49-26-95.pdf

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Honeywell International Inc. 111 S. 34th Street Phoenix, Arizona 85034-2802 U.S.A. CAGE: 99193 Telephone: 800-601-3099 (Toll Free U.S.A./Canada) Telephone: 602-365-3099 (International Direct) Website: www.myaerospace.com

Engine Manual Gas Turbine Engine Part Number 3800702-1

Model 131-9[B]

CAGE 99193

Legal Notice Export Control

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This document contains technical data and is subject to U.S. export regulations. These commodities, technology, or software were exported from the United States in accordance with the export administration regulations. Diversion contrary to U.S. law is prohibited. ECCN: 9E991.

49-26-95 Publication Number 49-26-95, Revision 13

Page T-1 Initial 14 Aug 1997 Revised 18 Dec 2019

© Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] Proprietary Information

HONEYWELL - CONFIDENTIAL COPYRIGHT BY HONEYWELL INTERNATIONAL INC. (“HONEYWELL”). ALL RIGHTS RESERVED. THIS DOCUMENT AND ALL INFORMATION CONTAINED HEREIN ARE THE CONFIDENTIAL AND PROPRIETARY INFORMATION OF HONEYWELL AND CONTAIN HONEYWELL TRADE SECRETS. NEITHER THIS DOCUMENT NOR THE INFORMATION CONTAINED HEREIN MAY, IN WHOLE OR IN PART, BE USED, DUPLICATED, OR DISCLOSED FOR ANY PURPOSE WITHOUT PRIOR WRITTEN PERMISSION OF HONEYWELL. PLEASE REVIEW THE TERMS OF THIS AGREEMENT CAREFULLY BEFORE USING THIS DOCUMENT, AS BY USING IT, YOU ACKNOWLEDGE THAT YOU HAVE REVIEWED THIS AGREEMENT AND AGREE TO BE BOUND BY ITS TERMS AND CONDITIONS.

HONEYWELL MATERIALS LICENSE AGREEMENT This document and the information contained herein (“the Materials”) are the proprietary data of Honeywell. These Materials are provided for the exclusive use of Honeywell-authorized Service Centers; Honeywell-authorized repair facilities; owners of a Honeywell aerospace product that is the subject of these Materials (“Honeywell Product”) that have entered into a written agreement with Honeywell relating to the repair or maintenance of Honeywell Product; and direct recipients of Materials from Honeywell via https://myaerospace.honeywell.com/wps/portal/ that own a Honeywell Product. The terms and conditions of this Honeywell Materials License Agreement (“License Agreement”) govern your use of these Materials, except to the extent that any terms and conditions of another applicable agreement with Honeywell regarding the maintenance or repair of a Honeywell Product and that is the subject of the Materials conflict with the terms and conditions of this License Agreement, in which case the terms and conditions of the other agreement will govern. However, this License Agreement will govern in the event of a conflict between these terms and conditions and those of a purchase order or acknowledgement. Your access or use of the Materials represents your acceptance of the terms of this License Agreement. 1. License Grant - If you are a party to an applicable written agreement with Honeywell relating to the repair or maintenance of the subject Honeywell Product, subject to your compliance with the terms and conditions of this License Agreement, Honeywell hereby grants you, and you accept, a limited, personal, non-transferable, non-exclusive license to use these Materials only in accordance with that agreement. If you are a direct recipient of these Materials from Honeywell’s MyAerospace Technical Publication website and are not a party to an agreement related to the maintenance or repair of the subject Honeywell Product, subject to your compliance with the terms and conditions of this License Agreement, Honeywell hereby grants you, and you accept, a limited, personal, non-transferable, non-exclusive license to use a single copy of these Materials to maintain or repair only the subject Honeywell Product installed or intended to be installed on the aircraft you own and/or operate and only at the facility to which these Materials have been shipped (“the Licensed Facility”). Transfer of the Materials to another facility owned by you is permitted only if the original Licensed Facility retains no copies of the Materials, the transferee accepts all of your obligations and liabilities under this License Agreement, and you provide prior written notice to Honeywell with the name and address of the transferee. You agree not to use these Materials for commercial purposes.

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2. Restrictions on Use - You may not sell, rent, lease, or (except as authorized under any applicable airworthiness authority regulation) lend the Materials to anyone for any purpose. You may not use the Materials to reverse engineer any Honeywell product, hardware or software, and may not decompile or disassemble software provided under this License Agreement, except and only to the extent that such activity is expressly permitted by applicable law notwithstanding this limitation. You may not create derivative works or modify the Materials in any way. You agree that Materials shall only be used for the purpose of the rights granted herein. The Material furnished hereunder may be subject to U.S. export regulations. You will adhere to all U.S. export regulations as published and released from time to time by the U.S. Government. You may not design or manufacture a Honeywell part

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ENGINE MANUAL 131-9[B] or detail of a Honeywell part, to create a repair for a Honeywell part, design or manufacture any part that is similar or identical to a Honeywell part, compare a Honeywell part or design of a Honeywell part to another part design, or apply for FAA PMA or other domestic or foreign governmental approval to manufacture or repair a Honeywell part. 3. Rights In Materials - Honeywell retains all rights in these Materials and in any copies thereof that are not expressly granted to you, including all rights in patents, copyrights, trademarks, and trade secrets. The Materials are licensed and not sold under this License Agreement. No license to use any Honeywell trademarks or patents is granted under this License Agreement. 4. Changes - Honeywell reserves the right to change the terms and conditions of this License Agreement at any time, including the right to change or impose charges for continued use of the Materials. Honeywell may add, delete or otherwise modify any portion of the Materials (“Updated Materials”) at any time. You agree to stop using outdated Materials upon issuance of any Updated Materials. 5. Confidentiality - You acknowledge that these Materials contain information that is confidential and proprietary to Honeywell. You agree to take all reasonable efforts to maintain the confidentiality of these Materials. 6. Assignment And Transfer - This License Agreement may be assigned to a service center approved and formally designated as a service center by Honeywell, provided, however, that you retain no copies of the Materials in whole or in part. However, the recipient of any such assignment or transfer must assume all of your obligations and liabilities under this License Agreement. No assignment or transfer shall relieve any party of any obligation that such party then has hereunder. Otherwise, neither this License Agreement nor any rights, licenses or privileges granted under this License Agreement, nor any of its duties or obligations hereunder, nor any interest or proceeds in and to the Materials shall be assignable or transferable (in insolvency proceedings, by merger, by operation of law, by purchase, by change of control or otherwise) by you without Honeywell’s written consent. 7. Copies of Materials - Unless you have the express written permission of Honeywell, you may not make or permit making of copies, digital or printed, of the Materials. You agree to return the Materials and any such copies thereof to Honeywell upon the request of Honeywell. 8. Term - This License Agreement is effective until terminated as set forth herein. This License Agreement will terminate immediately, without notice from Honeywell, if you fail to comply with any provision of this License Agreement or will terminate simultaneously with the termination or expiration of your applicable agreement with Honeywell relating to the repair or maintenance of the subject Honeywell Product. Upon termination of this License Agreement, you will return these Materials to Honeywell without retaining any copies, in whole or in part, and will have one of your authorized officers certify that all Materials have been returned with no copies retained. 9. Audit Rights - Honeywell, through its authorized representatives, with no less than thirty (30) calendar days notice from Honeywell, has the right during normal business hours during the term of this License Agreement and for three (3) years thereafter to visit you and have access to the inside and outside of your facility for the purpose of inspecting, observing and evaluating your compliance under this License Agreement. 10. Remedies - Honeywell reserves the right to pursue all available remedies and damages resulting from a breach of this License Agreement.

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ENGINE MANUAL 131-9[B] INFORMED OF THE POSSIBILITY OF SUCH DAMAGES. TO THE EXTENT PERMITTED BY APPLICABLE LAW, THESE LIMITATIONS AND EXCLUSIONS WILL APPLY REGARDLESS OF WHETHER LIABILITY ARISES FROM BREACH OF CONTRACT, WARRANTY, INDEMNITY, TORT (INCLUDING BUT NOT LIMITED TO NEGLIGENCE), BY OPERATION OF LAW, OR OTHERWISE. 12. Controlling Law - This License Agreement shall be governed and construed in accordance with the laws of the State of New York without regard to the conflict of laws provisions thereof. 13. Severability - In the event any provision of this License Agreement is determined to be illegal, invalid, or unenforceable, the validity and enforceability of the remaining provisions of this License Agreement will not be affected and, in lieu of such illegal, invalid, or unenforceable provision, there will be added as part of this License Agreement one or more provisions as similar in terms as may be legal, valid and enforceable under controlling law. 14. Integration and Modification - This License Agreement and all attachments set forth the entire agreement and understanding between the parties on the subject matter of the License Agreement and merges all prior discussions and negotiations among them. This License Agreement may be modified only by a duly-authorized representative of Honeywell.

