to the eyes. Do not breathe vapors.
Use in well-ventilated area. Wear eye
protection and gloves.
(2)
Prepare alkaline cleaning solution consisting of one part alkaline cleaner,
MIL-C-87936, to nine parts of distilled
or deionized water. Heat solution to
160-180oF in an air-agitated tank.
(3)
Immerse parts in alkaline cleaning solution for 3-5 minutes minimum.
(4)
Scrub surface of parts with a sof t-bristle
brush, MIL-B-15319, type I, class 2, to
remove surface contamination.
(5)
Rinse parts with fresh water.
(6)
Allow parts to air dry to remove excess
water, then place parts in an oven set at
160-250oF for 1 hour.
WARNING
Dichromate Solution, MIL-M-3171, is
toxic and harmful to the exposed skin.
Avoid breathing vapors and avoid skin
contact.
PPE:
Gloves, goggles/
faceshield, apron and adequate
ventilation.
(4)
4-2
Small or localized areas may be blasted
with glass beads per MIL-G-9954, size
Change 17
Remove excessive oils with cleaning
solvent, P-D-680, type II or III.
T.O. 2G-T62T-43
f.
Vapor Blasting Turbine Nozzle (2, f igure
3-10), Seal Plate (57), and Turbine Wheel
(55).
(1)
Using masking tape, MIL-T-21595,
mask any surface that can be damaged
by blasting.
(2)
Ensure all open ports are closed with
protective caps.
(6)
Glass bead, MIL-G-9954, peen corroded
areas to remove corrosion.
(7)
Rinse surface free of glass beads with
fresh water at 50-90oF.
WARNING
When using compressed air for cleaning or drying, regulate pressure not to
exceed 30 psi. Wear eye protection.
WARNING
(8)
Cleaning solvent, P-D-680, type II, is
toxic and f lammable. Do not breathe
vapors. Use in well-ventilated area.
Wear eye protection and gloves.
(3)
g.
Cleaning Reduction Drive Unit.
(1)
Remove all oil and grease from parts
prior to vapor blasting by degreasing
with P-D-680, type II or III.
WARNING
When using compressed air for cleaning or drying, regulate pressure not to
exceed 30 psi. Wear eye protection.
(4)
Dry
parts
with
lint-free
cloth,
MIL-C-85043, type II, or dry with compressed air.
WARNING
.
.
Corrosion inhibitor, Rustlick 606, is
toxic and f lammable. Do not breathe
vapor. Use in well-ventilated area.
Wear eye protection and gloves.
Dry parts with compressed air or in an
oven at 250oF for 2 hours.
Clean reduction drive unit housing (142,
f igure 3-12) and accessory pad cover
(108) as follows:
(a)
Soak parts in silicate soap solution,
MIL-M-7752, at 190oF - 200oF for 1015 minutes.
(b)
Rinse thoroughly with fresh water.
(c)
Dry part with clean lint-free cloth,
MIL-C-85043, Type II.
WARNING
Dichromate Solution, MIL-M-3171, is
toxic and harmful to the exposed skin.
Avoid breathing vapors and avoid skin
contact.
PPE:
Gloves, goggles/
faceshield, apron and adequate
ventilation.
(d)
Perform vapor blasting only in a suitable enclosure with protective doors and
shields in place. Do not direct blasting
nozzle at any part of the body.
CAUTION
Regulate nozzle air pressure to 70-90
psi to keep erosion of base metal to a
minimum. Keep nozzle in motion to
prevent blast from eroding any one
spot.
(5)
Vapor blast using water containing
1/4-1/2 percent corrosion inhibitor,
Rustlick 606.
(2)
Small or localized areas may be
blasted with glass beads per MIL-G9954, size 13. Blasting shall be to
the extent required to remove foreign
material and oxidation, but not to
the extent to distort or remove metal,
and shall be followed by thorough
cleaning of blasting debris from
blasting area. Surface treat part by
Type VIII chromate treatment per
MIL-M-3171.
Ultrasonically degrease reduction drive
unit parts as follows:
(a)
Prepare ultrasonic cleaner using
aqueous cleaner, MIL-C-87937,
diluted to manufacturer
specifications.
Change 17
4-3
T.O. 2G-T62T-43
(b)
(c)
WARNING
Remove parts and rinse with fresh
water.
When using compressed air for cleaning or drying, regulate pressure not to
exceed 30 psi. Wear eye protection.
WARNING
(6)
When using compressed air for cleaning or drying, regulate pressure not to
exceed 30 psi. Wear eye protection.
Using compressed air, blow out residue
of blasting material and carbon from
external and internal surfaces.
(7)
Visually check internal passages to verify all material has been removed.
(d)
h.
Immerse parts in ultrasonic cleaner
until contamination has been
removed.
Dry parts with clean, lint-free cloth,
MIL-C-85043, type II, or compressed
air.
WARNING
Cleaning Combustor Housing.
(1)
Prepare ultrasonic cleaner using aqueous cleaner, MIL-C-87937, diluted to
manufacturer specif ications.
(2)
Immerse
combustor
housing
in
ultrasonic cleaner until all traces of
contamination have been removed.
(3)
Remove combustor housing and rinse
with fresh water.
(4)
Cover all threaded bosses, inserts, and
f ittings with pressure sensitive tape,
MIL-T-22085, type II, or protective
caps.
Alkaline cleaner, TT-C-490, is toxic,
irritating to the skin, and harmful to
the eyes. Do not breathe vapors. Use
in well-ventilated area. Wear eye protection and gloves.
CAUTION
Steel-plated parts having protective
coating, either cadmium, chromium,
nickel, or zinc, must be cleaned using
alkaline cleaner solution only.
(8)
Prepare alkaline cleaning solution per
MIL-D-26549, using 6-8 oz. of alkaline
cleaner, TT-C-490C, or equivalent, per
nine gallons of water. Maintain solution at a temperature of 160-180oF.
(9)
Immerse combustor housing in alkaline
cleaning solution for 3-5 minutes
minimum.
(10)
Remove combustor housing and rinse
with fresh water.
WARNING
Perform dry blasting only in a suitable
enclosed area with protective doors
and shields in place. Wear protective
face shield and clothing.
CAUTION
WARNING
Use care to avoid thinning of metal
during blasting operation.
When using compressed air for cleaning or drying, regulate pressure not to
exceed 30 psi. Wear eye protection.
NOTE
Clean bare metal indicates an acceptable degree of cleanliness.
(5)
4-4
Using sof t abrasive grain, MIL-G-5634,
or equivalent, vapor blast at 30-50 psig
to remove all oxides and carbon
deposits.
Change 17
(11)
i.
Allow combustor housing to air dry or
dry with compressed air.
Cleaning Combustor Liner.
T.O. 2G-T62T-43
(7)
Rinse combustor liner with fresh water.
CAUTION
To prevent damage to venturi throat
and U-tubes, use care in cleaning combustor liner.
(1)
WARNING
When using compressed air for cleaning or drying, regulate pressure not to
exceed 30 psi. Wear eye protection.
Clean venturi throat (figure 4-1) using
soft-bristle brush, MIL-B-15319, type I,
class 2. Rotate brush to remove carbon
deposits.
(2)
Prepare ultrasonic cleaner using aqueous cleaner, MIL-C-87937, diluted to
manufacturer specifications.
(3)
Immerse combustor liner in ultrasonic
cleaner until all traces of contamination
have been removed.
(4)
Remove combustor liner and rinse with
fresh water.
WARNING
Alkaline cleaner, TT-C-490, is toxic,
irritating to the skin, and harmful to
the eyes. Do not breathe vapors. Use
in well-ventilated area. Wear eye protection and gloves.
CAUTION
(8)
j.
Cleaning Oil Cooler.
WARNING
MIL-PRF-680 type 2/3 Dry Cleaning
Solvent may cause eye and skin irritation. Over exposure may cause dizziness and other central nervous system
effects. Wear nitrile gloves and chemical protective goggles. Dry cleaning
solvent is manufactured by several
companies, and its composition varies.
Therefore, it is very important that
you consult the applicable Material
Safety Data Sheet (MSDS) and local
Occupational Safety and Health (OSH)
regulations for additional information.
(1)
Steel-plated parts having protective
coatings, either cadmium, chromium,
nickel, or zinc, must be cleaned using
alkaline cleaner solution only.
(5)
(6)
Prepare alkaline cleaning solution per
MlL-D-26549, using 6-8 oz. of alkaline
cleaner, TT-C-490C, or equivalent, one
part per nine gallons of water. Maintain solution at a temperature of
160-180oF.
Immerse combustor liner in alkaline
cleaning solution for 3-5 minutes
minimum.
Allow combustor liner to air dry or dry
with compressed air.
Flush clean oil cooler with dry cleaning
solvent until solvent flow is clear and
particle free.
WARNING
When using air for cleaning or drying,
regulate pressure not to exceed 30 psi.
Wear eye protection.
(2)
Remove excess cleaning solvent from
the oil cooler using clean compressed
air.
Change 24 4-5
T.O. 2G-T62T-43
Figure 4-1.
4-6
Change 17
Cleaning Combustor Liner
T.O. 2G-T62T-43
SECTION V
INSPECTION, REPAIR, AND REPLACEMENT
5-1. GENERAL This section covers inspection,
repair, and replacement of all worn or damaged
parts of the APU. Perform a visual inspection of all
parts, checking for signs of wear, damage, cracks,
and evidence of erosion, corrosion or pitting.
Nondestructive inspection techniques will be
accomplished per TO 33B-1-1, unless otherwise
specified.
a.
Magnetic particle inspection is used to
reveal near surface cracks in parts made of
magnetic material.
Table 5-1.
Term
b.
Fluorescent penetrant (black light) inspection is used to detect surface cracks in parts
made of non-magnetic material.
c.
Description terms used to describe the condition of parts are defined in Table 5-1.
d.
For replacement procedures, refer to Section
III - Disassembly and Section VI - Assembly.
e.
Check that Unique Identification (UID)
label on part number(s) identified in
paragraphs 6-8 to 6-9 is present and readable. Manufacture or replace as required.
Reference paragraphs 6-8 to 6-9 of this technical manual for supporting information.
General Physical Conditions
Definition
Probable Cause
Abrasion
A roughened area, light to heavy, dependent upon amount of rework necessary to
restore surface
Foreign particles between moving parts
Blistering
Raised areas indicating separation of the
surface from the base: usually found on
plated or painted surfaces
Imperfect bond with base, usually aggravated by presence of moisture, gas, heat,
or pressure
Break
Complete separation by force into two or
more pieces
Fatigue, shock, or overload
Brinelling
Indentions occasionally found on surfaces
of ball or roller bearing parts/shaft surfaces
Improper assembly or disassembly technique
Burning
Injury to surface by excessive heat: evidence by discoloration or by flow or loss of
metal
Improper clearance or lack of lubrication
due to plugged oil passages or other lubrication malfunctions
Burr
A sharp projection or rough edge
Excessive wear; careless handling
Chafing
A rubbed action between two parts having limited motion
Improper assembly techniques; improper
fits
Chipping
Breaking out of small particles of metal
Careless handling of parts; concentration
of stresses due to shock, nicks, scratches,
etc.
Corrosion
Breakdown or pitting of surfaces by
chemical action
Improper surface treatment, wear or
damage on treated surfaces
Crack
A break in material
Excessive stress due to shock, overloading
or faulty processing: extension of a nick
or scratch; damaged material or overheating
Change 23 5-1
T.O. 2G-T62T-43
Table 5-1.
Term
General Physical Conditions - Continued
Definition
Probable Cause
Dent
Small, smoothly rounded, hollow in surface
Careless handling of parts
Distortion
A change from original shape
Application of severe heat
Erosion
Wearing away of metal by the flow of hot
gases, grit or chemical
Flow of corrosive liquids, hot gases or
grit-laden oil
Fatigue failure
Progressive damage as the stress on a
piece is repeatedly applied and removed
Stress at a surface nick or scratch
Flaking
Breaking away of pieces of a plated/painted surface
Incomplete bond, excessive load or blistering
Grooving
Smooth, rounded furrows whose sharp
edges have been polished off
Concentrated wear: parts out of alignment
Heat oxidizing
(discoloration)
Characterized by discoloring film. Color
varies from yellow to brown and blue to
purple.
High temperature operation
Nick
A sharp indentation
Careless handling or foreign particles in
unit during operation
Pitting
Small indentions in a surface
Breakdown of surface by chemical action
(corrosion); or pressure of foreign material (mechanical)
Scoring
Deep scratches
Presence of foreign particles between
loaded surfaces having motion
Scratch
Narrow, shallow marks on surface
Careless handling: foreign particles in
unit during operation
Stripped
Part of thread is torn away
Improper installation or thread size
5-2 Change 23
T.O. 2G-T62T-43
Table 5-1.
Term
General Physical Conditions - Continued
Definition
Probable Cause
Tear
Parting of parent material
Excess tension, caused by an external force
Wear
Slow removal of parent material
Result of abrasive substances contacting
rolling surfaces, and acting as a lapping
compound
5-2. INSPECTION. A careful inspection to reveal
any evidence of excessive temperature, deterioration or other damage, which may lead to eventual
malfunction or failure, shall be made. Inspection
procedures for the APU are covered in Table 5-2.
Refer to Figure 3-2 through Figure 3-10, Figure 312, and Figure 3-28 for part identification. Inspection procedures for the fuel control and fuel pump
Table 5-2.
Inspect/
Item No.
can be found in T.O. 6J3-4-112-3, for the starter in
T.O. 2JA3-64-3, the IGV actuator in T.O. 6J3-8-193, and the surge control valve in T.O. 6J15-3-160-3.
All parts listed in Table 5-2 with less than ten
percent of painted surface flaked or chipped shall
not be stripped and repainted.
Inspection Requirements (APU)
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Air filter (Figure 3-2,
37, detail F)
Check for contamination and obstructions
No contamination
or obstructions permitted
None
Replace air filter
Check for leakage
No leakage permitted
None
Pressure test air filter at 75 psig
per AMS 2606. Replace air filter
if leaking
Visually inspect for
cracks
No cracks permitted
None
Weld cracks or holes in fusion
zone only per Specification MILW-8611, using CRES welding
rod
Check screen for
loose or broken
wires
No loose or damaged wires permitted
Loose wires may be
welded
Weld loose wires at joints per
ES9-63, class B. If wires are
broken, replace screen
Check sealing
flanges for distortion of duct assembly
No distortion permitted
Sealing flanges
may be straightened. No distortion
permitted after
straightening
Straighten sealing flanges per
T.O. 1-1A-1
Check for deterioration of cushion
No deterioration
permitted
None
Replace support clamps
Check for cracks or
distortion
No cracks or distortion permitted
None
Replace support clamps.
Air inlet duct (Figure
3-6, 13)
Clamps, support (Figure 3-2)
Change 22 5-3
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Containment ring (Figure 3-5, 37)
Visually inspect
pads on the containment ring extension for cracks
and degradation
None
None
Replace pads per Para. 5-3w(1)(6).
Visually inspect. If
damage is evident,
check for cracks by
fluorescent-penetrant inspection,
ASTM E1417, type
I, method A
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Weld cracks or holes in fusion
zone only per MIL-STD-2219 using AWS 5.9, ER308L, ER316L
or ER347 welding rods.
Visually inspect
mounting brackets
for distortion
No distortion permitted
Distorted mounting
brackets may be
straightened. No
distortion permitted after straightening
Cold straighten mounting brackets.
Check for cracks by
fluorescent-penetrant inspection,
ASTM E1417, type
I, method A
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Braze repair cracks or holes in
brazed joints using braze alloy
per AMS 4777.
Visually inspect for
dents
Dents are allowed
up to an area of
4.00 square inches
and less than 0.100
inch deep. Dents
that exhibit a
sharp crease are
not allowable. The
total number of
dents is not limited; however, there
must be a minimum separation of
1.00 inch between
dents.
Dents that are accessible may be
cold worked. No
creases permitted
after cold working.
Straighten and/or remove dents
with a soft-faced mallet or replace duct as required.
Duct assembly (Figure
3-5, 6 and 17)
5-4 Change 22
T.O. 2G-T62T-43
Table 5-2. Inspection Requirements (APU) - Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Duct assembly (6 and
17, figure 3-5)
- continued
Check for leakage
No leakage
permitted
None
Static pressure test duct
assembly at 60-70 psig per AMS
2606. Replace duct assembly if
leaking
Check sealing
flanges for
distortion
Maximum distortion
permitted is 0.20 in.
None
Replace duct assembly if out of
limits
Check for wrinkles
or dents in tubing of
duct assembly (6)
Wrinkles or dents
shall not exceed
0.030 in. deep
None
Replace duct assembly (6) if out
of limits
Check for wrinkles
or dents in tubing of
duct assembly (17)
Wrinkles or dents
shall not exceed
0.150 in. deep
None
Replace duct assembly (17) if
out of limits
Check for
deterioration
No deterioration
permitted
Minor deterioration
can be repaired
Repair engine control harness
per T.O. 1-1A-14
Check cable
terminals for
looseness
Cable lugs must be
secure
None
Tighten, repair, or replace cable
lugs
No corrosion
None
Replace connectors per
T.O. 1-1A-14
Check connectors
for bent or broken
pins
No bent or broken
pins permitted
Bent pins may be
straightened
Repair connectors per
T.O. 1-1A-14
Check for stripped
or damaged threads
No stripped or
damaged threads
permitted
Damaged threads
may be chased
Chase connector threads or
replace connector if length
allows per T.O. 1-1A-14
Check cover for
dents and warpage
No warpage
permitted. Dents
shall not exceed
0.040 in. deep
Dents greater than
0.040 in. deep may
be peened out
Peen dents that exceed limits or
replace fuel control enclosure
cover
Check for damaged
or missing
fasteners in cover
No damaged or
missing fasteners
permitted
None
Replace damaged or missing
fasteners
No damaged gasket
permitted
None
Replace damaged gasket
Engine control
harness (13, figure
3-2, detail A)
Check connectors
for corrosion
permitted
Fuel control enclosure
cover (5, figure 3-4)
Check for
damaged gasket
Change 11 5-5
T.O. 2G-T62T-43
Table 5-2. Inspection Requirements (APU) - Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Check for cracks in
cover
No cracks permitted
None
Replace fuel control enclosure
cover
Check sealing
flanges for
distortion
No distortion
permitted
Sealing flanges may
be straightened. No
distortion is
permitted after
straightening
Straighten sealing flanges per
T.O. 1-1A-1
Check for
deterioration
No deterioration
permitted
Minor deterioration
may be repaired
Repair fuel electronic harness
per T.O. 1-1A-14
Check cable
terminals for
looseness
Cable lugs must be
secure
None
Tighten or replace connectors
per T.O. 1-1A-14
Check connectors
for corrosion
No corrosion
permitted
None
Replace connectors per
T.O. 1-1A-14
Check connectors
for bent or broken
pins
No bent or broken
pins permitted
Bent pins may be
straightened
Repair fuel electronic harness
per T.O. 1-1A-14
Check for
stripped or
damaged threads
No stripped or
damaged threads
permitted
Damaged threads
may be chased
Chase threads per T.O. 1-1A-14
or replace connector if length
allows
No Obstruction
None
Clean per Section IV, Paragraph
4.3.b.
No Obstructions
None
Clean per Section IV, Paragraph
4.3.c.
Fuel electronic
harness (16, figure
3-4)
Air Flow Sensor
Housing (25, figure
3-5)
Visually inspect
holes for
obstructions
Air Flow Sensor
Fitting (22, figure
3-5)
Visually inspect
holes for
obstructions
5-6 Change 11
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Fuel purge valve (25,
Figure 3-2, detail B)
Check connectors
for bent or broken
pins
No broken pins permitted
Bent pins may be
straightened
Straighten bent pins per TO 11A-14 or replace fuel purge valve
Check connector
and valve body for
corrosion
Corrosion permitted if operation not
affected
None
Remove corrosion per Section IV
- Cleaning
Check valve body
for nicks, burrs, or
scratches
Nicks, burrs, or
scratches repairable
None
Blend nicks, burrs, or scratches
per Section 5-3a
Check for cracks
No cracks permitted
None
Replace fuel purge valve
Check electrical
connector for
stripped or damaged threads
No more than 4%
of thread damage
permitted
Damaged threads
may be chased
Chase threads or replace fuel
purge valve
Check for dents in
valve body
Dents that do not
affect valve operation are permitted
None
Replace fuel purge valve if dents
affect valve operation
Check connectors
for bent or broken
pins
No broken pins permitted
Bent pins may be
straightened
Straighten bent pins per TO 11A-14 or replace high-oil temperature switch
Check for corrosion
Corrosion permitted if operation not
affected
Check for stripped
or damaged
No more than 4%
of thread damage
permitted
Damaged threads
may be chased
Chase threads per TO 1-1A-14 or
replace high-oil temperature
switch
Check for nicks,
burrs, or scratches
Nicks, burrs, or
scratches repairable
None
Lend nicks, burrs, or scratches
per Section 5-3a
Damage shall not
exceed 3% of total
core face area or
1.5 linear inch fin
damage on core
face
None
Contact Engineering for disposition instructions
High-oil temperature
switch (57, Figure 3-2,
detail G)
Remove corrosion per Section IV
- Cleaning
Oil cooler (76,
Figure 3-2, detail I)
Check cooler for fin
damage
Change 24 5-7
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Oil cooler (76,
Figure 3-2, detail I) Continued
Threaded surfaces
and fittings for
crossed, stripped,
galled or worn
threads
None
--
Contact Engineering for disposition instructions
Brackets (84, 85,
and 86, Figure 3-2,
detail I)
None
None
Contact Engineering for disposition instructions
Hoses (81 and 82,
Figure 3-2, detail I)
None
None
Contact Engineering for disposition instructions
Check hourmeters
and event counter
for broken or cracked glass
No broken or cracked glass permitted
None
Replace hourmeters or event
counter
Check for dents
and deformation of
hourmeter junction
box
Dents or deformation permitted if
operation not affected
None
Replace hourmeter junction box
Check for nicks and
scratches on
hourmeter junction
box
Nicks and
scratches permitted
if operation not affected
None
Treat per Specification MIL-C5541
Check for wear
Ensure that no tinnickel plating is
worn through
None
Replace IGV drive link
Check for movement of each ball
Each ball must
move freely
None
Replace IGV drive link
Check for misalignment of link bearings
Angle of misalignment shall not exceed 20o
None
Replace IGV drive link if out of
nits
Hourmeter junction
box assembly (18,
Figure 3-8)
IGV drive link (8,
Figure 3-7)
5-8 Change 24
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Ignition cable (Figure
3-5, 27)
Check for frayed
braiding
No frayed braiding
permitted
None
Replace ignition cable
Check for stripped
threads
No stripped
threads permitted
None
Replace ignition cable
Check insulator or
terminals for damage
No damage permitted
None
Replace ignition cable
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, Type
I, Method B or D,
Sensitivity Level 3
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace inlet housing manifold
Check for leakage
in internal
passages
No leakage permitted
None
Hydrostatic pressure test internal passages at 40-50 psi per
AMS 2606. If leakage occurs, impregnate per MIL-STD-276.
Check connector for
bent or broken pins
No broken pins permitted
Bent pins may be
straightened
Straighten bent pins per T.O. 11A-14 or replace oil pressure
switch
Check connector
and switch body for
corrosion
Corrosion permitted on switch body
if operation not affected
None
Remove corrosion per Section IV
- Cleaning and anodize treat per
Specification MIL-A-8625, type
II, class 1. Replace oil pressure
switch if operation affected
Perform functional
check
None
None
Functional check per Section 53e. Replace oil pressure switch if
operation affected
Inlet housing manifold
(Figure 3-6, 3)
Oil pressure switch
(Figure 3-3, 18)
Change 22 5-9
TO 2G-T62T-43
Table 5-2. Inspection Requirements (APU) - Continued
lnspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Oil pressure switch
(18, figure 3-3)
- continued
Check oil pressure
connection for
damaged or
stripped threads
No more than 4%
of thread damage
permitted
Damaged threads
nay be chased
Chase threads per TO 1-1A-14
or replace oil pressure switch
Check switch body
for nicks, burrs,
or scratches
Nicks, burrs, or
scratches permitted if operation
not affected
None
Remove nicks, burrs, or
scratches per Section 5-3a.
Replace oil pressure switch if
operation affected
Check for dents,
distortion, or
cracks
Dents and distortion permitted if
Operation not
affected. No
cracks permitted
None
Replace oil pressure switch if
operation affected
Check for nicks
and scratches
Nicks and scratches
permitted
None
Treat per MIL-C-5541
Visually check for
cracks
No cracks permitted
Cracks less than
1 in. may be
welded. Cracks in
excess of 1 in.
shall be cause
for rejection
Weld aluminum alloy cracks as
required per TO 1-1A-9 and
grind to return to original contour. Treat per MIL-C-5541
No broken pins
permitted
Bent pins may be
straightened
Straighten bent pins per
TO 1-1A-14 or replace
temperature sensor
Reduction drive cover
(16, figure 3-3)
Temperature sensor
(13, figure 3-6)
Check connectors
for bent or
broken pins
5-10
T.O. 2G-T62T-43
Table 5-2. Inspection Requirements (APU) -Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Thermocouple harnesses (14 and 15, figure
3-2, detail A)
Check for damage
or distortion
No damage or distortion permitted
None
Replace thermocouple harness
Check B-nut for
stripped threads
No stripped threads
permitted
None
Replace thermocouple harness
Check tubing for
chafing, kinks,
cracks, twisting or
distortion
No chafing, kinks,
cracks, twisting or
distortion permitted
None
Replace tube assembly
Check for obstructions
No obstructions permitted
None
Remove any obstructions with
low pressure air (30 psig)
Check for corrosion
No corrosion permitted
None
Remove corrosion per Section IV Cleaning
Check B-nuts for
cracks or stripped
threads
No cracks or
stripped threads
permitted
None
Replace tube assembly
Visually check
flared tubing for
cracks
No cracks permitted
None
Replace tube assembly
Check for nicks,
burrs or scratches
Nicks, burrs or
scratches permitted
Nicks, burrs or
scratches shall
not exceed 0.030
in. long
Blend nicks, burrs or scratches
per Section 5-3a
Check for dents,
distortion or cracks
Minor dents and
distortion permitted
if operation not affected. No cracks
permitted
None
Replace turbine ignition exciter if
operation affected
Tube assemblies
(figure 3-2)
Turbine ignition exciter
(31, figure 3-5)
Change 6 5-11
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Turbine ignition exciter
(Figure 3-5, 31) - continued
Check connectors
for corrosion
No corrosion permitted
None
Remove corrosion per Section IV
- Cleaning
Check connectors
for bent or broken
pins
No bent or broken
pins permitted
Bent pins may be
straightened
Straighten pins per T.O. 1-1A-14
or replace turbine ignition exciter
Check for stripped
or damaged
No stripped or
damaged threads
permitted
Damaged threads
may be chased
Chase threads per T.O. 1-1A-14
or replace turbine ignition exciter
Perform functional
check for spars per
Section 5-3m
Spark rate shall be
a minimum of 2.7/
second at 28 Vdc
and maximum input current is 1.0 A
None
Replace turbine ignition exciter
if out of limits
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method D, Sensitivity Level 4
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace adapter assembly if out
of limits
Visually check for
obstructions in
passages
No obstructions
permitted
None
Remove any obstructions with
low pressure air (30 psig)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method D, Sensitivity Level 4
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace adapter assembly if out
of limits
Check for nicks,
burrs, and
scratches on
machined surfaces
Minor nicks, burrs,
and scratches repairable
Nicks, burrs, and
scratches less than
0.020 inch, may be
repaired
Blend nicks, burrs, and scratches
per Section 5-3a and treat per
Specification MIL-C-5541
Check for nicks,
burrs, and
scratches on nonmachined surfaces
Minor nicks, burrs,
and scratches repairable
Nicks, burrs, and
scratches less than
0.020 inch may be
repaired
Treat per Specification MIL-C5541
TURBINE ASSEMBLY
(Figure 3-10)
Adapter assembly (Figure 3-10, 17)
5-12 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Bearing aft carrier
(Figure 3-10, 53)
Check for cracks by
magnetic particle
inspection, Specification MIL-M47230, class B
No cracks permitted
None
Replace bearing aft carrier
Check oil passages
for obstructions
No obstructions
permitted
None
Remove any obstructions with
low pressure air (30 psig)
Visually check
bearing bore diameter for signs of
race rotation
Make sure diameter and flatness
meet original
dimensions
Maximum diameter
is 1.5751 inch (Figure 5-1, dimension
A). Runout shall
not exceed 0.0002
inch (Figure 5-1,
area B)
Electroless nickel plate per AMS
2404 to original dimensions
Check sleeve of
bearing aft carrier
assembly for wear,
scoring, scratches,
nicks, and burrs
Minor wear, scoring, scratches,
nicks or burrs permitted
Maximum inside
diameter is 1.6038
inch, installed in
inlet housing (Figure 5-1, dimension
C)
Sleeve of bearing aft carrier is
non-separable. Replace bearing
aft carrier
Check housing for
nicks, burrs,
scratches, and corrosion
Nicks, burrs,
scratches, and corrosion repairable
None
Blend nicks, burrs, scratches,
and corrosion per Section 5-3a
Check for cracks by
magnetic particle
inspection, Specification MIL-M47230, grade B
No cracks permitted
None
Replace bearing front carrier
Check oil passages
for obstructions
No obstructions
permitted
None
Pressure wash passages to remove any obstructions
Check for nicks and
scratches
Minor nicks and
scratches repairable
Nicks and
scratches shall not
exceed 0.200 inch
long, 0.050 inch
wide, and 0.020
inch deep
Electroless nickel plate per AMS
2404 to original dimensions
Check pin for looseness
No looseness permitted
None
Replace pin if loose per T.O. 11A-1
Bearing front carrier
(Figure 3-10, 7)
Change 22
5-13
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Bearing front carrier
(Figure 3-10, 7) - continued
Check that inside
diameter of bearing
front carrier is
within limits
Inside diameter
shall not exceed
1.344 inch (Figure
5-2, dimension A)
Coating thickness
shall not exceed
0.070 inch after
machining. Drill 12
holes 0.075-0.080
inch through
abradable coating
(Figure 5-2, area F)
Abradable coat using Metco 601
NS powder per AMS 2437 to restore to original dimensions. Repair per paragraph 5-3aa.
Visually check plating for corrosion
(Figure 5-2, dimensions B, C, D, and
E)
Minor corrosion repairable
None
Electroless nickel plate per AMS
2404 to restore to original
dimensions
Visually check
bearing bore diameters for signs of
race rotation
Make sure diameter and flatness
meet original
dimensions
Maximum diameter
is 1.5751 inch (Figure 5-2, dimension
C). Runout shall
not exceed 0.0002
inch
Electroless nickel plate per AMS
2404 to restore to original
dimensions
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace diffuser if out of limits
Check for nicks and
scratches on vane
leading edges
Minor nicks and
scratches permitted
Nicks and
scratches shall not
exceed 0.016 inch
deep or 0.125 inch
long
Replace diffuser if out of limits
Check vane throat
diameters (17
places)
Vane throat area
average diameter
shall not exceed
0.463 inch. Measure diameter 0.16
−0.190 inch from
root of vane
None
Replace diffuser if out of limits
Check for roundness of outside
diameter
Outside diameter
may have a free
state variation of
0.04 inch roundness on diameter
None
Replace diffuser if out of limits
Diffuser (Figure 3-10,
41)
5-14 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Diffuser housing (Figure 3-10, 45)
Check for cracks by
fluorescent penetrant inspection per
ASTM E1417; using type I, Method
A, B or D, Sensitivity Level 3 materials.
No cracks allowed
None
Replace diffuser if out of limits
Check for nicks,
burrs, and
scratches on
machined surfaces
Nicks, burrs, and
scratches repairable
None
Blend nicks, burrs, and scratches
per paragraph 5-3a. Treat reworked surfaces per paragraph
5-3p.
Check for nicks,
burrs, and
scratches on nonmachined surfaces
Nicks, burrs, and
scratches repairable
None
Treat surfaces per paragraph 53p.
Check for loose
thread inserts
No loose thread inserts permitted
Inserts must be
flush with housing
surface
Replace inserts
Check for local
compressor rub on
profile
Minor rub repairable on surface A,
Figure 5-3
Not to exceed 0.005
inch in depth
Remove burrs and raised edges
with abrasive cloth. (Federal
Specification PC-458). Do not
blend. Touch up exposed surfaces per paragraph 5-3p
Check for rub damage on profile and
scoring on throat
are due to contact
with inducer
Major rub repairable, surface A, Figure 5-3
Not to exceed 0.033
inch in depth
Plasma spray using Metco 450 to
restore to original dimensions.
See paragraph 5-3z.
Check for damage/
out-of-roundness on
the 11.100-11.104
inch diameter
Damage/out-ofroundness repairable
Not to exceed
11.185 inches diameter
Plasma spray using Metco 450 to
restore to original dimensions.
See paragraph 5-3z.
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace engine compressor wheel
if out of limits
Diffuser housing (Figure 3-10, 45)
Engine compressor
wheel (Figure 3-10, 60)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method A, B or
D, Sensitivity Level
3 materials
Change 25
5-15
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Check for nicks or
scratches on blades
and air passages
Minor nicks and
scratches repairable
Nicks or scratches
shall not exceed
0.030 inch long or
0.005 inch deep
Blend nicks and scratches per
Section 5-3a and balance per
Section VI - Assembly
Check for broken or
missing blades
No broken or missing blades permitted
None
Replace engine compressor wheel
Check diamond
knurl for wear.
Measure outer
diameter (OD) of
the knurl
No wear permitted.
Diameter shall be
1.5985 - 1.5990 inches
See paragraph 53f(1)
Repair diamond knurl per Section 5-3f(1) as required
Check blade tuning
First mode frequencies of all long
blades shall be
1950-2500 Hz. Second mode shall not
fall between 59006600 Hz
None
Blade tune engine compressor
wheel per Section 5-3f(3) and
balance per Section VI - Assembly
Check for rub
marks
Minor rub marks
acceptable if balanced, finished,
machined surfaces,
and tuning within
limits
None
Remove minor rub marks per
Section 5-3a and balance per
Section VI - Assembly
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace inlet guide vane if out of
limits
Corrective Action
Engine compressor
wheel (Figure 3-10, 60)
- continued
Inlet guide vane (Figure 3-10, 39)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials. Only
vane airfoil needs
to be inspected.
Items 37-40 (Figure
3-10) do not need to
be disassembled to
NDI IGV airfoil
section
5-16 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Inlet guide vane (Figure 3-10, 39) - continued
Check for nicks,
burrs, and
scratches
Nicks, burrs, and
scratches repairable
Nicks shall not exceed 0.030 inch on
vane edges
Blend nicks, burrs, and scratches
per Section 5-3a
No damage permitted
None
Replace labyrinth seal
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials for all
non-rotating parts
Acceptance criteria
per Specification
MIL-P-47158, Table
III, Method C
None
Replace load compressor diffuser
Check for bent or
broken vanes
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace load compressor diffuser
Check for nicks and
scratches on vane
leading edge
Minor nicks and
scratches permitted
Nicks and
scratches shall not
exceed 0.016 inch
deep or 0.125 inch
long (Figure 5-4, dimension A)
Replace load compressor diffuser
if out of limits
Check vane throat
area diameter (19
places)
Vane throat area
average diameter
shall not exceed
0.307 inch at 0.190
inch from vane root
(Figure 5-4, dimension B)
None
Replace load compressor diffuser
if out of limits
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace load compressor scroll if
out of limits
Labyrinth seal (Figure
3-10, 52)
Check for nicks,
scratches, wear or
other damage
Load compressor diffuser (Figure 3-10, 18)
Load compressor scroll
(Figure 3-10, 23)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Change 22
5-17
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Load compressor scroll
(Figure 3-10, 23) - continued
Check for nicks,
burrs, and
scratches on
machined surfaces
Nicks, burrs, and
scratches repairable
None
Blend nicks, burrs or scratches
per Section 5-3a and treat per
Specification MIL-C-5541
Check for nicks,
burrs, and
scratches on nonmachined surfaces
Nicks, burrs, and
scratches repairable
None
Treat per Specification MIL-C5541
Check for broken or
missing blades
No broken or missing blades permitted
None
Replace load compressor wheel
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method D, Sensitivity Level 4
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace load compressor wheel if
out of limits
Check for nicks or
scratches on vanes
and air passages
Minor nicks and
scratches repairable
Nicks or scratches
shall not exceed
0.030 inch long or
0.005 inch deep
Blend nicks and scratches per
Section 5-3a, shotpeen per Section 5-3f(2), and balance per Section VI - Assembly
Check for rub
marks
Minor rub marks
on blade ends acceptable if balance,
finished, machined
surfaces, and tuning within limits
None
Blend rub marks in a radial direction per Section 5-3a and balance per Section VI - Assembly
Check blade tuning
All blades must
have a first mode
frequency of 43504600 Hz
None
Blade tune load compressor
wheel per Section 5-3f(3) and
balance per Section VI - Assembly
Check seal (21) for
wear, nicks or damage
No wear, nicks or
damage permitted.
Inspection criteria
per Figure 5-27
None
Replace seal (21). Install new
seal per paragraph 6-5e(1)
No damaged
threads or broken
pins permitted
Bent pins may be
straightened
Chase damaged threads and
straighten bent pins per T.O. 11A-14
Load compressor wheel
(Figure 3-10, 20)
Magnetic pickup (Figure 3-10, 3)
Check connector for
damaged threads
and broken or bent
pins
5-18 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Magnetic pickup (Figure 3-10, 3) - continued
Check for cracks or
dents in pole piece
No cracks or dents
permitted
None
Replace magnetic pickup
Check resistance
between J304 pins
A to B
1190-1450 ohms
None
Replace magnetic pickup
Change 22
5-19
TO 2G-T62T-43
Table 5-2. Inspection Requirements (APU) - Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Pinion assembly (5,
figure 3-10)
Check gear teeth
for wear
No wear permitted
None
Replace pinion assembly
Check for chips or
cracks by magnetic
particle inspection,
MIL-M-47230,
grade A
No chips or cracks
permitted
None
Replace pinion assembly
Check for scoring
on gear teeth
Slight scoring is
permitted 1/3 the
way in from tip of
teeth
None
Replace pinion assembly if
out of limits
Check for pitting
on gear teeth
Pitting on tooth
contact area shall
not exceed 0.010
in. deep and 4%
of tooth contact
pattern
None
Replace pinion assembly if
out of limits
Check for loose
or missing oil
retainer
Loose or missing
oil retainer not
permitted
None
Replace pinion assembly
Check measurement
of external involute
spline
Minimum pinion
diameter is 0.5517
in.
None
Measure external involute spline
between two pins of 0.060 in.
diameter. Ensure pins are
flush to surface of splines.
Replace pinion assembly if out
of limits
Check for wear on
external spur gear
Minimum pinion
diameter is 0.7543
in.
None
Measure external spur gear
spline wear between two pins
of 0.0657 in. diameter.
Ensure pins are flush on
surface of spline. Replace
pinion assembly if out of limits
5-20
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Rotor shaft (59,
figure 3-10)
Check for worn,
damaged, or
stripped threads
No more than 4% of
thread damage
permitted
Damaged threads
may be chased
Chase damaged threads per T.O.
1-1A-14 or replace rotor shaf t
Check for cracks by
magnetic particle
inspection, MILSTD-1907, grade A
No cracks permitted
None
Replace rotor shaf t
Check for nicks
and scratches
Nicks and scratches
repairable
None
Blend nicks and scratches per
Section 5-3a and balance per
Section VI - Assembly
Visually check
nickel-plated
surfaces for pitting,
erosion, or scoring
No pitting, erosion,
or scoring permitted
at bearing, load
compressor, or
labyrinth seal
journals
Minimum plating
thickness is 0.002
in. Finish shall be
16 microinches
Repair minor damage by hand
polishing while maintaining minimum diameter limits. If minimum
diameter limits cannot be maintained, repair per Section 5-3s,
5-3t, or 5-3u as applicable
Check surface for
corrosion, pitting, or
erosion
Corrosion, pitting or
erosion shall not
exceed 0.020 in.
deep
None
Replace seal plate if out of limits
Visually check spot
welds and diaphragms for cracks
No cracks permitted
None
Replace seal plate
Check for signs of
compressor wheel
rub at inside
diameter
Minimum inside
diameter is 1.6761.674 in., and up to
0.020 in. deviation
in diameter roundness is permitted
(f igure 5-6, dimension A)
None
Replace seal plate
Check for warpage
Maximum diaphragm protrusion
from seal plate is
0.025 in.
None
Seal plate (57,
Figure 3-10)
Replace seal plate
Change 17
5-21
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Stud (Figure 3-10, 15)
Check for cracks by
magnetic particle
inspection, Specification MIL-M47230, grade A
No cracks permitted
None
Replace stud
Check for damaged
threads
No damaged
threads permitted
Damaged threads
may be chased
Chase damaged threads per T.O.
1-1A-14 or replace stud
Check for damaged
threads
None allowed
None
Replace stud
Check for cracks by
fluorescent penetrant inspection
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
No cracks permitted
None
Replace Stud
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace inlet housing and support housing as a matched set
Check for nicks,
burrs, and
scratches
Minor nicks, burrs,
and scratches repairable
Nicks, burrs, and
scratches shall not
exceed 0.010 inch
deep, 0.015 inch
wide, or 0.250 inch
long
Blend nicks, burrs, and scratches
per Section 5-3a
Check helical coil
inserts for looseness
Inserts shall not be
less than 3/4 turn
below flange surface
None
Replace inserts per T.O. 1-1A-8
Dimensionally inspect 1.800 inch
bore area (Figure
5-26)
1.7997 to 1.8003
1.804
Restore to original dimensions
in accordance with Section 5-3r
Stud (Figure 3-10, 58)
Support housing and
inlet housing, matched
set (Figure 3-10, 30
and 31)
5-22 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Turbine nozzle (Figure
3-10, 2)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace turbine nozzle if out of
limits
Check vane
passages for nicks,
scratches, and erosion
Minor nicks,
scratches, and erosion repairable
Nicks, scratches or
erosion shall not
exceed 0.010 inch
deep and 0.015
inch wide (Figure
5-7, dimension E)
Repair per Section 5-3h
Check vane throat
area diameter (17
places)
Vane throat area
average diameter
shall not exceed
0.464 inch diameter
over 17 places
None
Replace turbine nozzle if out of
limits
Check radial runout for surface deviations
Radial runout of
any surface deviations shall not exceed 0.010 inch
total in any two
inch circumferential increment.
Minimum diameter
is 10.048 inch (Figure 5-7, dimension
D)
A coating thickness
of 0.020 - 0.060
inch is acceptable
Restore to original dimensions
per Section 5-3h
Check that inside
profile is within
contour
Inside profile to be
within 0.0035 inch
from basic contour
of 0.765 radius
(Figure 5-7, dimension A) and inside
diameter of 4.975
inch (Figure 5-7, dimension C)
None
Replace turbine nozzle if out of
limits
Check for signs of
turbine wheel rub
Minor rub marks
removable. No
more than 3 rub
marks permitted
Rub marks shall
not exceed 0.020
inch deep (Figure
5-7, dimension B)
Repair per section 5-3h. Replace
turbine nozzle if out of limits
Change 22
5-23
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Turbine wheel (Figure
3-10, 55)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method D, Sensitivity Level 4
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace turbine wheel if out of
limit
Check for bore
cracks using eddy
current method per
Section 5-3g
No cracks permitted
None
Replace turbine wheel
Check for broken or
missing blades
No broken or missing blades permitted
None
Replace turbine wheel
Check for nicks and
scratches
Minor nicks and
scratches permitted
Nicks and
scratches shall not
exceed 0.015 inch
wide or 0.075 inch
long
Blend nicks and scratches per
Section 5-3a and balance per
Section VI - Assembly
Check for erosion
Minor erosion permitted
Overall diameter
shall not be less
than 6.416 inch
Replace turbine wheel
Check blade tuning
All blades must
have a first mode
frequency of 34003650 Hz
None
Blade tune turbine wheel per
Section 5-3f(3) and balance per
Section VI - Assembly
Check for cracks by
magnetic particle
inspection, Specification MIL-M47230, grade A
No cracks permitted
None
Replace accessory drive pinion
Check for chipped
gear teeth
No chipped gear
teeth permitted
None
Replace accessory drive pinion
Check for scoring
Slight scoring is
permitted 1/3 the
way in from tip of
teeth
None
Replace accessory drive pinion if
out of limits
REDUCTION DRIVE
UNIT (Figure 3-12)
Accessory drive pinion
(Figure 3-12, 52)
5-24 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Accessory drive pinion
(Figure 3-12, 52) - continued
Check for pitting
Minor pitting shall
not exceed 0.010
inch deep and 4
percent of tooth
contact pattern
None
Replace accessory drive pinion if
out of limits
Check bore for
wear
Maximum diameter
shall not exceed
0.5886 inch (Figure
5-8, dimension A)
None
Replace accessory drive pinion if
out of limits
Check for cracks by
magnetic particle
inspection, Specification MIL-M47230, grade A
No cracks permitted
None
Replace accessory gear
Check for chipped
gear teeth
No chipped teeth
permitted
None
Replace accessory gear
Check for wear of
shaft (2 places)
Minimum diameter
is 0.4723 inch (Figure 5-9, dimension
A)
None
Replace accessory gear if out of
limits
Check for scoring
on gear teeth
Slight scoring is
permitted 1/3 the
way in from tip of
teeth
None
Replace accessory gear if out of
limits
Check for scoring
on shaft
Scoring shall not
exceed 0.005 inch
deep and must not
affect bearing fit
0.438 inch diameter, 0.405 inch
length on internally-splined end
Repair accessory gear per Section 5-3x. Replace accessory gear
if out of limits
Check for pitting
on gear teeth
Minor pitting shall
not exceed 0.010
inch deep and 4
percent of tooth
contact pattern
None
Replace accessory gear if out of
limits
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace bevel gear support if out
of limits
Accessory gear (Figure
3-12, 120)
Bevel gear support
(Figure 3-12, 40)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Change 22
5-25
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Check housing for
nicks, burrs, and
scratches
Minor nicks, burrs,
and scratches repairable
Nicks and
scratches shall not
exceed 0.10 inch
deep or 0.1 inch
wide
Blend nicks, burrs or scratches
per Section 5-3a
Check bearing
bores for signs of
bearing race rotation
No race rotation
permitted
None
Replace bevel gear support liners
per Section 5-3l
Check for loose helical coil inserts
Inserts shall not be
less than 3/4 turn
below flange surface
None
Replace loose inserts per T.O. 11A-8
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace bypass valve housing if
out of limits
Check for nicks and
scratches
Nicks and
scratches repairable
None
Blend nicks and scratches per
Section 5-3a and treat with
Specification MIL-C-83286 or
Specification MIL-C-85285
Check passages for
obstructions
No obstructions
permitted
None
Remove any obstructions with
low pressure air (30 psig)
Check for cracks
and through porosity by fluorescent
penetrant inspection ASTM E1417,
type I, Method B or
D, Sensitivity Level
3 materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace carrier assembly and
cover as a matched set if out of
limits
Check for nicks or
scratches
Minor nicks or
scratches repairable
Nicks or scratches
or erosion shall not
exceed 0.010 inch
deep and 0.01 inch
long
Blend nicks or scratches per Section 5-3a
Corrective Action
Bevel gear support
(Figure 3-12, 40) - continued
Bypass valve housing
(Figure 3-12, 6)
Carrier assembly (Figure 3-12, 60) (Matched
set with cover, Figure
3-12, 63)
5-26 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Carrier assembly (Figure 3-12, 60) (Matched
set with cover, Figure
3-12, 63) - continued
Check for obstructions in holes and
passages
No obstructions
permitted
None
Pressure wash to remove any obstructions
Check for wear in
bearing sleeves and
shaft bore
Maximum sleeve
diameter shall not
exceed 1.3788 inch
in 3 places (Figure
5-10, dimension A)
None
Replace sleeve per Section 5-3j
Flow check oil jet
cartridge per
ASTM 2422
All four jets of cartridge must flow
freely. Total flow is
0.3-0.5 gpm at 20
psi
None
Flow test oil jet cartridge
per Section 5-3d(3)
Check oil jet cartridge and spring
pin for looseness or
damage
No looseness or
damage permitted
None
Replace oil jet cartridge and
spring pin per Section 5-3j(1)
Check for cracks
and through porosity by fluorescent
penetrant inspection, ASTM E1417,
type I, Method B or
D, Sensitivity Level
3 materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace cover and carrier assembly as a matched set if out of
limits
Check for scratches
and scoring
Minor scratches
and scoring repairable
Scratches and scoring shall not exceed
0.010 inch deep or
0.250 inch long
Blend scratches and scoring per
Section 5-3a and dichromate
treat per Specification MIL-M3171, type I or VI
Check for obstructions in holes and
passages
No obstructions
permitted
None
Pressure wash to remove any obstructions
Check bearing
sleeve and inside
diameter
Maximum inside
diameter shall not
exceed 1.3788 inch
in 3 places (Figure
5-11, dimension A)
None
Replace sleeve per Section 5-3j
Cover (Figure 3-12, 63)
(Matched set with carrier assembly, Figure
3-12, 60)
Change 22
5-27
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Cover (Figure 3-12, 63)
(Matched set with carrier assembly, Figure
3-12, 60) - continued
Check bearing bore
inside diameter
Maximum inside
diameter shall not
exceed 1.2604 inch
(Figure 5-11, dimension B)
None
Replace cover and carrier assembly as a matched set if out of
limits
Minor wear permitted. No elongated
pin holes permitted
Wear limits shall
not exceed those
specified in Table
5-3
Replace driver/driven shaft if out
of limits
Inspect for silver
braze repairs
Silver braze shall
be removed
None
Passivate oil sump as required
to remove silver braze in accordance with AMS 2700, Method 1,
type 6. Replace oil sump if silver
braze has not been removed
after two attempts. Furnace
braze as required in accordance
with AWS C3.6
Check for cracks by
fluorescent penetrant inspection
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Weld cracks or holes in fusion
zone only per Specification MILW-8611, using Specification
MIL-R-5031, class 7 welding rod
Check for leakage
using Figure 5-29
diagram and instructions
No leakage permitted
None
Hydrostatic pressure test at 5
psi per AMS 2615. Replace engine oil sump if leaking
Check lockwire tab
holes for tears
No tears permitted
None
Weld repair or replace tabs per
Specification MIL-W-8611, using
Specification MIL-R-5031, class
7, welding rod
Check sealing
flanges for warpage
No warpage permitted
Warped flanges
may be straightened
Straighten warped flanges per
T.O. 1-1A-1
Check enging oil
sump for dents
Dents shall not exceed 0.20 inch long
and 0.040 inch
deep
None
Straighten dents per T.O. 1-1A-1
Driver/driven shaft
(Figure 3-12, 37 and
38)
Check shaft diameter and for elongated pin holes
Engine oil sump (Figure 3-12, 22)
5-28 Change 25
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Gear planet set (Figure
3-12, 65)
Check for cracks by
magnetic particle
inspection, Specification MIL-M47230, grade A
No cracks permitted
None
Replace gear planet set (all 3)
Check for scoring
on gear teeth
Slight scoring is
permitted 1/3 the
way in from tip of
teeth
None
Replace gear planet set (all 3) if
out of limits
Check for scoring
on shaft
Scoring shall not
exceed 0.005 inch
deep and must not
affect bearing fits
None
Replace gear planet set (all 3) if
out limits
Check for wear of
shaft (2 places)
Minimum diameter
is 0.5905 inch (Figure 5-12, dimension
A)
None
Replace gear planet set (all 3) if
out of limits
Check for wear on
external spur gear
Minimum diameter
of gear is 2.3055
inch
None
Measure diameter of gear over
0.06565 inch diameter pins. Ensure measurement pins reflect
true diameter by being flush to
surface of gear teeth. Replace
gear planet set (all 3) if out of
limits
Check for pitting
on gear teeth
Minor pitting shall
not exceed 0.010
inch deep and 4
percent of tooth
contact pattern
None
Replace gear planet set (all 3) if
out of limits
Check for chipped
gear teeth
No chipped teeth
permitted
None
Replace gear planet set (all 3)
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace housing if out of limits
Housing (Figure 3-12,
142)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B, C or
D, Sensitivity Level
3 materials. Inspect
all non-painted areas including bearing seats, bolt
holes, and web
Change 22
5-29
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Housing (Figure 3-12,
142) - continued
Visually check
bearing bores for
bearing race rotation
Make sure diameter and flatness
meet original
dimensions
None
Replace housing sleeves per Section 5-3i
Check housing for
nicks, burrs or
scratches
Nicks, burrs or
scratches are repairable
Nicks, burrs or
scratches shall not
exceed 0.100 inch
long or 0.030 inch
deep
Blend nicks, burrs or scratches
and treat per Section 5-3a
Check for wear on
main output pad
bearing sleeve
Inside diameter of
output pad bearing
sleeve shall be
2.1665 - 2.1653
inch
None
Replace sleeve per Section 5-3i if
out of limits
Check for loose helical coil inserts
Inserts shall not be
less than 3/4 turn
below flange surface
None
Replace inserts that are loose or
out of limits per T.O. 1-1A-8
Check for wear,
corrosion,
scratches, out-ofroundness, out-ofconcentricity of
6.000 - 6.002 inch
diameter
Wear spots are permitted except within 0.500 inch
around oil passage
hole. Corrosion pits
are acceptable up
to 0.010 inch deep
by 0.125 inch diameter. Scratches
deeper than 0.010
inch deep and up to
0.250 inch in
length are acceptable in other areas.
Out of roundness or
out of concentricity
greater than 0.0005
TIR are not acceptable except in local
wear spots.
None
Repair housing per paragraph 53v
Inspect air oil
separator sleeve
(Figure 3-12, 140)
retaining pins for
looseness or protrusion from sleeve
No looseness or
protrusion of pin
None
Repair per paragraph 5-3y
5-30 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Housing (Figure 3-12,
142) - continued
Inspect for sealant
between air-oil
separator sleeve
(Figure 3-12, 140)
and reduction drive
housing (Figure 312, 142), denoted
by an ‘‘R’’ etched on
the sleeve
Presence of sealant
NA
Apply sealant as required per
paragraph 5-3y
Check for cracks or
through porosity by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace housing carrier
Check housing for
nicks, burrs, and
scratches
Minor nicks, burrs,
and scratches repairable
Nicks, burrs or
scratches shall not
exceed 0.1 inch
long or 0.01 inch
deep
Blend nicks, burrs or scratches
and treat per Section 5-3a
Check bearing
bores for bearing
race rotation
No race rotation
permitted
None
If indication of race rotation, replace liner per Section 5-3k
Check for loose helical coil inserts
Inserts shall not be
less than 3/4 turn
below flange surface
None
Replace inserts that are loose or
out of limits per T.O. 1-1A-8
Check for chipped
gear teeth
No chipped teeth
permitted
None
Replace hub ring gear
Check for cracks by
magnetic particle
inspection, Specification MIL-M47230, grade A
No cracks permitted
None
Replace hub ring gear
Check for scoring
on gear teeth
Slight scoring is
permitted 1/3 the
way in from tip of
teeth
None
Replace hub ring gear if out of
limits
Housing carrier (Figure
3-12, 77)
Hub ring gear (Figure
3-12, 85)
Change 22
5-31
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Hub ring gear (Figure
3-12, 85) - continued
Check for pitting
on gear teeth
Minor pitting shall
not exceed 0.010
inch deep and 4
percent of tooth
contact pattern
None
Replace hub ring gear if out of
limits
Check for wear on
external splines
Minimun diameter
of gear is 1.8585
inch
None
Measure diameter of gear over
0.0864 inch diameter pins. Ensure measurement pins reflect
true diameter by being flush to
surface of gear teeth. Replace
hub ring gear if out of limits
Check for wear in
bore of gear
Maximum diameter
is 0.9694 inch (Figure 5-13, dimension
A)
None
Replace hub ring gear if out of
limits
Check for cracks by
magnetic particle
inspection, Specification MIL-M47230, grade A
No cracks permitted
None
Replace intermediate gear
Check for pitting
on gear teeth
Minor pitting shall
not exceed 0.010
inch deep and 4
percent of tooth
contact pattern
None
Replace intermediate gear if out
of limits
Check for chipped
gear teeth
No chipped teeth
permitted
None
Replace intermediate gear
Check for scoring
on gear teeth
Slight scoring is
permitted 1/3 the
way in from tip of
teeth
None
Replace intermediate gear if out
of limits
Check for wear on
inside diameter of
gear
Maximum diameter
is 1.378 inch (Figure 5-14, dimension
A)
None
Replace intermediate gear if out
of limits
No cracks permitted
None
Replace intermediate gear shaft
Intermediate gear (Figure 3-12, 117)
Intermediate gear shaft
(Figure 3-12, 113)
Check for cracks by
magnetic particl inspection, Specification MIL-M-47230,
grade A
5-32 Change 22
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Intermediate gear shaft
(Figure 3-12, 113) continued
Check outside
diameter of shaft
Minimum shaft
diameter is 0.5899
inch
None
Replace intermediate gear shaft
if out of limits
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Replace oil pump housing if out
of limits
Oil pump housing (Figure 3-12, 26)
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, type
I, Method B or D,
Sensitivity Level 3
materials
Change 22 5-33/(5-34 blank)
TO 2G-T62T-43
Table 5-2. Inspection Requirements (APU) - Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Oil pump housing
(26, figure 3-12)
- continued
Check for nicks or
dents
No nicks or dents
permitted
None
Replace oil pump housing
Check for wear or
elongated shaft
holes
Minor wear permitted. No elongated
shaft holes permitted (figure,
5-15)
Wear limits shall
not exceed those
specified in table
5-3
Replace oil pump housing if
out of limits
Check for cracks by
magnetic particle
inspection, MIL-M47230, grade A
No cracks permitted
None
Replace pump drive gear
Check for pitting
on gear teeth
Pitting on tooth
contact area shall
not exceed 0.010
in. deep and 4%
of individual gear
tooth contact
pattern
None
Replace pump drive gear if out
of limits
Check for scoring
on gear teeth
Slight scoring is
permitted 1/3 the
way in from tip
of teeth
None
Replace pump drive gear if out
of limits
Check for chipped
teeth
No chipped teeth
permitted
None
Replace drive gear
Check for wear on
gear teeth
Minimum diameter
is 2.6078 in.
(figure 5-16,
dimension A)
None
Measure drive gear diameter
over 0.0864 in. diameter
pins. Ensure measurement
pins reflect true diameter by
being flush to surface of
gear teeth. Replace pump
drive gear if out of limits
Pump drive gear (33,
figure 3-12)
5-35
TO 2G-T62T-43
Table 5-2. Inspection Requirements (APU) - Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Pump drive gear (33,
figure 3-12)
- continued
Maximum diameter
is 0.2505 in.
(figure 5-16,
dimension B)
None
Replace pump drive gear if out
of limits
Check for cracks in
teeth by magnetic
particle inspection,
MIL-M-47320,
grade A
No cracks permitted
None
Replace both pump element
gears
Check for scoring
and chipped gear
teeth
No scoring permitted. No chipped
teeth permitted
None
Replace both pump element
gears
Check for wear on
gear teeth and/or
housing
Gear to housing
clearance not to
exceed 0.004 in.
(see figure 5-15,
table 5-3, ref. 15)
None
Replace both pump element
gears or housing if necessary
Check gear bore
inside diameter
Pump element gear
(36, figure 3-12)
Ring gear (69,
figure 3-12)
None
Replace ring gear
Check for cracks by
magnetic particle
inspection, MIL-M47230, grade A
No cracks permitted
Check for chipped
gear teeth
No chipped gear
teeth permitted
None
Replace ring gear
Check for scoring
Slight scoring
is permitted 1/3
the way in from
tip of teeth
None
Replace ring gear if out of
limits
5-36
TO 2G-T62T-43
Table 5-2. inspection Requirements (APU) - Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Ring gear (69,
figure 3-12)
- continued
Check for pitting
Minor pitting
shall not exceed
0.010 in. deep
and 4% of tooth
contact pattern
None
Replace ring gear if out of
limits
Check for wear on
internal spur gear
teeth
Maximum diameter
is 5.0503 in.
None
Measure diameter of ring gear
between 0.06382 in. diameter
pins. Ensure measurement
pins are flush to surface.
Replace ring gear if out of
limits
Check for wear on
internal involute
spline
Maximum diameter
is 1.6313-0.0864
in. diameter
None
Measure diameter of involute
spline teeth between pins.
Ensure measurement pins
are flush to surface. Replace ring gear if out of limits
Check for cracks by
magnetic particle
inspection, MIL-M47230, grade A
No cracks permitted
None
Replace straight drive shaft
Check for worn or
damaged threads
No worn or damaged
threads permitted
Damaged threads
may be chased
Chase threads per TO 1-1A-14
or replace straight drive
shaft
Check wear of
internal splines
Maximum shaft diameter is 0.6790 in.
None
Measure inside diameter of
internal spline between
0.0864 in. diameter pins.
Ensure pins are flush with
splines. Replace straight
drive shaft if out of limits
Straight drive shaft
(78, figure 3-12)
5-37
TO 2G-T62T-43
Table 5-2. Inspection Requirements (APU) - Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Zerol bevel gear (45,
figure 3-12)
Check for cracks in
teeth by magnetic
particle inspection,
MIL-M-47320,
grade A
No cracks permitted
None
Replace Zerol bevel gear
Check for pitting
on gear teeth
Minor pitting not
to exceed 0.010 in.
deep and 4% of
tooth contact
pattern
None
Replace Zerol bevel gear if
out of limits
Check for chipped
gear teeth
No chipped teeth
permitted
None
Replace Zerol bevel gear
Check for scoring
on gear teeth
Slight scoring is
permitted 1/3
the way in from
tip of teeth
None
Replace Zerol bevel gear
if out of limits
Check for wear on
gear teeth
No abnormal wear
permitted
None
Replace Zerol bevel gear
Check for wear on
internal spline
Maximum diameter
of internal spline
is 0.679 in.
None
Measure inside diameter of
internal spline between
0.0864 in. diameter pins.
Ensure pins are flush with
splines. Replace Zerol
bevel gear if out of limits
Check for cracks by
magnetic particle
inspection, MIL-M47230, grade A
No cracks permitted
None
Replace Zerol pinion
Check for chipped
gear teeth
No chipped gear
teeth permitted
None
Replace Zerol pinion
Zerol pinion (91,
figure 3-12)
5-38
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Zerol pinion (Figure 312, 91) - continued
Check for pitting
Minor pitting shall
not exceed 0.010
inch deep and 4
percent of tooth
contact patter
None
Replace Zerol pinion if out of
limits
Check for scoring
Slight scoring is
permitted 1/3 the
way in from tip of
teeth
None
Replace Zerol pinion if out of
limits
Check bore for
wear
Maximum diameter
shall not exceed
1.0005 inch (Figure
5-17, dimension A)
None
Replace Zerol pinion if out of
limits
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, Type
I, Method B or D,
Sensitivity Level 3
materials (Figure
5-18)
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Braze cracks per Section 5-3n
Check for warping
of housing forward
and aft flanges
No warpage permitted
Flanges may be
straightened
Straighten flanges per T.O. 11A-1
Check for burn deformation between
manifold bosses or
in tail cone
No burn deformation permitted between manifold
bosses or in tail
cone
None
Replace combustor housing assembly
Check for leakage
using penetrant,
Specification MILI-25135, type I,
method A, level 2,
to interior surfaces
only
No leakage permitted to exterior surface
None
Braze cracks per Section 5-3n
COMBUSTOR ASSEMBLY (Figure 3-28)
Combustor housing
(Figure 3-28, 17)
Change 22
5-39
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Combustor housing
(17, figure 3-28) Continued
Check combustor
housing alignment,
igniter plug alignment, and injector
alignment
No misalignment
permitted
None
Check housing alignment, igniter
plug alignment, ring alignment,
and injector alignment using
inspection f ixture, ST62880
(10, f igure 2-1). Replace combustor
housing if out of limits
Check that all ports
are free of foreign
objects
No foreign objects
permitted
None
Remove any foreign objects using
low pressure air (30 psig)
Check for wear on
combustor housing
diffuser
Inside diameter of
housing diffuser is
5.098 - 5.103 in.
(f igure 5-18,
dimension A)
(average of four
places)
None
Using inspection f ixture, ST62880
(10, f igure 2-1), measure diameter
of combustor housing diffuser.
Replace combustion housing if out
of limits
Check for wear on
tail cone of
combustor housing
assembly
Outside diameter of
tail cone is 6.672 6.702 in.
(f igure 5-18,
dimension B)
(average of four
places)
None
Using inspection f ixture, ST62880
(10, f igure 2-1), measure tail cone
diameter of combustor housing.
Replace combustor housing if out
of limits
Check for damaged
thermocouple boss
No damage
permitted
None
Repair thermocouple boss per
paragraph 5-3n. (3)
5-40
Change 17
T.O. 2G-T62T-43
Table 5-2.
Inspect/
Item No.
Inspection Requirements (APU) - Continued
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Combustor liner (Figure 3-28, 15)
Check atomizer fittings for clogs or
restrictions
No clogs or restrictions permitted
None
Flow check atomizer fitting per
Section 5-3d(4). Repair atomizer
fitting if clogged
Check for carbon
deposits
No carbon deposit
permitted
None
Remove carbon deposits by ultrasonic cleaning per Section IV
- Cleaning
Check for cracks by
fluorescent penetrant inspection,
ASTM E1417, Type
I, Method B or D,
Sensitivity Level 3
materials (Figure
5-19)
Acceptance criteria
per MIL-STD-1907,
Table III, grade C
None
Braze cracks per Section 5-3n
Ensure freedom of
movement of
igniter plug grommet
No damage permitted
None
Apply non-carbon penetrating
oil, VV-P-216, to free igniter plug
grommet or replace grommet per
Section 5-3o
Check for burn
away of parent
metal immediately
behind indentations
on cooling rings
No burn away permitted
None
Replace combustor liner if out of
limits
Check inside diameter, in a restrained condition,
for roundness
Minimum/maximum wear limits
are specified in Figure 5-19 (dimensions A and B). A
tight fit through
360o between seal
ring and combustor
housing must be
maintained
None
Measure both inner diameters
using inspection fixture,
ST61404 (Figure 2-1, 9). Replace
combustor liner if out of limits
Check for erosion
or distortion of fuel
nozzle
No erosion or distortion permitted
None
Replace fuel manifold
Check for looseness
of tube assemblies
in distribution boss
No looseness permitted
None
Braze cracks per AWS C3.6 using brazing alloy per AWS A5.862T BAU 4
Check for cracks,
kinks or distortion
No cracks, kinks or
distortion permitted
None
Replace fuel manifold
Fuel manifold (Figure
3-28, 9)
Change 22
5-41
T.O. 2G-T62T-43
Table 5-2. Inspection Requirements (APU) -Continued
Inspect/
Item No.
Max Serviceable
Limits
Max Repairable
Limits
Corrective Action
Fuel manifold (9, figure
3-28) - continued
Check for looseness
of tube assemblies
in distribution boss
No looseness permitted
None
Braze cracks per MIL-B-7883,
Type II, grade B, using brazing
alloy per AWS A5.8-62T BAU 4
Check for cracks,
kinks or distortion
No cracks, kinks or
distortion permitted
None
Replace fuel manifold
Check for bent or
plugged fuel nozzles
No bent or plugged
fuel nozzles permitted
None
Flow check fuel manifold per Section 5-3d (2). Replace fuel manifold if out of limits
Check filter fitting
for clogs or restrictions
No clogs or restrictions permitted
None
Flow check fuel manifold per Section 5-3d (2). Replace filter fitting if out of limits
Check for cracks or
dents
No cracks or dents
permitted
None
Replace fuel nozzle and fitting
Check for damaged
or stripped threads
No damaged or
stripped threads
permitted
None
Replace fuel nozzle and fitting
Check for clogs or
restrictions
No clogs or restrictions permitted
None
Flow check per Section 5-3d (2).
Replace fuel nozzle if out of limits
Fuel nozzle and fitting
(3 and 2, figure 3-28)
5-42 Change 6
T.O. 2G-T62T-43
Figure 5-1.
Inspection of Bearing Aft Carrier
Change 22
5-43
T.O. 2G-T62T-43
Figure 5-2.
5-44
Change 16
Inspection of Bearing Front Carrier
TO 2G-T62T-43
Figure 5-3. Inspection of Diffuser Housing
5-45
TO 2G-T62T-43
Figure 5-4. Inspection of Load Compressor Diffuser
5-46
T.O. 2G-T62T-43
Figure 5-5. Inspection of Rotor Shaft
Figure 5-6. Inspection of Seal Plate
Change 9 5-47
T.O. 2G-T62T-43
Figure 5-7. Inspection of Turbine Nozzle
5-48 Change 3
TO 2G-T62T-43
Figure 5-8. Inspection of Accessory Drive Pinion
Figure 5-9. Inspection of Accessory Gear
5-49
TO 2G-T62T-43
Figure 5-10. Inspection of Carrier Assembly
Figure 5-11.
5-50
Inspection of Cover
TO 2G-T62T-43
Figure 5-12. Inspection of Gear Planet Set
Figure 5-13.
Inspection of Hub Ring Gear
5-51
TO 2G-T62T-43
Figure 5-14. Inspection of Intermediate Gear
5-52
TO 2G-T62T-43
Figure 5-15. Inspection of Oil Pump Housing Assembly
5-53
TO 2G-T62T-43
Table 5-3. Oil Pump Housing Assembly, Dimensional Limits
Ref.
Fig. 5-15
Description
1
Pump drive gear to housing. Total clearance
0.0300L
2
Pump drive gear to driver shaft
0.0020L
3
Pump drive gear keyway width (two places)
0.1000
4
Pin outside diameter (OD) (3 each)
0.0900
5
Driver shaft OD
0.2485
6
Pin to driver shaft (two places)
0.0010L
7
Pump drive gear to driver shaft
0.0020
8
Pump drive gear keyway width (two places)
0.1000
9
Driven shaft OD
0.2485
10
Pump drive gear keyway width (two places)
0.1000
11
Pin to driven shaft
0.0010L
12
Driven shaft to pump element gear
0.0020L
13
Driver and driven shafts housing holes (four places)
0.0020L
14
Pump element gears end play (two places)
0.0030L
15
Pump element gear OD to housing bore
0.0040
NOTES:
1. Pump drive gear inside diameter (ID) - 0.2500-0.2505 in.
2. Pump element gear ID - 0.2500-0.2505 in.
3. Driver shaft and drive shaft OD - 0.2490-0.2492 in.
5-54
Replace if
dimension exceeds
TO 2G-T62T-43
Figure 5-16. Inspection of Pump Drive Gear
Figure 5-17. Inspection of Zerol Pinion
5-55
TO
2G-T62T-43
Figure 5-18. Inspection of Combustor Housing
5-56
TO 2G-T62T-43
Figure 5-19. Inspection of Combustor Liner
5-57
TO 2G-T62T-43
REPAIR AND REPLACEMENT.
5-3.
a.
of Nicks, Scratches, Burrs and Surface Blemishes. Repair nicks, scratches,
burrs, and surface blemishes as follows:
(1)
(2)
(3)
Clean component using applicable
cleaning instructions per Section IV Cleaning.
(2)
Place sheet of abrasive crocus cloth,
P-C-458, on a true flat surface.
(3)
Place contact surface down on abraded
or scored end of component (table
5-4).
(4)
Ensure even metal removal by applying
light hand pressure while moving part in
figure-8 pattern.
(5)
Remove minimum amount of metal
necessary to eliminate scoring.
(6)
Polish surface with abrasive stone,
SS-S-736.
Remove minor nicks, scratches, burrs,
rubs, or surface blemishes from components (table 5-4) with abrasive crocus
cloth, P-C-458.
Immediately after cleaning and repair,
treat and paint the surface per subparagraph o.
Immediately after cleaning and repair,
treat and paint the surface per subparagraph o.
b. Removal of Scoring. Remove scoring on flat
surfaces as follows:
(1)
Clean component using applicable
cleaning instructions per Section IV Cleaning.
Table 5-4.
Fig.1
Index No.
Components
C.
Using Abrasive
Remove and repair
threaded inserts, threads, O-rings, studs,
dowel pins, and pins per TO 1-1A-8.
Crocus
Cloth,
P-C-458
Fig.1
Index No.
Component
Component
3-10/17
Adapter
assembly
3-10/31
Inlet housing
3-10/53
Bearing aft carrier
3-10/39
Inlet guide vane
3-12/40
Bevel gear support
3-10/20
Load compressor
3-12/6
By-pass
3-3/18
Oil pressure
3-12/60
Carrier Assembly
3-10/59
Rotor shaft
3-12/63
3-10/45
Cover
3-3/16
Reduction
drive cover
3-12/142
Reduction
drive housing
3-10/60
Engine compressor
3-5/31
Turbine
ignition exciter
3-2, detail
B/25
Fuel purge valve
3-10/2
Turbine
nozzle
3-12/77
Housing carrier
3-10/55
Turbine wheel
5-58
valve housing
Diffuser Housing
wheel
wheel
switch
T.O. 2G-T62T-43
Figure 5-19A Combustor Liner Assembly, Exploded View
Change 9 5-58A
T.O. 2G-T62T-43
Figure 5-19B. Atomizer Fitting Repair
5-58B Change 9
T.O. 2G-T62T-43
Figure 5-19C. Flow Test of Atomizer Fittings
Change 9 5-58C
T.O. 2G-T62T-43
NOTES:
UNEVEN WEAR PATTERNS ON THE EXTERNAL SPLINE OR EXTERNAL GEAR ARE NOT ACCEPTABLE.
2
3.
4.
5.
6.
THE OIL RETAINER MUST BE LOCATED .13" TO .14" FROM THE EXTERNAL GEAR END AND MUST BE TIGHT.
8.
9.
10.
PARTS WHICH DO NOT MEET THESE REQUIREMENTS
DISPOSITION AT A LATER DATE.
5-58D) Change 9
SHOULD BE TAGGED UNSERVICEABLE
AND HELD FOR
T.O. 2G-T62T-43
d.
Flow Testing.
(1) Flow test fuel nozzle (3, figure 3-28) as
follows:
(a)
Connect flow check fixture, ST92300
(75, figure 2-1) to a fuel manifold
flow bench, 164101-100 (85, figure
2-1).
(b)
Install fuel nozzle (3) in flow check
fixture, ST92300.
warning
Calibrating fluid, MIL-C-7024, type II, is
toxic to eyes, skin, and respiratory tract.
Do not breathe vapors. Use in a wellventilated area. Wear eye and skin protection. Avoid use around sparks, open
flame, and heated surfaces.
(c)
(d)
(e)
(2)
Connect a source of calibrating fluid,
MIL-C-7024, type II, at a pressure of
350 psig, 70-90°F, to fuel nozzle (3).
Minimum fuel flow must be 14-16
pph.
Observe fluid spray from nozzle.
Spray must be conical, symmetrical,
and free of voids and streaks. Verify
that spray angle, when measured 1/2
in. downstream of nozzle, is greater
than 70°.
Replace fuel nozzle if it does not satisfactorily meet test parameters.
Flow test fuel manifold (9, figure 3-28)
as follows:
(a)
Install filter fitting (4, figure 3-28)
in fuel manifold (9).
(b)
Install fuel manifold on fuel manifold
flow bench, 164101-100 (85, figure
2-1) with fuel nozzles directed into
the beakers provided with flow
bench.
Calibrating fluid, MIL-C-7024, type II, is
toxic to eyes, skin, and respiratory tract.
Do not breathe vapors. Use in a well
ventilated area. Wear eye and skin protection. Avoid use around sparks, open
flame, and heated surfaces.
(c)
Use calibrating fluid, MIL-C-7024,
type II, specific gravity of 0.815, at
80°F, as test fluid. Adjust inlet fluid
pressure to 145 psig. Verify that
flow rate is 288-312 pph.
(d) The flow rate from each fuel nozzle
shall not exceed ±4% from the
average.
(e) Test all fuel nozzles. Replace fuel
manifold (9, figure 3-28) if it does not
satisfactorily meet test parameters.
(3) Flow test oil jet cartridge (75, figure
3-12) as follows:
(a) Using oil, grade S 150, per ASTM
2422, flow test oil jet cartridge.
NOTE
All four jets of oil jet cartridge must
flow freely.
(b) Flow test at 0.3-0.5 gpm at 20 psi.
(4) Flow test atomizer fitting (4, figure
5-19A) as follows: (See figure 5-19C.