SAFETY ADVISORY WARNING: BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW THE HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO OBEY THE MANUFACTURERS’ OR SUPPLIERS’ RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR DISEASE. This publication describes physical and chemical processes which can make it necessary to use chemicals, solvents, paints, and other commercially available materials. The user of this publication must get the Material Safety Data Sheets (OSHA Form 174 or equivalent) from the manufacturers or suppliers of the materials to be used. The user must know the manufacturer/supplier data and obey the procedures, recommendations, warnings and cautions set forth for the safe use, handling, storage, and disposal of the materials.

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

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

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ENGINE MANUAL 131-9[B]

Copyright - Notice Copyright 1997, 2019 Honeywell International Inc. All rights reserved. Honeywell is a registered trademark of Honeywell International Inc.

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All other marks are owned by their respective companies.

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ENGINE MANUAL 131-9[B]

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ENGINE MANUAL 131-9[B]

TRANSMITTAL INFORMATION TO HOLDERS OF GAS TURBINE ENGINE PUBLICATION NUMBER 49-26-95 ISSUED FOR USE IN SUPPORT OF THE FOLLOWING: Table TI-1 shows the applicable components. Table TI-1. Applicable Engines Engine PN

Boeing Part Number

Engine Model Number

Aircraft Application

3800702-1

S351A401-201

131-9[B]

B737-600/-700/-800/-900 B737-8/-9

Revision History Table TI-2 shows the revision history of this EM. Table TI-2. Revision History Revision Number

Revision Date

0

14 Aug 1997

1

18 Aug 2000

2

6 Jan 2003

3

28 Feb 2006

4

5 Oct 2007

5

14 Dec 2009

6

30 Nov 2011

7

31 May 2013

8

24 Nov 2014

9

28 Aug 2015

10

14 Jul 2016

11

9 Nov 2017

12

17 Aug 2018

13

18 Dec 2019

This revision is a full replacement. All changed pages have a new date, as identified in the List of Effective Pages. Revision bars identify the changed data. A revision bar adjacent to the Fig./Item column identifies changes in the Detailed Parts List. See Transmittal information for history of revisions to this EM. Remove and discard all pages of the manual and replace them with the attached pages. Write the revision number, revision date, and replacement date on the Record of Revisions page.

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Revision bars mark the technical data that changed in this revision; those changes are described in the table of highlights. Editorial changes are not marked with a revision bar. EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] The table of highlights tells users what has changed as a result of the revision. The table consists of three columns. The task/page column identifies the blocks of changed information, such as a task, subtask, graphic, or parts list, and the page on which that block starts. The block of information often includes the JEMTOSSJet Engine Maintenance Task Oriented Support System code. Revision marks, when provided, identify the location of the change within the block. The description of change column tells about the change or changes within each block. The description of change is often preceded by a paragraph or figure reference that applies to the block of information. The effectivity column tells the user the part number(s) to which the block of information applies. The default value for this column is "All." "All" means that the block applies to all parts. The table of highlights tells users what has changed as a result of the revision. The table consists of three columns. The Task/Page column identifies the blocks of changed information, such as a task, subtask, graphic, or parts list, and the page on which that block starts. The block of information often includes the MTOSS code. Revision marks, when provided, identify the location of the change within the block. The Description of Change column tells about the change or changes within each block. The description of change is often preceded by a paragraph or figure reference that applies to the block of information. The Effectivity column tells the user the part number(s) to which the block of information applies. The default value for this column is "All." "All" means that the block applies to all parts.

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Table of Highlights Task/Page

Description of Change

TRANSMITTAL INFORMATION

Global Change: Changed the content and format to All agree with the Honeywell processes in effect at the time of the release of this revision.

TRANSMITTAL INFORMATION

Global Change: The editorial changes and data that were moved or reformatted are not identified with revision bars

All

RECORD OF TEMPORARY REVISIONS

Added TR 49-70 thru 49-72, incorporated in Rev 13.

All

SERVICE BULLETIN LIST

Changed revision 7 to 8 for SB 131-49-7933.

All

SERVICE BULLETIN LIST

Added service bulletin 49-8252, 131-49-8128, All 131-49-8269, 131-49-8272, 131-49-8273, 131-49-8277, 131-49-8290, 131-49-8098, 131-49-8233, 2024215-2-SB NO. 1, and GTCP331-49-8064, to the Service Bulletin List.

SERVICE BULLETIN LIST

Changed service bulletin number 131-49-8128, R1 to 131-49-8182, R2.

49-00-00 INTRODUCTION

Paragraph 1.C. Step (c).4. Table INTRO-1. Deleted the All text from the series No. 41 and added series No. 45 thru 47.

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

Effectivity

All

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ENGINE MANUAL 131-9[B]

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Table of Highlights (Cont) Task/Page

Description of Change

49-00-00 INTRODUCTION

Paragraph 1.A. Table INTRO-4. Changed the Generator All Control Unit to Starter/Generator.

49-00-00 INTRODUCTION

Paragraph 1.A. Table INTRO-6. Added row for Engineering Technical Review.

All

49-00-00 INTRODUCTION

Paragraph 2.A. Table INTRO-7. Added Ref. Turbine Rotor Assy Part Number 3840165-9 for second stage turbine rotor.

All

49-20-00 SYSTEMS DESCRIPTION SECTION

Paragraph 2. Table 3. Deleted existing table content and added service bulletin 49-8252 reference.

All

49-20-00 SYSTEMS DESCRIPTION SECTION

Figure 8. (Sheet 1 of 2). Changed the sheet to add the All engineering drawing number.

49-20-00 SYSTEMS DESCRIPTION SECTION

Figure 8. (Sheet 2 of 2). Changed the sheet to add the All engineering drawing number.

49-20-00 APU - FAULT ISOLATION

Paragraph 181.B. Step (2)(b).1. Changed Necessary value: <25 ohms to Necessary value: <50 ohms.

All

49-20-00 APU - FAULT ISOLATION

Paragraph 181.B. Step (2)(c).2. Changed Necessary value: <25 ohms to Necessary value: <50 ohms.

All

49-20-00 APU - FAULT ISOLATION

Paragraph 184.B. Step (2)(b).1. Changed Necessary value: <25 ohms to Necessary value: <50 ohms.

All

49-20-00 APU - FAULT ISOLATION

Paragraph 184.B. Step (2)(c).2. Changed Necessary value: <25 ohms to Necessary value: <50 ohms.

All

49-20-00 IGNITION UNIT REMOVAL-22

Paragraph 4.B. Added Pre SB 131-49-7527 procedure All for ignition unit removal and renumbered subsequent paragraph.

49-20-00 IGNITION UNIT REMOVAL-22

Paragraph 4.C. Added text "(Post SB 131-49-7527)" All and changed figure reference from 3001 to 3002 in title.

49-20-00 IGNITION UNIT REMOVAL-22

Figure 3001. Changed figure and title for Pre SB All 131-49-7527 and added Items 50, 100 in key for figure.

49-20-00 IGNITION UNIT REMOVAL-22

Figure 3002. Added figure and key for figure for Post SB 131-49-7527.

49-20-00 FUEL CONTROL UNIT (FCU) INSTALLATION-18

Paragraph 5.A. Step (1). Changed to apply All MIL-PRF-23699 or MIL-PRF-7808, lubricating oil to the new packing (30).

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

Effectivity

All

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ENGINE MANUAL 131-9[B]

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Table of Highlights (Cont) Task/Page

Description of Change

49-20-00 IGNITION UNIT INSTALLATION-28

Figure 4001. Changed figure and title for Pre SB All 131-49-7527 and added Items 50, 100 in key for figure.

49-20-00 IGNITION UNIT INSTALLATION-28

Figure 4002. Added figure and key for figure for Post SB 131-49-7527.

49-20-00 IGNITION UNIT INSTALLATION-28

Paragraph 5.A. Added Pre SB 131-49-7527 procedure All for ignition unit installation and renumbered subsequent paragraph.

49-20-00 IGNITION UNIT INSTALLATION-28

Paragraph 5.B. Added text "(Post SB 131-49-7527)" All and changed figure reference from 4001 to 4002 in title.

49-20-00 APU CLEANING-01

Paragraph 2.A. Table 6001. Changed ATA No 49-20-04 All to ATA No 24-21-14.

49-21-00 GEARBOX ASSEMBLY DISASSEMBLY-01

Figure 5004. Changed the orientation of the Item 60.

All

49-21-00 GEARBOX ASSEMBLY DISASSEMBLY-01

Figure 5005. Changed the orientation of the Item 30.

All

49-21-00 GEARBOX GEARSHAFTS ASSEMBLY-01

Figure 10001. Changed the orientation of the Item 60. All

49-21-00 GEARBOX GEARSHAFTS ASSEMBLY-01

Figure 10002. Changed the orientation of the Item 30. All

49-22-00 POWER SECTION ASSEMBLY DISASSEMBLY-02

Figure 5003. Added Item 70B and 70C in Key To Figure.

All

49-22-00 POWER SECTION ASSEMBLY DISASSEMBLY-02

Paragraph 4.A. Step (3).(b). Added Post SB 131-49-7953 and Post SPB D20181000017.

All

49-22-00 POWER SECTION ASSEMBLY DISASSEMBLY-02

Paragraph 4.A. Step (3).(d). Added Post SB 49-7953 and Post SPB D20181000017.

All

49-22-00 POWER SECTION ASSEMBLY DISASSEMBLY-02

Figure 5005. Changed figure to show the correct orientation of Item 70.

All

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

Effectivity

All

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ENGINE MANUAL 131-9[B]

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Table of Highlights (Cont) Task/Page

Description of Change

Effectivity

49-22-00 POWER SECTION ASSEMBLY DISASSEMBLY-02

Figure 5006. Changed figure to show the correct orientation of Item 80.

All

49-22-00 POWER SECTION ASSEMBLY DISASSEMBLY-02

Figure 5007. Changed figure to show the correct location of protrusion for Item 70B.

All

49-22-00 INLET GUIDE VANE ASSEMBLY ASSEMBLY-01

Figure 10002. Added Dimensional limits table.

All

49-22-00 INLET GUIDE VANE ASSEMBLY ASSEMBLY-01

Figure 10002. Changed figure to show the correct BB view.

All

49-22-00 INLET GUIDE VANE ASSEMBLY ASSEMBLY-01

Paragraph 5.C. Step (2).(h). Added the Alternate All Method for Install cotter pins (10) into spring pins (20).

49-22-00 DIFFUSER HOUSING ASSEMBLY ASSEMBLY-03

Figure 10001. Changed the position of hole for Items 170, 180 and 190.

All

49-22-00 DIFFUSER HOUSING ASSEMBLY ASSEMBLY-03

Figure 10002. Changed the position of hole for Items 170B, 180B and 190B.

All

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5. Table 10004. Changed the Check Point 80 and 140.

All

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (4).(e). thru (i). Rearranged the assembly sequence.

All

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (7).(d). Changed step to remove pin alignment reference.

All

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (8).(a). Added step to install shim All pack.

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (11).(p). Changed the Check Point All 80.

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

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Table of Highlights (Cont) Task/Page

Description of Change

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Figure 10021. Changed the reference for Item 90 from All IPC FIG. 25 to IPC FIG. 26.

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (14).(r). Changed the Check Point All 140.

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (15). Changed statement of the procedural step.

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (15).(ab). Changed step to remove All the diffuser housing assembly.

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (16).(b)3. thru (b)7. Changed nuts All to bolts and added torque value.

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (20).(c). Changed the step reference.

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (20).(d). Added NOTE to this step. All

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (20).(e). Added step.

All

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Figure 10046. Key to Figure 10046. Added Item 70C.

All

49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06

Paragraph 5.A. Step (25).(e)4b. Added steps for Post SPB D20181000017 and Post SPB D20181000017.

All

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

Effectivity

All

All

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ENGINE MANUAL 131-9[B]

RECORD OF REVISIONS For each revision, write the revision number, revision date, date put in the manual, and your initials in the applicable column. NOTE:

Refer to the Revision History in the TRANSMITTAL INFORMATION section for revision data.

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Revision Number

EFFECTIVITY ALL

Revision Date

Date Put in Manual

By

Revision Number

Revision Date

Date Put in Manual

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

By

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EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

RECORD OF TEMPORARY REVISIONS Instructions on each page of a temporary revision tell you where to put the pages in your manual. Remove the temporary revision pages only when discard instructions are given. For each temporary revision, put the applicable data in the record columns on this page. Definition of Status column: A TR may be active, incorporated, or deleted. “Active” is entered by the holder of the manual. “Incorporated” means a TR has been incorporated into the manual and includes the revision number of the manual when the TR was incorporated. “Deleted” means a TR has been replaced by another TR, a TR number will not be issued, or a TR has been deleted.

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Temporary Revision Number

Status

Page Number

Issue Date

Date Put in Manual

49-1

INC Rev 1

20 Mar 1998

18 Aug 2000

49-2

INC Rev 1

7 Apr 1998

18 Aug 2000

49-3

INC Rev 1

7 Apr 1998

18 Aug 2000

49-4

INC Rev 1

19 Aug 1998

18 Aug 2000

49-5

INC Rev 1

19 Aug 1998

18 Aug 2000

49-6

INC Rev 1

19 Aug 1998

18 Aug 2000

49-7

INC Rev 1

23 Oct 1998

18 Aug 2000

49-8

INC Rev 1

23 Oct 1998

18 Aug 2000

49-9

INC Rev 1

23 Oct 1998

18 Aug 2000

49-10

INC Rev 1

23 Oct 1998

18 Aug 2000

49-11

INC Rev 1

23 Oct 1998

18 Aug 2000

49-12

INC Rev 1

16 Nov 1998

18 Aug 2000

49-13

INC Rev 1

16 Nov 1998

18 Aug 2000

49-14

INC Rev 1

26 Apr 1999

18 Aug 2000

49-15

INC Rev 1

26 Apr 1999

18 Aug 2000

49-16

INC Rev 1

23 Oct 1998

18 Aug 2000

49-17

INC Rev 1

23 Oct 1998

18 Aug 2000

49-18

INC Rev 1

23 Oct 1998

18 Aug 2000

49-19

INC Rev 1

16 Nov 1998

18 Aug 2000

49-20

INC Rev 1

16 Nov 1998

18 Aug 2000

49-21

INC Rev 1

26 Apr 1999

18 Aug 2000

49-22

INC Rev 1

16 Nov 1998

18 Aug 2000

49-23

INC Rev 1

26 Apr 1999

18 Aug 2000

49-24

INC Rev 1

26 Apr 1999

18 Aug 2000

49-25

INC Rev 1

28 Feb 2000

18 Aug 2000

EFFECTIVITY ALL

By

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

Date Removed From Manual

By

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ENGINE MANUAL 131-9[B]

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Temporary Revision Number

Status

Page Number

Issue Date

Date Put in Manual

49-26

INC Rev 1

28 Feb 2000

18 Aug 2000

49-27

INC Rev 1

3 Mar 2000

18 Aug 2000

49-28

INC Rev 2

22 Oct 2001

6 Jan 2003

49-29

INC Rev 2

26 Nov 2001

6 Jan 2003

49-30

INC Rev 2

26 Nov 2001

6 Jan 2003

49-31

INC Rev 2

28 Feb 2002

6 Jan 2003

49-32

INC Rev 2

10 May 2002

6 Jan 2003

49-33

INC Rev 3

31 Mar 2003

5 May 2005

49-34

INC Rev 3

31 Mar 2003

5 May 2005

49-35

INC Rev 3

27 Jun 2003

5 May 2005

49-36

INC Rev 3

7 Jan 2004

5 May 2005

49-37

INC Rev 3

9 May 2005

7 Dec 2005

49-38

INC Rev 3

9 May 2005

7 Dec 2005

49-39

INC Rev 3

9 May 2005

7 Dec 2005

49-40

INC Rev 3

2 Aug 2005

7 Dec 2005

49-43

INC Rev 5

23 Jan 2008

14 Dec 2009

49-44

INC Rev 6

10 Jun 2011

30 Nov 2011

49-45

INC Rev 6

10 Sep 2011

30 Nov 2011

49-46

INC Rev 6

10 Oct 2011

30 Nov 2011

49-47

INC Rev 7

17 Feb 2012

31 May 2013

49-48

INC Rev 7

11 Apr 2012

31 May 2013

49-49

INC Rev 7

26 Apr 2012

31 May 2013

49-50

INC Rev 7

16 May 2012

31 May 2013

49-51

INC Rev 7

27 Jul 2012

31 May 2013

49-52

INC Rev 7

6 Sep 2012

31 May 2013

49-53

INC Rev 7

19 Dec 2012

31 May 2013

49-54

INC Rev 7

16 Jan 2013

31 May 2013

49-55

INC Rev 7

10 Jun 2013

31 May 2013

49-56

INC Rev 8

11 Mar 2014

24 Nov 2014

49-57

INC Rev 8

8 Aug 2014

24 Nov 2014

49-58

INC Rev 8

4 Sep 2014

24 Nov 2014

EFFECTIVITY ALL

Date Removed From Manual

By

By

(Replaced by T.R. 49-32)

(Replaced by TR 49-53)

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ENGINE MANUAL 131-9[B]

UP552142

Temporary Revision Number

Status

Page Number

Issue Date

Date Put in Manual

49-59

INC Rev 9

3 Dec 2014

28 Aug 2015

49-60

INC Rev 9

2 Feb 2015

28 Aug 2015

49-61

INC Rev 9

4 Feb 2015

28 Aug 2015

49-62

INC Rev 9

14 Aug 2015

28 Aug 2015

49-63

INC Rev 10

21 Oct 2015

14 Jul 2016

49-64

INC Rev 10

8 Mar 2016

14 Jul 2016

49-65

INC Rev 11

27 Oct 2016

31 May 2017

49-66

INC Rev 11

3 Feb 2017

31 May 2017

49-67

INC Rev 11

28 Apr 2017

31 May 2017

49-68

INC Rev 12

22 Feb 2018

15 May 2018

49-69

INC Rev 12

22 Mar 2018

15 May 2018

49-70

INC Rev 13

49-71

INC Rev 13

49-72

INC Rev 13

EFFECTIVITY ALL

Date Removed From Manual

By

By

(Replaced by TR 49-61)

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UP552142

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EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

SERVICE BULLETIN LIST

UP552142

Service Bulletin/ Revision Number

Title

Date Put in Manual

131-49-7365

Replace Clevis Assembly, Part No. 3827166-2 with 18 Aug 2000 Clevis, Part No. 3827165-2, Bolt, Part No. NAS6704-9, and Washer, Part No. NAS1149C0432R, on Power Section Assembly, Part No. 3801103-1.