(a) Using a hydrometer, measure the
specific gravity of test fluid.
NOTE
Atomizer fittings must be free of carbon deposits or other obstructions.
Clean per paragraph 4.3.i.
(b) Using a flow test bench, P/N 164101100, or equivalent, adjust test flow to
45.0 - 46.0 pounds per hour (pph).
With a test fluid specific gravity of
0.78, pressure shall not exceed 2
psig.
( c To adjust variations in test fluid
flow and specific gravity, verify pressure in accordance with the following
formula:
Pressure = Fluid Flow
Specific Gravity x 1294
( d ) Repeat step b. and c. for all atomizer
fittings in each liner.
( e Repair atomizer fitting assemblies
(4, figure 5-19A) if flow test indicates obstruction as follows:
1 Remove grommet (3).
2 Machine off clogged atomizer tube.
Redrill fitting as shown in figure
5-19B.
Clean,
blast, and wrap fitting for
3
brazing.
4 Position tube and brazing onto
atomizer fitting as shown in figure
5-19B.
Change 9 5-59
T.O. 2G-T62T-43
5
e.
Install new grommet per paragraph
5-30.
Functional Test of Oil Pressure Switch.
(e)
Manufacture sleeve from 6A1-4V,
AMS 4928, titanium bar material.
(f)
Inner Diameter (ID) of the sleeve,
prior to installation on the compressor wheel, shall be 1.399-1.400
inches, with a (0.030-0.040 inch) x
(44.5-45.5o) chamfer on the base of
the sleeve ID. Verify ID (measure at
top and bottom) and record in Table
5-6.
WARNING
Lubricating oil, Specification MIL-L7808, may cause skin rash. Do not
breathe vapors. Use in well-ventilated
area. Wear eye protection and gloves.
(1)
Connect oil pressure switch (Figure 3-3,
18) to low pressure source of lubricating
oil, Specification MIL-L-7808.
(2)
With no pressure applied, check that
there is continuity through pins B and
C.
(3)
f.
NOTE
Initial knurl depth may be increased
as required to compensate for material
removed during finish machining of
OD. A 20 knurl/inch pitch is recommended for ease of fabrication.
(g)
Slowly apply pressure and observe
when switch closes (continuity through
pins B and C). Switch shall close at 6
(±1-1/2) psig on increasing pressure.
Turbine Wheel, Engine Compressor Wheel,
and Load Compressor Wheel Repair.
(1)
Repair diamond knurl (Figure 5-20) hub
on engine compressor wheel (Figure 310, 60) as follows:
(a)
Measure runout on length ‘‘B’’ of the
center bore diameter datum B per
Dwg No. (55820) 161636. Maximum
allowable runout is 0.0004 inch with
respect to datum A . Replace wheels
that fail inspection; do not proceed
with sleeve repair.
(b)
Measure end (axial) runout on the
backface of the wheel datum C per
Dwg No. (55820) 161636. Maximum
allowable runout is 0.0002 inch with
respect to datum A . Replace wheels
that fail inspection; do not proceed
with sleeve repair.
(c)
Record engine compressor wheel
S/N, located on the backface of
wheel, in Table 5-6.
(d)
Machine compressor wheel hub, to
remove damaged knurl, to an OD of
1.4015-1.4020 inches and a 0.030
inch max radius at the base, per Figure 5-20. Verify OD (measure at top
and bottom) and record in Table 5-6.
5-60 Change 22
Cold-roll a pattern of 15-25 knurls/
inch into sleeve, per requirements of
Figure 5-20. Cutting of the knurled
pattern is not allowed.
WARNING
ASTM E1417 Fluorescent Penetrant
materials may cause irritation to skin
and eyes. Avoid inhaling powder or
vapors, and use only in well-ventilated
area. Avoid prolonged or repeated contact with skin. Wear nitrile gloves and
safety glasses. Consult the applicable
Material Safety Data Sheet (MSDS)
and local Occupational Safety and
Health (OSH) regulations for additional information.
(h)
Fluorescent penetrant inspect compressor wheel hub OD and sleeve ID
area per ASTM E1417, Type I,
Method A, B or D, Sensitivity Level
3. No defects allowed.
(i)
As required, bag and tag (CAGE
96916) P/N 161636-3 in accordance
with MIL-STD-130. Destructive
etching/marking of the sleeve is not
allowed.
T.O. 2G-T62T-43
.
.
1
Record APU S/N and engine compressor wheel S/N in Table 5-6.
Include a completed copy of Table 56 with the permanent APU records
for historical filing.
2
Record APU S/N and engine compressor wheel S/N in an electronic
database (APU final assembly shop
database may be utilized for this).
Denote that the wheel has a sleeve
repair.
WARNING
Liquid nitrogen is extremely cold and
can injure human skin or tissue on
contact. Liquid nitrogen will expand
696 times as it vaporizes, and if the
liquid vaporizes in a sealed container,
it can produce enormous pressures
that could rupture the vessel. Nitrogen
can displace oxygen in poorly ventilated or confined areas. Boiling and
splashing occurs when filling a warm
container with or when inserting
objects into liquid nitrogen. Perform
these tasks slowly to minimize boiling
and splashing. Use tongs to withdraw
objects immersed in a cryogenic liquid.
Wear chemical splash goggles, face
shield, and approved cryogenic gloves/
outer wear when handling liquid nitrogen. Consult the applicable MSDS and
local OSH regulations for additional
information.
Wear protective gloves when handling
heated parts to avoid injury.
(j)
(k)
(l)
Oven-heat sleeve to 400 (±15)oF for
approximately 30 minutes. Cool compressor wheel in liquid nitrogen for
20-30 minutes. Immediately install
sleeve onto compressor wheel hub
(chamfered ID facing down), ensuring sleeve bottoms out against wheel;
there should be no gap between the
sleeve and the compressor wheel.
Machine sleeve OD to 1.5895-1.5990
inches. Apply the (0.18-0.22 inch) x
(13-17o) chamfer and surface finish
per requirements of Figure 5-20.
Verify OD and record in Table 5-6.
(3)
Glass shotpeen aero surface of engine
compressor wheel (Figure 3-10, 60), turbine wheel (55), and load compressor
wheel (20) as follows:
(a)
Mask knurled area and bores.
(b)
Glass shotpeen per AMS 2430 to an
intensity of ALMEN 0.010-0.012 N,
using size AB shot and pressures not
to exceed 70 psig.
(c)
Peenscan process inspect per Specification MIL-S-13165.
Blade tune engine compressor wheel
(Figure 3-10, 60), turbine wheel (55) or
load compressor wheel (20) as follows:
(a)
Install engine compressor wheel, turbine wheel or load compressor wheel
in vibration analysis tool, ST63939
(Figure 5-21).
(b)
Plug spectrum analyzer, SD340, of
vibration analysis tool, ST63939 (figure 5-21), into power source.
(c)
Select voltage.
(d)
Turn on analyzer. No warmup time
is necessary.
(e)
Secure accelerometer, M93, on vibration analysis tool, ST63939 (Figure
5-21), to steel base plate and plug
cord into SIGNAL connector on analyzer panel.
(f)
Set steel base plate on dense neoprene pad.
(g)
Set analyzer controls as follows:
Verify knurl depth and record in
Table 5-6.
NOTE
A locally assigned S/N for denoting a
repaired wheel is allowed, but not
required. The only authorized inscription method is electro-chemical etch.
Location to be on backface of wheel,
but not on balancing ring. Do not tamper with existing information etched
on back of wheel.
(m)
(2)
The following documentation shall
be provisioned for each knurl repair:
1
Cursor units - Hz
2
Cursor mode - Normal
3
Analysis mode - Peak
4
Start/Stop - Press if ready button
light is steady
5
Display mode - Spect
Change 22
5-60A
T.O. 2G-T62T-43
6
Display Y-gain - LOG 0dB
7
Input frequency range (Hz) - 5K or
10K
8
Input level - 1
9
Sensitivity switch - MV/EU
10
Sensitivity dial - 0707
11
X-gain - X1
(h)
To calibrate frequency pickup, install
tuning fork (known frequency) into
steel base plate (Figure 5-21). Pluck
tuning fork and determine frequency
5-60B Change 22
with cursor. The frequency must be
within ±25 Hz of the known
frequency.
(i)
1
Frequency check engine compressor
wheel (Figure 3-10, 60), turbine
wheel (55) or load compressor wheel
(20) as follows:
Install engine compressor wheel,
turbine wheel or load compressor
wheel on steel base plate, making
sure the wheel is flat on and in
direct contact with the steel base
plate.
TO 2G-T62T-43
Figure 5-20. Repair of Diamond Knurl
5-61
TO 2G-T62T-43
Figure 5-21.
5-62
Blade Tuning
TO 2G-T62T-43
_
2.
If the analyzer was calibrated,
return controls to positions
listed in step (g).
_3.
Pluck blade of engine compressor wheel, turbine wheel,
or load compressor wheel.
_4.
Determine blade frequencies
by moving the cursor to the
peak y-axis values on the
CRT. The first significant
peak left to right is the first
mode, the second is the second mode, and the third
peak is the third mode.
_5.
(j)
Engine compressor wheel long
blades shall have first mode natural frequencies between 19502500 Hz and second mode natural
frequencies which must not fall between 5900 Hz and 6600 Hz.
(k) Load compressor wheel blades
must have a first mode frequency
of 4350-4600 Hz.
(1)
Turbine wheel blades must have a
first mode frequency of 34003650 Hz.
(m) Provided all dimensional requirements are met, the required frequencies can be obtained as follows:
NOTE
Engine compressor wheel long blade second mode natural frequency is the primary
concern. In case conflict arises in corrected first and second mode frequencies, a
0.12 cutback will increase first mode frequency approximately 150 Hz and second
mode frequency approximately 480 Hz.
To increase frequency, cut
back leading edge of long
blades (figure 5-21, view
A-A). Reradius leading edge
and blend with existing hub
radius.
2.
_
To decrease frequency, reduce blade thickness by burnishing, but maintain thickness tolerance.
(n) Thin blades with second mode frequency of 5600-5800 Hz.
(o) Thin or crop blades with second
mode frequency of 5800-5900
Hz, depending upon first mode
frequency.
Clear the CRT prior to the
next blade check by pressing
START/STOP button so that
red light blinks.
_ Proceed with next blade
6.
check.
1.
_
(p) Crop blades with second mode frequency of 5900-6400 Hz.
(4)
Balance engine compressor wheel, turbine wheel, and load compressor wheel
per Section VI - Assembly.
g. Eddy Current Inspection. Eddy current inspection is used for detection of surface or
subsurface discontinuities in holes and/or
bores. An eddy current tester, FD-100 (1,
figure 2-1), or equivalent should be used.
The tester shall be calibrated using eddy current inspection master, 163000 (84, figure
2-1).
(1) Set-Up Procedure.
warning
Properly ground equipment prior to use.
Failure to do so may result in possible electrical shock.
(a) Attach scanner head, power cord,
and probe to eddy current tester,
FD-100 (1, figure 2-1). Ensure
probe is proper size and check for
snug fit in bore.
(b) Install chart paper for recording
tests.
5-63
TO 2G-T62T-43
(h) Insert probe into eddy current inspection master, 163000 (84), and
rest scanner head on eddy current
tester, FD-100 (1). Adjust meter
needle to 50 using balance control.
(c) Turn panel power and mode selector switches to “ON” position and
allow equipment to warm up for
15 minutes.
(2) Set eddy current tester, FD-100 (1,
figure 2-1) function controls as follows:
(a) Mode selector - Low
(i)
Scan bore of eddy current inspection master, 163000 (84), and observe stylus deflection on chart paper.
(j)
System is now ready for inspection.
(b) Sensitivity - 12:00 position
(c) Filter - 50 rpm
(d) Scanner rpm - 50
(e) Chart:
OFF - Calibration
AUTO - Scanning
ON - Paper feed
(f)
Chart speed - Slow
(g) Zero - 5K or 10K
(h) Heat - As required for legible
trace
NOTE
Do not change controls after set-up is established, except for “zero” stylus adjustment. Zero stylus control is to be used to
“mark” chart paper before and after each
scanning sequence. The length of all scan
charts must be within ±0.500 in. of eddy
current inspection master, 163000, chart.
( i ) Balance - Zero
(k)
(j) Lift off/frequency - Zero
(3) Calibrate eddy current tester, FD-100
(1, figure 2-1) as follows:
(a) Position eddy current inspection
master, 163000 (84, figure 2-1) in
eddy current tester, FD-100 (1)
with backface up.
(b) Extend probe to maximum extended position.
(c) Turn balance control to 0.50 (approximately).
(d) Place probe coil on flat surface of
eddy current inspection master,
163000 (84).
(e) Turn lift off/frequency control until meter needle is at “NULL” position.
( f ) Remove probe from eddy current
inspection master, 163000 (84),
and readjust balance control to
bring needle on scale.
(g) Retract probe.
5-64
Scan eddy current inspection master, 163000 (84), before and after
each test and periodically during
inspection (not to exceed 8
hours). Record date and times on
calibration run.
NOTE
If any periodic scan does not conform to
requirements, recalibrate equipment.
(4)
Inspection procedure for turbine wheel
(55, figure 3-10)
(a) Visually examine turbine wheel
and ensure bore is clean and free
of foreign material.
(b) Install turbine wheel in top ring of
eddy current holder, ST64037
(15, figure 2-1), with backface
up.
(c) With probe in retracted position,
place probe in bore of turbine
wheel and check for proper alignment. Verify recorder stylus is
centered.
T.O. 2G-T62T-43
(d)
Eddy current inspection of center
bore is to be performed for entire
length of bore except for 0.250
(±0.125) inch from each end.
(5)
(e)
Scan bore to extended probe position.
(f)
Remove probe and turn turbine
wheel over.
Be careful not to thin metal when dry
blasting.
(g)
Place probe in turbine wheel bore
and check for proper alignment.
(h)
Scan bore to retracted probe position.
(i)
Remove scanner head and turbine
wheel from eddy current holder,
ST64037 (Figure 2-1, 15).
(j)
(k)
h.
CAUTION
(6)
(2)
Use protective gloves when handling
heated parts to avoid injury.
Review trace for any obvious indication of cracks. Typical indication of a
crack would display a signal-to-noise
ratio of 3:1.
(3)
WARNING
Use protective gloves when handling
heated parts to avoid injury.
(4)
Put turbine nozzle into an oven maintained at 250oF for one hour. Remove
turbine nozzle from oven and allow to
cool.
Preheat turbine nozzle in an oven maintained at 250oF.
(8)
Plasma spray as follows:
Mask part for metal spraying.
NOTE
Ensure parent material thickness is
0.100 inch minimum.
Machine to reduce diameter of turbine
nozzle assembly (Figure 3-10, 2) by
0.020-0.024 inch at dimensions D and F,
Figure 5-7.
Remove nicks, scratches, erosion or rub
marks per Section 5-3a with abrasive
crocus cloth, A-A-1206.
(7)
(a)
After completion of test, switch panel
and mode selector switch to ‘‘OFF’’.
Clean turbine nozzle assembly ultrasonically with aqueous cleaner, Specification MIL-C-87937, diluted to manufacturer specifications.
Dry blast machined outside diameter
with coarse-grit aluminum oxide.
WARNING
Turbine Nozzle Repair.
(1)
Mask part for dry blasting.
i.
(b)
Plasma spray abraded coat using
welding power, Metco 443 NS or
equivalent per AMS 2437 to a coating thickness of 0.020-0.060 inch
(c)
Machine to dimensions D and F, Figure 5-7.
Repair of Reduction Drive Housing Sleeves.
(1)
Check sleeves (Figure 3-12, 97 and 137)
in reduction drive housing (142) to
make sure it is within limits (Figure 522), in proper position, is not loose or
damaged on inside diameter of surface.
If necessary, remove sleeve (Figure 312, 137) and repair. If necessary, manufacture new sleeve (137) per Drawing
(96916) 1B2270. Maximum dimension of
bore for new sleeve (137) is 2.330 inch.
Interference fit between sleeve and
housing shall remain at 0.0035 to
0.0055 inch.
Change 22
5-65
T.O. 2G-T62T-43
inch. Materials shall be AISI 4130 or
4340. Heat treat to 125-145 ksi, 26-32
HRC, per AMS 2759. Phosphate coat
sleeves per Specification MIL-P-16232,
Type M.
WARNING
Chemical conversion coating, Specification MIL-C-81706, type III, is toxic
and flammable.
Do not breathe
vapors. Use in well-ventilated area.
Wear eye protection and gloves. Avoid
contact with skin. After preparation,
wash hands and face thoroughly.
(2)
Apply chemical conversion coating,
Specification MIL-C-81706, type III, per
Specification MIL-C-5541 to opening in
housing (142).
(3)
Apply sealant, Specification MIL-S22473, grade A, to new sleeve (Figure 312, 137) and install in housing (142).
(4)
Drill hole in sleeve (137) and reduction
drive unit housing (142) (Figure 5-22)
and install pin (Figure 3-12, 136).
Machine pin (136) flush with inside
diameter (ID) of sleeve (137).
(5)
j.
.
.
WARNING
Blacklights emit UV-A (ultraviolet)
radiation. Overexposure to UV-A radiation can cause premature skin aging
and may cause skin cancer and cataracts. The required intensity for this
process is above the threshold limit
value for UV-A radiation at 15 tested.
Wear long sleeve clothing, ultraviolet
protective safety glasses, and gloves.
(2.1)
Magnetic particle inspect per ASTM
E1444. Reject for cracks or indications
extending over an edge.
(3)
With carrier assembly (60) or cover (63)
warm (up to 300oF), apply sealant,
Specification MIL-S-22473, grade A, to
new sleeve (73 or 74) and install in
either carrier assembly or cover. Press
sleeve in bore of component to a full
depth until sleeve firmly seats.
(4)
Finish grind/machine bore depth and
inside diameter of sleeve to dimensional
requirements of Figure 5-23. Machine
snap ring groove into sleeve (75) per
Drawing (55820) 161779.
Grind ID of sleeve (137) to dimensional
and finish requirements (Figure 5-22).
Replacement of Carrier Assembly Sleeves.
WARNING
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
Wear protective gloves when handling
heated parts to avoid injury.
(1)
(2)
Heat carrier assembly (60) or cover (63)
to 300oF and place dry ice, CGA G6.2, in
sleeves (73 or 74) to facilitate pressing
sleeves from either carrier assembly or
cover.
If necessary, manufacture new standard
or oversized sleeve (Figure 5-23) to provide an interference fit of 0.002-0.004
5-66 Change 22
WARNING
Chemical conversion coating, Specification MIL-C-81706, type III, is toxic
and flammable.
Do not breathe
vapors. Use in well-ventilated area.
Wear eye protection and gloves. Avoid
contact with skin. After preparation,
wash hands and face thoroughly.
(5)
Touch up with chemical conversion
coating, Specification MIL-C-81706,
type III, per Specification MIL-C-5541,
all machined surfaces.
T.O. 2G-T62T-43
j1.
.
.
Replacement of Carrier Assembly Oil Jet
Ring.
WARNING
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
Wear protective gloves when handling
heated parts to avoid injury.
(1)
Heat carrier assembly (Figure 3-12, 60)
to 350oF and cool oil jet cartridge (75)
with dry ice.
WARNING
ASTM D 5363 AN0151 sealant may
cause eye and skin irritation. Wear
gloves and safety glasses. Consult the
applicable MSDS and local OSH regulations for additional information.
(2)
Apply sealant, ASTM D 5363 AN0151,
Grade A, to the contact surfaces of the
oil jet cartridge (75). Use sealant sparingly, ensuring that no excess sealant
enters oil cavity.
(3)
Press oil jet cartridge (75) into carrier
assembly (60), ensuring oil jet cartridge
(75) is fully seated in housing. Ensure
that each of the three prongs of the oil
jet cartridge face into the metal webs of
the housing and not towards the three
bearing bore bushings, as per HamiltonSundstrand Drawing No. 161779-101.
(4)
With oil jet cartridge (75) installed,
locate and machine drill a new 1/32 inch
retaining pin hole 120 (±15) degrees
right or left from previous hole. Do not
drill into metal web with oil passage. If
both metal webs have been previously
used, replace housing. Previously used
oil jet cartridges will have an existing
hole, which can be used as a pilot hole
for the drill. New oil jet cartridges will
require a newly drilled hole. Housings
with new oil jet cartridges shall be
drilled as an assembly in one operation.
k.
(5)
Install new spring pin (76) into drilled
hole.
(6)
Flow test carrier assembly per Table 53d(3).
Replacement of Housing Carrier Liners and
Pipe Plugs.
(1)
Heat housing carrier (Figure 3-12, 77)
up to 300oF and press housing liner (96)
and pipe plugs (81) from housing carrier. Discard housing liner (96) and
pipe plugs (81).
WARNING
Cleaning solvent, MIL-PRF-680, Type
II or III, is toxic and flammable. Do
not breathe vapors. Use in well-ventilated area. Wear goggles and solventresistant gloves.
(2)
Clean bores of housing carrier (77)
using a brush, Specification MIL-B15319, type I, class 2, or equivalent and
cleaning solvent, MIL-PRF-680, Type II
or III.
(3)
After cleaning, dichromate treat bores
and oil passages of housing carrier (77)
per subparagraph p.
WARNING
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
(4)
Cool a new housing liner (96) in dry ice
or liquid nitrogen for 1 hour minimum
and heat housing carrier (77) in an oven
maintained at 250-300oF for 1 hour
minimum.
(5)
Apply a coat of structural adhesive, EC1386, or equivalent to lip of housing
liner (96) and press into housing carrier
(77) until lip of housing liner is seated.
Cure 1 hour in an oven maintained at
340-360oF.
Change 22 5-66A/(5-66B blank)
T.O. 2G-T62T-43
Figure 5-22.
Repair of Reduction Drive Unit Housing Sleeves
Change 22
5-67
T.O. 2G-T62T-43
Figure 5-23.
5-68 Change 22
Manufacture of Carrier Assembly Sleeves
T.O. 2G-T62T-43
(6)
Install pipe plugs (81) in housing carrier
(77).
Ensure that oil inlet port is
plugged and that oil ejector hole is
capped.
WARNING
ASTM D 5363 AN0151 sealant may
cause eye and skin irritation. Wear
gloves and safety glasses. Consult the
applicable MSDS and local OSH regulations for additional information.
WARNING
When using compressed air for cleaning or drying, regulate pressure not to
exceed 30 psi. Wear eye protection.
(7)
(8)
l.
.
.
Apply compressed air of 20 psi or more
to oil inlet port and check for leakage at
lip of housing liner (96). If leaking
occurs, apply structural adhesive, EC1386, or equivalent around housing
liner (96) and cure for 1 hour in an oven
maintained at 340-360oF. Recheck for
leakage.
(4)
With bevel gear support (40) warm (up
to 300oF), apply either retaining compound 680 or sealant, ASTM D 5363
AN0151, to new liners (42 or 43) and
install in bevel gear support. Press
liners in bore of component to a full
depth until liners firmly seat.
(5)
Install pin (41) and machine flush with
inside diameter of liner (42).
Machine housing liner (96) to 0.9070.912 depth (Figure 5-24, dimension A).
WARNING
Replacement of Bevel Gear Support Liners.
Blacklights emit UV-A (ultraviolet)
radiation. Overexposure to UV-A radiation can cause premature skin aging
and may cause skin cancer and cataracts. The required intensity for this
process is above the threshold limit
value for UV-A radiation at 15 tested.
Wear long sleeve clothing, ultraviolet
protective safety glasses and gloves.
WARNING
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
(6)
Magnetic particle inspect per ASTM E
1444.
(7)
Finish grind/machine bore depth and
inside diameter of liners (42 and 43) to
dimensional requirements of Figure 525.
Wear protective gloves when handling
heated parts to avoid injury.
(1)
(2)
(3)
Heat bevel gear support (Figure 3-12,
40) to 300oF and place dry ice, CGA G6.2, or liquid nitrogen, A-A-59503, in
liners (42 or 43) to facilitate pressing
liners from bevel gear support.
If necessary, manufacture new liners
from AISI 4130 per Figure 5-25 or
Drawing (96916) 1B2270.
Dichromate treat bevel gear support
(Figure 3-12, 40) per Specification MILM-3171, type III, before installing liners
(42 or 43).
m.
Turbine Ignition Exciter Functional Test.
(1)
Equipment used to perform the functional test shall consist of the following:
(a)
DC power supply - variable voltage
(b)
Range of 0-30 Vdc (minimum)
(c)
Igniter plug (Figure 3-5, 39)
(d)
Ignition cable (Figure 3-5, 27)
Change 22
5-69
T.O. 2G-T62T-43
Figure 5-24.
5-70
Change 18
Manufacture of Housing Liner
T.O. 2G-T62T-43
Figure 5-25.
Manufacture of Bevel Gear Support Liners
Change 22 5-70A/(5-70B blank)
T.O. 2G-T62T-43
Figure 5-25.1.
Repair of Bevel Gear Support Housing
Change 22
5-71
T.O. 2G-T62T-43
(2)
(3)
(e)
DC ammeter - current range of 0-5A
(f)
Test leads
Limits for the turbine ignition exciter
are as follows:
(a)
Input voltage - 14-30 Vdc
(b)
Input current (maximum) - 1.0 A
(c)
Spark rate - 2.7/sec minimum at 14
Vdc
(d)
Duty cycle - 1 minute on, 5 minutes
off
(e)
Polarity - Pin B (+), Pin A (-)
(b)
Connect circuit.
(c)
Apply voltage and observe operation.
Acceptable operation consists of
proper spark rate (2.7/sec) and input
current below maximum allowable
value (1.0 A).
(d)
(a)
Clean combustor housing (Figure 328, 17) or combustor liner (15) per
Section IV - Cleaning.
(b)
Remove any oxide layer or scale
using a stainless steel wire brush to
brush down to bare shiny metal the
brazed areas to be repaired.
Methyl-ethyl-ketone, TT-M-261 and
acetone, O-A-51, are toxic and flammable. Do not breathe vapors. Use in
well-ventilated area. Wear face protection and rubber gloves.
.
.
NOTE
Braze repair areas must be free of oil,
grease, dirt, scale, artificial oxide films
or any other foreign substance.
Do not use flux.
Turn off power supply.
(c)
Clean local area of braze repair using
acetone, O-A-51.
(d)
Braze repair cracked area using
tungsten arc process, with inert
welding gas, and filler material per
AMS 4777. Use minimum heat to
perform repair.
(e)
Inspect repaired braze area by fluorescent penetrant inspection, MILSTD-6866, type I, method A. Acceptance criteria per MIL-STD-1907,
Table III, grade C.
(f)
If any cracks or incomplete repair
areas are detected, repeat previous
steps and reinspect.
(g)
Check dimensions of combustor
housing on inspection fixture,
ST62880 (Figure 2-1, 10).
(h)
Check dimensions of combustor liner
on inspection fixture, ST61404 (Figure 2-1, 9).
Operation at maximum voltage (30
Vdc).
(a)
n.
Set power supply to the minimum
input voltage (14 Vdc) and current
limiter to maximum input current
valve (1.0 A).
Tungsten Arc Braze Repairs.
WARNING
Operation at minimum voltage (14 Vdc).
(a)
(4)
(1)
Set power supply to the maximum
input voltage (30 Vdc) and current
limiter to the maximum input current value (1.0 A).
(b)
Connect circuit.
(c)
Apply voltage and observe operation.
Acceptable operation consists of
proper spark rate (2.7/sec) and input
current below maximum allowable
value (1.0 A).
(d)
Turn off power supply.
(e)
Disconnect test circuit.
Repair of Combustor Housing and Combustor Liner. Cracks or holes in welded or
brazed areas may be repaired using either
tungsten arc braze or vacuum furnace braze.
Cracks in brazed area can be repaired by
brazing per AWS C3.6 using brazing alloy
per AMS 4777.
5-72 Change 22
(2)
Vacuum Furnace Braze Repairs.
(a)
Clean combustor housing or combustor liner per Section IV - Cleaning.
T.O. 2G-T62T-43
Figure 5-26.
Inspection of Air Inlet Housing
Change 18
5-72A
T.O. 2G-T62T-43
Figure 5-27.
5-72B
Change 18
Inspection of Load Compressor Wheel Seal
T.O. 2G-T62T-43
WARNING
Methyl-ethyl-ketone, TT-M-261 and
acetone, O-A-51, are toxic and flammable. Do not breathe vapors. Use in
well-ventilated area. Wear face protection and rubber gloves.
.
.
NOTE
Braze repair areas must be free of oil,
grease, dirt, scale, artificial oxide films
or any other foreign substance.
(a)
Clean combustor housing per Section
IV - Cleaning.
(b)
Remove damaged fitting from combustor housing.
(c)
Place Thermocouple fitting, P/N
(55820) 24003-1, inside hole. Fitting
may be removed from P/N 24003-0 or
manufactured from stainless steel
rod QQ-S-763, Type 347 per drawing,
P/N (55820) 161637.
(d)
Weld fitting to plate using AWS A5.9
(ER 347) or AMS 5680 (347) with 1/
16" fillet.
Do not use flux.
(3)
(b)
Clean local area of braze repair using
acetone, O-A-51.
(c)
Using a circular or semi-circular pattern, apply Stop-Off within 1/2 inch
of the area to be braze repaired to
prevent excess flow of braze.
(d)
Load braze filler material, BNI-2 per
AMS 4777, to cover braze cracks
using an eye dropper or equivalent.
(e)
Vacuum furnace braze per AWS
C3.6. Brazing temperature range
shall be 1950 (±25)oF.
(f)
Braze repair areas shall conform to
the requirements of AWS C3.6.
(g)
Visually inspect repaired areas using
a 10x magnifier.
(h)
Inspect repaired braze area by fluorescent penetrant inspection, MILSTD-6866, type I, method A. Acceptance criteria per MIL-STD-1907,
Table III, grade C.
WARNING
Fluorescent Penetrant, ASTM E1417,
is toxic and can cause injury to skin
and eyes. Avoid inhaling powder or
vapors, and use only in well-ventilated
area. Avoid prolonged or repeated contact with skin. PPE: gloves and
goggles.
(e)
o.
Fluorescent penetrant inspect per
ASTM E1417, using Type I, Sensitivity Level 3 or 4 materials. No indications permitted.
Igniter Plus Grommet Installation. Install
new igniter plug grommet (Figure 3-28, 18),
new washers (19), and new spring (20) in
combustor liner as follows:
(1)
Install igniter plug grommet (18) with
flange of grommet inside combustor
liner (16).
(2)
Hold igniter plug grommet (18) in position and insert clevis of flaring fixture,
ST91064 (Figure 2-1, 74), through the
grommet.
(3)
Install washers (Figure 3-28, 19) and
spring (20) over igniter plug grommet
(18).
(i)
If any cracks or incomplete repair
areas are detected, repeat previous
steps and reinspect.
(j)
Clean combustor housing or combustor liner per Section IV - Cleaning, to
remove penetrant and Stop-Off.
(k)
Check dimensions of combustor
housing on inspection fixture,
ST62880 (Figure 2-1, 10).
WARNING
(l)
Check dimensions of combustor liner
on inspection fixture, ST61404 (Figure 2-1, 9).
Lubricating oil, Specification MIL-L7808, may cause skin rash. Do not
breathe vapors. Use in well-ventilated
area. Wear eye protection and gloves.
Weld repair to Thermocouple boss for
combustor housing (Figure 3-28, 17).
Change 22
5-73
T.O. 2G-T62T-43
(4)
Apply a light coat of lubricating oil,
MIL-L-7808, to tapered end of f laring
f ixture, ST91064 (74, f igure 2-1).
(5)
Place cone on clevis of f laring f ixture,
ST91064 (74).
III and V, class 1A, per MIL-C-5541
to carrier assembly, bevel gear support assembly, reduction drive housing, and housing carrier reworked or
exposed surfaces.
(c)
Apply black oxide coating per MIL-C13924, class I, to straight drive shaf t
reworked or exposed surfaces.
(d)
Apply anodize per MIL-A-8625, type
II, class I, to diffuser housing assembly reworked or exposed surfaces.
CAUTION
To ensure correct insertion of igniter
plug, the igniter plug grommet must
move freely; therefore, do not overf lare grommet.
(6)
(7)
Unscrew nut and remove f laring f ixture
ST91064 (74, f igure 2-1), from combustor liner (16, f igure 3-28).
(8)
Check igniter plug grommet (18) to
ensure it moves freely, and f lare is
enough to retain it in the combustor
liner (16).
(9)
p.
Install nut on clevis of f laring f ixture,
ST91064 (74). While holding handle of
shank, use wrench and tighten nut until
the cone f lares the igniter plug grommet (18, f igure 3-28) over the washers
(19) and the spring (20).
Check that diameter of igniter plug
grommet (18) across top of f lare is
0.59-0.65 in.
(2)
Repair painted exterior surfaces as
follows:
WARNING
Epoxy polyamide primer, MIL-P23377, type II, and epoxy polyamide
paint, MIL-C-22750, class I, type I, are
toxic and f lammable. Do not breathe
vapors. Use in well-ventilated area.
Wear face protection and rubber
gloves.
NOTE
Do not paint holes, threads, internal
surfaces, or machined surfaces.
(a)
Apply one coat of epoxy primer,
MIL-P-23377, type I, class C or N, or
water
borne
epoxy
primer,
MIL-P-85582, type I, class 2 to component. Allow primer to dry for 4
hours.
(b)
Apply two coats of epoxy polyamide
paint, MIL-C-22750, class I, type I,
to component. Allow 4 hour drying
time between coats of paint and 24
hour curing time af ter painting.
Treatment of Surfaces and Metals.
(1)
Treat reworked and exposed surfaces as
follows:
WARNING
Chemical
conversion
coating,
MIL-C-81706, type III, is toxic and
f lammable. Do not breathe vapors.
Use in well-ventilated area. Wear eye
protection. Avoid contact with skin.
(a)
(b)
5-74
Apply chemical conversion coating,
MIL-C-81706, type III, class 1A, per
MIL-C-5541 to inlet housing assembly, hourmeter junction box, housing
by-pass valve, adapter assembly, and
diffuser housing assembly reworked
or exposed surfaces.
Dichromate treat per MIL-M-3171,
type I or VI, or apply chemical conversion coating MIL-C-81706, type
Change 17
WARNING
Sealant, MIL-C-81733, type III, is
toxic.
Use rubber or polyethylene
gloves. Wash hands thoroughly with
soap and water before eating or
smoking.
(c)
Apply sealant, MIL-C-81733, type
III, to housing carrier (77, f igure
3-12).
T.O. 2G-T62T-43
(d)
(3)
Paint and treat exterior surface corrosion on adapter assembly, reduction drive housing, and housing
bypass valve with Specification MILC-83285.
Table 5-5 lists cleaning, treatment, finish and preservation of metals used in
the APU and their areas of application.
applicable MSDS and local OSH regulations for additional information.
(4)
Mask and chemically strip any remaining anodize coating from 1.800 inch
bore.
(5)
Thoroughly
housing.
(6)
Machine inside bore on the first bearing
landing to make concentric with lower
bearing bore in accordance with Hamilton-Sundstrand
Drawing
(55820)
161327. Thoroughly clean area to be
anodized and protect non-anodized
surfaces.
WARNING
Lubricating oil, MIL-PRF-7808, may
cause skin rash. Do not breathe
vapors. Use in well-ventilated area.
Wear eye protection and gloves.
q.
r.
Preserve the accessory gear and gear planet
set with either preservation oil, MIL-PRF6081, grade 1010, or lubricating oil, MILPRF-7808.
Repair of Air Inlet Housing Bore.
(1)
Remove locking pin and retain for
reuse.
WARNING
ASTM E1417 Fluorescent Penetrant
materials may cause irritation to skin
and eyes. Avoid inhaling powder or
vapors, and use only in well-ventilated
area. Avoid prolonged or repeated contact with skin. Wear nitrile gloves and
safety glasses. Consult the applicable
MSDS and local OSH regulations for
additional information.
(2)
Fluorescent penetrant inspect bore in
the locking pin area per ASTM E1417
using Type I, Method C, Sensitivity
Level 3 materials. No cracks allowed.
(3)
Aqueous clean air inlet housing using
procedures outlined in Section IV.
cold
water
rinse
the
WARNING
Specification MIL-A-8625 Anodizing
Solution may burn eyes or skin. Avoid
contact. Highly reactive; avoid contact
with any other chemicals. Use in a
well-ventilated area. PPE: chemical
resistant gloves, chemical splash goggles, and face shield. Consult to applicable MSDS and local OSH regulations
for additional information.
(7)
Apply a Type III anodize per AMS-A8625 (formerly Specification MIL-A8625) to the first carrier bearing landing
machined surface, using one of the following techniques:
WARNING
Specification MIL-A-8625 Anodizing
Solution may burn eyes or skin. Avoid
contact. Highly reactive; avoid contact
with any other chemicals. Use in a
well-ventilated area. PPE: chemical
resistant gloves, chemical splash goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
WARNING
(a)
Isoprep 184 may burn eyes or skin on
contact. Prolonged contact with eye
can cause blindness. Inhalation can
cause respiratory tract irritation. For
protection, wear chemical goggles and
chemical protective gloves. Consult the
For housings that do not exceed
1.802 inch diameter, either brush or
tank anodize per AMS-A-8625 to
1.7996 to 1.8003 inch.
(b)
For housings with diameter of 1.802
to 1.804 inches, tank anodize per
AMS-A-8625 to bring diameter down
to 1.7996 to 1.8003 inches.
Change 22
5-75
TO 2G-T62T-43
(8)
Thoroughly cold water rinse the anodized area.
(9)
Demask housing and thoroughly rinse
to remove any remaining anodize
residue.
(10)
Install locking pin.
(11)
Alternate air inlet housing bore repair
process.
(a)
(b)
Set up and indicate housing in accordance with the callout for datum feature D in accordance with Drawing
(55820) 161327.
s.
Machine upper bore A, as required to
remove existing hard anodize, to a
maximum dimension of 1.806 inches.
To the extent possible, maintain
runout and perpendicularity in
accordance with Drawing (55820)
161327. If bore does not clean up at
1.806 inches, place housing on MRB.
NOTE
If bore B falls within the required ID of
1.7997 to 1.8003 inches, no processing
of bore B is required.
(c)
(d)
Machine lower bore B, only as
required, to a maximum dimension
of 1.806 inches. To the extent possible, maintain runout and perpendicularity in accordance with Drawing
(55820) 161327. If bore does not
clean up at 1.806 inches, condemn
housing.