131-49-7366

Replace IGV Assembly, Part No. 3810821-4, with 18 Aug 2000 IGV Assembly, Part No. 3810821-5, Bolt, Part No. NAS6703-9 and Washer, Part No. NAS1149C0332R, on Power Section Assembly, Part No. 3801103-1.

131-49-7373

Replace Compressor Coupling Shaft, Part No. 18 Aug 2000 3822510-1, with Compressor Coupling Shaft, Part No. 3822510-2.

GTCP131-49-7431

Rework/Replace Upper Inlet Duct, Part No. 18 Aug 2000 3810828-6 with/to Part No. 3810828-7 and Lower Inlet Duct, Part No. 3810829-3 with/to Part No. 3810829-4.

131-49-7476

Rework/Replace Turbine Bearing Support, Part 18 Aug 2000 No. 3844863- 2 to/with Part No. 3844863-3 or Replace Turbine Bearing Support, 3844863-2 with 3844863-1 and Rework/Replace Rear Bearing Seal Retainer, Part No. 3844599-1 to/with Part No. 3844599-2.

131-49-7480, R1

On Power Section, Part No. 3801103-1, L/C Seal 18 Aug 2000 Cavity Improvements. Replace Driven Compressor Coupling Shaft, Part No. 3822529-1 with Part No. 3822529-4, Rework or Replace Compressor Bearing Housing, Part No. 3827265-3 to/with Part No. 3827265-4, Rework or Replace Driven Compressor Bearing Housing, Part No. 38273204 to/with Part No. 3827320-5.

131-49-7483, R1

Replace/Rework Surge Duct, Part No. 3885003-1 18 Aug 2000 with/to Surge Duct, Part No. 3885003-2.

131-49-7513

Ground Strap, Part No. MS25083-5BB7, Installation 18 Aug 2000 for Ground-Loop Current Path.

131-49-7527

Replace Eductor Housing, Part No. 3850100-4 with 18 Aug 2000 Part No. 3850100-5 and Eliminate Ignition Unit Adapter Bracket, Part No. 3617110-2.

131-49-7541, R1

Replace Static Pressure Tube, Part No. 3884980- 18 Aug 2000 2 with Part No. 3884980-3 and Total Pressure Tube, Part No. 3884984-2 with Part No. 38849843.

EFFECTIVITY ALL

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Status

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ENGINE MANUAL 131-9[B]

UP552142

Service Bulletin/ Revision Number

Date Put in Manual

Title

131-49-7561, R2

Replace Turbine Seal Gasket, Part No. 3844707- 6 Jan 2003 1 with Part No. 3844707-2.

131-49-7577, R2

AIRBORNE AUXILIARY POWER - GAS TURBINE 6 Jan 2003 ENGINE - Rework and/or Replace Power Section, PN 3801103-1 to/with PN 3801103-2, by Replacing Three Turbine Shroud Segments, PN 3844575-2 with PN 3844575-3, and Rework the Turbine Stator Support Assembly, PN 3844797-9, -10 to PN 3844797-17, -18 or to PN 3844797-13, -14, and Replace and/or Rework Containment Ring, PN 3844587-3 with/to PN 3844587-4, on 131-9[B] Auxiliary Power Unit (APU).

131-49-7597, R3

Rework and/or Replace Power Section, PN. 28 Feb 2006 3801103-2 to/with PN 3801103-3 and Plumbing and Electrical Assembly, PN 3616850-1 to/with PN 3616850-2, for the 131-9[B].

131-49-7629, R1

Turbine Bearing Retainer, PN 3844917-1, Sleeve No Effect Installation Discrepancy on 131[B] APU.

131-49-7643, R1

Rework Bleed Duct, Part No. 3885004-1 by Replacing the Internal Flow Liner if Cracked or Applying a Continuous Weld.

131-49-7667

Incorporate Combustor Case Drain Plug Lockwire 6 Jan 2003 Feature on Engine Assembly 3800702-1.

131-49-7688

Replace Fuel Control Unit (FCU), Part No. 441921- No Effect 4 with Part No. 441921-5.

131-49-7743, R1

Replace Oil Cooler, Part No. 160564-1 with Part No. 160564-2.

No Effect

131-49-7750, R6

Replace Load Compressor Seal Assembly, PN 3827350-3 with PN 3827608-3 and Rotor, PN 3822418-1 with PN 3822635-2, on the 131-9[B] Engine Models.

No Effect

131-49-7776, R2

Replace/Return for Rework First Stage Turbine No Effect Wheel Assembly, Part No. 3840160-5 with/to Part No. 3840303-1.

131-49-7857, R1

Replace/Rework First Stage Turbine Rotor Assembly, Part No. 3840303-1, to First Stage Turbine Rotor Assembly, Part No. 3840160-7.

131-49-7860, R1

Replace First Stage Turbine Rotor Assembly, Part No Effect No. 3840303-1, with First Stage Turbine Rotor Assembly, Part No. 3840160-8, Replace/Rework First Stage Turbine Rotor Assembly, Part No. 3840160-5, with/to First Stage Turbine Rotor Assembly, Part No. 3840160-8.

EFFECTIVITY ALL

Status

No Effect

No Effect

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ENGINE MANUAL 131-9[B] Service Bulletin/ Revision Number

Date Put in Manual

Title

131-49-7881

Replace Rear Bearing Seal, Part No. 3844561-1 with Rear Bearing Seal, Part No. 3844561-3.

No Effect

131-49-7902

Rework and/or Replace Plumbing and Electrical Assembly, Part No. 3616850-2, to/with Part No. 3616850-3.

30 Nov 2011

Status

UP552142

3888449-49-7903, R1 Rework Engine Wiring Harness, Part No. 3888449- No Effect 1, to Part No. 3888449-2. 131-49-A7925

Inspection of Specific ECU Controller Serial Numbers for Part Number 2118966-222.

No Effect

131-49-7933, R8

Oil - General - Approved Oils.

5 Oct 2007

131-49-7949, R2

Replace Fitting, Part Number 3879006-1 with Flow 14 Dec 2009 Divider Tee, Part Number 3883830-1, and Check Valve, Part Number 3879005-1 with Union-Flared Fitting, Part Number MS24392J4.

131-49-7951, R1

Examine Starter/Generator, Part Number 28B545- No Effect 7 for Specific Serial Numbers before Return to Service.

131-49-7953, R1

Replace the Scavenge Tube, PN 3881826-1 with No Effect PN 3881826-2, and Incorporate Gasket, PN AS4824N06, on the 131-9[B] Auxiliary Power Unit (APU).

131-49-7971, R5

Replace First Stage Turbine Assembly, PN No Effect 3840160-5, -7, -8 or PN 3840303-1, and Stationary Seal Assembly, PN 3844738-5, with First Stage Turbine Assembly, PN 3840310-3 and Stationary Seal Assembly, PN 3844738-6, on the 131-9[B] APU.

131-49-7988

Replace Turbine Seal Gasket, PN 3844705-1 with No Effect PN 3844705-2.

131-49-7997, R5

Standard Storage and Preservation Guidelines.

131-49-8023, R1

Replace the Fuel Drain Tube, PN 3883848-3 with 30 Nov 2011 FCU Drain Tube Assembly, PN 3879078-1, SCV Drain Tube Assembly, PN 3879078-2, IGV Drain Tube Assembly, PN 3879078-3, Fuel Drain Tube Assembly, PN 3879078-4, and Drain Tube Assembly, PN 3879078-5, on the 131-9[B] APU.

131-49-8027

Replace the Inlet Guide Vane Actuator, PN 3886188-2 with PN 3886188-3.

No Effect

131-49-8037

Replace the Upper Inlet Duct Assembly, PN 3810948-1.

No Effect

131-49-8052, R1

Replacement of Second Stage Turbine Rotor Assembly, PN 3840165-4.

No Effect

EFFECTIVITY ALL

14 Dec 2009

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ENGINE MANUAL 131-9[B]

UP552142

Service Bulletin/ Revision Number

Date Put in Manual

Title

131-49-8054

Replace the Flow Divider Tee, PN 3883830-1 with No Effect PN 3883830-2.