Measure ID of bores A and B. Record
both dimensions for use during the
brush nickel process.
t.
WARNING
Nickel plating solution can cause irritation and burns to the skin and eyes.
Skin contact can cause sensitivity and
allergic reaction. Mist can cause
respiratory irritation if inhaled.
Repeated, long term overexposure may
cause cancer. Wear nitrile gloves,
chemical splash proof goggles, face
shield and apron. Consult the applicable Material Safety Data Sheet
(MSDS) and most recent industrial
hygiene
survey
for
additional
information.
5-76 Change 25
(e)
Apply brush nickel coat in accordance with MIL-STD-865 to bores A
and B to achieve an ID slightly below
the required 1.7997 to 1.8003 inches
to allow for final machine cleanup.
(f)
Machine bores A and B to requirements of Drawing (55820) 161327.
Final ID shall be 1.7997 to 1.8003
inches.
(g)
Re-install locking pin.
Repair of Rotor Shaft (Figure 3-10, 59) Bearing Journals.
(1)
Grind bearing journals (Figure 5-5, A
and D) as required to obtain a diameter
of 0.6593 to 0.6651 inch. Grind radius
shall be 0.062 to 0.125 inch. Concentricity shall be maintained within 0.0005
inch.
(2)
Magnetic particle inspect bearing journals per ASTM E1444.
(3)
Shotpeen ground bearing journals with
0.0138 to 0.0280 inch diameter (S-170)
shot 0.007 to 0.014 A2 intensity.
(4)
Chrome plate ground bearing journals
in accordance with Federal Specification
QQ-C-320 to obtain a diameter of 0.6691
to 0.6693 inch after finish grinding.
(5)
Bake at a temperature of 260 to 290oF
for 5 hours.
(6)
Finish grind bearing journals as
required to meet dimensional, concentricity, and surface finish requirements
of drawing (55820) 161504.
(7)
Magnetic particle inspect finished shaft
per ASTM E1444.
Repair of Rotor Shaft (Figure 3-10, 59) Load
Compressor Journal.
(1)
Grind load compressor journal (B, Figure 5-5) as required to obtain a diameter of 0.6701 to 0.6759 inch. Grind
radius shall be 0.062 to 0.125 inch. Concentricity shall be maintained within
0.0005 inch.
(2)
Magnetic particle inspect load compressor journal per ASTM E1444.
(3)
Shotpeen ground load compressor journal with 0.0138 to 0.0280 inch diameter
(S-170) shot 0.007 to 0.014 A2 intensity.
TO 2G-T62T-43
(4)
(5)
Bake at a temperature of 260 to 290oF
for 5 hours.
(6)
Finish grind load compressor journal as
required to meet dimensional, concentricity, and surface finish requirements
of drawing (55820) 161504.
(7)
u.
Magnetic particle inspect finished shaft
per ASTM E1444.
Repair of Rotor Shaft (Figure 3-10, 59) Labyrinth Seal Journal.
(1)
v.
Chrome plate ground load compressor
journal in accordance with Federal
Specification QQ-C-320 to obtain a
diameter of 0.6799 to 0.6801 inch after
finish grinding.
Grind labyrinth seal journal (Figure 55, C) as required to obtain a diameter of
1.1005 to 1.1055 inch. Grind radius
shall be 0.062 to 0.125 inch. Concentricity shall be maintained within 0.0005
inch.
dimension of 4.261-4.263 inches and a
surface finish of AA125 to AA250.
(2)
Aqueous degrease housing for 20 to 30
minutes in accordance with NA 01-1A509.
WARNING
Fluorescent Penetrant, ASTME-1417,
is toxic and can cause injury to skin
and eyes. Avoid inhaling powder or
vapors, and use only in well-ventilated
area. Avoid prolonged or repeated contact with skin. PPE: gloves and
goggles.
(3)
Fluorescent penetrant inspect per
ASTM E1417, using Type I, Sensitivity
Level 3 materials. No cracks allowed.
(4)
Oven bake housing at 250oF for 2 hours.
(2)
Magnetic particle inspect labyrinth seal
journal per ASTM E1444.
WARNING
(3)
Shotpeen ground labyrinth seal journal
with 0.0138 to 0.0280 inch diameter (S170) shot 0.007 to 0.014 A2 intensity.
Wear protective gloves when handling
heated parts.
(4)
Chrome plate ground labyrinth seal
journal in accordance with Federal
Specification QQ-C-320 to obtain a
diameter of 1.1095 to 1.1105 inch after
finish grinding.
(5)
Bake at a temperature of 260 to 290oF
for 5 hours.
(6)
Finish grind labyrinth seal journal as
required to meet dimensional, concentricity, and surface finish requirements
of drawing (55820) 161504.
(7)
Magnetic particle inspect finished shaft
per ASTM E1444.
Repair of Reduction Drive Housing (Figure
3-10, 142).
(1)
Machine the ID (6.000 to 6.001 inches)
by 0.900 to 0.920 inch deep to a dimension of 6.024 to 6.030 inches and surface
finish of AA250 and the ID (4.250-4.249
inches) by 0.980-1.040 inches deep to a
(5)
With the exception of the machined surface, mask all areas for grit blast. Plug
all oil passages.
WARNING
Aluminum Oxide Powder may release
toxic materials during abrasive blasting. Avoid exposure to skin and
breathing of dust. Ensure dust is contained in blasting cabinet. Allow ventilation to clear dust before opening cabinet door. Wear safety glasses and
hearing protection during glove-box
blasting. Consult local industrial
hygiene
survey
for
additional
information.
(6)
Blast the machined surfaces using 20grit aluminum oxide (Metcolite C) or
equivalent.
Change 25
5-77
TO 2G-T62T-43
w.
WARNING
HFE does not have established occupational exposure limits. It is not
expected to cause adverse health
effects under normal conditions. However, as with any chemical, exposure
should be avoided. This material is
very volatile and should be used only
with adequate ventilation. Inhalation
of this material can cause absorption of
fluoride. Safety glasses and gloves are
recommended during use. Consult the
applicable MSDS and more recent
industrial hygiene survey for more
information.
(6.1)
Vapor Degrease housing prior to metal
spray. Do not handle or contaminate
machined surfaces.
(7)
Mask the part for metal spraying.
(8)
Mount the part in a fixture for rotation.
Replacement of Retaining Ring (Figure 3-5,
37) Silicone Pads.
(1)
Adhesive and/or silicone padding residue must be removed. Ensure that the
surfaces of the containment rings are
free of dirt and oil. Clean surface area
with isopropyl (rubbing) alcohol. Apply
alcohol with a clean, lint-free cloth.
(2)
Existing silicone pads may be reattached if they are not brittle or excessively cracked. If new pads are required,
they are to be cut from Silicone Rubber
Sheeting (0.3125-inch thickness), P/N
M46089MSE3, NSN 9320-01-192-3040,
or ASTM D1056, Grade 2D3, 0.3125
inch thick. Silicone Pads, P/N (96916)
IC3556-1, IC3556-2, and IC3556-3, are
to be cut in accordance with Drawing
No. (96916) 1C3556.
(3)
Treat surface of silicone rubber with
180-grit sandpaper in order to create a
rough surface to improve adhesion.
Clean padding with ispropyl (rubbing)
alcohol, TT-I-735. Apply alcohol with a
clean, lint-free cloth.
WARNING
Aluminum/Nickel powder may cause
skin dermatitis and eye irritation.
Nickel is a suspected carcinogen, don’t
permit spray dust to enter eyes, mouth
or open wounds. PPE: NIOSH
approved respirator, aluminized gloves
and goggles.
(9)
Rotate the part and plasma spray the
prepared surface with aluminum nickel
powder (Metco 450, or equivalent).
(10)
Build the prepared surface to 0.030 inch
oversize.
(11)
Clean all masking material from the
part.
NOTE
For machining, use hard alloy tool
(Kenametal No. 7 or harder) at surface
speed to 10 to 20 feet per minute and a
maximum feed of 0.002 inch per
revolution.
(12)
Machine the part to applicalbe dimensional requirements of Drawing (55820)
161781-103.
(13)
Inspect to the requirements of drawing,
(55820) 161781-103.
5-78 Change 25
WARNING
RTV-3145 Electrical Insulating compound is an irritant to skin and eyes.
PPE: safety glasses, butyl rubber
gloves, and good ventilation. Consult
the applicable MSDS and local OSH
regulations for appropriate safety
precautions.
(4)
Apply a thin coat of RTV-3145 High
Temperature Adhesive or GE Silicone
Adhesive to one surface of each silicone
pad.
(5)
Attach silicone pads to inner surface of
containment ring extension at 60degree intervals in accordance with
Sundstrand Drawing No. (55820)
168347.
(6)
Hold silicone pads in place with either
tape or clamps in order to prevent pads
from detaching from the containment
ring while drying. Allow 24 hours curing
time.
TO 2G-T62T-43
x.
Repair of Accessory Gear (Figure 3-12, 120).
NOTE
Subject gears shall not be repaired if
new gears are available. If gears
become available, make buy vs. repair
decision for all worn/damaged gears
before performing repairs.
(1)
(3)
WARNING
Grind the internally splined end of
Accessory Gear, P/N 163057-101, as
required to remove scoring to a diameter of 0.440 (+0.0220/-0.0025) inch and
grind length of 0.400 (±0.005) inch, measured from the internally splined end of
the shaft. Grind radius shall be 0.062 to
0.125 inch. Concentricity shall be maintained within 0.0005 inch. Gear shall be
scrapped if scoring still exists beyond
0.4375 inch diameter.
Nickel plating solution can cause irritation and burns to the skin and eyes.
Skin contact can cause sensitivity and
allergic reaction. Mist can cause
respiratory irritation if inhaled.
Repeated, long-term overexposure may
cause cancer. Wear nitrile gloves,
chemical splash-proof goggles, face
shield, and apron. Consult the applicable MSDS and most recent industrial
hygiene
survey
for
additional
information.
(4)
Hard Nickel Sulfamate plate ground
shaft surface in accordance with Local
Processing Specification (LPS) CP01-2B-826, Revision C, to obtain diameter of
0.468 to 0.470 inch after finish grinding.
(5)
Finish grind plated gear shaft as
required to meet dimensional, concentricity, and surface finish requirements
of Hamilton-Sundstrand Drawing No.
(55820) 163057.
(6)
Magnetic particle inspect finished
accessory gear shaft per (96916) Inspection and Testing LPS CP09-2-J-4060
and ASTM E1444. No cracks allowed.
WARNING
ASTM E1444 Magnetic Particle materials may irritate skin and eyes. Avoid
prolonged or repeated contact and
avoid inhaling powder and vapors.
Wear goggle, nitrate gloves, and apron.
Consult the applicable MSDS and local
OSH regulations for appropriate safety
precautions.
(2)
Magnetic particle inspect machined
shaft surface per (96916) Inspection and
Testing LPS CP09-2-J-4060 and ASTM
E1444. No cracks allowed.
Table 5-5.
MATERIAL
CLEANING
Aluminum
Section IV
Cres
Magnesium
Steel
Section IV
Section IV
Section IV
Titanium
Section IV
Shotpeen ground shaft surface with
0.0138 to 0.0280 inch diameter (S-170)
shot, 0.007 to 0.014, A2 intensity.
Materials Application Table
TREATMENT
FINISH
PRESERVE
Specification MIL-C-5541/
Anodize
None
Specification MIL-M-3171
Black oxide, chrome/
nickel plating
Prime, paint
None
None
Prime, paint
Specification
MIL-C-83285
None
None
None
None
Preservation oil, Specification MIL-L-6081, grade
1010
None
Change 25
5-79
TO 2G-T62T-43
Table 5-6.
Engine Compressor
Knurled Sleeve Data
Inspection
Required Dimension
(inches)
Actual Dimension
(inches)
Wheel S/N
Pre-sleeve hub OD (top)
1.4015-1.4020
Pre-sleeve hub OD (bottom)
1.4015-1.4020
Sleeve ID (top)
1.399-1.400
Sleeve ID (bottom)
1.399-1.400
Finished sleeve OD (top)
1.5985-1.5990
Finished sleeve OD (bottom)
1.5985-1.5990
Knurl depth
0.010-0.015
APU S/N
y.
Repair of Reduction Drive Housing (Figure
3-12, 142).
(2)
NOTE
If sealant has been previously applied
and is still intact, the following procedures are not necessary.
(1)
Remove Air-Oil Separator Sleeve from
reduction drive housing and inspect for
corrosion on mating surfaces. Prepare
surface for sealant by removing corrosion, and cleaning mating surfaces per
Section IV or applicable local process
specifications.
WARNING
PR1826 B-2 Sealing Compound may
cause irritation of eyes, skin, nose, and
throat. Prolonged or repeated exposure
to skin may cause allergic reaction.
Very large dose by inhalation may
cause dizziness, drowsiness or liver
damage. Wear butyl rubber gloves and
safety glasses. Use with adequate ventilation. Consult the applicable MSDS
and local OSH regulations for additional information.
CAUTION
Ensure holes in Air-Oil Separator
Sleeve are not blocked.
5-80 Change 25
Sparingly apply PR1826 B-2 sealing
compound in the location where the AirOil Separator Sleeve, P/N 163056-2,
mates to the Reduction Drive Housing,
P/N 161781-103. Allow 16 hours to cure.
Use C-clamps to maintain pressure on
sleeve while sealant is curing.
WARNING
AMS-S-8802 Sealant can irritate skin
and eyes. Repeated or prolonged contact can cause an allergic skin reaction. Do not sand or grind on cured
material. Use gloves, safety glasses,
and adequate ventilation. Consult the
applicable MSDS and local OSH regulations for additional information.
CAUTION
Ensure holes in Air-Oil Separator
Sleeve are not blocked.
(3)
Alternate procedure: Sparingly apply
AMS-2-8802 sealing compound in the
location where the Air-Oil Separator
Sleeve, P/N 163056-2, mated to the
Reduction Drive Housing, P/N 161781103. Allow 72 hours to cure. Use Cclamps to maintain pressure on sleeve
while sealant is curing.
(4)
Reattach Air-Oil Separator Sleeve by
match drilling new pin holes and
installing new pins in accordance with
TO 2G-T62T-43
Hamilton-Sundstrand (55280) Drawing
No. 161781. Do not install pins in same
location as the old pin holes.
(f)
Face off any remaining material
from the threaded plug flush to the
face of generator pad bore.
(5)
Etch the letter R on the Air-Oil
Separator Sleeve to denote that this
repair has been performed.
(g)
(6)
Reduction Drive Housing 10-32 Helicoil
Insert repair for generator pad (6.000 to
6.001 inches) bore damaged/eroded/
worn beyond normal repairs. Any 10-32
helicoil/inserts that can simply be
replaced with a 10-32 shall be replaced
with a 10-32 helicoil or insert. Housings
that are damaged beyond the following
repair or cannot accept a 5/16-24 UNF3A machine bolt, shall be replaced.
Adhering to the center datum locations, drill and tap plugs to accept a
10-32 UNF-3B helicoil. Lightly
deburr the plugs.
(a)
Remove damaged 10-32 inserts.
(b)
Adhering to the center datum locations of the insert holes per drawing
(55820) 161781, thread the 10-32
insert hole as necessary to accommodate a 5/16-24 UNF-3A machine bolt.
(c)
Ensure that all damage and debris
has been removed from the three 1032 insert holes. Housings that
exhibit oversized holes too large for
the plug repair shall be replaced.
(d)
Manufacture Reduction Drive Housing Plugs. Make plug from bolt, part
No. AN5CH6A.
WARNING
Epoxy Primer is flammable and toxic.
Avoid inhaling. Use only with adequate ventilation, away from heat or
open flame. Wear gloves and goggles.
It can irritate skin and cause burns. In
case of contact, immediately flush skin
or eyes with water for at least 15 minutes. Get medical attention for eyes.
(h)
Apply epoxy primer (Specification
MIL-P-23377, type I, class C or N) to
all tapped holes and sparingly to the
OD of the 10-32 UNF-3B helicoils.
(i)
Sparingly apply sealant (Specification MIL-S-22473, grade A) to
tapped holes to ensure full thread
coverage and to ensure that sealant
does not interfere with the ID of the
inserts.
(j)
Install the 10-32 UNF-3B helicoils
into each plug.
(k)
Allow sealant to cure 24 hours at
room temperature or oven heat for 1
hour at 200 (±10)oF (93oC). Verify
that sealant will not prevent installation of assembly bolts.
(l)
Machine housing to re-establish the
O-ring groove. Maintain concentric
and dimensional tolerances.
WARNING
Sealant can irritate skin and cause
burns. Avoid contact with skin, eyes,
and clothing. Wear gloves, goggles,
and apron. In case of contact, immediately flush skin or eyes with water for
at least 15 minutes. Get medical attention for eyes.
z.
Repair of Diffuser Housing (Figure 3-10, 45).
(1)
NOTE
Oversized holes may extend (break
through) the thin-walled area of the
(6.214 to 6.218 inches) O-ring groove.
The plugs, once installed, will extend
into the groove. The plugs will restore
any broken out areas of the O-ring
groove.
(e)
Install the threaded plugs, slotted
side up, using sealant.
Inspect throat area and diffuser mating
surface for damage or other surface
deviations. Housings which meet the
following repair limitations shall be
repaired per step (2) through (11).
(a)
Scoring on the throat area due to
contact with the inducer which
exceeds 0.005 inch in depth, but does
not exceed 0.033 inch in depth.
(b)
Damage/out-of-roundness of the diffuser mating surface which is less
Change 25
5-81
TO 2G-T62T-43
than 11.100 inches in diameter, but
not more than 11.185 inches.
(2)
(3)
(4)
it is absolutely imperative that the
air reaching the work surface be
absolutely clean and free of oil and
moisture.
Machine the damaged throat area to a
depth of 0.030-0.033 inch, and the damaged/out-of-round diffuser mating surface as necessary up to 11.181/11.185
inches, ensuring 0.010 inch minimum
metal spray thickness. Fillet radius
0.030-0.050 inch. Refer to Figure 5-28 as
necessary. The surface finish shall be no
finer than 250 RMS.
Vapor degrease housing per LPS CP 030-GG-9533 Hydrofluoroether Vapor
Degreasing.
All areas shall be masked as required to
protect areas not designated for metal
spray. Rubber plugs, masking tape, polished metal masks, masking compounds, etc., are acceptable. Plugs
should extend 0.015-0.020 inch above
finished coating.
(5)
Blast areas to be sprayed with Metcolite
‘C’ powder. Housings should be sprayed
immediately after blasting operation. A
maximum of 1 hour between blasting
operation and application of metal
spray coating is allowed.
(6)
Preheat housing to a temperature of
200-250oF.
(10)
WARNING
Aluminum/nickel powder may cause
skin dermatitis and eye irritation.
Nickel is a suspected carcinogen; don’t
permit spray dust to enter eyes, mouth
or open wounds. PPE: NIOSH
approved
respirator,
aluminized
gloves, and goggles.
(7)
Apply Metco 450 ‘bondcoat’ until a
thickness of approximately 0.006 inch is
obtained.
(8)
Apply up to 0.045 inch thickness of
Metco SF aluminum wire (I/S inch
diameter).
(9)
The following should be observed during
application of metal spray:
(a)
Clean cooling air shall be directed to
the housing during each spraying
operation, preferably to surfaces
immediately adjacent to the surface
to be sprayed. If this is not possible,
5-82 Change 25
(b)
Surface temperature must be controlled by use of touch pyrometers
while observing the preheat temperature of 200-250oF throughout the
metal spray procedure.
(c)
Gun to workpiece distance shall be
maintained at a distance of 4 to 6
inches.
(d)
Metal spray coating buildup shall be
accomplished by two or more passes
with gun. In no instance shall single
pass coating thicknesses exceed
0.010 inch.
(e)
Metal spray coatings shall be applied
with the gun angle to the substrate
at no less than 45 degrees.
(f)
Unless otherwise directed, nitrogen
shall be used in combination with
hydrogen bottled gas to accomplish
metal spray operations. In the event
that Argon gas is employed, its
purity shall be maintained.
Machine the throat or diffuser mating
surface to the dimensional finish
requirements of the drawing P/N
(55820) 161625. Ensure a smooth transition of all the metal sprayed areas into
adjacent surfaces of the housing using
appropriate machining practices.
WARNING
Specification MIL-C-81706 Chemical
Conversion Coating contains carcinogenic chromates and contact may irritate or burn skin and eyes. Burns may
not be immediately obvious. Avoid contact with eyes, skin or clothing. Keep
away from oils, fuels, and other chemicals. Personnel shall wear butyl gloves,
splash-proof goggles, and face shield. A
respirator may be required when handling dry material. Consult the applicable MSDS and local OSH regulations
for appropriate safety precautions.
(11)
Apply Specification MIL-C-81706 Class
1A Chemical Conversion Coating per
Specification
MIL-C-5541
to
all
machined surfaces.
TO 2G-T62T-43
Figure 5-28.
Metal Spray Repair; Diffuser Housing, Part No. 161625
Change 25
5-83
TO 2G-T62T-43
Figure 5-29.
5-84 Change 25
Oil Sump Leak Test Plate
TO 2G-T62T-43
aa.
Repair of inside diameter of bearing front
carrier (Figure 3-10, 7).
(1)
Lightly machine the 2.01/1.98-inch
diameter groove located behind diameter (A), per Figure 5-2, to remove any
residual abradable coating in this area.
(2)
Drill all (12 each) diameter (F) holes,
one at a time, before finish machining
Diameter (A).
(3)
All final dimensions shall be in accordance
with
Hamilton-Sundstrand
Drawing No. (55820) 161412.
Change 25 5-85/(5-86 blank)
T.O. 2G-T62T-43
SECTION VI
ASSEMBLY
6-1. GENERAL. This section contains procedures
for assembly of the APU, including combustor
assembly, reduction drive unit, and turbine
assembly.
(17). Torque each pin to 40 to 60 inchpounds.
f.
Safety wire each pin (14) individually with
lockwire, MS20995C32.
6-2. GENERAL ASSEMBLY PROCEDURES. Note
the following before beginning assembly procedures:
g.
If removed, install loop clamp cushions (13)
and loop clamps (12) on fuel manifold (9),
approximately 45 degrees each way from 12o’clock position. There must be a minimum
of 0.050 inch clearance.
a.
Perform assembly in a clean work area.
b.
Inspect all parts, not being replaced, per
section V - Inspection, Repair, and Replacement, before reinstalling in APU.
h.
Assembly clearances are listed in procedural
steps.
Secure loop clamps (12) with bolts (10),
washers (8), and nuts (11).
i.
Remove protective caps from tips of fuel
manifold (9) and lubricate tips of fuel manifold with assembly f luid, RT-403A, No. 1.
Be careful not to get assembly f luid in hole
of nozzles.
c.
6-3. ASSEMBLY OF COMBUSTOR ASSEMBLY.
This section contains procedures for assembly of the
combustor assembly. Unless otherwise indicated,
index numbers, refer to f igure 3-28.
a.
b.
If previously removed, install spring (20),
washers (19), and igniter plug grommet (18)
per section V - Inspection, Repair, and
Replacement.
CAUTION
To prevent damage to fuel manifold
tips and subsequent failure, do not
bend tubes during installation of fuel
manifold. Make sure tips do not damage O-rings in combustor liner.
Lightly coat O-rings (16) with assembly
f luid, RT-403A, No. 1.
CAUTION
j.
Align fuel manifold (9) with mounting
bracket on combustor housing (17). Carefully insert tips of fuel manifold (9) into six
tube f ittings around combustor housing
(17).
k.
Apply antiseize compound, Specif ication
MIL-A-907, to threaded area of tube f ittings
on combustor housing (17) and top of collar
on fuel manifold (9). Torque to 55 to 65 inchpounds.
l.
Apply antiseize compound, Specif ication
MIL-A-907, to threads and mating surfaces
of bolts (6) and install bolts, washers (8), and
nuts (7), securing fuel manifold (9) to combustor housing (17). Torque to 24 to 27 inchpounds.
m.
Apply a small amount of assembly f luid, RT403A, No. 1, to O-ring (5) and install O-ring
and f ilter f itting (4) in fuel manifold (9).
Torque to 135 to 150 inch-pounds.
Do not use a sharp tool when inserting
O-rings, as damage may occur.
NOTE
Exposure to heat causes O-rings to
crystallize and deteriorate. Ensure all
old O-ring material is removed, otherwise new O-rings may not f it properly.
c.
Using a 1/8-inch diameter pin punch, install
O-rings (16) in atomizer f ittings of combustor liner (15).
d.
Insert pin punch, with rounded end into
each atomizer f itting to make sure O-rings
are seated in grooves.
e.
Lightly coat pins (14) with antiseize compound, Specif ication MIL-A-907, and install
pins, securing combustor liner (15) to combustor housing (17). Align igniter grommet
with igniter plug hole in combustor housing
Change 19
6-1
T.O. 2G-T62T-43
inserts (128, 129, 130, 131 or 139) per section V - Inspection, Repair, and
Replacement.
WARNING
Primer and adhesive may cause eye
and skin irritation. Wear protective
goggles and gloves. Avoid prolonged
breathing of vapors.
e.
CAUTION
Determine shim (88) thickness as follows:
(1)
Add mounting distance stamped on
Zerol pinion (91) to dimension A (bearing width) etched on outer race of bearing (92). This provides dimension B
(Figure 6-1).
(2)
Subtract dimension E stamped on
housing carrier (77) from dimension D
stamped on housing (142) . This provides dimension C (Figure 6-1).
(3)
Subtract dimension B from dimension C
(Figure 6-1). This provides thickness
required for shim (88). Allowable tolerance on shim is ±0.001 inch.
Do not allow primer or adhesive to get
in orifice, as this will change/restrict
flow pattern.
n.
If removed, install start fuel nozzle (3) in
fitting (2) as follows: apply a thin film of
primer, Specification MIL-S-22473, to three
threads nearest top hex of fitting (2) and
allow to dry. Apply adhesive, Specification
MIL-R-46082, Type II, to the same area.
Install start fuel nozzle (3) into fitting (2)
and torque 35 to 40 inch-pounds. Stake in
two places.
o.
Install fitting (2) into combustor housing
(17). Torque to 95 to 105 inch-pounds.
p.
Install igniter plug (1) as follows:
(1)
Lightly coat first two threads of igniter
plug (1) with antiseize compound, Specification MIL-A-907.
(2)
Install igniter plug (1) into mounting
boss on combustor housing (17). Torque
to 108 to 132 inch-pounds.
f.
6-4. ASSEMBLY OF REDUCTION DRIVE UNIT.
This section contains procedures for assembly of the
reduction drive unit. Unless otherwise indicated,
index numbers refer to Figure 3-12.
a.
Heat bearings (64), accessory pad cover
(108), Zerol pinion (91), and housing (142) in
an oven maintained at 250 to 300oF for a
minimum of 30 minutes.
b.
Heat housing carrier (77) and hub ring gear
(85) in an oven at 200oF for 10 minutes.
c.
If previously removed, install spring-slotted
pins (141), oil/air separator sleeve (140),
sleeve (137) or pin (136) per section V Inspection, Repair, and Replacement.
d.
If previously removed, install studs (133,
134 or 135), lockrings (132 and 138) or
6-2 Change 22
Determine shim (46) thickness as follows:
(1)
Establish dimension D, by placing ball
bearing (55) in mounting block,
ST90682 (Figure 2-1, 69), and measuring the movement between the inner
race and the outer race of ball bearing
(55) (Figure 6-2). Subtract the movement of inner race and the outer race of
ball bearing (55) from the width of the
outer race stamped on outer race of ball
bearing (55).
(2)
Add mounting distance stamped on
Zerol bevel gear (Figure 3-12, 45) to
dimension D + A. This provides dimension B.
(3)
Subtract dimension B from C stamped
on housing (142) . This provides thickness required for shim (46). Allowable
tolerance on shim is ±0.0001 inch.
g.
Place accessory gear (120) and ball bearing
(118) in a freezer for a minimum of 30
minutes.
h.
Install valve housing (103) as follows:
(1)
Install relief valve spring (105) into
valve housing (103).
(2)
Install ball (104) into seat of housing
(142).
(3)
Place relief valve spring (105) and valve
housing (103) over ball (104) seat.
T.O. 2G-T62T-43
housing (103) to housing (142). Torque
to 20 to 25 inch-pounds.
CAUTION
Ensure that ball (104) and relief valve
spring (105) are in proper position.
Otherwise, valve housing (103) will be
locked open and oil pressure will not
develop. Severe damage to APU will
result.
(4)
i.
Install intermediate gear (117) as follows:
(1)
Install one retaining ring (127) in inside
diameter of groove on intermediate gear
(117) and heat in an oven not to exceed
250oF for a minimum of 30 minutes.
(2)
Install oil shield (119) in housing (142).
Install vent plate (102), screws (99), and
washers (100 and 101) securing valve
Change 22 6-2A/(6-2B blank)
TO 2G-T62T-43
Figure 6-1. Gear Shimming
6-3
TO 2G-T62T-43
Figure 6-2. Determination of Shim Thickness
6-4
T.O. 2G-T62T-43
.
.
WARNING
WARNING
Wear protective gloves when handling
heated parts to avoid injury.
Wear protective gloves when handling
chilled parts to avoid injury.
Wear protective gloves when handling
chilled parts to avoid injury.
(1)
Remove accessory gear (120) from
freezer and install oil/air separators
(121 and 122) on accessory gear (120).
If previously removed, install plug (124)
and dowel pin (125) per Section V Inspection, Repair, and Replacement.
(3)
Remove intermediate gear (117) from
oven and ball bearing (118) from
freezer.
(2)
(4)
Using arbor plate and driver, ST70286
(Figure 2-1, 37), and driver set,
ST70414 (Figure 2-1, 38), press new ball
bearing (Figure 3-12, 118) into inside
diameter of intermediated gear (117).
Ensure that outer race of bearing makes
contact with retaining ring (127).
NOTE
If ball bearings (123) do not slide into
place easily, it may be necessary to
heat ball bearings.
(5)
Install another retaining ring (127)
securing ball bearing (118) to intermediate gear (117).
If necessary, heat ball bearings (123) in
an oven maintained at 250-300oF for a
minimum of 30 minutes.
(4)
Place accessory gear (120) on an arbor
press.
(6)
Position bearing space (116) in housing
(142).
(7)
Position intermediate gear (117) over
bearing spacer (116).
WARNING
(8)
Lubricate O-rings (114 and 115) with
assembly fluid, RT-403A, No. 1, and
install O-rings on intermediate gear
shaft (113).
Wear protective gloves when handling
heated parts to avoid injury.
(9)
Ensure that O-rings (114 and 115) are
not cut and oil shield (119) does not
slip when installing intermediate gear
shaft (113).
(10)
(5)
Remove ball bearings (123) from oven
and press onto shaft of accessory gear
(120) using bearing assembly tool,
ST90671 (Figure 2-1, 68). Ensure that
inner race of ball bearings contact
shoulders of oil/air separators.
(6)
Remove accessory pad cover (Figure 317, 108) from oven and place in an arbor
press.
If previously removed, install inserts
(111) or lockrings (110) per Section V.
CAUTION
j.
(3)
Using puller, ST70235 (Figure 2-1, 20),
install intermediate gear shaft (Figure
3-12, 113) into housing (142), carefully
slipping intermediate gear shaft (113)
through ball bearing (118), bearing
spacer (116), and oil shield (119). Secure
with retaining ring (112).
Install accessory gear (120) as follows:
NOTE
Index plugged end of accessory gear
shaft away from accessory pad cover.
(7)
Install accessory gear (120) into accessory pad cover (108). A slight amount of
pressure may be required to seat the
bearing in accessory pad cover housing.
NOTE
If accessory gear (120) and accessory
pad cover (108) won’t assembly easily,
it may be necessary to place in freezer.
(8)
If necessary, place assembled accessory
gear (120) and accessory pad cover (108)
in a freezer for 30 minutes.
Change 22 6-5
T.O. 2G-T62T-43
(3)
If previously removed, install key (95)
using a soft mallet and tapping key into
slot of straight drive shaft (78).
(4)
If previously removed, install housing
liner (96) and pipe plugs (81) in housing
carrier (77) per Section V - Inspection,
Repair, and Replacement.
WARNING
Wear protective gloves when handling
heated or chilled parts to avoid injury.
(9)
If placed in freezer, remove assembled
accessory gear (120) and accessory pad
cover (108).
(10)
Lubricate O-ring (109) with assembly
fluid, RT-403A, No. 1, and install in
groove provided on accessory pad cover
(108).
(11)
Remove housing (142) from oven and
install in assembly fixture, ST70370
(Figure 2-1, 37).
(12)
Install accessory gear (120) into housing
(142).
(13)
Press accessory pad cover (108) into
housing (142). Ensure bolt holes are
aligned, and index pad on cover aligns
with the housing pad.
.
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
Wear protective gloves when handling
heated parts to avoid injury.
(5)
Place straight drive shaft (78) in dry ice,
CGA G-6.2, for 20-30 minutes.
(14)
Temporarily install screws (106) and
washers (107), securing accessory pad
cover (108) to housing (142).
(6)
(15)
Lubricate inner lip of shaft seal (126)
with assembly fluid, RT-403A, No. 1.
Remove Zerol pinion (91) from oven and
straight drive shaft (78) from dry ice,
CGA G-6.2.
(7)
(16)
Using guide tool set, ST90889-01 (Figure 6-3), install shaft seal (126) so that
it bottoms against inner shoulder of
housing (142) and accessory pad cover
(108).
Install Zerol pinion (91) over straight
drive shaft (78).
(8)
Install retainer bearing ring (93) over
straight drive shaft (78) with groove up.
(17)
k.
.
WARNING
Install protective cover on accessory
drive pad (108) and secure.
Install straight drive shaft (78) and housing
carrier (77) as follows:
(1)
If previously removed, install inserts
(98) in housing carrier per Section V Inspection, Repair, and Replacement.
(2)
Apply solid lubricant, MIL-PRF-46010,
to threaded portions of straight drive
shaft (78).
6-6 Change 22
NOTE
Thrust race of bearings (90 and 92)
must be away from Zerol pinion (91).
Bearing inner race must contact Zerol
pinion. Recessed face of retainer bearing ring (93) must face down (against
bearings).
(9)
Using arbor press, arbor plate,
ST70236, and driver, ST70282 (Figure
6-4), press bearings (90 and 92) onto
straight drive shaft (78).
TO 2G-T62T-43
Figure 6-3. Installation of Shaft Seal
6-7
TO 2G-T62T-43
Figure 6-4. Installation of Bearings on Straight Drive Shaft
6-8
T.O. 2G-T62T-43
(10)
Place assembly into holding fixture,
ST70266 (Figure 2-1, 28). Install
locknut (Figure 3-12, 83). Using spanner wrench, ST70241 (Figure 2-1, 24),
torque locknut (83) to 450-500 inchpounds. Stake locknut (83) in place.
(11)
Using a soft mallet, tap key (94) into
slot on straight drive shaft (78).
WARNING
(12)
Remove housing carrier (77) and hub
ring gear (85) from oven.
(13)
Position shim (88) in housing carrier
(77).
(14)
Position housing carrier
straight drive shaft (78).
(15)
Secure retainer bearing ring (93) to
housing carrier (77) with screws (86)
and lockwashers (87). Torque screws
(86) to 30-40 inch-pounds. Bend
lockwashers (87) tabs to lock one end
down in hole in housing carrier (77).
(17)
(77)
over
Using arbor press and driver, ST70283
(Figure 6-5), install hub ring gear (Figure 3-12, 85) and retainer (84) on
straight drive shaft (78).
Using holding fixture, ST70266 (Figure
2-1, 28) and spanner wrench, ST70243
(Figure 2-1, 26), install locknut (Figure
3-12, 89) on straight drive shaft (78) and
torque locknut (89) to 450-500 inchpounds. Stake locknut (89) in place.
(18)
Heat housing (142) until it is warm to
touch (100 (±10)oF).
(19)
Lubricate O-rings (79 and 80) with
assembly fluid, RT-403A, No. 1, and
install O-rings in housing carrier (77).
NOTE
Make sure O-ring (80) is seated in
groove of housing (142) and O-ring (79)
does not move.
(20)
(21)
NOTE
Shaft seal (97) will be installed after
all interior components of housing
(142) are installed and after backlash
check is completed.
l.
Wear protective gloves when handling
heated parts to avoid injury.
(16)
washers (59) to equal thickness of carrier assembly (60). Torque in three
stages 10-12, 20-25. Torque sequence: 1,
4, 7, 2, 5, 8, 3, 6. Torque bolts (58) to 2025 inch-pounds.
Install housing carrier (77) and assembled parts into housing (142), using
aligning pin or equivalent.
Temporarily secure housing carrier (77)
in housing (142) with bolts (58), using
Install Zerol level gear (45) and bevel gear
support (40) as follows:
(1)
If previously removed, install inserts
(44) in bevel gear support (40) per Section V - Inspection, Repair, and
Replacement.
(2)
If previously removed, install liners (42
and 43) and pin (41).
NOTE
Side of retainer (49) with countersink
holes must face Zerol bevel gear (45).
(3)
Position retainer (49) on Zerol bevel
gear (45).
(4)
Using driver, ST70281 (Figure 2-1, 32),
press ball bearing (Figure 3-12, 55) on
Zerol bevel gear (45) with thrust side
up.
(5)
Install spacer (56) on Zerol bevel gear
(45).
(6)
Using driver, ST70282 (Figure 6-6),
press ball bearing (54) onto Zerol bevel
gear (45). Ensure inner races of bearing
contact spacer (56).
(7)
Install locknut (51) finger tight.
(8)
Position balls (53) in groove in Zerol
bevel gear (45), and using bearing
installation tool, ST71240 (Figure 2-1,
56), install accessory drive pinion (52)
on Zerol bevel gear (45).
(9)
Install locknut (50) finger tight.
(10)
Mount Zerol bevel gear (45) in holding
fixture, ST70267 (Figure 6-6).
(11)
Using spanner wrench, ST70241 (Figure 2-1, 24), torque locknut (Figure 312, 51) to 450-500 inch-pounds.
(12)
Using spanner wrench, ST70243 (Figure 2-1, 26) torque locknut (Figure 3-12,
50) to 450-500 inch-pounds.
Change 22 6-9
T.O. 2G-T62T-43
Figure 6-5.
6-10 Change 22
Installation of Hub Ring Gear and Retainer
T.O. 2G-T62T-43
Figure 6-6.