131-49-8065, R1

Replace Duplex Ball Bearing Assembly, Matched 31 May 2013 Set, PN 3822478-1, with PN 3822666-2, Compressor Bearing Housing, PN 3827265-4, with PN 3827265-8, Compressor Bearing Retainer Plate, PN 3827385-1, with PN 3827385-2, and Compression Spring Washer, PN 3827075-1, with PN 791-548-9301. Remove Bearing Damper Ring, PN 3827173-3, and Spring Retainer, PN 38270744.

131-49-8079, R1

Replacement of Discrepant Data Memory Module No Effect (DMM), PN 3876287-1.

131-49-8084

Replace the Starter/Generator, PN 28B545-7A, 7B or -7C, with PN 28B545-9A.

No Effect

131-49-8091, R2

Remove and Inspect the Second stage Turbine Rotor Assembly, PN 3840165-4, for Linear Indications.

No Effect

131-49-8098

AIRBORNE AUXILIARY POWER - GAS TURBINE No Effect ENGINE - Replacement of the Bearing Set (Turbine Roller Bearing), PN 3840242-1, with the Incorrect Rolling Element Material

131-49-8100, R2

Remove and Replace Starter/Generator Assembly, No Effect PN 28B545-9.

131-49-8128

Airborne Auxiliary Power - Gas Turbine Engine - No Effect Approve the use of Ignition Unit PN 3888058-5 in place of Ignition Unit PN 3888058-7 for the 1319[B] Auxiliary Power Unit (APU).

131-49-8182, R2

Airborne Auxiliary Power - Gas Turbine Engine – No Effect Replace the Aft Right Bracket, PN 3870264-1 with PN 70722031-1, and Aft Left Bracket, PN 38702642 with PN 70722031-2, for the 131-9[B] Auxiliary Power Unit (APU).

131-49-8142

Replace Stationary Air Seal, PN 3844738-6 With No Effect PN 3844738-7 for the 131-9[B] and 131-9[D] APU.

131-49-8145

Replace Load Compressor Seal Rotor, PN 3822635-2 With PN 3822635-3, for the 131-9[B] and 131-9[D] APU.

131-49-8161

Replace the Compressor Discharge Duct, PN No Effect 3884988-1 With PN 70721302-1, on the 131-9[B] APU.

131-49-8122, R1

Inspect the Starter/Generator, PN 28B545-7 and -9, and Rework as Necessary.

EFFECTIVITY ALL

Status

No Effect

No Effect

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ENGINE MANUAL 131-9[B]

UP552142

Service Bulletin/ Revision Number

Date Put in Manual

Title

131-49-8233, R1

AIRBORNE AUXILIARY POWER - GAS TURBINE No Effect ENGINE - Replace the Bleed Air Duct, PN 3885004-2 with PN 3885004-5, on the 131-9[B] Auxiliary Power Unit (APU).

131-49-8236

Airborne Auxiliary Power - Gas Turbine Engine – Replace First Stage Dual-Alloy Turbine (DAT) Rotor, PN 3840310-3 with PN 3840310-4, for the 131-9[B] Auxiliary Power Unit (APU).

49-8252, R1

Airborne - Auxiliary Power Unit (APU) - Approved No Effect Fuels for Honeywell Commercial APUs.

131-49-8269

Airborne Auxiliary Power - Gas Turbine Engine - 18 Dec 2019 Replace the Containment Ring, PN 3844587-4 with PN 70721926-1, on the 131-9[B] Auxiliary Power Unit (APU).

131-49-8272, R1

Airborne Auxiliary Power - Gas Turbine Engine Replace the Fuel Control Unit, PN 441921-5 with PN 70722365-1, on the 131-9[B] Auxiliary Power Unit (APU).

131-49-8273

AIRBORNE AUXILIARY POWER - GAS TURBINE No Effect ENGINE - Replace the Fuel Control Unit, PN 441921-5 with PN 70722365-1, on the 131-9[B] Auxiliary Power Unit (APU).

131-49-8277, R1

Airborne Auxiliary Power - Gas Turbine Engine - 18 Dec 2019 Replace The Second Stage Turbine Wheel, PN 3840165-4 with PN 3840165-9 for the 131-9[B] and 131-9[D].

131-49-8290

Airborne Auxiliary Power - Gas Turbine Engine - 18 Dec 2019 Replace the Fuel Control Unit, PN 441921-5 or PN 70722365-1, with PN 70722492-1 or PN 707223652 for the 131-9[B] Auxiliary Power Unit (APU).

GTCP331-49-8064

Airborne Auxiliary Power - Gas Turbine Engine Rework or Replace the Load Control Valve Filter Bracket, PN 70720853-1 to/with PN 70720853-2.

No Effect

2024215-2-SB NO. 1

TESTING - DATA MEMORY MODULE (DMM) READER - PN 2024215-2; Improper firmware programming with PN 2024215-2.

No Effect

EFFECTIVITY ALL

Status

No Effect

18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

SPARE PARTS BULLETIN LIST Spare Parts Bulletin/ Revision Number

Title

Date Put in Manual

3844766-GTE1099

Self-locking Nut.

No Effect

131-GTE1110

Packing.

No Effect

131-GTE1116

Identification Plate.

No Effect

131-GTE1118, R1

Eductor Housing Assembly.

No Effect

131-GTE1120, R1

Upper Inlet Duct, Lower Inlet Duct and Access Door.

No Effect

131-GTE1147, R1

Combustor Assembly, PN 3830461-5 replaces PN No Effect 3830461-3.

131-GTE1165

Replace Turbine Bearing Housing Stud.

No Effect

131-GTE1170

Authorize use of alternate Upper and Lower Inlet Ducts.

No Effect

131-GTE1181

Authorize the use of Engine Compressor Shroud, No Effect Part No. 3827504-3 in place of Part No. 38273223.

131-GTE1183, R1

Annular Combustion Chamber, PN 3830461-6 Replaces PN 3830461-5.

131-GTE1185

Authorize the use of Surge Duct Assembly, Part No Effect No. 3885057-1 in place of Part No. 3885003-1 and 3885003-2.

131-GTE1191

Authorize the use of Ignition Unit, Part No. No Effect 3888058-7 as an alternate to Part No. 3888058-5.

131-GTE1195

Authorize the use of Pneumatic Duct Clamp, Part No Effect Nos. AS1895/4-300 and AS1895/4-350 in place of Part Nos. 234-591-9300 and 234-591-9350, respectively.

131-GTE1197

Authorize the use of Fuel Tube, Part Nos. 3883846- No Effect 3, 3883895-2 and 3883920-2 in place of Part Nos. 3883846-2, 3883895-1 and 3883920-1, respectively.

131-GTE1198

Authorize the use of Identification Plate, Part No. S21022-3 in place of Part No. S20022-3.

No Effect

131-GTE1201

Authorize the use of Oil Pickup Tube, Part No. 3863541-1 in place of Part No. 3863344-1.

No Effect

131-GTE1202

Authorize the use of Sightglass, Part No. 421-529- No Effect 9101 in place of Part No. 421-529-9003.

131-GTE1245

Authorize the use of Fuel Control Unit Clamp, Part No Effect No. 234-511-9059 as an alternate for Part No. 234591-3030.

EFFECTIVITY ALL

Status

No Effect

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ENGINE MANUAL 131-9[B]

UP552142

Spare Parts Bulletin/ Revision Number

Date Put in Manual

Title

131-GTE1247

Authorize the use of Load Compressor Seal, Part No Effect No. 3827350-3 in place of Part No. 3827350-2.

131-GTE1255

Authorize the use of Bleed Duct, Part No. 3885004- No Effect 2 in place or Part No. 3885004-1.

131-GTE1257

Authorize the use of Generator Harness, Part No. No Effect 3888448-2 in place of Part No. 3888448-1.

131-GTE1259

Authorize the use of Surge Duct, Part No. 3885057- No Effect 2 in place of Part No. 3885057-1.

131-GTE1279

Authorize the use of Second Stage Stationary Air No Effect Seal, Part No. 3844582-2 in place of Part No. 3844582-1.

131-GTE1323

Approve the use of Ignition Unit, Part No. WE3888439-1 in place of Part No. 3888058-5 for the 131-9[B] APU.

EFFECTIVITY ALL

Status

No Effect

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ENGINE MANUAL 131-9[B]

LIST OF EFFECTIVE PAGES Subheading and Page

Date

Title T-1 18 Dec 2019 T-2 18 Dec 2019 T-3 18 Dec 2019 T-4 18 Dec 2019 T-5 18 Dec 2019 T-6 18 Dec 2019 Transmittal Information TI-1 18 Dec 2019 TI-2 18 Dec 2019 TI-3 18 Dec 2019 TI-4 18 Dec 2019 TI-5 18 Dec 2019 TI-6 18 Dec 2019 Record of Revisions RR-1 18 Dec 2019 RR-2 18 Dec 2019 Record of Temporary Revisions RTR-1 18 Dec 2019 RTR-2 18 Dec 2019 RTR-3 * 18 Dec 2019 RTR-4 18 Dec 2019 Service Bulletin List SBL-1 18 Dec 2019 SBL-2 18 Dec 2019 SBL-3 * 18 Dec 2019 SBL-4 * 18 Dec 2019 SBL-5 * 18 Dec 2019 SBL-6 18 Dec 2019 SBL-7 18 Dec 2019 SBL-8 18 Dec 2019 List of Effective Pages LEP-1 18 Dec 2019 LEP-2 18 Dec 2019 Table of Contents TC-1 18 Dec 2019 TC-2 18 Dec 2019 Introduction INTRO-1 18 Dec 2019 INTRO-2 18 Dec 2019

Subheading and Page

INTRO-3 INTRO-4 INTRO-5 INTRO-6 INTRO-7 INTRO-8 INTRO-9 INTRO-10 INTRO-11 INTRO-12 INTRO-13 INTRO-14 INTRO-15 INTRO-16 INTRO-17 INTRO-18 INTRO-19 INTRO-20 INTRO-21 INTRO-22 INTRO-23 INTRO-24 INTRO-25 INTRO-26 INTRO-27 INTRO-28 INTRO-29 INTRO-30 INTRO-31 INTRO-32 INTRO-33 INTRO-34 INTRO-35 INTRO-36

Date

*

* *

*

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

UP552142

* Indicates a changed or added page. F Indicates a foldout page. EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TABLE OF CONTENTS INTRODUCTION Title

Page

INTRODUCTION ............................................................................................................................. 1.

How to Use This Manual ...............................................................................................

INTRO-1

A.

General .................................................................................................................

INTRO-1

B.

Engine Hardware Configuration ............................................................................

INTRO-10

C.

External Tubes, Cables, and Leads ......................................................................

INTRO-10

D.

Accessory Components ........................................................................................

INTRO-10

E.

Function Titles and Pagination ..............................................................................

INTRO-10

F.

Chapter/Section/Subject Explanation ...................................................................

INTRO-13

2.

ATA–JEMTOSS TASK and SUBTASK Number System ...............................................

INTRO-15

3.

Customer Support .........................................................................................................

INTRO-27

A.

Honeywell Aerospace Online Technical Publications Website .............................

INTRO-27

B.

Honeywell Aerospace Contact Team ....................................................................

INTRO-27

References ....................................................................................................................

INTRO-27

A.

Honeywell/Vendor Publications ............................................................................

INTRO-27

B.

Other Publications .................................................................................................

INTRO-28

Acronyms and Abbreviations .........................................................................................

INTRO-29

A.

General .................................................................................................................

INTRO-29

Process Verification .......................................................................................................

INTRO-30

A.

Verification Data ....................................................................................................

INTRO-30

Geometric Tolerance .....................................................................................................

INTRO-30

A.

Symbols ................................................................................................................

INTRO-30

8.

Standard Definitions ......................................................................................................

INTRO-33

9.

Rotating Group Life Limited Components .....................................................................

INTRO-34

A.

Check Requirements and Interval. ........................................................................

INTRO-34

B.

Rotating Group Life Limited Components. ............................................................

INTRO-34

4.

5. 6. 7.

UP552142

INTRO-1

EFFECTIVITY

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EFFECTIVITY

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ENGINE MANUAL 131-9[B]

INTRODUCTION 1.

How to Use This Manual A.

General (1)

This manual has been structured to support the on-condition maintenance concept by providing a total data package arranged for easy extraction of information in task-oriented units that can be tailored to different concepts and capabilities. This manual supports maintenance of the engine "off-aircraft."

(2)

Each page has certain consistent features controlling information on that page. Understanding these features is essential to proper application of the information.

(3)

Refer to Table INTRO-1 for equipment identification data. (a)

The configuration of the equipment is shown by the part number, dash number, series number, and change number stamped on the identification plate. Compare this data with the data shown in Table INTRO-1 (through last alpha suffix).

(b)

A part number, a service bulletin number (Pre SB, Post SB), or an effectivity code symbol identifies the special procedures or illustrations necessary for each configuration. The procedures and illustrations not identified are applicable to all the configurations of the equipment.

(c)

The effectivity coding system identifies the differences between unit configurations. 1

Modifications to the basic unit make it necessary to re-identify the unit. For example: PN 123456-1 becomes PN 123456-2.

2

Each different part number and dash number has its own effectivity code.

3

In the text, if no effectivity codes or part numbers are shown, then the procedures are applicable to all the configurations of the unit.

4

In the text, if one or more effectivity codes or part numbers are shown, then the procedures are applicable only to the related configuration of the unit.

Table INTRO-1. Equipment Identification List For Part No. 3800702-1 Effectivity Code Symbol

Series Number

Change No.

Description

-

1

-

Original configuration.

2

Same as Series 1 plus Change Numbers 1, 3, 4, 5, 7 and 8

UP552142

1

EFFECTIVITY ALL

Service Bulletin Number

Replace Ignition Lead Part No. 3876132-1 with Part No. 3876132-12

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ENGINE MANUAL 131-9[B] Table INTRO-1. Equipment Identification List For Part No. 3800702-1 (Cont) Effectivity Code Symbol

Series Number

Change No. 3

Replace First Stage Stator Part No. 3844797-5 and Alternate Part No. 3844797-6 with First Stage Stator Part No. 3844797-9 and Alternate Part No. 3844797-10. Replace Turbine Housing Assy Part No. 3844790-4 with Turbine Housing Assy Part No. 3844863-2

4

Replace Tube Clamp Part No. 36164751 with Tube Clamp Part No. 3617284-2

5

Replace Generator Part No. 28B545-5 with Generator Part No. 28B545-7

7

Replace Fireshield Part No. 3881394-1 with Fireshield Part No. 3881788-1

8

Replace Wiring Harness Part No. 3888444-1 with Wiring Harness Part No. 3888449-1 and Generator Wiring Harness Part No. 3888383-1 with Generator Wiring Harness Part No. 3888448-1

3

Same as Series 2 plus Change Numbers 2 and 6 2

Replace IGV Assy Part No. 3810821-4 131-49-7366 with IGV Assy Part No. 3810821-5, Add Bolt Part No. NAS6703-9 and Washer Part No. NAS1149C0332R

6

Replace Clevis Assy Part No. 3827166- 131-49-7365 2 with Clevis Assy Part No. 3827165-2, Add Bolt Part No. NAS6704-9 and Washer Part No. NAS1149C0432R

4

Same as Series 3 plus Change Number 9 9

5

UP552142

EFFECTIVITY ALL

Replace Shaft Assy Part No. 3822510- 131-49-7373 1 with Shaft Assy Part No. 3822510-2 Same as Series 2 plus Change Number 9

9 6

Description

Service Bulletin Number

Replace Shaft Assy Part No. 3822510- 131-49-7373 1 with Shaft Assy Part No. 3822510-2 Same as Series 4 plus Change Number 10

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ENGINE MANUAL 131-9[B] Table INTRO-1. Equipment Identification List For Part No. 3800702-1 (Cont) Effectivity Code Symbol

Series Number

Change No.

10

Replace Upper Inlet Duct Part No. 3810905-1 with Upper Inlet Duct Part No. 3810828-7. Replace Lower Inlet Duct Part No. 3810906-1 with Lower Inlet Duct Part No. 3810829-4

7

Same as Series 5 plus Change Number 11 11

8

9

10

UP552142

ALL

131-GTE1120

Replace Upper Inlet Duct Part No. 3810828-7 with Upper Inlet Duct Part No. 3810905-1. Replace Lower Inlet Duct Part No. 3810829-4 with Lower Inlet Duct Part No. 3810906-1

131-GTE1120

Same as Series 5 plus Change Number 10 10

11

Replace Upper Inlet Duct Part No. 3810828-7 with Upper Inlet Duct Part No. 3810905-1 Replace Lower Inlet Duct Part No. 3810829-4 with Lower Inlet Duct Part No. 3810906-1

GTCP131-497431

Same as Series 6 plus Change Number 11 11

EFFECTIVITY

Description

Service Bulletin Number

Replace Upper Inlet Duct Part No. 3810905-1 with Upper Inlet Duct Part No. 3810828-7. Replace Lower Inlet Duct Part No. 3810906-1 with Lower Inlet Duct Part No. 3810829-4

GTCP131-497431

Same as Series 3 plus Change Number 10 and Change Number 11 10

Replace Upper Inlet Duct Part No. 3810905-1 with Upper Inlet Duct Part No. 3810828-7. Replace Lower Inlet Duct Part No. 3810906-1 with Lower Inlet Duct Part No. 3810829-4

GTCP-131-497431

11

Replace Upper Inlet Duct Part No. 3810828-7 with Upper Inlet Duct Part No. 3810905-1. Replace Lower Inlet Duct Part No. 3810829-4 with Lower Inlet Duct Part No. 3810906-1

131-GTE1120

Same as Series 8 plus Change Number 12

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ENGINE MANUAL 131-9[B] Table INTRO-1. Equipment Identification List For Part No. 3800702-1 (Cont) Effectivity Code Symbol