Installation of Bearings on Zerol Bevel Gear
Change 22
6-11
T.O. 2G-T62T-43
(13)
Stake locknuts (50 and 51) into grooves
of Zerol bevel gear (45) shaft.
(24)
Remove holding bar, ST70254, and
backlash gage, ST60811 (Figure 6-7).
(14)
Install Zerol bevel gear (45) and assembled parts into bevel gear support (40)
housing and secure with screws (48).
Torque to 24-27 inch-pounds.
(25)
Place housing (142) in holding fixture,
ST70278 (Figure 6-9).
(26)
Using adapter, ST70242 (Figure 6-9),
provide friction drag on Zerol bevel gear
(45) until adapter, ST70242, just starts
to move and check tooth pattern (Figure
6-9).
(27)
If required, remove bevel gear support
(40) and shim (46) and adjust thickness
of shim (46) to achieve desired pattern.
Either add or remove 0.003 inch laminations. (Figure 6-8).
(28)
If shim (46) thickness is adjusted,
repaint gear teeth with gear marking
compound, Dykem blue, or equivalent.
(29)
Reinstall shim (46) and bevel gear support (40) and secure with screws (48).
Torque to 24-27 inch-pounds.
(30)
Repeat steps (17), (21), and (22) to
recheck backlash.
(31)
Lubricate inner lip of shaft seal (57)
with assembly fluid, RT-403A, No. 1.
(32)
Using guide tool set, ST90889-04 (Figure 6-10), install shaft seal (57) in housing (142). Ensure that seal bottoms
against flange end.
(33)
Remove housing (142) from holding fixture, ST70278 (Figure 6-9).
(15)
Lubricate O-ring (47) with assembly
fluid, RT-403A, No. 1, and install O-ring
(47) on bevel gear support (40).
(16)
Install shim (46) on housing (142).
(17)
Lightly apply gear marking compound,
Dykem blue, or equivalent, to teeth of
Zerol bevel gear (45).
WARNING
Wear protective gloves when handling
heated parts to avoid injury.
(18)
Oven heat housing (142) to approximately 100oF for installation of bevel
gear support (40).
(19)
Install assembled bevel gear support
(40) into housing (142). Engage gears,
using nuts in three places to hold bevel
gear support in place.
(20)
Secure bevel gear support (40) with cap
screws (39). Torque to 20-25 inchpounds.
(21)
Insert holding bar, ST70254 (Figure 67), into spline of straight drive shaft (78)
and lock in place.
(22)
Install backlash gage, ST60811 (Figure
6-7), and rotate straight drive shaft (78)
in clockwise direction, to determine
maximum backlash reading between
accessory drive pinion (52) and Zerol
bevel gear (45).
m.
Install ring gear (69) as follows:
(1)
Lubricate inner gear teeth on ring gear
(69) with assembly fluid, RT-403A, No.
1.
(2)
Install ring gear (69) and retaining ring
(68).
(3)
Using disassembling tool, ST70284 (Figure 2-1, 35), insert each leg of tool in
equally spaced access slots inside ring
gear (Figure 3-12, 69). Slots are
recessed around perimeter of teeth that
mate with splines of hub ring gear (85).
Turn knurled knob of tool to compress
retaining ring (68), then pull ring gear
(69) into hub ring gear (85). Withdraw
tool, allowing retaining ring (68) to seat
in groove in hub ring gear (85).
(4)
Ensure that ring gear (69) is axially
secure.
NOTE
Back lash tolerances must be between
0.002-0.010 inch.
(23)
If backlash is not within tolerance, correct as follows:
(a)
Over maximum tolerance, move gear
toward cone center reduce shim (46)
(Figure 6-8).
(b)
Under minimum tolerance, move
gear away from cone center increase
shim (46) .
6-12 Change 22
TO 2G-T62T-43
Figure 6-7. Installation of Backlash Gage
6-13
TO 2G-T62T-43
Figure 6-8. Backlash and Pattern Requirements
6-14
TO 2G-T62T-43
Figure 6-9. Installation of Adapter
6-15
TO 2G-T62T-43
Figure 6-10. Installation of Shaft Seal
6-16
T.O. 2G-T62T-43
n.
Assemble and install carrier assembly (60)
as follows:
(1)
(2)
If previously removed, install dowels
(67), inserts (72), spring-slotted pin (76),
oil jet cartridge (75), and sleeves (73 and
74) per Section V.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
(3)
Install retaining ring (66) in carrier
assembly (60).
Freeze gear planet set (65) in dry ice,
CGA G-6.2, for a minimum of 30
minutes.
WARNING
WARNING
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Figure 6-11.
Wear protective gloves when handling
heated parts to avoid injury.
(4)
Remove bearings (64) from oven.
(5)
Using driver, ST90133 (Figure 6-11),
press bearings (64) onto gear planet set
(65). Ensure inner race of bearings contact shoulders of gear shafts.
Installation of Bearings
Change 22
6-17
T.O. 2G-T62T-43
(6)
Using arbor press and driver, ST90142
(figure 6-12) install bearings (64) gear
planet set (65) in carrier assembly (60).
Make sure etched side is up.
(7)
Install cover (63) on carrier assembly
(60), and secure with bolts (61) and
washers (62). Torque to 55-70 in. lb.
(8)
Install cover (82) in housing carrier (77).
(9)
Remove temporarily installed bolts (58)
from housing carrier (77).
(10) Install lube oil elbow (71) in carrier
assembly (60).
(11) Install gasket (70) on housing carrier
(77).
Figure 6-12. Installation of Gear Planet Set and Bearings
NOTE
(1)
Make sure cover (82) is not loose and
lube oil elbow (71) is installed
correctly.
If previously removed, install dowel pin
(25) in housing (142) per Section V Inspection, Repair, and Replacement.
(2)
Install one dowel pin (34) in driver shaft
(37) and one dowel pin (34) in driven
shaft (38).
(12)
Install carrier assembly (60) on housing
carrier (77).
(13) Install bolts (58) and washers (59).
Torque in three stages 10-12, 22-25, and
30-37 in. lb. Torque sequence: 1, 4, 7, 2,
5, 8, 3, and 6.
o.
Assemble and install oil pump housing (26)
as follows:
6-18 Change 13
(3) Install pump element gears (36) on
driver shaft (37) and driven shaft (38).
(4)
Install assembled gears and shafts in
oil pump housing (26).
T.O. 2G-T62T-43
(5)
Install cover (35) on oil pump housing
(26) and ensure that dowel holes are
aligned.
(12)
Replace pump drive gear (33) or oil
pump housing (26) if required to meet
requirements of test.
(6)
Install pump drive gear (33) and
remaining dowel pin (34) on driver shaft
(37).
(13)
Remove oil pump housing (26) from
adapter, ST90030 (Figure 6-13).
(7)
Secure pump drive gear (33) with
washer (32) and self-locking nut (31).
Torque to 20-25 inch-pound.
(14)
Lubricate O-ring (Figure 3-12, 30) with
assembly fluid, RT-403A, No. 1, and
install on oil suction tube (29).
(8)
Install assembled oil pump housing (26)
on flow bench using adapter, ST90030
(Figure 6-13).
(15)
Install oil suction tube (29) in oil pump
housing (26) and secure with cap screw
(28). Torque to 20-25 inch-pound.
(16)
Lubricate gasket (27) with assembly
fluid, RT-403A, No. 1, and install on oil
pump housing (26) mounting face.
(17)
Install oil pump housing (31) in housing
(142).
(18)
Apply thread locking compound, Specification MIL-A-46146, type III, under
head of screws (23 and 24) extend
approximately 1 inch along shank.
(19)
Install screw (24) in hole next to oil port
and shorter screw (23) in hole below
screw (24). Torque to 20-25 inch-pound.
WARNING
Lubricating oil, Specification MIL-L7808, may cause skin rash. Do not
breathe vapors. Use in well-ventilated
area. Wear eye protection and gloves.
(9)
Flow-check oil pump housing (Figure 312, 26) at 15 psig outlet pressure and
zero inlet pressure, using lubricating
oil, Specification MIL-L-7808, at 70oF.
NOTE
Flow rates are equivalent to 0.0364
cubic inch per revolution.
(10)
Run oil pump at 2400 rpm and measure
flow. Minimum flow must be 144.0 pph
(0.378 gallons per minute).
(11)
Increase pump speed to 4000 rpm and
measure flow. Minimum flow must be
241.0 pph (0.630 gallons per minute).
p.
Using guide tool set, ST90889-01 (Figure 21, 71), install shaft seal (Figure 3-17, 97) in
housing (142).
q.
Install oil filter element (11) as follows:
(1)
If removed, or new bypass valve housing
(6) is required, install ball bearings (10)
and valve spring (9). Make sure spring
is against ball bearings (10).
Change 22
6-19
T.O. 2G-T62T-43
Figure 6-13. Oil Pump Test Setup
6-20
T.O. 2G-T62T-43
(2)
Mount bypass valve housing (6) onto oil
filter cap assembly fixture, ST70433
(Figure 2-1, 39).
NOTE
Spring pin (Figure 3-12, 8) should be
flush with bypass valve housing (6). Do
not push too hard or bypass valve
housing will crush.
(3)
r.
Tighten set screw and put bypass valve
housing (6) under arbor press. Using a
screw, press spring pin (8) into housing
until flush with housing.
(4)
Lubricate O-ring (Figure 3-12, 7) with
assembly fluid, RT-403A, No. 1.
(5)
Install O-ring (7) in groove around
bypass valve housing (6).
(6)
Install oil filter element (11) on bypass
valve housing (6).
(7)
Installed assembled oil filter element
(11) and bypass valve housing (6) in
housing (142) and sevure with retaining
ring (5).
Lubricate O-ring (21) with assembly
fluid, RT-403A, No. 1, and install on
housing (142) flange groove of engine oil
sump (22).
(2)
Install clamp (20) around engine oil
sump (22) at attaching flange in 3
o’clock position away from carrier
assembly (60).
(3)
Install engine oil sump (22) flange
against housing (142) flange and secure
with clamp (20). Orient the engine oil
sump (22) drain with the turbine face.
Torque nut on clamp to 20-25 inchpounds.
(4)
Install caplug (19) in engine oil sump
(22).
(5)
Check that magnetic-drain plug (15)
will hold its own weight when magnetically attached to a steel surface. Replace
if weak.
Lubricate O-rings (16 and 18) with
assembly fluid, RT-403A, No. 1.
(7)
Install O-ring (18) self-closing valve (17)
and install self-closing valve (17) in
engine oil sump (22). Torque self-closing
valve to 45-50 inch-pounds.
(8)
Install O-ring (16) on magnetic-drain
plug (15) and install magnetic-drain
plug (15) in self-closing valve (17).
Torque magnetic-drain plug to 25-30
inch-pounds.
(9)
Safety wire magnetic-drain plug (15)
with lockwire, MS20995C20.
s.
Install accessory drive gasket (14) and
accessory pad cover (13) on housing (142)
and secure with bolts (12). Torque to 20-25
inch-pounds.
t.
Install caplug (1) and plug (2) as follows:
Install engine oil sump (22) as follows:
(1)
(6)
u.
(1)
Lubricate O-ring (3) with assembly
fluid, RT-403A, No. 1.
(2)
Install O-ring (3) on plug (2).
(3)
Install plug (2) in housing (142) and
safety wire with lockwire, MS20955C20.
(4)
Install caplug (1) in housing (142) and
safety wire with lockwire, MS20995C20.
If removed, install nameplate (4) with adhesive, Specification MIL-A-46146, type III.
6-5. ASSEMBLY OF TURBINE ASSEMBLY This
section contains procedures for balancing and
assembly of the turbine assembly and rotor assembly. Unless otherwise indicated, index numbers
refer to Figure 3-10.
a.
If removed, install load compressor seal
(Figure 3-10, 21) on load compressor wheel
(Figure 3-10, 20) as follows:
Change 25
6-21
T.O. 2G-T62T-43
.
.
load compressor. Hold pressure until
both
pieces
stabilize
at
room
temperature.
WARNING
Liquid nitrogen is extremely cold and
can injure human skin or tissue on
contact. Liquid nitrogen will expand
696 times as it vaporizes, and if the
liquid vaporizes in a sealed container,
it can produce enormous pressures
that could rupture the vessel. Nitrogen
can displace oxygen in poorly ventilated or confined areas. Boiling and
splashing occurs when filling a warm
container with or when inserting
objects into liquid nitrogen. Perform
these tasks slowly to minimize boiling
and splashing. Use tongs to withdraw
objects immersed in a cryogenic liquid.
Wear chemical splash goggles, face
shield, and approved cryogenic gloves/
outer wear when handling liquid nitrogen. Consult the applicable MSDS and
local OSH regulations for additional
information.
(5)
b.
Handle load compressor seal (21) carefully to avoid damage to knife-edges.
(1)
(2)
Heat load compressor seal (21) to 600650oF and immerse load compressor
wheel (20) in liquid nitrogen, A-A59503, for 10 minutes.
Remove load compressor wheel (20)
from liquid nitrogen and install on
locally fabricated holder (Figure 2-1,
90), with hub shaft facing upward.
Balance re-worked rotor shafts (59) as
follows:
NOTE
New rotor shafts are pre-balanced
from the factory, thus do not require
re-balancing.
(1)
Set rotor shaft (59) on V-blocks of rotor
assembly inspection fixture, ST64016
(Figure 2-1, 14). Set up on Datums -Aand -B- (Figure 6-18) and check runout.
Runout at Datums -A- and -B- is 0.0002
inch.
NOTE
Forward bearing (Figure 3-10, 11) and
aft bearing (Figure 3-10, 61) may be
installed on shaft and used in lieu of
the balancing supports (Figure 2-1, 80
and 81).
Thermal burns can result from exposure to or contact with hot materials
with a temperature above 115oF. Long,
asbestos-free heat-resistant gloves,
chemical goggles, and a full face shield
must be worn when handling hot
materials.
CAUTION
Machine grind OD of load compressor
seal (21) to 1.3395 to 1.3405 inches as
required. Replace load compressor seal
(21) if dimensional requirement is not
met.
(2)
.
.
.
.
Install balancing support, ST94276
(Figure 2-1, 80) and balancing support,
ST94281 (81), in balancer, HBH-003 (2)
or locally approved equivalent.
NOTE
Do not move balancing belt once in
position or balancing may be thrown
off.
Rotor shaft must move freely in balancing supports or balancing may be
thrown off.
Balancing supports must be kept clean
or balance may be thrown off.
Nominal rotor shaft speed is 940 rpm.
(3)
Remove load compressor seal (21) from
oven and position over hub shaft of load
compressor wheel (20) with chamfered
side facing down.
(3)
Install rotor shaft in balancer, HBH-003
(2) or locally approved equivalent and
position balancer belt near plane B (Figure 6-18).
(4)
Using locally fabricated driver (Figure
2-1, 89) and hydraulic or arbor press,
press load compressor seal (21) onto hub
shaft of load compressor wheel (20). Be
sure seal is flush against backface of
(4)
Dynamically balance rotor shaft not
greater than 0.001 inch-ounce (1 moz) in
planes A and B (Figure 6-18). Material
may be removed from noted areas on
rotor shaft diameter.
6-22 Change 22
T.O. 2G-T62T-43
WARNING
Compressed air used for cleaning can
create airborne particles that may
enter the eyes. Use approved goggles,
face shield, and hearing protection
when using compressed air for cleaning, cooling or drying. Air pressure
shall not exceed 30 psig. Compressed
air shall not be directed towards self or
other personnel.
c.
(5)
Remove any loose particles from balancing procedure with shop air.
(6)
Remove rotor shaft (59) from balancer
(Figure 2-1, 2).
Assemble load compressor wheel (Figure 310, 20), engine compressor wheel (60), and
rotor shaft (59) as follows:
(1)
Using micrometers, measure and record
dimensions J, H, and N on Table 6-1
(Figure 6-22, detail J, N, H). Replace
parts that do not meet dimensional
requirements.
WARNING
Thermal burns can result from exposure to or contact with hot materials
with a temperature above 115oF. Long,
asbestos-free, heat-resistant gloves,
chemical goggles, and a full face shield
must be worn when handling hot
materials.
(2)
Place engine compressor wheel (Figure
3-10, 60) and load compressor wheel
(20) in an oven stabilized at 650 (±25)oF
for a minimum of 2 hours.
WARNING
Liquid nitrogen is extremely cold and
can injure human skin or tissue on
contact. Liquid nitrogen will expand
696 times as it vaporizes, and if the
liquid vaporizes in a sealed container,
it can produce enormous pressures
that could rupture the vessel. Nitrogen
can displace oxygen in poorly ventilated or confined areas. Boiling and
splashing occurs when filling a warm
container with or when inserting
objects into liquid nitrogen. Perform
these tasks slowly to minimize boiling
and splashing. Use tongs to withdraw
objects immersed in a cryogenic liquid.
Wear chemical splash goggles, face
shield, and approved cryogenic gloves/
outer wear when handling liquid nitrogen. Consult the applicable MSDS and
local OSH regulations for additional
information.
(3)
Install rotor shaft in rotor assembly
tool, ST71234 (Figure 6-19), place in
liquid nitrogen, A-A-59503, cool for 10
minutes prior to installation.
(4)
Remove rotor shaft from liquid nitrogen
and place in base plate of load compressor rotor assembly tooling, ST71219
(Figure 6-19).
(5)
Install aft bearing (61) on rotor shaft
(59), thrust side down (Figure 6-19).
(6)
Remove engine compressor wheel (60)
from oven and install on rotor shaft (59).
(7)
Install shaft on rotor assembly (tool),
ST71234, ener-pak of stretch tool,
ST71078, and nut of rotor assembly tool,
ST71234 (Figure 6-19), on engine compressor wheel (60). Set pump to 8,000
pounds and hold until parts equalize to
room temperature.
WARNING
Liquid nitrogen is extremely cold and
can injure human skin or tissue on
contact. Liquid nitrogen will expand
696 times as it vaporizes, and if the
liquid vaporizes in a sealed container,
it can produce enormous pressures
that could rupture the vessel. Nitrogen
can displace oxygen in poorly ventilated or confined areas. Boiling and
splashing occurs when filling a warm
container with or when inserting
objects into liquid nitrogen. Perform
these tasks slowly to minimize boiling
and splashing. Use tongs to withdraw
objects immersed in a cryogenic liquid.
Wear chemical splash goggles, face
shield, and approved cryogenic gloves/
outer wear when handling liquid nitrogen. Consult the applicable MSDS and
local OSH regulations for additional
information.
Change 22
6-23
T.O. 2G-T62T-43
(8)
Remove assembly from base plate of
ST71219 and place the load compressor
end of rotor shaft (59) into liquid nitrogen, A-A-59503, for 10 minutes. Ensure
aft bearing (61) does not contact the
liquid nitrogen.
(2)
(9)
Remove load compressor wheel (20)
from oven and install on load compressor wheel assembly (tool), ST71236 or
18D8325-1 (Figure 2-1, 54).
(10)
Install stretch tool, ST71078 (40), and
locally manufactured adapter, 18C87861, on rotor shaft (59) and press load
compressor wheel (20) on rotor shaft
(59). Set pump on stretch tool, ST71078
(Figure 2-1, 40) to 8,000 pounds and
hold set until temperature of parts stabilize to room temperature, then remove
pump and load compressor wheel
assembly (tool), ST71236 or 18D8325-1
(54).
NOTE
Runout measurements may be taken
on balancer in lieu of rotor assembly
inspection fixture, ST64016.
(3)
Install rotor assembly on V-blocks of
rotor assembly inspection fixture,
ST64016 (Figure 2-1, 14).
(4)
Measure and record runout at engine
compressor wheel face. Mating face
runout is 0.0002 inch maximum (Figure
6-20, surface X) and inside diameter is
0.0008 inch maximum (Figure 6-20,
diameter Y), full indicator movement.
(5)
Remove material as required from
engine compressor wheel (60) in accordance with Figure 6-16 or load compressor wheel (20) in accordance with Figure
6-17. Do not undercut backface of
wheels or remove material from areas
not allowed by Figure 6-16 and Figure
6-17.
NOTE
Record part and serial numbers of aft
and forward bearings.
d.
(11)
Remove rotor assembly from stretch
tool, ST71078 (Figure 2-1, 40), and
install in rotor fixture, ST70137 (17).
(12)
Install forward bearing (Figure 3-10,
11) with thrust side toward load compressor wheel (20).
(13)
Using wrench, ST71191 (42), install forward bearing (11) on rotor shaft (59)
with thrust side toward engine compressor wheel (60). Locate forward bearing
(11) at edges of threads (Figure 6-20).
Install nut (4) on rotor shaft and tighten
with wrench, ST71191, until forward
bearing (11) bottoms out on load compressor wheel (20).
e.
Check balance at nominal rotor speed of
940 rpm. Amount of unbalance shall not
exceed 0.010 inch-ounce (10 moz) on left
plane and 0.030 inch-ounce (30 moz) in
right plane (Figure 6-21). Remove
assembly from balancer.
Assembly turbine wheel (Figure 3-10, 55) to
the load compressor wheel (20), engine compressor wheel (60), and rotor shaft (59)
assembly as follows:
(1)
Install rotor assemly in rotor fixture,
ST70137 (Figure 2-1, 17).
(2)
Using turbine stud torque wrench,
ST71238 (Figure 2-1, 55) or ST383169,
install stud (58) into rotor shaft (59).
Torque to 190-230 inch-pounds. Remove
turbine stud torque wrench.
CAUTION
WARNING
Protect bearings from contamination
when removing material from engine
compressor wheel during balancing.
MIL-PRF-907 Antiseize Compound
may irritate skin upon repeated contact or in sensitive individuals. Avoid
contact with eyes and skin. Wear
nitrile gloves and safety glasses. Consult the applicable MSDS and local
OSH
regulations
for
additional
information.
Balance load compressor wheel (Figure 3-10,
20), engine compressor wheel (60), and rotor
shaft (59) assembly as follows:
(1)
Install rotor assembly in balancer,
HBH-003 (Figure 2-1, 2) or a locally
approved equivalent balancer, and
install balancer guide piece over rotor
assembly.
6-24 Change 22
T.O. 2G-T62T-43
NOTE
Do not install seal plate (57) at this
time.
(3)
Ensure mating surfaces of engine compressor wheel (60) and turbine wheel
(55) are clean. Apply thin coating of
antiseize compound, MIL-PRF-907, to
turbine wheel.
(4)
Install turbine wheel (Figure 3-10, 55)
over stud (58) and mate with engine
compressor wheel (60).
(5)
f.
Check for unbalance of rotor assembly.
Maximum unbalance allowance for left
plane is 0.010 inch-ounce (10 moz) and
0.030 inch-ounce (30 moz) for right
plane (Figure 6-21). Runout at turbine
wheel hub shall not exceed 0.0015 inch
for right plane (Figure 6-22, detail GG).
NOTE
A single digit number on the face of
load compressor seal (Figure 3-10, 21)
represents the runout of the seal OD in
ten thousandths. For example, for a
load compressor seal (21) with number
‘‘2’’ on the backface, add 0.0002 to
0.0012; runout shall not exceed 0.0014
inch.
(2)
(3)
Turbine wheel shall be indexed (up to 3
times) first to obtain runout or minimum balance conditions prior to material removal from turbine wheel. Any
material removed shall conform to the
requirements of Figure 6-15.
(4)
Remove slave nut (54).
(5)
Install turbine wheel puller, ST71186
(Figure 2-1, 41) and remove turbine
wheel (Figure 3-10, 55).
(6)
Install seal plate (57) with chamfered
outside diameter adjacent to engine
compressor wheel (60).
(7)
Install turbine wheel (55), aligning
match-marks, and using stretch tool,
ST71078 (Figure 2-1, 40), locally manufactured adapter, 18C8786-1, and enerpak of stretch tool, measure stud (Figure 3-10, 58) at 4,000 pounds.
(8)
Stretch stud (58) at 6,000 to 8,000
pounds and remeasure (Table 6-1, position 7, and Figure 6-22, detail 7). If
stretch does not equal 0.017-0.019 inch,
unstretch and discard stud. Repeat procedures from paragraph 8.5.2.
Install slave nut (54).
Balance the final rotor assembly as follows:
(1)
runout etched on load compressor seal
(21) (Figure 6-22, detail AA).
Install rotor assembly on V-blocks of
rotor assembly inspection fixture,
ST64016 (Figure 2-1, 14). Check runout
on the forward-most ring of the load
compressor seal (Figure 3-10, 21) outer
diameter. Total indicated reading shall
not exceed 0.0012 inch more than
NOTE
Ensure entire rotor assembly is matchmarked and aligned.
(9)
Match-mark load compressor wheel
(20), turbine wheel (55), engine compressor wheel (60), rotor shaft (59), and
stud (58).
Change 22
6-25
T.O. 2G-T62T-43
Figure 6-14.
6-26 Change 22
Balancer Setup (Ref) for Legacy Component-Balance Process
T.O. 2G-T62T-43
Figure 6-15.
Balancing Turbine Wheel
Change 22
6-27
T.O. 2G-T62T-43
Figure 6-16.
6-28 Change 22
Balancing Engine Compressor Wheel
T.O. 2G-T62T-43
Figure 6-17.
Balancing Load Compressor Wheel
Change 22
6-29
T.O. 2G-T62T-43
Figure 6-18.
6-30 Change 22
Balancing Rotor Shaft
T.O. 2G-T62T-43
Figure 6-19.
Installation of Engine Compressor Wheel
Change 22
6-31
T.O. 2G-T62T-43
6-32 Change 22
Figure 6-20.
Balancing Rotor Assembly
Figure 6-21.
Balancing Rotor Assembly
T.O. 2G-T62T-43
Table 6-1.
Clearance Chart
Diametral Fits
Fig. 6-22
Position
Description
J
Aft bearing carrier inside diameter
and bearing outside diameter
H
Labyrinth seal inner diameter and rotor shaft journal outer diameter
N
Aft bearing carrier inner diameter
and engine compressor wheel (knurl
outer diameter)
Inside
Diameter
Outside
Diameter
Clearance
1.5751
1.5748
0.0005
1.5748
1.5746
0.0000
1.1135
1.1105
0.0040
1.1105
1.1095
0.0000
1.6038
1.6000
0.0053
1.6030
1.5985
0.0030
Maximum
Minimum
Record
Radial Clearances
Fig. 6-22
Position
R
Description
Turbine wheel to turbine nozzle radial clearance
0.050
Record
0.025
Axial Dimensions
Fig. 6-22
Position
Description
Manufacturing
1
Pinion assembly to adapter assembly clearance
1.120 - 1.204
2
Load compressor wheel to spacer clearance
0.015 - 0.020
3
Tolerance between rotor assembly and inlet
housing
0.0175 - 0.0225
4
Turbine wheel tip to turbine nozzle clearance
0.010 - 0.031
5
Shim thickness
0.029 - 0.084
6
Shim thickness
0.037 - 0.082
7
Stud play
0.017 - 0.019
8
Shim tolerance
0.012 - 0.015
9
Turbine wheel tip to seal plate clearance
0.055 - 0.120
Record
Actual
Stretch
Pages 6-35 and 6-36 have been
deleted in their entirety.
Change 22 6-33/(6-34 blank)
T.O. 2G-T62T-43
Figure 6-22. Clearance Limits
6-37
T.O. 2G-T62T-43
NOTE
Any limits exceeded which require
removal, rotation or replacement of
parts
will
require
complete
rebalancing.
g.
Assemble turbine assembly as follows:
(1)
Remove rotor assembly (Figure 3-10,
22) from rotor assembly inspection fixture, ST64016 (Figure 2-1, 14), and set
up in rotor fixture, ST70137 (17).
NOTE
Ensure alignment pins are engaged
properly when support housing (30)
and inlet housing (31) are mated.
Local manufactured tool, PE0014DAC
can be used to aid in alignment.
(12)
Secure support housing (30) to inlet
housing (31) with bolts (25) and washers
(14). Torque to 24-27 inch-pound.
(13)
Place assembly in a horizontal position.
Using tension tester, ST64038 (Figure
2-1, 16), or LKG 05, measure the
amount of pressure in grams, needed to
move IGV drive gear (34). The pressure
shall not exceed 226 grams to move IGV
drive gear in either direction. If pressure exceeds tolerance, disassemble and
locate cause before proceeding.
NOTE
When removing nut (4), use a 7/16inch diameter dowel pin to protect the
splines on the rotor shaft before applying pressure.
(2)
Remove nut (Figure 3-10, 4), and load
compressor wheel (20), using assembly
aid (4 inch long x 0.437 inch diameter
steel dowel), press off load compressor
wheel (20) from rotor assembly (22).
(3)
If previously removed, install inserts
(36) in IGV drive gear (34) per Section V
- Inspection, Repair, and Replacement.
(4)
If previously removed, install inserts
(27) and pins (28 and 29) in support
housing (30) per Section V - Inspection,
Repair, and Replacement.
(5)
Install IGV bushings (40) on inlet guide
vanes (39).
(6)
Install IGV sector gears (38) on inlet
guide vanes (39) and secure with locknuts (37). Torque to 1-5 inch-pound.
Above run on torque.
(7)
Remove temporarily installed bolts (25)
from inlet housing (30). Remove support housing (30) from inlet housing
(31).
(8)
Install IGV drive gear bearing (35) and
IGV drive gear (34) on support housing
(30). Ensure IGV drive gear (34) is
aligned with slot on support housing
(30).
(9)
Install pin drive-flange (33) with bolts
(32). Torque to 24-27 inch-pound.
(10)
Install inlet guide vanes (39) in support
housing (30).
(11)
Align marks (dimples) between IGV sector gears (38) and IGV drive gear (34).
6-38 Change 22
WARNING
Liquid nitrogen, Specification MIL-P27401, will freeze eyes and skin. Wear
face protection, gloves, and apron during use.
(14)
Freeze labyrinth seal (52) and bearing
aft carrier (53) in liquid nitrogen, Specification MIL-P-27401, (-250oF) for
approximately 5 minutes.
(15)
Using manual press and arbor press
guide, ST71207 (Figure 2-1, 45), install
labyrinth seal (52) and bearing aft carrier (53) in inlet housing (31). Ensure
keying dowel pin in inlet housing (31)
matches cutaway in bearing aft carrier
(53). Hold minimum pressure for seating until thermal fit is completed.
(16)
Deleted
(17)
Install O-rings (42) in inlet housing (31).
(18)
Set up rotor assembly (22) in rotor fixture, ST70137 (Figure 2-1, 17).
(19)
Determine
follows:
(a)
shim
(51)
thickness
as
Using flat surface, press down on
assembly function gage, ST63929
(Figure 2-1, 11), to preset dial indicator to zero. Preset length, dimension
X (Figure 6-23), is 4.0080. Using an
assembly aid (bullet shaped), to protect threads of rotor, install assembly
function gage, ST63929 (Figure 2-1,
11), over engine compressor wheel
T.O. 2G-T62T-43
(60) and press down. If dial reading
is plus, subtract from 4.0080, if dial
reading is minus, add to 4.0080. The
result from this circulation is to be
used as new dimension X in rest of
equation. Remove assembly function
gage, ST63929.
(b)
Install bridge gage, ST60051 (Figure
2-1, 5), and assembly check gage
plate, ST71217 (48). Measure dimensions A on inlet housing (31) and B
on diffuser housing (45) (Figure 624). Subtract dimension of legs
etched (7 inches if no etching) on
bridge gage, ST60051 (Figure 2-1, 5),
from dimension A and B.
NOTE
0.020 inch is desired clearance.
(c)
Determine shim (Figure 3-10, 51)
thickness
using
the
following
formula:
contain a neurotoxin that can be
absorbed through the intact skin.
Symptoms of overexposure include tingling or numbness in hands or feet.
Wear nitrile gloves and chemical protective goggles. Consult the applicable
MSDS and local OSH regulations for
additional information.
.
.
NOTE
Proper indexing of housing assembly
to inlet housing assembly is when,
looking forward, the air inlet boss is at
the 2:30 o’clock position.
It may be necessary to secure diffuser
housing (45) to inlet housing (31) with
a shorter bolt (model 161327-104, use
MS9914-12).
(20)
Apply assembly fluid, RT-403A, No. 1,
or lubricating oil, MIL-PRF-23699, on
outside diameter and around top of diffuser housing (45).
(21)
Using shim thickness determined in
step (17), install shim (51) on diffuser
housing (45) with guide pins.
(22)
Using arbor press, install diffuser housing (45) on inlet housing (31) and secure
with bolts (43) and washers (44).
(23)
Record selected shim (51) thickness as
position 6 on Table 6-1, (Figure 6-22,
detail 6).
(24)
Coat threads and shanks of bolts (1)
with antiseize compound, Specification
MIL-A-907.
Dimension X - (Dimension A +
Dimension B + 0.020)
(d)
Select appropriate shim size from following:
P/N
161793-1
161973-2
161793-3
161973-4
161973-5
161973-6
161973-7
161973-8
161793-9
161793-10
161793-11
161793-12
161793-13
161793-14
161793-15
Dimension
0.010
0.015
0.020
0.040
0.050
0.052
0.054
0.056
0.058
0.060
0.062
0.064
0.066
0.068
0.070
WARNING
.
.
Assembly fluid may cause irritation of
the skin and eyes upon overexposure.
PPE: chemical goggles and protective
gloves. Consult the applicable MSDS
and local OSH regulations for additional information.
MIL-PRF-23699 Lubricating Oil can
irritate skin or eyes upon contact. May
WARNING
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
(25)
If necessary, put diffuser (Figure 3-10,
41) in dry ice and then install in diffuser
housing (45) and secure with bolts (1).
Torque to 24-27 inch-pounds.
Change 22
6-39
T.O. 2G-T62T-43
Figure 6-23.
6-40 Change 22
Determination of Shim Thickness
TO 2G-T62T-43
Figure 6-24. Installation of Bridge Gage
6-41
TO 2G-T62T-43
(26) To ensure that correct shim (51) thickness has been determined, perform the
following function as a double check:
(a) Install rotor assembly (22) in rotor
fixture, ST70137 (17, figure 2-1).
(b)
Install ring gage, ST61186-06 (8),
on engine compressor wheel (60,
figure 3-10). Ensure ring gage is
properly seated and thickness of
ring gage is 0.063 in.
(c)
Place inlet housing (31) over rotor
assembly (22) with ring gage,
ST61186-06 (8, figure 2-1), still
in place. Do not damage labyrinth
seal (52, figure 3-10).
NOTE
Be sure bolts (1) do not cause diffuser
housing to bind on rotor fixture, ST70137.
(d) Install bridge gage, ST60051 (figure 6-25), on inlet housing (31,
figure 3-10). Measure depth and
record measurement.
(e) Remove inlet housing (31) and
bridge gage, ST60051 (figure
6-24). and ring gage, ST6118606 (8, figure 2-1), from rotor assembly (22, figure 3-10).
(f) Install inlet housing (31) over rotor assembly (22) without ring
gage, ST61186-06 (8, figure 2-1).
(g) Install bridge gage, ST60051 (figure 6-25), over inlet housing (31,
figure 3-10). Measure depth and
record measurement.
(h) Subtract recorded depth obtained
in step (g) from recorded depth
obtained in step (d). Then subtract the answer from 0.063 in.
Tolerance should be within
0.0175-0.0225 in. range, position
3, table 6-1 (figure 6-22, detail
3).
NOTE
If shim thickness obtained in step (23) is
different from shim thickness obtained in
step (17), use shim thickness obtained in
step (23).
6-42
(27) If correct shim (51, figure 3-10) thickness has not been selected, disassemble
turbine assembly, recalculate shim
thickness, and install correct shim
thickness.
(28) Using flat surface and gage set block,
preset functional gage assembly,
ST63931 (figure 6-26), dial indicator
to zero. Present length dimension X
(figure 6-26) is 1.6950 in. gage block.
(29) Install functional gage assembly,
ST63931 (figure 6-26), over load compressor wheel (20, figure 3-10). Record reading on dial indicator. If dial
reading is a minus, subtract from
1.6950. If the reading is a plus, add to
1.6950. The result from this calculation is to be used as new dimension X
to determine shim thickness.
(30) Determine and record thickness of
shim (24) using the following formula:
Dimension X - (Dimension A + Dimension B + 0.0175)
(a) Install bridge gage, ST60051 (5,
figure 2-1), across the front flange
of the inlet housing (31, figure
3-10) and measure to load compressor wheel (20) seat to obtain
dimension A. Subtract dimension
of legs etched (7 in. if no etching)
on bridge gage, ST60051 (5, figure 2-1), from measurement.
(b) Dimension B is determined by installing load compressor scroll (23)
on assembly check gage plate,
ST71214 (47, figure 2-1). Position bridge gage, ST60051 (5, figure 2-1), across load compressor
scroll (23, figure 3-10) and measure to base plate of assembly
check gage plate, ST71214 (47,
figure 2-1). Subtract dimension
of legs etched (7 in. if no etching)
on bridge gage, ST60051 (5),
from measurement.
TO 2G-T62T-43
Figure 6-25. Determination of Depth
6-43
TO 2G-T62T-43
Figure 6-26. Installation of Functional Gage Assembly
(31) To ensure correct shim (24, figure
3-10) thickness has been determined,
perform the following steps as a double
check:
(a) Remove load compressor scroll
(23) from assembly check gage
plate, ST71214 (47, figure 2-1)
and turn load compressor scroll
over.
(b) Set load compressor wheel (20,
figure 3-10) into load compressor
scroll (23).
(c) Set up load compressor clearance
tool, ST93950 (77, figure 2-1).
over hub of load compressor wheel
(20, figure 3-10) and set dial indicator to zero and lock.
(d) Using a felt tip pen, mark position
of load compressor scroll (23)
6-44
where load compressor clearance
tool, ST93950 (77, figure 2-1) is
positioned, then remove load
compressor
clearance
tool,
ST93950, and load compressor
wheel (20, figure 3-1) from load
compressor scroll (23).
(e) Use a depth micrometer to determine the exact height difference
between load compressor wheel
(20) and spacer of load compressor clearance tool, ST93950 (77,
figure 2-1). Record value.
(f)
Install shim (24) and secure load
compressor scroll (23) to inlet
housing (31) temporarily with
setup bolts, washers, and nuts
(three or more).
T.O. 2G-T62T-43
(g)
Install spacer on load compressor
clearance tool, ST93950 (Figure 2-1,
77), on rotor shaft (Figure 3-10, 59).