Series Number

Change No. 12

12

13

14

Replace Driven Compressor Bearing 131-49-7480 Housing Part No. 3827320-4 with Driven Compressor Bearing Housing Part No. 3827320-5

Replace Compressor Bearing Housing 131-49-7480 Part No. 3827265-3 with Compressor Bearing Housing Part No. 3827265-4 Same as Series 13 plus Change Number 13

13

15

Replace Rotating Group Assembly Part 131-49-7480 No. 3822505-5 with Rotating Group Assembly Part No. 3822505-7 Same as Series 14 plus Change Number 14

14

16

Add Jumper Assembly Part No. 131-49-7513 MS25083-5BB7, Clamp Part No. 211592-9004, Clamp Part No. 211-5929002, Bolt Part No. MS9556-05 and Nut Part No. MS21043-3 Same as Series 11 plus Change Number 14

14

17

Add Jumper Assembly Part No. 131-49-7513 MS25083-5BB7, Clamp Part No. 211592-9004, Clamp Part No. 211-5929002, Bolt Part No. MS9556-05 and Nut Part No. MS21043-3 Same as Series 15 plus Change Number 16

16

UP552142

131-49-7476

Same as Series 12 plus Change Number 13 13

ALL

Replace the Turbine Bearing Spring Retainer Part No. 3844599-1 with Turbine Bearing Spring Retainer Part No. 3844599-2 Same as Series 11 plus Change Number 13

13

EFFECTIVITY

Description

Service Bulletin Number

Replace Static Pressure Tube Part No. 131-49-7541 3884980-2 with Static Pressure Tube Part No. 3884980-3 and Replace Total Pressure Tube Part No. 3884984-2 with Total Pressure Tube Part No. 38849843

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ENGINE MANUAL 131-9[B] Table INTRO-1. Equipment Identification List For Part No. 3800702-1 (Cont) Effectivity Code Symbol

Series Number

Change No.

18

Same as Series 17 plus Change Number 17 and Change Number 18 17

Replace Surge Duct Part No. 3885003- 131-49-7483 1 with Surge Duct Part No. 3885003-2 and Delete Bolt Part No. MS9556-05, Nut Part No. MS21046C3 and 2 Washers Part No. NAS1149C0332R

18

Replace Rear Bearing Seal Gasket Part 131-49-7561 No. 3844707-1 with Rear Bearing Seal Gasket Part No. 3844707-2

19

Same as Series 18 plus Change Number 15 15

20

21

22

131-49-7577

Power Section Assembly Part No. 131-49-7597 3801103-2 Replaces Power Section Assembly, Part No. 3801103-2 and Plumbing and Electrical Assembly Part No. 3616850-2 Replaces Plumbing and Electrical Assembly Part No. 36168501 Same as Series 21 plus Change Number 21

No Series

UP552142

Power Section Assembly Part No. 3801103-2 Replaces Power Section Assembly Part No. 3801103-1 Same as Series 20 plus Change Number 20

20

ALL

Replace Eductor Housing Assembly 131-49-7527 Part No. 3850100-4 with Eductor Housing Assembly Part No. 3850100-5 and Delete Ignition Bracket Part No. 3617110-2, 2 Bolts Part No. MS948906 and Part No. Bolt MS9556-10; Add Bolt Part No. MS9556-05 Same as Series 19 plus Change Number 19

19

EFFECTIVITY

Description

Service Bulletin Number

21

Incorporate Combustor Case Drain Plug 131-49-7667 Lockwire Feature on Engine Assembly Part No. 3800702-1

22

Never used

23

Provide Identification for Units Incorporating SB 49-7597 on Power Section Part No. 3801103-1

49-00-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

131-49-7597

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ENGINE MANUAL 131-9[B] Table INTRO-1. Equipment Identification List For Part No. 3800702-1 (Cont) Effectivity Code Symbol

Series Number

Change No.

23

Same as Series 22 plus Change Number 25 25

24

25

26

27

Replace Power Section Part No. 131-49-7750 3801103-3 with Power Section Part No. 3801103-4

31

Replace Rotating Group Assembly Part 131-49-7860 No. 3822505-8 with Rotating Group Assembly Part No. 3822505-12

32

Provide Rotating Group Assembly Part 131-49-7857 No. 3822505-11 for Aftermarket Use Only

28

Same as Series 27 plus Change Number 33 33

29

UP552142

Replace Rotating Group Part No. 131-49-7776 3822505-7 with Rotating Group Part No. 3822505-8

Same as Series 26 plus Change Number 31

No Series

ALL

131-49-7743

Same as Series 25 plus Change Number 30 30

EFFECTIVITY

Replace Oil Cooler Part No. 160564-1 with Oil Cooler Part No. 160564-2 Same as Series 24 plus Change Number 29

29

31

Replace Fuel Control Part No. 441921- 131-49-7688 4 with Fuel Control Part No. 441921-5 Same as Series 23 plus Change Number 28

28

30

Description

Service Bulletin Number

Replaces Rear Bearing Seal Part No. 131-49-7881 3844561-1 with Rear Bearing Seal Part No. 3844561-3 Same as Series 28 plus Change Number 34

34

Replace Plumbing and Electrical 131-49-7902 Installation Part No. 3616850-2 with Plumbing and Electrical Installation Part No. 3616850-3

-

Not used for production support

-

Same as Series 30 plus Change Number 35

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ENGINE MANUAL 131-9[B] Table INTRO-1. Equipment Identification List For Part No. 3800702-1 (Cont) Effectivity Code Symbol

Series Number

Change No. 35

32

Description

Service Bulletin Number

Replace Plumbing and Electrical Assembly Part No. 3616850-3 with Plumbing and Electrical Assembly Part No. 3616850-4 Same as Series 31 plus Change Number 36

36

Replace Power Section Part No. 3801103-4 with Power Section Part No. 3801103-5 Note: Change Number 37 and 38 not used for production

33

Same as Series 32 plus Change Number 39, 41 and 43 39

Replace Plumbing and Electrical 131-49-7949 Installation Part No. 3616850-4 with Plumbing and Electrical Installation Part No. 3616850-3

40

Not used for production support

41

Replace Gasket Part No. 3844705-1 with Gasket Part No. 3844705-2.

131-49-7988

43

Replace Flex Line PN 3616850-3 with rigid tube PN 3616850-5

131-49-8023

34

Same as Series 33 plus Change Number 44 44

35

36

UP552142

EFFECTIVITY ALL

131-49-8027

Same as Series 34 plus Change Number 45 45

37

Replace IGV Actuator, PN 3886188-2 with IGV Actuator, PN 3886188-3.

Replace Fuel Flow Divider, PN 3616850-5 with Fuel Flow Divider, PN 3616850-7

131-49-8054

Same as Series 35 plus Change Number 46 and 47 46

Replace Ceramic Ball Bearing, PN 3801103-5 with Ceramic Ball Bearing, PN 3801103-6.

131-49-8065

47

Replace Power Sect Assy PN 3801103- 131-49-7971 6 with Power Sect Assy PN 3801103-7. Same as Series 36 plus Change Number 42

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ENGINE MANUAL 131-9[B] Table INTRO-1. Equipment Identification List For Part No. 3800702-1 (Cont) Effectivity Code Symbol

Series Number

Change No. 42

38

Description

Service Bulletin Number

Replace Starter Generator PN 28B545- 131-49-8084 7 with Starter Generator PN 28B545-9 Same as Series 37 plus Change Number 48

48 39

Replace Air Seal PN 3844738-6 with Air 131-49-8142 Seal PN 3844738-7 Same as Series 38 plus Change Number 49

49 40

Replace Duct PN 3884988-1 with Duct 131-49-8161 PN 70721302-1 Same as Series 39 plus Change Number 50

50 41

Replace Seal PN 3822635-2 with Seal 131-49-8145 PN 3822635-3 Same as Series 40 plus Change Number 51

51

Replace Mount PN 3870264-1 with Mount PN 70722031-1

131-49-8182

Replace Mount PN 3870264-2 with Mount PN 70722031-2 42

Same as Series 41 plus Change Number 52 52

43

Replace Scroll Housing, PN 3827320-5 131-GTE1327 with Scroll Housing, PN 70722113-1. Same as Series 42 plus Change Number 53

53

Replace Exhaust Cap, PN 3850104-2 with Exhaust Cap, PN 3850104-4.

131-GTE0001

Same as Change 53 plus Change Number 54 54

Replace Bleed Duct, PN 3885004-2 with 131-49-8233 Bleed Duct, PN 3885004-5.

UP552142

Replace Sheet Metal Clamps, PN 131-GTE1328 AS1895/4-300, with Sheet Metal Clamps, PN 234-607-9001, and replace Sheet Metal Clamps, PN AS1895/4-350, with Sheet Metal Clamps, PN 234-6079002

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table INTRO-1. Equipment Identification List For Part No. 3800702-1 (Cont) Effectivity Code Symbol

Series Number

Change No.