(32)
Clean bore of load compressor wheel
(20) and apply a very thin coating of
antiseize compound, MIL-PRF-907.
WARNING
WARNING
MIL-PRF-23699 Lubricating Oil can
irritate skin or eyes upon contact. May
contain a neurotoxin that can be
absorbed through the intact skin.
Symptoms of overexposure include tingling or numbness in hands or feet.
Wear nitrile gloves and chemical protective goggles. Consult the applicable
MSDS and local OSH regulations for
additional information.
Wear protective gloves when handling
heated parts to avoid injury.
(h)
Apply a light coat of lubricating oil,
MIL-PRF-23699, to knurl of engine
compressor wheel (60).
(i)
Install inlet housing (31) over rotor
shaft (59).
(j)
Install load compressor clearance
tool, ST93950 (Figure 2-1, 77), over
load compressor scroll (Figure 3-10,
23) at the same position marked in
step (d). Set pin of dial indicator on
top of spacer of load compressor
clearance tool, ST93950 (Figure 2-1,
77). Dial indicator reading will
reflect clearance of load compressor
wheel (20), plus or minus height difference between spacer of load compressor clearance tool and load compressor wheel (Figure 3-10, 20).
Record valve obtained as position 2
(Table 6-1) (required clearance is
0.015-0.020 inch).
(k)
Remove load compressor clearance
tool, ST93950 (Figure 2-1, 77), from
load compressor scroll (Figure 3-10,
23) and spacer from rotor shaft (59).
(l)
Remove inlet housing (31) from rotor
shaft (59).
(m)
Remove load compressor scroll (23)
from inlet housing (31).
NOTE
Problems with axial fit of the load compressor wheel to the shoulder of the
rotor shaft, may occur if too much antiseize compound is applied.
(33)
Reheat load compressor wheel (20) in an
oven to 650oF for 1 hour.
(34)
Install predetermined shim (24) thickness and load compressor scroll (23) into
inlet housing (31). Record shim thickness as position 5, Table 6-1 (Figure 622, detail 5). Appropriate shims are:
P/N
161972-1
161972-2
161792-3
161972-4
161972-5
161972-6
161972-7
1619724
161792-9
161792-10
161792-11
161792-12
161792-13
161792-14
161792-15
Dimension
0.010
0.015
0.020
0.040
0.050
0.052
0.054
0.056
0.058
0.060
0.062
0.064
0.066
0.068
0.070
NOTE
To check for proper indexing, the right
IGV actuator pad should be 1/2 hole to
the right of the 12 o’clock position,
looking forward.
(35)
Secure load compressor scroll (Figure 310, 23) to inlet housing (31) temporarily
with setup bolts, washers, and nuts
(three or more).
(36)
Check for proper seating by ensuring
that the shimmed space between the
load compressor scroll (23) and the inlet
housing (31) is closed.
(37)
Deleted
(38)
Deleted
(39)
Deleted
(40)
Deleted
(41)
Deleted
Change 22
6-45
T.O. 2G-T62T-43
(42)
.
.
Set
up
load
compressor
restrainer, ST93951-04 (78).
wheel
WARNING
Dry Ice, Carbon Dioxide (solid), CGA
G-6.2, can cause severe skin burns and
frostbite. Do not handle with bare
hands. Use in well-ventilated area.
Wear cryogenic gloves, chemical goggles, and face shield. Consult the applicable MSDS and local OSH regulations
for additional information.
Liquid nitrogen is extremely cold and
can injure human skin or tissue on
contact. Liquid nitrogen will expand
696 times as it vaporizes, and if the
liquid vaporizes in a sealed container,
it can produce enormous pressures
that could rupture the vessel. Nitrogen
can displace oxygen in poorly ventilated or confined areas. Boiling and
splashing occurs when filling a warm
container with or when inserting
objects into liquid nitrogen. Perform
these tasks slowly to minimize boiling
and splashing. Use tongs to withdraw
objects immersed in a cryogenic liquid.
Wear chemical splash goggles, face
shield, and approved cryogenic glove/
outer wear when handling liquid nitrogen. Consult the applicable MSDS and
local OSH regulations for additional
information.
(43)
Chill rotor shaft (Figure 3-10, 59) with
dry ice, CGA G-6.2, or liquid nitrogen,
A-A-59503.
(44)
Remove load compressor wheel (20)
from oven and install load compressor
wheel onto rotor shaft (59).
(45)
Install load compressor wheel assembly
(tool), ST71236 (Figure 2-1, 54), stretch
tool, ST71078 (40), and load compressor
wheel (Figure 3-10, 20). Set pump on
tool to 8000 pounds. Maintain pressure
for approximately 30 minutes until temperature of part stabilizes.
CAUTION
Due to the close tolerance runout of
mating surfaces, any damage to mating surfaces will prevent obtaining a
good rotor assembly/turbine assembly.
(46)
Remove load compressor wheel assembly (tool), ST71236 (Figure 2-1, 54),
stretch tool, ST71078 (40), and install
load
compressor
clearance
tool,
ST93950 (77), previously set to zero, on
load compressor scroll (Figure 3-10, 23).
Indicator tip of tool is on hub of load
compressor wheel (20). Check and
record clearances at position 2, Table 61 (Figure 6-22, detail 2).
(47)
Remove temporarily installed bolts,
washers, and nuts holding load compressor scroll (Figure 3-10, 23) to inlet
housing (31).
(48)
Place adapter assembly (17) in freezer
for 10 minutes.
(49)
Install load compressor diffuser (18)
with aligning bolts, and O-ring (19).
WARNING
WARNING
Wear protective gloves when handling
heated parts to avoid injury.
Wear protective gloves when handling
chilled parts to avoid injury.
(50)
Use care when assembling thermal fit
components to prevent damage to mating surfaces.
Remove adapter assembly (17) from
freezer and install. Secure with bolts
(16), washers (14), and nuts (13). Align
hole adjacent to strut of adapter assembly (17) at 12 o’clock position. Torque to
24-27 inch-pounds.
(51)
NOTE
Note match marks on load compressor
wheel (20).
Install stud (15), adjacent to 6 o’clock
position, facing aft, using nut (13) and
washer (14). Torque to 24-27 inchpounds.
(52)
If previously removed, install pin (12) in
bearing front carrier (7).
CAUTION
6-46 Change 22
T.O. 2G-T62T-43
(53)
Install springs (8) in adapter assembly
(17).
(54)
Using hand pressure, install forward
bearing (11) in front bearing carrier (7).
Ensure thrust side of forward bearing
(11) is positioned down.
(55)
Determine and record spacer (9) thickness as follows:
(a)
(b)
Using bridge gage, ST60051 (Figure
2-1, 5), determine distance from top
of adapter assembly (Figure 3-10, 17)
to where forward bearing (11) seats
on load compressor wheel (20) (Figure 6-27, dimension A). Subtract
dimension of legs etched (7 inches if
no etching) on bridge gage, ST60051
(Figure 2-1, 5), from dimension A.
Using bridge gage, ST60051 (5),
determine distance from top of
adapter assembly (Figure 3-10, 17) to
where shim (24) seats (Figure 6-27,
dimension B). Subtract dimension of
legs etched (7 inches if no etching) on
bridge gage, ST60051 (Figure 2-1, 5),
from dimension B.
(c)
Subtract measurement obtained in
step (b) from step (a) and this will
give dimension C.
(d)
Using bar stock and depth gage,
determine distance from inner race
to forward bearing (Figure 3-10, 11)
face where spacer (9) sets on bearing
front carrier (7) dimension D (Figure
6-27) . Forward bearing must be
seated.
(e)
(57)
Using hand pressure, install predetermined spacer (9) on bearing front carrier (7). Appropriate spacers (9) are:
P/N
163223-11
163223-12
163223-13
163223-14
163223-15
163223-16
163223-17
163223-18
Dimension
0.209-0.211
0.212-0.214
0.215-0.217
0.218-0.220
0.221-0.223
0.224-0.226
0.227-0.229
0.230-0.232
0.233-0.235
0.236-0.238
0.239-0.241
0.242-0.244
0.245-0.247
0.248-0.250
0.251-0.253
0.254-0.256
Install bearing front carrier (7) in
adapter assembly (17) and nut (4),
aligning cutout in carrier with magnetic
pickup hole and nut (4).
CAUTION
Be careful not to damage rotor blades
when installing rotor assembly clearance gage.
(58)
Place turbine assembly in hydraulic
press and install assembly clearance
gage, ST71235 (Figure 2-1, 53), on top of
adapter assembly (Figure 3-10, 17).
Zero dial indicator.
(59)
Using hydraulic press, apply pressure to
compress bearing front carrier (7) and
springs (8). Measure and record as position 8, Table 6-1 (Figure 6-22, detail 8).
Reshimming to achieve position 8 tolerance may be necessary.
(60)
Remove assembly clearance
ST71235 (Figure 2-1, 53).
(61)
Install pinion installation and disassembly tool, ST71209 (Figure 3-11), or
locally manufactured tool, 18E2286-1
(96916) on to top of adapter assembly
(Figure 3-10, 17). Tighten screws on tool
and press down on toggle clamps until it
is secure on bearing front carrier (7).
(62)
Using wrench, ST71191 (Figure 2-1,
42), remove nut (Figure 3-10, 4).
(63)
Deleted
(64)
Deleted
(65)
Lubricate O-rings (10) with assembly
fluid, RT-403A, No. 1, and install on
bearing front carrier (7).
(66)
Deleted
(67)
Deleted
(68)
Deleted
To obtain spacer (Figure 3-10, 9)
thickness, use the formula:
C - D - 0.013
(56)
163223-19
163223-20
163223-21
163223-22
163223-23
163223-24
163223-25
163223-26
Change 22
gage,
6-47
T.O. 2G-T62T-43
Figure 6-27.
6-48 Change 22
Determination of Spacer Thickness
T.O. 2G-T62T-43
(69)
Install pinion assembly (Figure 3-10, 5),
using pinion installation and disassembly tool, ST71209 (Figure 2-1, 46), to
insert pinion into splined end of rotor
shaft (Figure 3-10, 59).
(70)
Apply a small amount of assembly fluid,
RT-403A, No. 1, to steel balls (6) and
install in groove provided at end of rotor
shaft (59).
(71)
Reinstall nut (4) and tighten using
wrench, ST71191 (Figure 2-1, 42).
Torque to 1200-1350 inch-pounds.
.
Remove pinion installation and disassembly tool, ST71209 (Figure 2-1, 46),
and stake nut (Figure 3-10, 4) in three
equally spaced places.
.
(72)
(73)
(74)
Install magnetic pickup (3) as follows:
WARNING
Loctite 272 sealing compound may
cause dermatitis in sensitive individuals upon prolonged contact. Keep
material away from skin. Wear butyl
rubber gloves and safety glasses. Consult the applicable MSDS and local
OSH
regulations
for
additional
information.
(a)
Apply a light coat of adhesive, Loctite 272, to threads of magnetic
pickup (3).
(b)
Locate the highest position of any of
the four lobes on the nut (4). If a lobe
of the nut is not at a highest point
when viewed through the magnetic
pickup boss on the adapter assembly
(17), rotate the turbine assembly.
Rotate until highest point of nut is
evidenced.
(c)
Install magnetic pickup (3) on loabe
ouside diameter on nut (4). Back off
magnetic pickup 1/4 turn and measure gap at four lobes (0.012-0.014
inch). If all gaps don’t meet clearance, take one with minimum clearance. Use key in electrical connector
as index.
(d)
Tighten locknut of magnetic pickup
(3) to 80-100 inch-pounds and safety
wire with lockwire, MS20955C32.
Install protective cap over connector
end.
Install bridge gage, ST60051 (Figure 21, 5) on adapter assembly (Figure 3-10,
17). Measure and record distance from
end of pinion assembly (5) to face of
adapter assembly (17) (position 1, Table
6-1, Figure 6-22, detail 1). Subtract
measurement from dimension of legs
etched on bridge gage, ST60051 (Figure
2-1, 5).
NOTE
Compare all measurements to the minimum and maximum limits specified
on clearance chart (Table 6-1).
Rotor shaft should be in forward direction (clockwise looking forward).
(75)
Install protective cap on pinion assembly (Figure 3-10, 5) before turning turbine assembly over.
(76)
Using wire gage, ST60880 (Figure 2-1,
7), measure distance from underside of
turbine wheel tips to top edge of seal
plate (Figure 3-10, 57) and record as
position 9, Table 6-1 (Figure 6-22, detail
9).
(77)
Install turbine nozzle (Figure 3-10, 2)
and secure with bolts (1). Torque to 2527 inch-pounds.
(78)
Using wire gage, ST60880 (Figure 2-1,
7), measure turbine wheel (Figure 3-10,
55) to turbine nozzle (2) radial clearance
and record as position R, Table 6-1 (Figure 6-22, detail R).
(79)
Using wire gage, ST60880 (Figure 2-1,
7), measure distance from turbine wheel
tip to turbine nozzle (Figure 3-10, 2) and
record as position 4, Table 6-1 (Figure 622, detail 4). Turbine nozzle can be repositioned
to
meet
measurement
requirements.
6-6. ASSEMBLY OF APU This section contains
procedures for assembly of the APU after the subassemblies have been assembled.
a.
Install reduction drive unit (Figure 3-3, 33)
in assembly build stand, ST71206 (Figure 21, 44).
b.
Install turbine assembly (Figure 3-3, 30) as
follows:
(1)
Install adapter gasket (32) and O-ring
(31) on reduction drive unit (33).
(2)
Install turbine assembly (30) on reduction drive unit (33) in a vertical position
Change 22
6-49
T.O. 2G-T62T-43
and secure with bolts (29). Torque to 55-70 inchpounds over running torque.
c.
Install containment ring (Figure 3-5, 37) as
follows:
(1)
(2)
If previously removed, attach identification plate (36) with adhesive, Specification MIL-A-46146, type III, to containment ring (37) and apply UID labels in
accordance with paragraph 6-8.
Using spanner wrench, ST93975 (Figure 2-1, 79), install locking ring (Figure
3-5, 35) on right side only, looking from
aft end, and engine mounting adapter
(34) on turbine assembly (Figure 3-3,
30). Torque to 45-55 inch-pounds. Stake
locking ring (Figure 3-5, 35) at three
equally spaced places.
6-50 Change 23
(3)
Lubricate O-ring (Figure 3-2, 51, detail
G) with assembly fluid, RT-403A, No. 1,
and install O-ring (51).
(4)
Coat elbow (50) with antiseize compound, Specification MIL-A-907, and
install in turbine assembly (68).
(5)
Position containment ring (Figure 3-5,
37) on turbine assembly (Figure 3-3,
30).
(6)
Using spanner wrench, ST93975 (Figure 2-1, 79), install locking ring (Figure
3-5, 35) on left side, looking from aft
end, and engine mounting adapter (34)
on turbine assembly (Figure 3-3, 30). Do
not torque or stake locking ring at this
time.
TO 2G-T62T-43
Install duct support bracket (16) on
containment ring (37) and secure with
bolts (15), washers (14). and nuts
(13). Do not torque at this time.
(2)
Install IGV drive link (8) to IGV actuator (6) and pin-drive flange (33, figure
3-10) and secure with bolt (7, figure
3-7) and nut (1).
d. Install air flow sensor (25) and surge control
valve (9) as follows:
(3)
Lubricate o-rings (7, 10, 18, 20, 23,
and 26) with assembly fluid, RT-403A,
No. 1.
Install insulation actuator bushings (5),
bolts (3), and washers (4) on IGV actuator (6).
(4)
Install IGV actuator (6) on turbine assembly and secure with self-locking
nuts (2). Torque to 100-130 in. lb.
(5)
Install nut (1) securing IGV drive link
(8) to turbine assembly (30, figure
3-3). Torque to 22-27 in. lb.
(6)
Using wire gage, ST60880 (7, figure
2-1) adjust stroke of IGV actuator (6,
figure 3-7) until gap between inlet
guide vanes is 0.060-0.100 in. in fully
closed position (17 places). Gap to be
measured at root of IGV.
(7)
(1)
(2)
Install O-ring (23) with fitting (22) in
air flow sensor (25).
(3)
Install bolt (21) securing fitting (22) to
air flow sensor (25).
(4)
Install O-ring (20) with temperature
sensor (19) in air flow sensor (25).
(5)
Install O-ring (26) with air flow sensor
(25) to load compressor scroll (38).
(6)
Install V-band clamp (24) securing air
flow sensor (25) to load compressor
scroll (38). Torque to 30 in. lb. above
prevailing torque.
(7)
Install O-ring (18) with duct assembly
(17) on air flow sensor (25).
Install eye bolt (20, figure 3-3) in reduction
drive unit (33).
g. Perform dimensional checks as follows:
(1)
Install lifting fixture, ST94409 (82, figure 2-1), in eye bolt (20, figure 3-3)
and attachment point on containment
ring (37, figure 3-5).
(2)
(10) Install duct assembly (6) to duct assembly (17) and secure with V-band clamp
(5). Torque to 30 in. lb. above prevailing, torque.
Using suitable hoist (minimum 2,000
lbs. lifting capacity) and lifting fixture,
ST94409 (82, figure 2-1), hoist APU
over layout table.
(3)
Lower APU onto assembly build stand,
ST71206 (44), attached to layout table,
and secure APU.
(11) Install O-ring (10) with surge control
valve (9) on duct assembly (17).
(4)
Remove hoist and lifting fixture,
ST94409 (82), from APU.
(5)
Remove bolts (32, figure 3-5) and
bushing (33) from bottom of containment ring (37) and install assembly aid
tool bolt.
(6)
Shim front engine trunion mounts and
adjust rear support of assembly build
stand, ST71206 (44, figure 2-1) to
level APU within 0.001 in.
(8)
Install V-band clamp (12) securing
duct assembly (17) to air flow sensor
(25). Torque to 30 in. lb. above prevailing torque.
(9)
Install O-ring (7) on duct assembly
(17).
(12) Install V-band clamp (8) securing
surge control valve (9) to duct assembly
(17). Torque to 30 in. lb. above prevailing torque.
e.
f.
Install IGV actuator (6, figure 3-7) as follows:
(1)
Install IGV actuator stop (9) to IGV
actuator (6).
6-51
TO 2G-T62T-43
Figure 6-28. Tolerance Specifications (Sheet 1 of 2)
6-52
TO 2G-T62T-43
Figure 6-28. Tolerance Specifications (Sheet 2 of 2)
6-53
TO 2G-T62T-43
NOTE
Refer to Figure 6-28 for location of all dimensions.
(7) Align dimension measuring equipment
to parallel with Z-axis of APU.
(8)
(9)
Measure dimension between pilot of reduction drive unit output shaft inside
diameter and centerline of front
trunion mounts (left and right). Dimension should be 2.44 ±0.01 in.,
both sides.
Measure dimension between Z-axis
centerline of reduction drive unit accessory pad cover (13, figure 3-12)
and Z-axis centerline of duct assembly
(17, figure 3-5) extension flange. Dimension should be 10.10 ±0.07 in.
(10) If necessary, loosen bolts (29, figure
3-3) securing turbine assembly (30) to
reduction drive unit (33) and adjust to
attain dimension in step (9). Retorque
bolts (29) to 55-70 in. lb. Recheck
steps (8) and (9).
(16) Measure dimension between Z-axis
centerline of turbine rotor shaft (59,
figure 3-10) and Z-axis centerline of
surge control valve (9, figure 3-5) aft
flange.
Dimension should be 6.78
±0.03 in.
(17) If necessary, adjust surge control valve
(9) or duct assembly (17) to attain tolerance in step (16). If duct assembly
(17) is adjusted, recheck step (9).
(18) Measure dimension between Y-axis
centerline of left rear trunion mount
and Y-axis centerline of surge control
valve (9, figure 3-5) aft flange. Dimension should be 6.79 ±0.03 in.
(19) If necessary, adjust surge control valve
(9) or duct assembly (17) to attain tolerance in step (18). If duct assembly
(17) is adjusted, recheck steps (9) and
(16).
(11) If necessary, loosen bolts (58, figure
3-12) to obtain more rotation of reduction drive unit. Retorque bolts (58) to
33-37 in. lb. in three steps. Torque
sequence shall be: 1, 4, 7, 2, 5, 8, 3,
and 6.
(20) Leave APU on layout table, and install
air inlet duct (13, figure 3-6) as follows:
(12) Measure height of both rear trunion
mounts from surface of layout table.
Both dimensions should be the same,
±0.015 in.
(b) Install O-ring (15) and bottom
half of air inlet duct (13).
(13) If necessary, loosen bolts (1, figure
3-10) in diffuser housing (45) and rotate powerhead (aft half of APU) to
align rear trunion mounts with Y-axis
centerline of APU. Retorque bolts (1)
to 24-27 in. lb. It adjustment is made,
recheck steps (8) through (12).
(14) Measure dimension between left, rear
trunion mount and X-axis centerline of
duct assembly (17, figure 3-5) extenDimension should be
sion flange.
11.280 ±0.057 in.
6-54
(15) If dimension obtained in step (14) is
not within tolerance, replace duct assembly (17, figure 3-5) and recheck
steps (9) through 14).
(a) Apply assembly fluid, RT-403A,
No. 1, to O-ring (15, figure 3-6).
(c) Install upper half of air inlet duct
(13)
(d) If removed, install bands (8) on
air inlet duct (13) and secure with
bolts (11), bushings (12), washers
(10), and nuts (9). Torque to
24-27 in. lb.
(e) Connect bands (8) and torque
nuts (16) to 20-22 in. lb. above
running torque.
(f)
Install temperature sensor (14) to
air inlet duct (13). Torque to
135-150 in. lb.
T.O. 2G-T62T-43
(21)
Measure dimension between X-axis centerline of left, aft trunion mount, and Xaxis centerline of air inlet duct (13).
Dimension should be 4,460 ±0.057 in.
(22)
If necessary, adjust or replace air inlet
duct (13) to attain tolerance in step (21).
(23)
Measure dimension between Z-axis centerline of reduction drive unit (33, figure
3-3) accessory pad and Z-axis centerline
of air inlet duct (13, figure 3-6). Dimension should be 1.25 ±0.03 in.
(24)
If necessary, adjust air inlet duct (13)
and recheck step (21).
(25)
Install lifting fixture, ST94409 (82, figure 2-1) in eye bolt (20, figure 3-3) and in
attachment point on containment ring
(37, figure 3-5).
(26)
(27)
(28)
Using suitable hoist (minimum 2,000 lbs.
lifting capacity) and lifting fixture,
ST94409 (82, figure 2-1), hoist APU from
layout table.
Lower APU onto assembly build stand,
ST71206 (44) , on service cart, MIL-T16549G. Secure APU to stand.
If removed, install band clamp (11, figure 35). Torque to 24-27in. lb.
i.
Torque duct support bracket (16) bolts (15) on
containment ring (37) to 24-27 in. lb.
j.
Install connector mounting bracket (23, figure 3-3) on reduction drive unit (33) and
secure with washers (22) and bolts (21).
Torque to 24-27 in. lb.
Install oil pressure switch (18) as follows:
(1)
Lubricate O-ring (19) with assembly
fluid, RT-403A, No. 1.
(2) Install O-ring (19) with oil pressure
switch (18) in reduction drive unit (33).
Hand tighten oil pressure switch (18).
(3)
l.
m.
Lubricate O-rings (5 and 6) with assembly fluid, RT-403A, No. 1.
(2)
Install O-rings (5 and 6) and spring pin
(7) in inlet housing manifold (3) and manifold assembly (4).
(3)
Install inlet housing manifold (3) on manifold assembly (4), and loosely secure
with bolts (1) and washers (2).
(4)
Lubricate O-rings (60, 62, and 64, figure
3-2, detail G) with assembly fluid, RT403A, No. 1.
(5)
Install O-ring (64) and straight adapter
(63) in inlet housing manifold (72).
(6)
Install O-ring (62) and orifice fitting (61)
in inlet housing manifold (72).
(7)
Install O-ring (60) and elbow (59) in inlet
housing manifold (72). Ensure elbow (59)
is facing forward.
(8)
Install inlet housing manifold (72) on turbine assembly (68) and tighten bolts (1,
figure 3-6) and washers (2). Torque to
24-27 in. lb.
(9)
Install diffuser to tee PCD air tube
assembly (65, figure 3-2, detail G) on
orifice fitting (61).
(10)
After steps 2 through 9 have been completed, torque straight adapter (63) to
180-200 in. lb., orifice fitting (61) to 135150 in. lb., and elbow (59) to 135-150 in.
lb.
Remove hoist and lifting fixture,
ST94409 (82), from APU.
h.
k.
(1)
n.
Install combustor assembly as follows:
(1)
Remove temporarily installed assembly
aid tool bolt from bottom of containment
ring (37, figure 3-5).
(2)
Remove engine mounting adapter (34)
and locking ring (35) on left side, looking
from aft end.
(3)
Slide containment ring (37) to one side.
(4)
Install diffuser to tee PCD air tube
assembly (65, figure 3-2, detail G) to turbine assembly (68). Torque both ends to
135-150 in. lb.
(5)
Reposition containment ring (37, figure
3-5) and install bushing (33) and bolts
(32). Torque to 190-230 in. lb.
(6)
Install seal ring (28, figure 3-3) on turbine assembly (30).
Safety wire oil pressure switch (18) with
lockwire, MS2095C32.
Install turbine ignition exciter (31, figure 3-5)
on containment ring (37) with three-pin connector (P302) facing forward, when looking
from side. Secure with bolts (29), washers
(30), and nuts (28). Torque to 24-27 in. lb.
Assemble and install inlet housing manifold
(3, figure 3-6) as follows:
Change 3 6-55
T.O. 2G-T62T-43
(7) Apply anti-seize compound, MIL-A-907,
to inside diameter of combustor liner and
cone.
(8)
Using combustor puller, ST71201 (42,
figure 2-1), install combustor assembly
(27, figure 3-3) on turbine assembly (30).
caution
Do not tap clamp (24) when tightening
nut. Do not use lubrication to assist
with assembly of clamp.
(9)
(10)
(11)
(12)
o.
Install clamp (24). Locate with drain
fitting at 6 o’clock, looking forward, and
clamp (24) at 45°. Torque to 45-55 in. lb.
above nut run on torque.
Install combustor puller, ST71201 (43,
figure 2-1), and tap three times on combustor puller. Retorque to 45-55 in. lb.
Install temporary shipping plug in place
of O-ring (26, figure 3-3) and check valve
(25).
If engine mounting adapter (34, figure 35) and locking ring (35) have not been
installed or have been removed; install
engine mounting adapter (34), using
spanner wrench, ST93975 (79, figure 2-1)
on left side of containment ring (37)
looking forward. Torque to 45-55 in. lb.
Stake locking ring (35) at one place.
washers (9) and self-locking nuts (8).
Torque to 190-230 in. lb.
(3)
p. Assemble and install fuel control enclosure
base (44, figure 3-4) as follows:
(1)
If removed, install gasket (45) on fuel
control enclosure base (44).
(2)
Remove temporarily installed bolts (42)
and washers (43) from reduction drive
unit (33, figure 3-3) accessory pad.
(3)
Install fuel control enclosure base (44,
figure 3-4) to reduction drive unit (46)
and secure with bolts (42) and washers
(43). Torque to 24-27 in. lb.
(4)
Install engine accessory drive gasket (34)
on fuel electronic control assembly (33).
(5)
Install fuel electronic control assembly
(33) to fuel control enclosure base (44)
and secure with bolts (31) and washers
(32). Torque 55-70 in. lb.
(6)
Install elbow (41) on fuel control enclosure base (44), parallel to flange, and
secure with locknut (38) and washers (39
and 40). Torque to 180-200 in. lb.
(7)
Lubricate O-ring (26) with assembly
fluid, RT-403A, No. 1, and install with
elbow (25) in fuel electronic control
assembly (33). Torque elbow (25) to 5070 in. lb.
(8)
Install enclosure elbow to fuel pump
tube assembly (24) on elbows (25 and 41).
Torque to 270-300 in. lb.
Install engine hydraulic starter (10, figure 33) as follows:
(1)
Install gasket (11) on reduction drive unit
(33).
(2) Install engine hydraulic starter (10) on
reduction drive unit (33) and secure with
6-56 Change 3
Lubricate O-ring (13) with assembly
fluid, RT-403A, No. 1, and install with
nipple (12) on engine hydraulic starter
(10). Torque to 135-150 in. lb.
T.O. 2G-T62T-43
(9)
Install support clamp (23) and bracket
(14) on enclosure elbow to fuel pump
tube assembly (24) and secure with bolt
(20), washer (22) and nut (21).
(10)
Lubricate O-ring (30) with assembly
fluid, RT-403A, No. 1 and install with
nipple (29) on fuel electronic control
assembly (33). Torque to 135-150 in. lb.
(21)
Install enclosure spacer assembly (18)
to fuel control enclosure base (44) and
tighten studs.
(22)
Connect connectors of fuel electronic
harness (16) to fuel electronic control
assembly (33).
(23)
Install tiedown straps (15) on fuel electronic harness (16).
(11)
Install main fuel control to elbow tube
assembly (28) on to nipple (29).
(24)
(12)
Install tube elbow (27) on to main fuel
control to elbow tube assembly (28).
If previously removed, install gasket (6)
on fuel control enclosure cover (5).
(25)
(13)
Lubricate O-ring (37) with assembly
fluid, RT-403A, No. 1 and install with
elbow (36) on fuel electronic control
assembly (33).
Install fuel control enclosure cover (5) to
enclosure spacer assembly (18) and
secure with studs (1), springs (2) and
washers (3 and 4).
(14)
(15)
Lubricate O-ring (18, figure 3-2, detail
B) with assembly fluid, RT-403A, No. 1
and install with start fuel control to tee
tube assembly (16), connecting elbow
(36, figure 3-4) to fuel control enclosure
base (44). Torque locknut (35) on elbow
(36) to 40-50 in. lb. and start fuel control
to tee tube assembly (16) to 135-150 in.
lb.
Lubricate O-ring (17, figure 3-2, detail
B) with assembly fluid, RT-403A, No. 1
and install with purge valve to fuel
manifold tube assembly (19) to fuel control enclosure base (44, figure 3-4).
Torque to 135-150 in. lb.
(16)
If removed, apply adhesive MIL-A46106, to gasket (19) and install on fuel
control enclosure base (44).
(17)
Remove protective caps and plugs from
all connectors of fuel electronic harness
(16).
(18)
Install gasket (17) and fuel electronic
harness (16) to enclosure spacer assembly (18) with large key at 12 o’clock
position on fuel control enclosure base
(44).
(19)
(20)
Secure fuel electronic harness (16) and
gasket (17) to enclosure spacer assembly (18) with screws (7), washers (9) and
self-locking nuts (8).
Install support clamp (13) on fuel electronic harness (16) and secure bracket
(14) to support clamp (13) with bolts
(10), washers (11) and nuts (12). Torque
to 24-27 in. lb.
q.
Install gasket (17, figure 3-3) and reduction
drive cover (16) on reduction drive unit (33)
and secure with washers (15) and self-locking nuts (14). Torque to 190-230 in. lb.
r.
Assemble and install hourmeter junction
box (18, figure 3-8), assembly as follows:
(1)
(2)
Install terminal lugs (7) to studs on
terminal boards (26) and secure with
washers (30), lockwashers (29) and nuts
(28).
Remove tags and connect wiring to components (see figure 3-9 for wiring
diagram).
(3)
Install terminal board strips (27, figure
3-8) and terminal boards (26) to
hourmeter junction box (18) and secure
with screws (23), lockwashers (25) and
nuts (24).
(4)
Install connector (22) to hourmeter
junction box (18) and secure with screws
(19), washers (21) and nuts (20).
(5)
Install hourmeter junction box (18) to
enclosure spacer assembly (31) and
secure with screws (16) and washers
(17).
(6)
Install event counter (15) to cover (4),
and secure with screws (12), washers
(14) and self-locking nuts (13).
(7)
If rotor assembly (22, figure 3-10) is
removed, reset events counter (15, figure 3-8) as follows:
(a)
Install test leads from function generator/synthesizer to connections on
events counter (15).
Change 5 6-57
T.O. 2G-T62T-43
(b)
Apply 28 Vdc to events counter (15)
and set frequency of function generator/synthesizer to zero. Run events
counter until events counter reaches
zero. Cycles per second should he
1-20.
(2)
Install start fuel control to tee tube
assembly (16) to bulkhead tee (35).
(3)
Install start fuel tee to start nozzle tube
assembly (21) to bulkhead tee (35) and
fuel nozzle (22). Torque to 75-80 in. lb.
(4)
Lubricate O-ring (32) with assembly
fluid, RT-430A, No. 1 and install with
orifice jet restrictor (31) to bulkhead tee
(35). Torque bulkhead tee (35) to 75-85
in. lb., orifice jet restrictor (31) to 135150 in. lb. and start fuel control to tee
tube assembly (16) to 75-85 in. lb.
(5)
Install tee tube (30) to orifice jet restrictor (31).
(6)
Install purge valve to tee tube assembly
(24) to tee tube (30).
(7)
Install fuel manifold to purge valve tube
assembly (20) to combustor assembly
(74).
warning
Soldering fumes are toxic. Do not
breath fumes. Solder in well-ventilated area.
caution
Use a minimum of heat when soldering components. Use a heat sink to
prevent damage.
Be careful not to break wires on event
counter.
(8)
Using solder, QQ-S-571, Type Sn63, solder wires to event counter (15).
NOTE
When rotor assembly (22, figure 3-10)
is overhauled, replace hour meters
(11).
(9) Install hour-meters (11) to cover (4) and
secure with screws (8), lockwashers (10)
and nuts (9).
s.
NOTE
Fuel purge valve can be assembled on
work bench prior to installation on
APU.
(8)
Lubricate O-ring (29) with assembly
fluid, RT-403A, No. 1 and install with
tee (28) on fuel purge valve (25).
(9)
Lubricate O-ring (27) with assembly
fluid, RT-403A, No. 1 and install with
straight adapter (26) on fuel purge valve
(25).
Install fuel manifold to purge valve tube
assembly (20), connecting tee (28) and
fuel purge valve (25) to fuel manifold on
combustor assembly (74).
(10)
Connect terminal lugs (6 and 7) to
hourmeters (11).
(10)
(11)
Install gasket (5) and cover (4) to
hourmeter junction box (18) and secure
with screws (1), lockwashers (2) and
washers (3).
(11)
Install fuel purge valve (25, figure 3-2,
detail B) and tubing as follows:
(1)
Install bulkhead tee (35) and secure
with washer (34) and locknut (33).
6-58 Change 5
Install fuel purge valve (25) and purge
valve to tee tube assembly (24), connecting fuel purge valve (25) to tee tube (30).
TO 2G-T62T-43
t.
u.
v.
(12) Remove protective caps and install
purge valve to fuel manifold tube assembly (19), connecting tee (28) to
fuel purge valve (25).
ab. Lubricate O-ring (44, figure 3-2, detail F)
with assembly fluid, RT-403A, No. 1, and
install with reducer (43) on surge control
valve (69). Torque to 180-200 in. lb.
(13) After fuel purge valve (25) has been installed on APU, torque tube nuts on
fuel manifold to purge valve tube assembly (20), purge valve to tee tube assembly (24), tee tube (30), tee (28),
and straight adapter (26) to 135-150
in. lb.
ac. Lubricate O-ring (46) with assembly fluid,
RT-403A, No. 1, and install with reducer
(43) on IGV actuator (70).
Install and connect ignition cable (27, figure
3-5) to turbine ignition exciter (31) and igniter plug (39). Torque both ends of turbine
ignition exciter to 90-100 in. lb.
Lubricate O-ring (49, figure 3-2, detail G)
with assembly fluid, RT-403A, No. 1, and
install with straight adapter (48) to engine oil
sump assembly (71). Torque to 180-200 in.
lb.
Install oil hose assembly (47), connecting engine oil sump assembly (71) to straight adapter (63), on inlet housing manifold (72).
Torque both ends to 270-300 in. lb.
w. Lubricate O-ring (56) with assembly fluid,
RT-403A, No. 1, and install with elbow (55)
in reduction drive unit, (73). Torque to
135-150 in. lb.
x.
Install oil pressure-manifold housing to reduction drive tube assembly (54), connecting
reduction drive unit (73) to elbow (59) on
inlet housing manifold (72). Torque tube
nuts to 135-150 in. lb.
y.
Lubricate O-ring (53) with assembly fluid,
RT-403A, No. 1, and install with straight
adapter (52) on turbine assembly (68).
Torque to 180-200 in. lb.
z.
Install tee to gearbox adapter tube assembly
(66) to turbine assembly (68) and orifice fitting (61). Torque both ends to 135-150 in.
lb.
aa. Lubricate O-ring (58) with assembly fluid,
RT-403A, No. I, and install with high-oil
temperature switch (57) in reduction drive
unit (73). Torque to 45-50 in. lb.
ad. Install tee (45) on IGV actuator (70).
ae. Install tee to surge valve PCD air tube assembly (42), connecting PCD air to surge control
valve (69) and tee (45) on IGV actuator
(70). Torque tee to surge valve PCD air tube
assembly (42) to 270-300 in. lb. and tee
(45) to 180-200 in. lb.
af. Lubricate O-ring (41) with assembly fluid,
RT-403A, No. 1, and install with straight
adapter (40) through containment ring (33)
to turbine assembly (68). Torque to 180-200
in. lb.
ag. Install elbow (39) to straight adapter (40) on
PCD air outlet on turbine assembly (68).
NOTE
Do not torque across body of air filter (37).
ah. Install air filter (37) and filter to tee PCD air
tube assembly (36) to tee (45) on IGV actuator (70). Torque 270-300 in. lb.
ai. Install diffuser to filter PCD air tube assembly
(38) to air filter (37) and elbow (39).
Torque diffuser to filter PCD air tube assembly (38) and elbow (39) to 270-300 in. lb.
aj. Remove all protective caps and plugs from
connectors of engine control harness (13, figure 3-2, detail A).
ak. Connect engine control harness (13) connector (J1) to connector mounting bracket (23,
figure 3-3), and secure with bolts (5), washers (7), and nuts (6). Make sure key on engine control harness connector is at 12
o’clock position. Torque to 24-27 in. lb.
al.
Connect engine control harness connectors
(13, figure 3-2, detail A) at:
(1) Fuel control enclosure spacer, P2
(2) Hourmeter junction box, P3
(3) Purge fuel valve, P4
6-59
TO 2G-T62T-43
(4) Turbine Ignition exciter, P302
(5)
Low oil pressure switch, P303
(6)
Magnetic speed pickup, P304
(7)
High oil temperature switch, P305
(8)
Surge control valve, P306
(9) Ambient temperature, P307
(10) IGV actuator, P308
(11)
Air flow sensor, P309
am. Apply anti-seize compound, MIL-A-907, to
threads of combustor assembly prior to installing thermocouple harnesses (14 and 15).
an. Install thermocouple harness (14) on left side
of combustor housing, looking from aft of
APU, and thermocouple harness (15) on
right side, looking from aft of APU. Torque
thermocouple harnesses (14 and 15) to
70-110 in. lb.
ao. Connect thermocouple harness (14 and 15)
connectors at:
(1) Thermocouple harness, P8-J8
(2) Thermocouple harness, P9-J9
ap. Install support clamp (4, figure 3-3) on connector mounting bracket (23) and engine
control harness (13, figure 3-2, detail A).
Secure with bolt (1, figure 3-3). washer (3),
and self-locking nut (2). Torque to 24-27
in. lb.
aq. Install support clamps (6, figure 3-2, detail
H) on filter to tee PCD air tube assembly
(36, figure 3-2, detail F) and engine control
harness (13). Secure with bolts (3, figure
3-2, detail H), washers (5), and nuts (4).
Torque to 24-27 in. lb.
ar. Install six sets of support clamps (6) on tee to
gearbox adapter tube assembly (66, figure
3-2, detail G), oil pressure-manifold housing
to reduction drive tube assembly (54), and
engine control harness (13). Torque to
24-27 in. lb.
as. Install support clamps (6 and 7, figure 3-2,
detail C) on engine control harness (13).
purge valve to fuel manifold tube assembly
(19), and APU. Secure support clamps with
6-60
bolts (10), spacers (11), washers (5), and
nuts (4). Torque to 24-27 in. lb.
at. Install support clamps (6 and 9) on start fuel
control to tee tube assembly (16) and purge
valve to fuel manifold tube assembly (19),
and to engine control (13). Secure with bolts
(3), washers (5), and nuts (4). Torque to
24-27 in. lb.
au. Install two sets of support clamps (6 and 8)
on engine control (13), and thermocouple
harness (14). Secure with bolts (3), washers
(5), and nuts (4). Torque to 24-27 in. lb.
av. Install support clamps (4, figure 3-5, detail
A) on ignition cable (27) and thermocouple
harness (40). Secure with bolts (1), washers
(3), and nuts (2). Torque to 24-27 in. lb.
aw. Install support clamps (7, figure 3-2, detail
D) on engine control harness (13) at fuel
control enclosure base assembly (75, figure
3-2, detail B) and secure with bolts (3, figure
3-2, detail D), washers (5), and nuts (4).
Torque to 24-27 in. lb.
ax. Install support clamps (6, figure 3-2, detail
E) on fuel manifold to purge valve tube assembly (20), thermocouple harness (14),
and ignition cable (67). Secure with bolts
(3), washers (5), and nuts (4). Torque to
24-27 in. lb.
ay. Install support clamps (6, figure 3-2, detail
H) on purge valve to tee tube assembly (24,
figure 3-2, detail B) and thermocouple harness (14). Secure with bolts (3, figure 3-2,
detail H), washers (5), and nuts (4). Torque
to 24-27 in. lb.
az. Install support clamps (6, figure 3-2, detail
H) on purge valve to fuel manifold tube assembly (19, figure 3-2, detail B) and engine
control. harness (13). Secure with bolts (3,
figure 3-2, detail H), washers (5), and nuts
(4). Torque to 24-27 in. lb.
ba. Install tiedown strap (12) on engine control
harness (13, figure 3-2, detail A).
bb. Install lockwire, MS20995C20. on engine
control harness (13, figure 3-2, detail A)
and thermocouple harness (14 and 15) connectors.
T.O. 2G-T62T-43
NOTE
If build-up is for APU part No. 161331135A, follow steps bc. through bj. If for
part No. 161331-135 proceed to step bl.
bc.
Mount the oil cooler, (76, Figure 3-2, index I)
to the top bracket, (84, Figure 3-2, index I)
using seven bolts, (89, Figure 3-2, index I).
Coat bolts with anti-seize compound, Specification MIL-A-907 and screw into seven
self-locking nuts integral to the oil cooler.
Torque bolts 24 - 27 inch-pounds using standard sequence in accordance with TO 1-1A8.
bd.
Screw Bulkhead Fitting Nut (79, Figure 3-2,
index I) on to 45o Elbow Adapter Fitting (78,
Figure 3-2, index I). Coat O-rings, (87, Figure 3-2, index I) with assembly fluid, RT403A, No. 1, and install onto fittings (77,
Figure 3-2, index I) and (78, Figure 3-2,
index I). Install fitting (77, Figure 3-2, index
I) to the oil cooler inlet port and torque to
270 - 300 inch-pounds. Install assembled
fitting (78, Figure 3-2 index I) to the oil
cooler outlet port with end positioned
towards the APU gearbox assembly and
torque to 270 - 300 inch-pounds. Hold fitting
(78, Figure 3-2, index I) while applying
torque to nut (79, Figure 3-2, index I).
be.
bf.
bg.
bh.
If applicable, remove the ‘‘oil in’’ port plug,
part No. AN814-4DL, from the APU
gearbox. Coat O-ring, (88, Figure 3-2, index
I) with assembly fluid, RT-403A, No. 1, and
install onto fitting, (80, Figure 3-2, index I).
Install the fitting into the gearbox at the ‘‘oil
in’’ port, and torque to 135 - 150 inchpounds.
If applicable, remove the ‘‘oil out’’ port plug,
part No. AN814/4DL, from the APU
gearbox. Coat O-ring, (88, Figure 3-2, index
I) with assembly fluid, RT-403A, No. 1, and
install onto fitting, (80, Figure 3-2, index I).
Install the fitting into the gearbox at the ‘‘oil
out’’ port, and torque to 135 - 150 inchpounds.
Remove the plug between the ‘‘oil in’’ and
‘‘oil out’’ ports, part No. AN814-4DL, from
the gearbox. Replace it with plug, (83, Figure 3-2, index I) using O-ring, (88, Figure
32, index I). Torque plug to 135 - 150 inchpounds. Safetywire in series with fittings
(80, Figure 3-2, index I) in steps be. and bf.
with MS20995C32 lockwire.
Connect hose assembly, (81, Figure 3-2,
index I), to the ‘‘oil in’’ fitting on the APU
gearbox. Leave fittings finger tight to
accommodate test cell maintenance.
bi.
Connect hose assembly, (82, Figure 3-2,
index I) to the ‘‘oil out’’ fitting on the APU
gearbox. Leave fittings finger tight to
accommodate test cell maintenance.
bj.
Remove two forward bolts, part No.
MS21280-11, from the oil breather pad.
Apply anti-seize compound, Specification
MIL-A-907, to two bolts, (90, Figure 3-2,
index I), and use to mount the top bracket
(84, Figure 3-2, index I) of the oil cooler to
the breather pad. Torque bolts (90, Figure 32, index I) 55 - 70 inch-pounds.
bk.
If required, etch data plate with updated
NSN: 2835-01-607-1588 and add an A to the
existing part No. so that it reads 161331135A.
bl.
Remove APU from assembly build stand,
ST71206 (44, Figure 2-1).
6-7. PRESERVATION FOR SHIPMENT AND STORAGE. Following completion of final performance
runs and prior to removal of APU from test cell,
perform preservation run per T.O. 00-85-3 and as
follows:
a.
With APU operating in normal mode, simultaneously close the fuel supply valve to fuel
pump inlet and open valve to supply of oil,
MIL-L-6081, grade 1010.
b.
Continue to operate APU for a minimum of
1 minute on MIL-L-6081, grade 1010 oil.
c.
Shut down APU.
WARNING
Lubricating oil, MIL-L-7808 or MIL-L23699, may cause skin rash. Do not
breathe vapors. Use in well-ventilated
area. Wear eye protection and gloves.
d.
Remove magnetic-drain plug (1, Figure 3-2,
detail G) and self-closing valve (2).
e.
Place suitable container under engine oil
sump (27, Figure 3-12) and drain oil, MIL-L7808 or MIL-L-23699, from engine oil sump.
f.
Reinstall magnetic-drain plug (1, Figure 3-2,
detail G) and self-closing valve (2).
g.
Remove slave dipstick, if not previously
removed.
h.
Inspect and replace oil filter element (11,
Figure 3-12).
i.
Attach warning tag to APU stating ‘‘WARNING - No Oil in Gearbox.’’
Change 24
6-61
T.O. 2G-T62T-43
j.
Remove APU from test cell per Section VII Testing and prepare for storage as follows:
CAUTION
(1)
Ensure all test and slave equipment is
removed from APU.
(2)
Install lifting fixture, ST94409 (82, figure 2-1), in forward and aft eye bolts
(20, Figure 3-3) on APU.
(13)
Using an air evacuator, remove air from
barrier bag until bag clings snugly to
APU.
(3)
Using suitable hoist (minimum 2,000
lbs. lifting capacity) and lifting fixture,
ST94409 (82, Figure 2-1), hoist APU
over skid (4, Figure 3-1) of shipping
container, 166471-100 (86, Figure 2-1).
(14)
Remove air evacuator hose from barrier
bag and immediately seal opening.
(15)
Leave APU undisturbed for 10 minutes.
(16)
Inspect barrier bag for leaks. Bag
should remain taut and spring back
when pulled on.
(17)
Install any applicable documents to
outside of barrier material.
(18)
Install cover (3) over skid (4).
(19)
Secure cover (3) to skid (4) with lag
screws (1) and washers (2).
(20)
Mark container per MIL-STD-129.
(4)
(5)
Obtain bottom half of barrier material,
MIL-B-131, class III, and put in position
over skid (4, Figure 3-1).
Lower APU on to skid (4) and secure
APU to supports on skid with bolts (5),
P/N MS9557-12, washers (7) and nuts
(6). Torque to 30 - 35 in-lb.
(6)
Remove hoist and lifting fixture,
ST94409 (82, Figure 2-1), from APU.
(7)
Install humidity indicator, MIL-I-8835A6, on the inside of barrier material
bag. Humidity indicator must show
through window in shipping container,
166471-100 (86, Figure 2-1).
(8)
Do not over evacuate air from bag.
Wrap engine in cellulosic cushioning,
PPP-C-843, and seal with pressure sensitive tape, MIL-T-22085, type II. Make
sure there are no protruding corners
and edges that will cut barrier material.
(9)
Place 88 units of desiccant, MIL-D3464, in bottom half of barrier material.
(10)
Position top half of barrier material,
MIL-B-131, class III, over APU and
place 104 units of desiccant, MIL-D3464, in top half of barrier material.
(11)
Align seam edges of the top and bottom
pieces of barrier material. Staple near
edge of seam around bag to keep even.
(12)
Heat seal seam, except for an opening
large enough for insertion of air vac
tube. Make sure there are no wrinkles
in the seam that will cause fabric to pull
and cause leaks.
6-62 Change 24
6-8.
a.
GENERAL PART MARKING.
Label Part Marking (LPM).
Where practical, the mark may appear on a
data plate or label, providing it can withstand normal wear and tear, including the
range of solvents or other chemicals that
may come in contact with the label.
b.
Polyacrylic Labels.
Polyacrylic labels are durable, flexible, and
forgery resistant. These labels can be
engraved using ND:YAG or CO2 lasers.
Polyacrylic labels consist of a doublelayered, highly cross-linked film with modified acrylic adhesive and a dimensionally
stable release paper. These labels are resistant to abrasion, grease, oils, and many
other chemicals and are easily applied. No
rivets or screws are needed as the label has
an adhesive backing, which adheres to most
plastics, metals, glass, and ceramics. The
labels are temperature resistant. These
labels can be formed into custom sizes and
shapes, offer flexible handling, provide tamper evident properties, and are economical
alternatives to rigid labels.
T.O. 2G-T62T-43
NOTE
Laser etched tapes should not be
applied to surfaces that exceed temperature extremes, are exposed to heavy
abrasive environments (without considerations for protective coatings),
and are exposed to operational wear.
Chemical compliance should be verified and referenced to the product-specific chemical testing list.
c.
Surface Preparation.
NOTE
Cleaning shall be performed in accordance with TO 1-1-169. Cleaning and
Corrosion Prevention and Control,
Aerospace and Non-Aerospace Equipment. For electrical equipment, cleaning and surface preparation shall be in
accordance
with
TO
00-25-234.
Observe all warnings and cautions
contained in these documents.
(1)
Surface should be dry and free from any
visible contaminants. If not, wipe with
dry
cheesecloth,
CCC-C-440
or
equivalent.
(2)
For metallic surfaces, apply Isopropyl
Alcohol, TT-I-735 or MIL-PRF-87937,
Type III or equivalent, liberally to the
surface, wipe surface to be labeled until
the surface is free from visible contaminants, dirt, hydraulic fluid, etc. and dry
with cheesecloth. For electrical equipment, cleaning and surface preparation
should be done in accordance with TO
00-25-234.
(3)
d.
Allow area to dry.
Inspection.
NOTE
All debris and corrosion must be
removed from the UII mark prior to
inspection.
(1)
Visually inspect for UII mark. If the
item is not marked and markings are
required, refer to Label Application for
instructions.
NOTE
Damage may include scratches, wear
and
tear
or
environmental
deterioration.
(2)
Visually inspect damage of UII mark. If
the mark is damaged, read the mark
and verify that it receives a PASS
condition.
(3)
Result 1: Reader displays a PASS condition (an unused error correction of ≥25%
or readability of ≤75%). Continue
processing part.
NOTE
If the mark continues to receive a fail
condition after numerous attempts and
the item is a label or Identification (ID)
plate, restoring is authorized. (See
Restoring Section). If not a label or ID
plate, contact Cognizant Engineer for
directions.
(4)
Result 2: Reader displays a FAIL condition (an unused error of <25% or readability of >75%). Proceed to step d.
(a)
If the mark receives a PASS condition, item passes inspection.
(b)
If the mark receives a FAIL condition up to five times, see above note.
Change 24 6-62A/(6-62B blank)
T.O. 2G-T62T-43
e.
2-D Label Print.
g.
NOTE
For Data Matrix Code symbols printed
on labels, the minimum grade level of
the mark (as defined in AIM DPM-12006 Direct Part Mark Quality Guideline) shall be as listed below.
.
.
.
.
DPM
2.0/7.5-25/640/(45Q|30Q|90),
where:
Minimum print quality grade = 2.0
X dimension range of the application =
7.5-25 mils
Inspection wavelength = 640 nanometers ±nanometers
Lighting conditions = Medium Angle
Four Direction (45Q) or Low Angle
Four Direction (30Q) or Diffuse Perpendicular (90).
f.
2-D Data Matrix Verification Process.
.
NOTE
The software may not automatically
confirm validation of the UII or verify
the grade of the 2-D data matrix mark.
The marking technician must select
validation and verification from the
menu.
.
.
.
When performing verification of mark,
adjustments of the verifier may be
required to obtain a proper pass
condition.
If the 2-D data matrix mark continues
to receive a failure, contact the Cognizant Engineer for remarking authority
and location.
Ensure proper lighting is available.
Dim ambient lighting as well as excessive ambient lighting will adversely
affect verification results.
6-9.
Label Application.
(1)
Perform the steps in the Surface Preparation paragraph, prior to label
application.
(2)
Ensure area is dry prior to label
application.
(3)
Clean hands to ensure they are free
from any dirt, hydraulic fluids, grease,
etc.
(4)
Peel label from backing by bending and
lifting at the corners and/or edges. Affix
label and apply pressure by rubbing the
label surface to thoroughly activate the
adhesive and to work out any air bubbles between the tape and surface. If
possible, allow the label to set for a
minimum of 6 hours prior to any use of
the labeled item. Maximum adhesion
occurs appoximately 24 to 48 hours
after applying the label.
UID SUPPLEMENTAL INFORMATION.
a.
Inspect UID label by using a 2D hand-help
electronic reader. Reference TO 00-25-260.
b.
If UID label is not present or damaged,
manufacture new label and install as shown
in Table 6-2.
c.
Do not cover any existing markings. Reference TO 00-25-260.
d.
Cage code is that of the activity responsible
for guaranteeing uniqueness of the sequencing code.
e.
For additional information, reference MILSTD-130( ) and TO 00-25-260.
f.
See applicable Illustrated Parts Breakdown
(IPB), specific component sections and parts
listing tables for additional part numbers
that require unique identification (i.e. interchangeable, superseding, and/or replacement part numbers).
Change 23
6-63
T.O. 2G-T62T-43
Table 6-2.
UID Label Requirements
Noun
Figure Showing UID Label
Location
161331-135,
*Figure 2-1
QSAS Engine
6-29
200733803-35
Reference TO 00-25-260
161347-1, *Figure 2-1,
Index 76
Valve, Surge
Control
6-30
200733803-17
200733803-35 (alt)
Reference TO 00-25-260
161367-1, *Figure 2-1,
Index 116
Actuator,
IGV
6-31
200733803-17
200733803-35 (alt)
Reference TO 00-25-260
161676-203, *Figure 21, Index 156
Control Assembly, Fuel,
Electronic
6-32
200733803-17
200733803-35 (alt)
Reference TO 00-25-260
161794-1, *Figure 2-1,
Index 177
Starter, Hydraulic Engine
6-33
200733803-17
200733803-35 (alt)
Reference TO 00-25-260
Marked Item Part Number(s), Figure, and Index
Figure 6-29.
6-64 Change 26
UID Label
Part Number
UID Label Application/
Verification Information
QSAS Engine UID Placement (Part Number(s): 161331-135) (Not to Scale)
T.O. 2G-T62T-43
Figure 6-30.
Surge Control Valve UID Placement (Part Number(s): 161347-1) (Not to Scale)
Figure 6-31.
IGV Actuator UID Placement (Part Number(s): 161367-1) (Not to Scale)
Change 26
6-65
T.O. 2G-T62T-43
Figure 6-32.
Figure 6-33.
6-66 Change 26
Fuel Control Assembly UID Placement (Part Number(s): 161676-203) (Not to Scale)
Hydraulic Start Motor UID Placement (Part Number(s): 161794-1) (Not to Scale)
TO 2G-T62T-43
SECTION VII
TESTING
7-1. GENERAL. This section contains information
for testing the APU. Included are test setup requirements and instructions for performing operational
checks. Tests are performed to make certain the
APU has been overhauled/repaired properly and will
fulfill the established operating requirements. Reference should be made to troubleshooting requirements
(paragraph 7-4) for aid in determining a possible
cause and remedy for malfunctions encountered during testing.
7-2. CALCULATIONS. Calculations that may be required to convert certain observed values to standard
values are provided in the text, figures, or tables
within this section.
7-3. TEST PROCEDURES. This section includes
procedures for installation and use of the test cell
Test cell
adapter kit, 164650-100 (figure 7-2).
adapter kit leading particulars are listed in Section I General Information. Maintenance, inspection, and
repair technical data for the adapter kit can be found
in the test cell adapter kit drawings.
(3)
Release ball lock pin (5) and install
other side of lifting fixture, ST94409
(4), onto containment ring lifting
bracket (6). Secure ball lock pin.
(4)
Connect lifting fixture, ST94409, (4) to
a suitable hoist (minimum 2,000 lbs.
lifting capacity) and carefully position
APU over APU cart (7).
(5)
Lower and position APU between forward engine support (8) and aft engine
support (9).
(6)
Align reduction drive unit mounting
holes (10) on both sides of APU with
pin assemblies (11) and place pin assemblies into mounting holes. Secure
pin assemblies (11) with spring plungers
(12) and jam nuts (13).
(7)
Loosen jam nut (14) on aft engine support (9) and adjust leveler (15) until aft
end of APU is in a level position.
Retighten jam nut when APU is in a
visually level position.
(8)
Remove hoist from lifting fixture,
ST94409 (4).
(9)
With APU being supported by forward
engine support (8) and aft engine supp o r t ( 9 ) , remove lifting fixture,
ST94409 (4), from eyebolt (1) and
containment ring lifting bracket (6).
NOTE
Prior to testing, the APU shall be inspected for loose or improper assembly,
dirt, or other contamination.
An APU not meeting test parameters
specified herein shall be rejected.
An APU that has been reworked to
correct faults found in testing shall be
retested.
a.
APU Installation. Using engine support kit,
166819-100 (87, figure 2-1), install APU
on APU cart, 167147-100 (7, figure 7-1),
as follows:
(1) Thread eye bolt (1) into reduction
drive unit threaded attachment point
(2).
(2)
Release ball lock pin (3) and install one
side of lifting fixture, ST94409 (4), into
eyebolt (1) located at reduction drive
unit threaded attachment point (2).
Secure ball lock pin.
b. Test Setup. Interface the test cell adapter
kit, 164650-100 (figure 7-2), with the
APU and the facility test cell as follows:
NOTE
Installation of test cell adapter kit can be
performed in order of convenience.
(1)
Connect exhaust duct pressure hose assembly from CAB AIR PRESS connector (6), on facility fluid panel (1), to
EXHAUST DUCT PRESS connector
(63) on APU cart (19).
7-1
TO 2G-T62T-43
Figure 7-1.
7-2
APU Installation
T.O. 2G-T62T-43
(2)
(3)
Connect compressor inlet pressure hose
assembly from EG PRESS/ACCESS
flexible hose (2) on facility fluid panel
(1), to COMP INLET PRESS connector
(81) on APU cart (19).
Connect oil cooling supply water hose
assembly from WBB (WATER BRAKE
B) SEAL COOL connector (7) on facility
fluid panel (1), to OIL CLR WATER
SUPPLY connector (90) on APU cart
(19).
(14)
Connect oil cooler water discharge hose
assembly (20), from OIL CLR DRAIN
connector (110), to facility floor drain.
(15)
Connect load compressor discharge
thermocouple connector (21) to mating
facility connectors (for load compressor
discharge temperature measurement)
BAIRT1.
(16)
Connect compressor inlet thermocouple
probes (22) to mating facility connectors
(for compressor inlet temperature measurements) COMPIT, FANDT1, and
FANDT2 (compressor inlet temperature
to
compressor
inlet
temperature
thermocouples).
(17)
Connect lower exhaust adapter (28),
from APU exhaust flange, to facility
lower exhaust duct (30).
(18)
Connect five exhaust gas temperature
thermocouple connectors (24) to mating
facility connectors (for exhaust gas temperature measurements). Connect facility AIRHIT/ENGINE T/C 1 to ENGINE
T/C 2.
(19)
Connect bypass duct flexible hose
assembly (25), from upper exhaust duct
adapter (27), to load compressor bypass
duct (119).
(20)
Connect elbow adapter (26), on pneumatic accumulator tank (33), to facility
hot bleed air duct (34).
(21)
Connect exhaust pressure flexible hose
assembly (29), from facility lower
exhaust duct (30), to EXHAUST DUCT
PRESS connector (63) on APU cart (19).
(4)
Connect fuel inlet hose assembly from
FUEL IN connector (8) on facility fluid
panel (1), to FUEL INLET connector
(82) on APU cart (19).
(5)
Install dynamometer assembly (108) on
reduction drive unit (38) with interface
gasket, MS9136-01, and secure with
bolts, nuts, and washers.
(6)
Connect dynamometer water inlet hose
assembly from WBA (WATER BRAKE
A) CONTR connector (9) on facility fluid
panel (1), to dynamometer water in (41).
(7)
Connect dynamometer seal water hose
assembly to WBA (WATER BRAKE A)
SEAL COOL connector (10), on facility
fluid panel (1), and to dynamometer seal
water connector (107), on seal water
control valve (42).
(8)
Connect LUBE OIL PRESS connector
(11), on facility fluid panel (1), to OIL
PRESS connector (84) on APU cart (19).
(9)
Connect facility compressor discharge
line to PCD connector (64) on APU cart
(19).
(10)
Connect hydraulic supply hose assembly (15), from panel HYD RTN A connector (12) on facility fluid panel (1), to
HYDRAULIC SUPPLY connector (103)
on APU cart (19).
(22)
Connect elbow adapter assembly (31), to
flange (32) on pneumatic accumulator
tank (33) then, connect flexible hose
assembly (23), to load compressor discharge duct hose assembly (35).
(11)
Connect preservation oil supply hose
assembly (16), from facility preservation
oil tank (14), to PRESERVATION OIL
INLET connector (83) on APU cart (19).
(23)
(12)
Connect hydraulic return hose assembly
(17), from HYD RET A connector (12) on
facility fluid panel (1), to HYD RTN
connector (89) on APU cart (19).
Connect engine (interconnect) control
harness (39), from electrical junction
box assembly, A4J3 (75), on APU cart
(19), to main harness electrical connector (37).
(24)
Connect oil sump thermocouple connector (36) to mating facility connector (for
oil temperature measurement).
(13)
Connect dynamometer water discharge
hose assembly (18), from dynamometer
water out (46), to facility floor drain.
(25)
Connect electrical cable connector from
load cell (43), on dynamometer assembly (108), to facility test cell electrical
interface WATER BRAKE A connector.
Change 24 7-3
T.O. 2G-T62T-43
.
.
.
NOTE
If APU has been fitted with Air/Oil
cooler (-135A) long plug is already
installed.
DRAIN connector (52) on APU cart (19),
to fuel nozzle tee bracket connector (62).
(33)
Install O-ring, MS9387-06, and slave
combustor drain valve, 163309-100 (58),
located at 6 o’clock position on combustor housing. Torque fitting to 180-200
inch-pounds.
(34)
Connect combustor drain flexible hose
assembly (57) from COMBUSTOR
DRAIN connector (53) on APU cart (19),
to combustor drain valve (58) on combustor assembly.
(35)
Remove combustor liner retaining pin 3
o’clock position, facing aft, and install
PCD connector (60).
(36)
Connect PCD flexible hose assembly
(59), from PCD connector (51) on APU
cart (19), to PCD connector (60) on combustor assembly.
(37)
Connect facility test cell electrical interface cables to READY TO LOAD, A4J5
(65); FIRE STOP, A4J8 (66); STOP,
A4J6 (67); ESCU PWR/PWR LATCH,
A4J9 (68); START FUEL/EXC, A4J12
(69); MAG PICKUP, A4J15 (70); INST
GND, A4J18 (71); 2-1/2 INCH (bypass)
VALVE, A4J14 (72); T/C 2, A4J17, (73);
T/C 1, A4J16 (74); MAIN FUEL, A4J13
(76); POWER GND, A4J11 (77); AND
GEN MODE ONLY, A4J10 (78); (EWO)
HI/LOW, A4J7 (79); and HYD ST
VALVE, A4J4 (80) connectors on electrical junction box assembly, A4J3 (75), on
APU cart (19).
(38)
Connect P exit facility cable (A5J1) to P
EXIT pressure transducer electrical
connector (85) on APU cart (19).
Long plug is used only with oil cooler.
Long plug is stored in APU cart receptacle when not in use.
(26)
If applicable (-135 APUs only), remove
short plug between oil out and oil in
ports, on reduction drive unit (38), and
install slave long plug, 162199-1, with
O-ring, MS9387-06.
(27)
For APU part No. 161331-135, remove
oil in and oil out short plugs and install
union fittings with O-ring MS9387-06.
For APU part No. 161331-135A disconnect oil cooler, oil in and oil out lines
from reduction drive unit.
(28)
Connect oil out flexible hose assembly
(44), from OIL OUT connector (48) on
APU cart (19), to cooler port on reduction drive unit (38).
(29)
Connect oil in flexible hose assembly
(45), from OIL IN connector (47) on
APU (19), to cooler port on reduction
drive unit (38).
(30)
Connect fuel drain flexible hose assembly (49), from FUEL DRAIN connector
(54) on APU cart (19), to fuel control
containment box fuel drain connector
(98).
(31)
Connect hydraulic start drain flexible
hose assembly (50), from HYD START
DRAIN connector (55) on APU cart (19),
to hydraulic starter fluid drain connector (100) on engine hydraulic starter
(97).
(32)
Connect start fuel drain flexible hose
assembly (56), from START FUEL
7-4 Change 24
TO 2G-T62T-43
Figure 7-2. Test Cell Adapter Kit Test Setup (Sheet 1 of 9)
7-5
TO 2G-T62T-43
Figure 7-2. Test Cell Adapter Kit Test Setup (Sheet 2 of 9)
7-6
TO 2G-T62T-43
Figure 7-2. Test Cell Adapter Kit Test Setup (Sheet 3 of 9)
7-7
T.O. 2G-T62T-43
Figure 7-2. Test Cell Adapter Kit Test Setup (Sheet 4 of 9)
7-8 Change 8
TO 2G-T62T-43
Figure 7-2. Test Cell Adapter Kit Test Setup (Sheet 5 of 9)
7-9
TO 2G-T62T-43
Figure 7-2. Test Cell Adapter Kit Test Setup (Sheet 6 of 9)
7-10
TO 2G-T62T-43
Figure 7-2. Test Cell Adapter Kit Test Setup (Sheet 7 of 9)
7-11
TO 2G-T62T-43
Legend for figure 7-2:
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.
35.
36.
37.
38.
39.
40.
Facility fluid panel
EG PRESS/ACCESS flexible hose
Compressor discharge pressure flexible hose
Reduction drive unit vibration
connector and cable
Powerhead vibration connector and cable
CAB AIR PRESS connector
WATER BRAKE B SEAL COOL connector
FUEL IN connector
WATER BRAKE A CONTR connector
WATER BRAKE A SEAL COOL connector
LUBE OIL PRESS connector
HYD RET A connector
HYD SUP A connector
Preservation oil tank
Hydraulic supply hose assembly
Preservation oil supply hose assembly
Hydraulic return hose assembly
Dynamometer water discharge
hose assembly
APU cart
Oil cooler water discharge hose assembly
Load compressor discharge
thermocouple
connector
Compressor inlet thermocouple
probe (3)
Flexible hose assembly
Exhaust gas temperature
thermocouple
connector (6)
Bypass duct flexible hose assembly
Elbow adapter
Upper exhaust duct adapter
Lower exhaust adapter
Exhaust pressure flexible hose assembly
Facility lower exhaust duct
Elbow adapter assembly
Flange
Pneumatic accumulator tank
Facility hot bleed air duct
Load compressor discharge
duct hose assembly
Oil sump thermocouple
connector
Main harness electrical connector
Reduction drive unit
Engine control harness
Reduction drive vibration sensor connector
Figure
7-12
7-2.
Test Cell Adapter
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.
76.
77.
78.
79.
80.
81.
82.
83.
84.
Dynamometer water in
Seal water control valve
Load cell
Oil out flexible hose assembly
Oil in flexible hose assembly
Dynamometer water out
OIL IN connector
OIL OUT connector
Fuel drain flexible hose assembly
Hydraulic start drain flexible hose
hose assembly
PCD connector
START FUEL DRAIN connector
COMBUSTOR DRAIN connector
FUEL DRAIN connector
HYD START DRAIN connector
Start fuel drain flexible hose assembly
Combustor drain flexible hose assembly
Combustor drain valve
PCD flexible hose assembly
PCD connector
Powerhead vibration sensor connector
Fuel nozzle tee bracket connector
EXHAUST DUCT PRESS connector
PCD connector
READY TO LOAD (A4J5)
FIRE STOP (A4J8)
STOP (A4J6)
ESCU PWR/PWR LATCH (A4J9)
START FUEL/EXC (A4J12)
MAG PICKUP (A4J15)
INST GND (A4J18)
2-1/2 IN (bypass) VALVE (A4J14)
T/C 2 (A4J17)
T/C 1 (A4J16)
Electrical junction box assembly (A4J3)
MAIN FUEL (A4J13)
POWER GND (A4J11)
GEN MODE ONLY (A4J10)
(EWO) HI/LOW (A4J7)
HYD ST VALVE (A4J4)
COMP INLET PRESS connector
FUEL INLET connector
PRESERVATION OIL INLET connector
OIL PRESS connector
Kit Test Setup
(Sheet 8 of 9)
Legend for figure 7-2 -
Continued:
85. P EXIT AFS pressure transducer
electrical connector
102. FUEL TO ENGINE connector
88. AP AFS pressure transducer electrical
104. Reduction drive unit vent drain
connector
connector
87. N2 Precharge pressure transducer
electrical connector
88. Accumulator charge pressure
103. HYDRAULIC SUPPLY connector
105. Dynamometer water out thermocouple
connector
106. Reduction drive unit drain flexible
hose assembly
transducer electrical connector
89. HYD RTN connector
107. Dynamometer seal water connector
90. OIL CLR WATR SUPPLY
108. Dynamometer assembly
91. Hydraulic flexible hose assembly
drain cap
109. Reduction drive unit vent connector
110. OIL CLR DRAIN connector
92. Hydraulic start return flexible
hose assembly
93. Hydraluic flexible hose assembly drain cap
94. Hydraulic starter supply flexible
hose assembly
95. Hydraulic starter fluid supply connector
96. Hydraulic starter fluid return connector
111. HYD START/DUMP (A2J2) (+28 VDC)
connector
112.
FUEL VALVE electrical connector
(A2J1) (+28 VDC)
113. P EXIT pressure connector
114. P NOZ pressure connector
115. P nozzle flexible hose assembly
97. Engine hydraulic starter
98. Fuel control containment box fuel
drain connector
116. P exit flexible hose assembly
117. P nozzle connector
99. Fuel in connector
118. P exit connector
100. Hydraulic starter fluid drain connector
119. Load compressor bypass duct
101. Fuel in flexible hose assembly
129. ESCU
Figure 7-2.
Test Cell Adapter
Kit Test Setup (Sheet 9 of 9)
Change 8
7-13
TO 2G-T62T-43
(39) Connect P AFS facility cable (A5J2)
to
P AFS pressure transducer electrical connector (86) on APU cart (19).
(A2J2) (+28 Vdc) connector (111)
and FUEL valve electrical connector
[(A2J1) (+28 Vdc)] (112), on APU
cart (19).
(40) Connect N2 precharge facility cable
(A5J3) to N2 precharge pressure
transducer electrical connector (87) on
APU cart (19).
(48) Connect P exit flexible hose assembly
(116), from P EXIT pressure connector (113) on APU cart (19), to P exit
connector (118) on load compressor
discharge assembly.
(41) Connect hydraulic accumulator charge
facility cable (A5J4) to accumulator
charge pressure transducer electrical
connector (88) on APU cart (19).
(49) Connect P nozzle flexible hose assembly (115), from P NOZ pressure connector (114) on APU cart (19), to P
nozzle connector (117) on load compressor discharge assembly.
NOTE
Hydraulic flexible hose assembly drain caps
(91 and 93) are provided to facilitate
draining hydraulic fluid from the hoses.
(42) Connect hydraulic start return flexible
hose assembly (92), from hydraulic
starter fluid return connector (96) on
engine hydraulic starter (97), to APU
cart (19).
(43) Connect hydraulic starter supply flexible hose assembly (94), from hydraulic
starter fluid supply connector (95) on
engine hydraulic starter (97), to APU
cart (19).
(44) Connect fuel in flexible hose assembly
(101), from FUEL TO ENGINE connector (102) on APU cart (19), to fuel
in connector (99) on fuel control containment box fuel drain connector
(98).
(45) Connect dynamometer water out thermocouple connector (105) to mating
facility FANCIT connector (for dynamometer water out temperature measurement) at the thermocouple.
(46) Connect reduction drive unit vent drain
flexible hose assembly (106), from reduction drive unit vent drain connector
(104) on APU cart (19), to reduction
drive unit vent connector (109) on reduction drive unit (38).
(47) Connect test cell facility electrical cable
to HYD START/DUMP VALVE
7-14
c.
Pretest Procedures. The following procedures are to be performed prior to testing
the APU. Controls and indicators for the
adapter kit are illustrated in figure 7-3 and
listed in table 7-1. Decoded BITE information is listed in figure 7-8. Refer to vendor
manuals and technical data for additional
operational data. Also refer to the test cell
adapter kit drawings for additional technical
data which includes detail component dimensions, functional schematics, and assembly descriptions.
NOTE
Facility calibration weights and dynamometer calibration support bracket assembly are used only during calibration of
load cell.
Load cell facility calibration weights
and dynamometer calibration support
bracket assembly should be removed from
the dynamometer torque arm prior to running APU.
d. Tare weight adjustment. Add tare weights
(11, figure 7-3) to dynamometer torque arm
(12), on dynamometer bracket assembly
(13) of dynamometer assembly (14), and
secure with through bolt, washers, and nut.
Adjust tare weights until load cell indicated
force, with dynamometer not turning, is
zero. This procedure compensates for the
dynamometer torque arm weight.
TO 2G-T62T-43
Figure 7-3. Test Cell Adapter Kit Controls and Indicators (Sheet 1 of 3)
7-15
TO 2G-T62T-43
Figure 7-3. Test Cell Adapter Kit Controls and Indicators (Sheet 2 of 3)
7-16
TO 2G-T62T-43
Legend for figure 7-3:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Seal water control valve
HYDRAULIC MANUAL DUMP valve
HYDRAULIC DUMP SHUTOFF (manual) valve
OIL COOLER DRAIN valve
N2 BLEED valve
N2 CALIBRATION ISOLATION valve
Accumulator
N2 PRECHARGE gauge
HYDRAULIC SUPPLY SHUTOFF (manual) valve
ACCUMULATION HYDRAULIC PRESS gauge
Water outlet valve
Tare weights
Dynamometer torque arm
Dynamometer
bracket assembly
Dynamometer
assembly
Hydraulic accumulator
N2 service connector
Bladder accumulator
Accumulator
Figure
7-3.
Test Cell Adapter
Kit Controls
and Indicators
(Sheet 3 of 3)
7-17
TO 2G-T62T-43
Table 7-1. Test Cell Adapter Kit Controls and Indicators
Figure/
Index No.
7-3-1
Control/Indicator
Seal water control valve
Regulate dynamometer seal cooling water
flow rate
-2
HYDRAULIC MANUAL DUMP
valve
Manually bleed hydraulic fluid pressure from
the accumulator
-3
HYDRAULIC DUMP shutoff
(manual) valve
Block hydraulic fluid flow from APU
cart, except for starter discharge
-4
OIL COOLER DRAIN valve
Control oil cooler supply cool-in water
outlet flow rate
-5
N2 BLEED valve
Bleed nitrogen gas (N2) pressure prior to
N2 precharge pressure gauge and N2
precharge transducer for calibration or
removal. Used in conjunction with the N2
CALIBRATION ISOLATION VALVE (6)
-6
N2 CALIBRATION ISOLATION
valve
Isolate ACCUMULATOR N2 PRECHARGE
gauge and N2 precharge transducer
during calibration. Used in conjunction
with the N2 BLEED valve (5)
-7
ACCUMULATOR N2 PRECHARGE
Reference nitrogen pressure gauge. Use
PRECHARGE gauge pressure transducer
readout from computer during
accumulator charging
gauge
7-18
Function
-8
HYDRAULIC SUPPLY
SHUTOFF (manual) valve
Block hydraulic fluid flow to APU CART
-9
ACCUMULATION HYDRAULIC
PRESS gauge
Reference hydraulic fluid pressure gauge.
Use pressure transducer readout from
computer during accumulator charging
-10
Water outlet valve
Regulate water outlet flow rate from dynamometer assembly
-15
Hydraulic accumulator N2
service connector
Charge nitrogen side of the hydraulic
accumulator. Remove protective cover
for access
T.O. 2G-T62T-43
e.
Seal water flow rate adjustment.
(1) Disconnect dynamometer water discharge hose assembly (18, figure 7-2)
from dynamometer water out (46).
(2) Open facility dynamometer water valve
and adjust seal water control valve (42)
for a flow of 12-14 fl. oz. (358-414 ml) per
minute at dynamometer water out (46).
(3) Reconnect dynamometer water discharge hose assembly (18) from dynamometer water out (46) to facility drain.
f. Accumulator charging (nitrogen).
warning
Never operate the
or system without
ing and adjusted
Serious injury and
could result.
N2 charging bottles
a properly functionpressure regulator.
component explosion
Insure that test cell and computer have
secured water, fuel, electrical signals
and power, or hydraulic power prior to
performing adapter kit maintenance.
Failure to do so could result in serious
injury or component failure.
(1)
Valve control settings on the adapter kit
are to be positioned as follows prior to
accumulator charging:
(a)
HYDRAULIC SUPPLY SHUT-OFF
(manual) valve (8, figure 7-3) - Closed
(b) Hydraulic accumulator N2 service
connector (15) - Closed
(2)
(c)
N 2 CALIBRATION ISOLATION
valve (6) - Open
(d)
N2 BLEED valve (5) - Closed
warning
Do not charge accumulator with
hydraulic fluid until immediately prior
to starting APU. If a start attempt is
aborted, discharge hydraulic fluid back
to hydraulic fluid reserve. Personnel
should not enter test cell with accumulator hydraulic fluid side in a pressurized condition.
When any maintenance is performed,
discharge nitrogen and hydraulic fluid
pressure to avoid personnel injury.
Hydraulic fluids often contain additives
which may affect skin, eyes, and respiratory tract. These additives can be
readily absorbed through the skin.
Ensure fluid does not remain on skin.
Use in well-ventilated area and do not
breathe vapors. Wear faceshield and
gloves. Keep away from sparks and
flames.
caution
Due to the inherent internal leakage of
the test cell adapter kit hydraulic start
system, there will be a gradual
decrease in hydraulic pressure. In the
event that the start cycle is not initiated
immediately and hydraulic pressure has
dropped below 2850 psi, the hydraulic
system must be recharged to 3000,
+350, -150 psi prior to
initiating
another start cycle of the APU.
(3)
Valve control settings on the adapter kit
are to be positioned as follows after accumulator charging:
(e) HYDRAULIC MANUAL DUMP
valve (2) - Open
(a)
HYDRAULIC SUPPLY SHUTOFF
(manual) valve (8) - Open
(f) HYDRAULIC DUMP SHUTOFF
(manual) valve (3) - Open
(b)
Hydraulic accumulator N2 service
connector (15) - Closed
(c)
N2 CALIBRATION ISOLATION
valve (6) - Open
(d)
N2 BLEED valve (5) - Closed
(e)
HYDRAULIC MANUAL DUMP
valve (2) - Closed
(f)
HYDRAULIC DUMP SHUTOFF
(manual) valve (3) - Open
Precharge accumulator with technical
nitrogen, BB-N-411, type I, class 1, grade
B, to 1500 ±50 psig at hydraulic accumulator N2service connector (15).
Change 3 7-19
T.O. 2G-T62T-43
(4)
Fill accumulator with hydraulic fluid,
MIL-H-5606, to 3000 + 150, -300 psig.
j.
Inlet Air System. The APU will be tested
with an inlet muff installed. Ambient temperature resistance thermal device (RTD)
will be installed and functional for all tests.
Inlet air is drawn from the prevailing test cell
environment.
k.
Water Dynamometer System. The APU will
be tested using a water dynamometer system
to simulate shaft loading of the reduction
drive unit.
l.
Instrumentation. Prior to the initiation of
the test, the instrumentation inspection, verification, and calibration will be performed
per MIL-P-8686, MIL-STD-45662 (section 5.4),
and TO 00-20-14.
m.
Safety Precautions. The following warnings
shall be observed during APU testing:
(5) Valve control settings on the adapter kit
are to be positioned as follows:
(6)
g.
h.
(a)
HYDRAULIC SUPPLY SHUTOFF
(manual) valve (8) - Open
(b)
Water outlet valve (10) - Partially
open (refer to dynamometer manual
for further instructions)
(c)
Seal water control valve (1) - Partially
open (refer to dynamometer manual
for further instructions)
(d)
HYDRAULIC MANUAL DUMP
valve (2) - Closed
(e)
HYDRAULIC DUMP SHUTOFF
(manual) valve (3) - Open
(f)
OIL COOLER DRAIN valve (4) - Partially open (set to control oil temperature between 185-215°F and never
exceed 275°F).
(g)
N2 BLEED valve (5) - Closed
(h)
N CALIBRATION ISOLATION
valve (6) - Open
(i)
Hydraulic accumulator N2 service
connector (15) - Closed
.
When accumulator (17) hydraulic fluid is
at 0 psi, pressurize bladder accumulator
(16) to 500 ±50 psi.
.
Fuel, Preservation Oil, and Lubrication Oil
Requirements.
(1)
Fuel used during test shall be fuel, MILT-5642, JP-4, at 5-40 psig.
(2)
Preservation oil used during the preservation run shall be MIL-L-6081, grade
1010.
(3)
Lubrication oil used shall be MIL-L-7808.
Add enough oil to bring oil sump to
“full” mark on the slave dipstick.
Exhaust System. APU exhaust will be
________________
ducted from the test cell through the facility
system.
i. Load Compressor Air System. Load compressor air will be discharged through the
APU air flow sensor (AFS) measuring device
and on to the adjustable facility flow throttling valve. The facility flow throttling valve
is used to set the delivery back pressure
during performance tests.
7-20 Change 3
warning
.
Fuel vapors are toxic and flammable.
Do not breathe vapors. Use in wellventilated area. Wear eye protection.
A suitable fire extinguisher should be
available.
All personnel within 25 feet of the area
shall wear ear protection when APU is
running.
Lubrication oils may cause skin rash.
Do not breathe vapors. Use in wellventilated area. Wear eye protection
and gloves.
. Personnel
contaminated with fuel
should immediately leave the area.
Remove clothing as soon as possible
and shower thoroughly. Do not remove
clothes near any possible source of
ignition.
. when
Do not stand next to turbine section
APU is operating. Turbine blade
failure could result in possible ejection
of fragmented pieces.
n.
Shutdown Conditions.
(1)
The mandatory limits are those which
would normally cause the APU to shutdown on its own protective circuits.
Operation in excess of these limits shall
be cause for immediate shutdown of the
test unit and determination of the cause
for failure of the automatic shutdown.
T.O. 2G-T62T-43
(2)
(3)
The discretionary limits are those limits
which rely on the observation of the test
operator to initiate an APU shutdown,
should APU operation exceed any of the
specified limits. The test operator shall
shut down the unit unless the test engineer is available for immediate consultation. These limits may be exceeded at
the instruction of the test engineer
within the limits of reasonable engineering practice.
The following are the limits of operation
to be observed during all phases of
testing:
as measured at the reduction drive
unit oil vent.
o.
CAUTION
Should any of the following conditions
occur during testing, immediately shut
down APU and take corrective action
prior to continued testing.
(a)
Evidence of fuel or air leak.
(b)
Abnormal noise, smoking or exhaust
flame.
(c)
Vibration in excess of 10 Gs at rotor
frequency when operating under
pneumatic and/or shaft load, or
vibration in excess of 20 Gs at rotor
frequency when operating under no
pneumatic load (IGVs closed) nor
shaft load.
(d)
Oil pressure falls below 18 psig at
100 percent speed (mandatory shutdown). Maximum oil pressure shall
not exceed 60 psig for more than 30
seconds.
(i)
Speed variation at constant load
exceeds 0.5 percent. Speed variation
during on/off load transient exceeds
2 percent.
(j)
AFS corrected bleed flow less than 30
ppm (mandatory shutdown).
(k)
Oil consumption greater than that
equivalent to 0.25 inch per 30 minutes, as measured on the engine oil
sump dipstick.
Preliminary Check.
(1)
Check APU mounting for security.
(2)
Check security of test equipment and
fuel, oil, hydraulic, instrumentation,
and electrical connections.
WARNING
Lubricating oil Specification MIL-L7808, may cause skin rash. Do not
breathe vapors. Use in well-ventilated
area. Wear eye protection and gloves.
p.
(3)
Check lubricating oil supply. Lubricating oil used shall be Specification MILL-7808. Add or remove enough oil to
bring engine oil sump level to ″full″
mark on the slave dipstick.
(4)
Ensure that all test cell switches, valve,
and computer commands are in the correct pre-test positions.
Recording Test Data.
(e)
Engine oil sump
exceeds
275oF
shutdown).
temperature
(mandatory
(1)
Record applicable APU test data and
instrument readings (Figure 7-4 and
Figure 7-5) during each test.
(f)
Surge at any time during operation
or acceleration.
(2)
(g)
Exhaust gas average temperature
exceeds 1320oF for more than 10
seconds.
Take a complete set of zero readings
before starting APU and after
shutdown.
(3)
Wait 2-5 minutes for APU temperature
to stabilize before recording operating
values.
(4)
Record time at each scheduled reading.
NOTE
CC/HR is the same as ML/HR.
(h)
Measurable oil consumption exceeds
20 cubic centimeters per hour (cc/hr)
q.
Deleted
Figure 7-4. Deleted
Change 22 7-21/(7-22 Blank)
TO 2G-T62T-43
Figure 7-5. Acceptance Run Test Data Sheet (Sheet 1 of 2)
7-25
T.O. 2G-T62T-43
Figure 7-5. Acceptance Run Test Data (Sheet 2 of 2)
7-26 Change 8
T.O. 2G-T62T-43
WB. AFS = 29.92
* AFS COEF
P. Bar0
AFS.
AFS.
PEX
PIN
Bleed
Flow Calculation
WHERE:
(l-
COEF
COEF
p’E;.‘:::F
PB. COEF
1 PSI
=
=
STANDARD
PAFSDIF
’
PEX. COEF)
l
=
=
0.54
0.65
)
- (P. INLET
Pressure
PIN. COEF)
l
t WB.
AFS
Calculation
[P. EXIT + (P. BAR012.036)]
’
l
29.92
p, BARO
407
2.036 IN. HG
BAR0
= 14.696
PSI
2.036
l
Data Point
PAFSDIF
DATAPTl=lOOO
’ (P, EXIT + ( P. BARO/2.036)1
T. AFS + 459.67
CONSTANT
CONSTANT
Bleed
PB. CORR =
Calculations
= 43.10 CONSTANT
1 .OO CONSTANT
=
COEF
COR
WB. AFS. C = (P. EXDUCT
WHERE:
7-2.
AFS COR
l
WHERE:
Table
/
y
= 29.92 IN. HG
Conversion
27.74
l
[ P. EXIT + (P. BAR0
/2.0360)]
>
1 PSI = 27.74 IN. H,O
Fuel Flow Calculation
-W FUEL
CW. FUEL =
sJ
4)
6=
P.BARO
29.92 (IN. HG)
Horsepower
CHP =
$I = T INlAVG t 59.67
516.674(“R)
IoF?1
Calculation
HP
s
Change 3
7-27
T.O. 2G-T62T-43
Table
7-2 Calculations
-Continued
Legend for Table 7-2:
Symbol
AFS
AFS. COEF
AFS. COR
CHP
CW. FUEL
OF
HP
IN. Hz0
IN. HG
P. BAR0
P. EXDUCT
P. EXIT
P. INLET
PAFSDIF
PB. CORR
PEX. COEF
PIN. COEF
PPH
PPM
PSI
PSIA
PSIG
“R
T. AFS
T IN/AVG
W FUEL
WB. AFS
6
@
a
Air flow sensor
Air flow sensor coefficient
Air flow sensor correction coefficient
Corrected horsepower
Fuel flow corrected
Degrees fahrenheit
Horsepower uncorrected
Inches of water
Inches of mercury
Barometric pressure
Exhaust duct pressure
AFS total pressure
Inlet pressure
Bleed air differential pressure at AFS
Bleed pressure corrected
Pressure exhaust coefficient
Inlet pressure coefficient
Pounds per hour
Pounds per minute
Pounds per square inch
Pounds per square inch absolute
Pounds per square inch gage
Degrees ranking
AFS bleed temperature
Compressor inlet temperature (average)
Fuel flow uncorrected
AFS bleed flow uncorrected
Barometer pressure correction factor
Inlet temperature correction factor
r.
Deleted
s.
Oil consumption Measurement Procedure.
The rate of oil consumption shall be measured using the following procedures:
(1)
(2)
7-28
During acceptance test run, step t, the
APU shall be operated in the normal
mode at a set point of 100 ±4 until
engine oil sump temperature reaches 200
±15°F. Shut APU down by initiating the
cool down stop command. Record rundown time.
Measure oil level on slave dipstick. Add
or remove enough oil to bring oil level to
“full” mark on slave dipstick.
Change 3
Units
Name
t.
HP
PPH
OF
HP
IN. Hz0
IN. HG
IN. HG.
IN. Hz0
PSIG
IN. Hz0
IN. Hz0
PSIA
.PPH
PPM
PSI
PSIA
PSIG
“R
OF
OF
PPH
PPM
(3)
Upon completion of acceptance test run,
engine oil sump oil level shall be measured on the sump dipstick when the
APU oil sump temperature reaches 200
±15°F.
(4)
Oil consumption greater than that equivalent to 0.25 in. per 30 minutes, as measured on the engine oil sump dipstick, is
cause for rejection.
Acceptance Run. If not previously removed,
remove reduction drive unit mounted dynamometer and perform acceptance run as
follows:
(1)
With the fuel and ignition system deenergized, initiate a cold crank and motor
T.O. 2G-T62T-43
APU for 10 seconds. Verify positive oil
pressure during APU cold crank.
Observe rundown and listen for any
abnormal noises. Check for fuel and oil
leaks in test cell.
(2) Reconnect fuel and ignition system.
(3) Initiate a start. Shut APU down by
initiating a stop command immediately
upon accelerating above 50 percent
speed. Observe rundown and listen for
any abnormal noises.
(4) Close test cell facility flow throttling
valve and initiate a normal mode start.
Allow APU to accelerate to 100 percent
speed and run at full bypass for 10
minutes. Record data in test 1
(figure 7-5).
(5) Adjust dynamometer/water control unit
until shaft load indicator (CHP.AX)
reads 40 ±3 HP. Run at this load for 15
minutes minimum and record data in
test 2 (figure 7-5). Reduce shaft load to
zero by adjusting dynamometer/water
control unit.
(6) Shut APU down and record rundown
time in test 3 (figure 7-5).
(7) With test cell facility flow throttling
valve fully closed, initiate a start in the
“normal” mode and allow APU to accelerate to 100 percent speed. Record data
in test 1 (figure 7-5). Start time shall be
11.0 seconds or less, with test cell ambient temperatures above +40°F at prevailing ambient barometric pressure.
Start time shall be 19.0 seconds (to 100
percent speed) or less, with test cell
ambient temperatures below 40°F to
-40°F. Initiate oil consumption measurement proceedings by performing
step (8) and (9).
NOTE
Oil cooler water flow on test cell
adapter kit should be adjusted to
obtain 200 ±15°F oil temperature in
the following step.
(8) Operate APU in normal mode at a set
point of 100 ±4 until engine oil sump
temperature reaches 200 ±15°F. Shut
APU down by initiating a stop command
and record rundown time in test 2 (figure 7-5).
(9) Measure oil level on slave dipstick.
Add/remove enough oil to bring oil level
to “full” mark on slave dipstick
(figure 7-5).
(10) Initiate a start. Run at no load for 10
minutes minimum. Initiate operation
in EWO mode after no load run.
NOTE
While conducting acceptance test, the
test facility must have its own capability to measure bleed air flow (within
±0.5%) and to quickly reduce the
observed test data to standard
conditions.
(11) Open the test cell facility flow throttling
valve until the APU by-pass valve is
fully closed by monitoring the bypass
valve angle (BYP.ANGLE). Close the
facility bleed valve until the APU
bypass valve just begins to open. Continue closing the facility bleed valve
until corrected bleed flow reaches a
point just above the minimum flow
requirement (figure 7-6) at the corresponding inlet temperature.
(12) Operate APU in EWO mode for 5 minutes and record corrected bleed pressure
(PB.CORR) and other data in Test 5
(figure 7-5). (See Table 7-2 for bleed
flow calculations.)
(13) Shut APU down by initiating stop command and record rundown time in test
6. Measure oil consumption on slave
sump dipstick when engine oil sump
temperature reaches 200 +15°F. Oil
consumption greater than 0.25 in. per
30 minutes of APU running time as
measured on slave sump dipstick is
cause for rejection.
(14) The fuel flow shall not exceed 254 lb./hr
corrected to sea level, 59°F standard
day conditions (see Table 7-2 for fuel
flow calculations). If the corrected
bleed flow, pressure and EGT maximum that have just been determined,
meet the minimum requirements shown
in figure 7-6, the APU is acceptable.
u. Heat Exchanger Removal. In the event an
oil to water heat exchanger system is used,
perform the following test.
(1) Upon completion of acceptance run,
steps (1) through (14) and confirmation
of acceptable performance, disconnect
the oil out flexible hose assembly (44,
figure 7-2) and oil in flexible hose
Change 14 7-29
T.O. 2G-T62T-43
assembly (45) from reduction drive
unit (38).
(2)
If applicable (-135 APU only), remove Oring and slave long plug between oil out
an oil in ports on the reduction drive
unit (38) and install short plug.
(3)
If applicable (-135 APU only), remove Oring and union fittings and install oil in
and oil out short plugs. For -135A
engines, connect oil in and oil out lines
from APU installed oil cooler to the
reduction drive unit in accordance with
paragraph 6-6, steps bh. and bi. Torque
fittings 135 - 150 inch-pounds.
(4)
With facility flow throttling valve fully
closed, initiate a normal mode start and
allow APU to accelerate to 100 percent
speed. Record maximum EGT observed
and start time from 0-100 percent speed
in test 7 (Figure 7-5).
(5)
Operate at full bypass for 2 minutes
minimum. Leak check oil lines connected in step (3), and record oil pressure in test 8 (Figure 7-5).
(6)
Shut down and record rundown time in
test 9 (Figure 7-5). If any leaks are
7-30 Change 24
observed, repair and repeat steps (4)
and (5) above.
v.
Preservation. Prior to removal of APU from
test cell, preserve APU per procedures listed
in Section VI - Assembly.
7-4. TROUBLESHOOTING PROCEDURES. Troubleshooting procedures are keyed to the decoded Builtin-Test Equipment (BITE) indicators on the test cell
information plate, mounted adapter kit electrical
junction box. During APU start, BITE indicators
identify APU warning and shutdown data after the
event has occurred.
The events that occur during APU startup are
shown in Figure 7-7 and decoded BITE information
is shown in Figure 7-8. Troubleshooting procedures
for the APU are listed in Table 7-3.
NOTE
Upon initiation of a start, if APU does
not start and if there are no obvious
mechanical malfunctions at time of
shutdown (i.e. loud noises at rundown,
noises at rundown, continuous fuel
flow from fuel drains or other detectable discrepancies), attempt a restart.
T.O. 2G-T62T-43
Figure 7-6.
APU Acceptance Test Performance
Change 1 7-31
T.O. 2G-T62T-43
Figure 7-7. APU Sequence Diagram
7-32 Change 8
T.O. 2G-T62T-43
Figure 7-8. Decoded BITE Information
Change 8 7-33
T.O. 2G-T62T-43
Table 7-3. Troubleshooting
BITE Code/Trouble
1.
Probable Cause
Correction
a.
No electrical power to electrical system
or ESCU
Check circuit breakers and electrical
circuit to ensure that electrical power is
available at the start switch. If ok,
replace slave ESCU
a.
Excess fuel from fuel control assembly
(33, Figure 3-4)
Perform start and monitor fuel control
servo voltage acress TB-4-pins
10(+) and 9(-). If ok, replace fuel control. Otherwise, excessive + volts is
probably shorted to fuel control servo
circuit. Isolate wiring fault and repair
per TO 1-1A-14
b.
Invalid (multiple) signal from magnetic
pickup (3, figure 3-10)
1. Check magnetic pickup J304 for
resistance (1190-1450 ohms) pin A
to pin B. Check magnetic pickup
clearance to gear
No BITE
activity when
initiating
electrical
power
2. Overspeed
2. Check harness wiring from magnetic pickup to APU pin A to pin T and
pin B to pin U. Check interface wiring
a.
Internal failure
Check rotor assembly (22, figure
3-10) by hand for freedom of rotation.
If not free to rotate, disconnect hydraulic starter and turn rotor again. If rotor
turns freely, replace hydraulic starter.
If rotor does not turn freely, return APU
to shop for inspection and repair as required
b.
Combustor assembly air leaks (figure
3-28)
Check for leaks around combustor assembly. If leaks are found, return APU
to shop for inspection and/or repair of
combustor assembly
c.
Faulty combustor section (figure 3-28)
Borescope inspect hot section. Check
for hot spots, erosion on rotor tips or
turbine nozzle, burn spots in combustor, evidence of FOD, and carbon
build-up at fuel atomizers. If faulty, return APU to shop for inspection and/or
repair as required
d.
Low fuel boost pressure
Check fuel pressure to APU
e.
Contaminated fuel
Check fuel for contaminants
3. Underspeed
7-34 Change 8
TO
Table 7-3.
Probable
BITE Code/Trouble
3.
ooome~
Underspeed
continued
f.
-
Troubleshooting
-
2G-T62T-43
Continued
Correction
Cause
Fuel purge valve (25, figure 3-2,
detail B) malfunction
1. Check to see if fuel purge
valve is mechanically stuck open.
If open, replace fuel purge valve
2. Check continuity at fuel purge
valve (L8) pin A to pin B. If open,
replace fuel purge valve
4.
5.
0.00..
No oil pressure
oa*oo*
High oil temp
Fuel control assembly
3-4) malfunctioning
a.
Low oil level
Check oil level.
b.
Low oil pressure
Verify oil pressure with direct
reading gauge at reduction drive
unit during motoring.
If oil pressure falls below 18 psig at 100
percent speed, return APU to shop
for inspection and repair as
required
c.
Test cell oil cooler by-pass
not removed
d.
Faulty oil pressure
(18, figure 3-3)
e.
Faulty wiring or ESCU
Verify continuity of wiring between
ESCU and oil pressure switch (18,
If faulty, repair per
figure 3-3).
TO 1-1A-14.
Otherwise, replace
slave ESCU
a.
Improper
Check oil level for proper servicing. Service as required
b.
Test cell oil cooler
servicing
(33, figure
If failure occurs after load applied,
replace fuel control assembly
g.
switch
plug
Service
if low
Remove oil cooler by-pass
plug
Oil pressure switch is normally
open, closes at 5-6 psig oil
pressure (incr), and opens at 5-7
Disconnect P303
psig (decr).
from oil pressure switch and
monitor continuity across J303 pins
C and B. While motoring APU,
monitor oil pressure with direct
reading gauge.
If switch does not
close (continuity) at 5-7 psig, replace switch
1. Ensure oil cooler water is
flowing and functioning properly
2. Remove oil cooler by-pass
plug if still in place
7-35
TO
2G-T62T-43
Table 7-3.
BITE Code/Trouble
5.
Probable
-
Correction
Cause
High-oil temperature switch
(57, figure 3-2, detail G)
Check for continuity between pin A
to pin B on J305 of the hot switch.
If open (at temperatures
less than
275°F), replace high-oil temperature switch
d.
High-oil temperature switch
(57, figure 3-2, detail G) faulty
Verify continuity of wiring between
ESCU and hot high-oil temperature
switch. If faulty, repair wiring per
TO 1-1A-14
e.
ESCU faulty
Check for 28 Vdc at TB4 pin 5 to
ground.
If no 28 Vdc, replace
slave ESCU
a.
Thermocouple
harnesses
(14 and 15, figure 3-2, detail A)
wiring open
Verify wiring between thermocouple and ESCU is not open. If
ok, replace both thermocouples.
Otherwise, repair faulty wiring per
TO 1-1A-14
a.
Thermocouple
harness (14,
figure 3-2, detail A) or wiring
shorted
Verify wiring between thermocouple and ESCU is not shorted.
If ok, replace thermocouple
(TC1).
Otherwise, repair faulty wiring per
TO 1-1A-14.
Thermocouple
probes (TC1
and TC2)
open.
Thermocouple
harness (TC1)
shorted
8.
0000e*
Start fuel
valve fail
a.
Faulty start fuel valve, wiring,
ESCU
9.
0000.0
No temperature
data, both
probes
a.
Thermocouple
harnesses (14 and
15, figure 3-2, detail A) or wiring
faulty
7-36
Continued
c.
High oil temp continued
6.
Troubleshooting
or
Verify wiring between start fuel
valve on fuel control assembly (33,
figure 3-4) and ESCU. If faulty,
repair wiring per TO 1-1A-14.
Otherwise, check continuity
(resistance, 28-30 ohms) of start
fuel valve. If open or shorted,
replace start fuel valve per
TO 6J3-4-112-3.
Otherwise, replace ESCU
Check continuity of wiring between
ESCU and thermocouples
(TC1 and
TC2). If faulty, repair wiring per
TO 1-1A-14.
Otherwise, replace
thermocouple
harnesses (14 and
15, figure 3-2, detail A)
TO 2G-T62T-43
Table 7-3. Troubleshooting - Continued
BITE Code/Trouble
10.
Probable Cause
Correction
a. Excessive drag on APU
Check rotor assembly (22, figure
3-10) by hand for freedom of
rotation. If not free to rotate,
disconnect engine hydraulic starter
and turn rotor again. If rotor turns
freely, replace engine hydraulic
starter. If rotor does not turn
freely, return APU to shop for inspection and repair as required
b. Faulty main fuel valve on fuel
electronic control assembly
(33, figure 3-4)
Check main fuel valve output for
fuel. If no fuel or limited flow, replace main fuel valve per TO
6J3-4-112-3
c. Fuel nozzle (3, figure 3-28)
clogged
Return APU to shop for inspection
and/or replacement of fuel nozzle
d. Fuel control assembly (33,
figure 3-4) malfunctioning
Check fuel control outlet pressure
by attaching pressure gauge to
port on fuel pump. If faulty, replace fuel control assembly
e. Low test cell fuel pressure
Check test cell fuel pressure (minimum 6 psig)
f. Contaminated fuel
Check fuel for contamination
g. Fuel purge valve (25, figure 3-2,
detail B) malfunction
1. Check if fuel purge valve mechanically stuck open. If open,
replace fuel purge valve
Fail to accelerate (30
seconds)
2. Check fuel purge valve for
continuity, pin A to pin B. If open,
replace fuel purge valve
11.
Temperature
exit overtemp
a. Temperature exit probe, wiring,
or ESCU
If test stand probe indicates no
overtemp, verify continuity of
wiring and temperature exit probe.
If wiring or probe is faulty, repair
per TO 1-1A-14 or replace as
required. Otherwise, replace slave
ESCU
If both BITE and test stand probe
indicate overtemp, return APU to
shop for inspection and/or repair
as required
7-37
TO 2G-T62T-43
Table 7-3. Troubleshooting - Continued
BITE Code/Trouble
12.
Fail to accelerate (5
seconds)
Probable Cause
a. Engine hydraulic starter (10, figure
3-3) or APU seized or binding
Check rotor assembly (22, figure
3-10) by hand for freedom of
rotation. If not free to rotate,
disconnect engine hydraulic starter
and turn rotor again. If rotor turns
freely, replace engine hydraulic
starter. If rotor does not turn
freely, return APU to shop for inspection and repair as required
b. Ignition system faulty
Check 28 Vdc power to engine
hydraulic starter valve. If no 28
Vdc, verify continuity of wiring between ESCU and valve. If faulty,
repair wiring per TO 1-1A-14. If
ok, replace ESCU
C.
13.
Thermocouple
probe (TC1)
open
14.
Thermocouple
probe (TC2)
shorted
15.
Speed data
done flag
16.
Overtemperature
average
7-38
Correction
No signal from magnetic pickup
(3, figure 3-10)
Check magnetic pickup for resistance (1190-1450 ohms) pin A
to pin B
a. Thermocouple harness (14,
figure 3-2, detail A) or wiring
open
Verify wiring between thermocouple and ESCU is not open. If
ok, replace thermocouple (TC1).
Otherwise, repair faulty wiring per
TO 1-1A-14
a. Thermocouple harness (15,
figure 3-2, detail A) or wiring
shorted
Verify wiring between thermocouple and ESCU is not shorted.
If ok, replace thermocouple (TC2).
Otherwise, repair faulty wiring per
TO 1-1A-14
a. Magnetic pickup (3, figure 3-10),
wiring, or ESCU faulty
Verify continuity of wiring between
ESCU and magnetic pickup. If
faulty, repair wiring per
TO 1-1A-14. If wiring ok, check
continuity (resistance, 1190-1450
ohms) across magnetic pickup. If
open or shorted, replace magnetic
pickup. If magnetic pickup is ok,
check magnetic pickup clearance
to gear
a. Duct assemblies (6 and 17, figure
3-5) or APU exhaust restricted or
obstructed
Check for obstructions in duct
assemblies and APU exhaust
b. Residual fuel in combustor assembly
(figure 3-28)
Inspect slave check valve for
obstructions. Clean or replace
slave check valve if sticking
T.O. 2G-T62T-43
Table 7-3. Troubleshooting - Continued
Probable Cause
BITE Code/Trouble
16 000.0.
Over-temperature
average continued
17
0.000.
Shorted oil
pressure switch
18 0.000.
Decelerate to
50%
19 ooeooe
Main fuel valve
fail
Correction
c. APU overload
Remove overload and restart.
faulty, check for mechanical
restrictions. Remove any
restrictions found
d. Faulty thermocouple harnesses (TC1
and TC2) (14 and 15, figure 3-2,
detail A) or ESCU
Compare thermocouple readings
against test stand readings. If APU
thermocouple readings ok, replace
slave ESCU. Otherwise, replace
thermocouples
e. Faulty combustor assembly (figure
3-28) section
Borescope inspect hot section.
Check for hot spots, erosion on rotor
tips or turbine nozzle, burn spots in
combustor liner, evidence of FOD,
and carbon buildup at fuel
atomizers. If faulty, return APU to
shop for inspection and/or repair as
required
f.
Check rotor for freedom of rotation.
If binding, return APU to shop for
inspection and/or repair as required
Rotor binding
If still
a. Oil pressure switch (18, figure 3-3)
or wiring shorted
Verify wiring between oil pressure
switch and ESCU is not shorted. If
ok, replace oil pressure switch.
Otherwise, repair faulty wiring per
T.O. 1-1A-14
a. Rotor (22, figure 3-10) binding
Remove load and check rotation of
rotor. Turn rotor by hand. If rotor
drags, then return APU to shop for
inspection and/or repair
b. Fuel manifold (9, figure 3-28)
clogged
Return APU to shop for inspection
and/or replacement of fuel manifold
c. Engine loaded prior to ready-to-load
or ESCU faulty
If load applied too soon, remove load
and restart. If still faulty, replace
slave ESCU
d. Fuel supply low
Check fuel control outlet pressure by
attaching gauge to port on fuel
pump (minimum 200 psig). If
faulty, check boost pressure. If ok,
replace fuel control assembly
a. Main fuel valve on fuel electronic
control assembly (33, figure 3-4),
wiring, or ESCU faulty
Verify continuity of wiring between
main fuel valve and ESCU. If
faulty, repair per T.O. 1-1A-14. If
ok, verify continuity (resistance, 2830 ohms) of main fuel valve
solenoid. If open or shorted, replace
main fuel valve per T.O. 6J3-4-112-3
Change
13
7-39
T.O. 2G-T62T-43
Table 7-3. Troubleshooting - Continued
BITE Code/Trouble
20.
Thermocouple
probe (TC2) open
21.
22.
23.
24.
25.
Both
thermocouple
probes (TC1 and
TC2) shorted
Fuel wrap test
fail
IGV wrap test
fail
By-pass wrap test
fail
Nozzle pressure
greater than exit
pressure
7-40 Change 13
Probable Cause
Correction
a. Thermocouple harness (15, figure
3-2, detail A) wiring open
Verify wiring between thermocouple
and ESCU is not open. If ok,
replace thermocouple (TC2).
Otherwise, repair faulty wiring per
T.O. 1-1A-14
a. Thermocouple harnesses (14 and 15,
figure 3-2, detail A) or wiring
shorted
Check continuity of wiring between
ESCU and thermocouples (TC1 and
TC2). If faulty, repair wiring per
T.O. 1-1A-14. Otherwise, replace
thermocouple harness assemblies
a. Fuel control servovalve on fuel
electronic control assembly (33,
figure 3-4), wiring, or ESCU faulty
Verify continuity of wiring between
ESCU and fuel control. If faulty,
repair wiring per T.O. 1-1A-14. If
the wiring is ok, check the ohms
resistance (75-100 ohms) across the
servovalve. If faulty, replace fuel
control. Otherwise, replace slave
ESCU
a. Inlet guide vane (IGV) actuator (6,
figure 3-7) or ESCU faulty
Verify continuity of wiring between
ESCU and IGV actuator. If faulty,
repair wiring per T.O. 1-1A-14. If
wiring ok, check continuity
(resistance, 28-30 ohms) across IGV
actuator. If faulty, replace IGV
actuator. Otherwise, replace slave
ESCU
a. Surge control valve (9, figure 3-5),
wiring, or ESCU faulty
Verify continuity of wiring between
ESCU and surge control valve. If
faulty, repair wiring per T.O. 1-1A14. If wiring ok, check continuity
(resistance, 28-30 ohms) across
surge control valve. If faulty,
replace surge control valve.
Otherwise, replace slave ESCU
a. Air flow sensor (25, figure 3-5) leak
Check for leaks at air flow sensor.
If leaks are found, return APU to
shop for inspection and/or repair as
required
T.O. 2G-T62T-43
Table 7-3.
Probable
BITE Code/Trouble
25. 0.0000
Nozzle pressure
Troubleshooting
-
Correction
Cause
b.
Powerhead assembly
Check P exit probe for clogged
orifice. If clogged, replace air flow
sensor (25, figure 3-5)
c.
Surge control valve (9, figure 3-5)
shut with test cell outlet duct valve
closed
Check surge control valve for
proper operation
d.
Inlet guide vanes (39, figure 3-10)
won’t open on demand
Check IGV actuator for proper
operation
e.
Leak in line from air flow sensor
(25, figure 3-5) to ESCU
Check for leaks in line, at connections in P nozzle line, and in P exit
line. If leaking, replace line
a.
Ambient temperature
wiring shorted
a.
Duct assemblies (6 and 17, figure
3-5) leaking
Check for ducting leaks. If leaking,
repair. Otherwise, replace slave
ESCU
b.
Leak in P nozzle line
Check for leaks at P nozzle line
and connections to ESCU
a.
Exit temperature probe or wiring
shorted
Verify continuity of wiring between
ESCU and exit temperature probe.
If faulty, repair wiring per TO
1-1A-14.
Otherwise, replace exit
temperature probe
a.
Improper load application
Remove load and reapply properly
b.
Surge control valve (9, figure 3-5)
faulty
Check surge control valve for
binding or erratic operation. If
faulty, replace surge control valve
C.
PCD air supply to IGV actuator (6,
figure 3-7)
Check PCD air lines for contamination, restrictions, or leaks. Remove
any contamination or restrictions.
If ok, replace IGV actuator
d.
Internal failure
Return APU to shop for inspection
and/or repair as required
e.
Air flow sensor (25, figure 3-5)
leaking
Replace air flow sensor or V-band
clamps if air flow sensor leaking
f.
Air flow sensor (25, figure 3-5) P
exit or P nozzle orifice clogged
Replace air flow sensor if orifice
clogged
greater than exit
pressure continued
26. oe*o*o
Ambient
temperature
probe shorted
27. l ooooo
Nozzle pressure
less than 5 psi
(3.5 psi for ESCU
163250-300 and
I
probe
or
above)
28. oeooeo
Exit temperature
probe shorted
29. APU surges
Continued
Verify continuity of wiring between
ESCU and ambient temperature
probe. If faulty, repair wiring per
TO 1-1A-14.
Otherwise, replace
temperature ambient probe
Change 8
7-41
TO
2G-T62T-43
Table 7-3.
Probable
BlTE Code/Trouble
Troubleshooting
- Continued
Cause
Correction
a.
Test stand sensor system or APU
internal failure
Verify calibration and continuity of
test stand vibration sensor system.
If no defects exist, return APU to
shop for inspection and/or repair
as required
31. Vibration from
reduction drive
unit exceeds
limits
a.
Test stand sensor system or APU
internal failure
Verify calibration and continuity of
test stand vibration sensor system.
If no defects exist, return APU to
shop for inspection and/or repair
as required
32. Excessive
oil
consumption
a.
Oil has lost its anti-foaming
qualities
Replace oil in sump
b.
Buffer air lines loose
Check all 1/4-inch
nut torque
c.
Orifice missing from fitting
Check fitting
orifice
Failure of labyrinth
Return APU to shop for inspection
and/or repair as required
30. Vibration
from
powerhead
exceeds
limits
d.
seal
7-42
seal or windback
air lines for B-
(61, figure 3-2) for
TO 2G-T62T-43
FO-1. Electrical Subsystem (Sheet 1 of 2)
FP-1/(FP-2 blank)
TO 2G-T62T-43
FO-1. Electrical Subsystem (Sheet 2 of 2)
FP-3/(FP-4 blank)