44

Same as Series 43 plus Change Number 55 55

45

Replace the Containment Ring, PN 3844587-4 with PN 70721926-1.

131-49-8271

57

70721608-3 Eductor added as an alternate to 3850100-5 Eductor

131-49-8273

58

Replace the Fuel Control Unit, PN 441921-5 with PN 70722365-1.

131-49-8272

Same as Series 45 plus Change Number 59

47

Replace the Fuel Control Unit, PN 441921-5 or PN 70722365-1, with PN 70722492-1 or PN 70722365-2.

131-49-8290

Same as Series 46 plus Change Number 60 60

Replace the Second Stage Turbine Wheel, PN 3840165-4 with PN 3840165-9.

131-49-8277

(4)

Standard maintenance procedures that technicians must know are not given in this manual.

(5)

This publication is written in agreement with the ATA Specification.

(6)

Refer to the Special Tools, Fixtures, and Equipment and Consumables tables in each section before the start of maintenance or repair procedures.

(7)

Warnings, cautions, and notes in this manual give the data that follows:

(8)

UP552142

131-49-8236

56

59

ALL

Replace DAT Wheel, PN 3840310-3 with DAT Wheel, PN 3840310-4. Same as Series 44 plus Change Number 56

46

EFFECTIVITY

Description

Service Bulletin Number

-

A WARNING gives a condition or tells personnel what part of an operation or maintenance procedure, which if not obeyed, can cause injury or death.

-

A CAUTION gives a condition or tells personnel what part of an operation or maintenance procedure, which if not obeyed, can cause damage to the equipment.

-

A NOTE gives data, not commands. The NOTE helps personnel when they do the related instruction.

Warnings and cautions go before the applicable paragraph or step. Notes follow the applicable paragraph or step.

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ENGINE MANUAL 131-9[B] B.

Engine Hardware Configuration (1)

C.

When hardware differences are substantial for a specified task, separate procedures are provided for each configuration.

(b)

hat the procedure is applicable to, or any Service Bulletins that modify the hardware configuration. If applicable to all models, the effectivity block will specify "ALL."

(c)

Less complex configuration differences are identified at the procedural step or substep level. Differences at this level are highlighted by specific text references to the configuration of the hardware concerned.

(d)

Configuration differences that affect illustrations are shown by either of the following methods: 1

Additional views within the illustration that are identified to the alternate configuration and, if necessary, the engine dash model designation.

2

Separate illustrations for each configuration. Differences in configurations are identified in the captions.

Maintenance procedures for these items are covered in Chapter/Section/Subjects 72-00-01 through 72-00-19. Removal, installation, cleaning, inspection, repair, and test procedures are located here. Refer to Chapter/Section/Subject Index for specific part identification.

Accessory Components (1)

E.

(a)

External Tubes, Cables, and Leads (1)

D.

Hardware configuration differences are identified by one of the following methods within the manual:

Maintenance procedures for these items are located in Chapter/Sections 72-01 thru 72-04, depending on the modules to which they are attached. For example, the fuel boost pump mounted on the gearbox (-04 module) is located in Chapter/Section/Subject 72-04-01; likewise, the fuel control procedures are located in 72-04-02.

Function Titles and Pagination (1)

The data in this manual is divided into sections. A standard page number block system is used. Page number blocks are shown in Table INTRO-2. (a)

System Description 1

(b)

Fault Isolation

UP552142

1

EFFECTIVITY ALL

This functional heading is used to provide general background information on the location, basic design characteristics, and function of the engine section being addressed. The information is essentially basic and uncomplicated. System Description for the entire engine is located in the Engine General section with brief descriptions of each major section. In the modular sections, system description for each module is provided in more detail. This section provides procedures for guiding the user from the identification of an engine fault, through possible causes, to isolation of the fault indication and corrective actions to be taken.

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ENGINE MANUAL 131-9[B] (c)

Special Procedures 1

(d)

(e)

(f)

(g)

Removal 1

Removal is used to describe the procedures for removal of a module, portion of a module, or components of the engine.

2

Required materials, tools, or equipment are listed in table format at the beginning of each removal procedure.

Installation 1

Installation is used to describe the procedures for installation of a module, portion of a module, or components of the engine.

2

Required tools, equipment, consumable materials (such as lubricants), and expendable materials (such as packings and tab washers) are listed in table format at the beginning of each pageblock.

3

All special installation procedures (such as measuring operating position of accessory drive gear) and special torques are contained in the text.

Disassembly 1

Disassembly function is used for complete disassembly of a module or portion of a module.

2

A list of required tools or equipment is provided in table format at the beginning of each disassembly pageblock.

Cleaning

UP552142

1

EFFECTIVITY ALL

Special Procedure function is used for self-contained procedures that are either preventive or restorative in nature. This function is used only when the information cannot be covered under other functions. Procedures addressing lubrication system contamination would be in this category.

Information on specific cleaning procedures as well as guidelines for use of cleaning solutions are provided at the detail part or unit level. For example, cleaning of the second turbine nozzle assembly is located at the part level in Chapter/Section/Subject 72-51-17 and referenced to the SPM.

(h)

Unassigned

(i)

Inspection/Check 1

At the engine level (72-00-00), general inspection standards and common procedures are provided. Requirements for magnetic-particle, radiographic, ultrasonic, and FPI are located at the detail part level.

2

Detail part inspection contains all the visual and dimensional information necessary to determine serviceability of the part.

3

Inspection/checks following the assembly and installation procedures contain all fits and clearances applicable to the assembly(ies), module(s), or component(s) being addressed.

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ENGINE MANUAL 131-9[B] (j)

(k)

(l)

Repair (Includes Painting) 1

Required equipment and materials are listed in table format at the beginning of each repair. Alternate tooling, equipment or materials must only be used with Honeywell approval.

2

A Repair-00 section has been included to relate part numbers to applicable repairs.

Assembly 1

Assembly function is used for assembly of a module or portion of a module.

2

A list of required materials, tools, equipment, expendable parts, and consumable materials is located in table format at the beginning of each procedure.

3

Assembly fits and clearances, backlash checks, and special torque requirements are also included.

Servicing 1

(m)

Servicing function includes items of a routine nature required as the result of other maintenance actions on the engine. Replenishment of the engine oil system would fall in this category.

Storage 1

(n)

Storage function covers procedures for preservation of the engine during storage and procedures for depreservation after storage. Procedures for shipment, packing, and unpacking the engine and modules are also included.

Testing 1

This section provides the necessary test procedures and parameters to make sure of the operational integrity of the engine after performance of other maintenance functions.

UP552142

Table INTRO-2. Page Number Blocks Section

Page Number Block

System Description

1

Fault Isolation

1000

Special Procedures

2000

Removal

3000

Installation

4000

Disassembly

5000

Cleaning

6000

Unassigned

7000

Inspection/Check

8000

Repair

9000

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table INTRO-2. Page Number Blocks (Cont) Section

Page Number Block

Assembly

10000

Servicing

11000

Storage

12000

Testing

13000

F.

Chapter/Section/Subject Explanation (1)

The ATA Specification 100, 3-element (6-digit) numbering system is used in this manual to identify the system/chapter (element one), the APU module or major assembly (element two) and the unit/subject or detail piece parts (element three). (Refer to Figure INTRO-2Figure INTRO-2.)

(2)

Element coverage. (Example 49-20-00) (a)

The first element (first two digits - 49) identifies the ATA chapter coverage of related engine data for this and all supporting/supplementary publications. Chapter 49 is the only chapter used in this publication.

(b)

The second element (second two digits - 20) identifies the coverage of the APU modules or major assemblies. The major sections used in this publication are as follows. Table INTRO-3. Module Sections

Section

Module

-20

Engine Assembly

-21

Gearbox Assembly

-22

Power Section Assembly (3)

The third element (third two digits - 00, 01, 02, 03, etc) identifies the individual subjects or units (sub-assemblies, piece parts, etc) in the second element section number. When double zero (-00) is used as the third element, it indicates coverage of a complete APU module or major assembly.

UP552142

When numbers -01 and up are used as the third element, it indicates coverage of a part of the major assembly identified by the second element section number.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure INTRO-1. APU Manual ATA Numbering Sequence

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

Figure INTRO-2. ATA Numbering System (3-Element) 2.

ATA–JEMTOSS TASK and SUBTASK Number System In accordance with the Air Transport Association Specification 100, this publication uses a Maintenance Task Numbering Standard which makes the maintenance procedures in this manual more compatible with an automated shop environment. A.

TASK and SUBTASK Number Assignments.

UP552142

(1)

EFFECTIVITY ALL

All procedures in this publication are assigned TASK and SUBTASK numbers at key data retrieval points. The numbers provide the following: (a)

Identification of the hardware (part or parts) primary to the TASK.

(b)

Identification of the maintenance function applied to the part or parts.

(c)

A unique identifier for a set of instructions (known as a TASK or SUBTASK).

(d)

Identification of alternate methods and configuration differences that can change the procedure applied to the TASK.

(e)

Identification of Airline changes to a TASK or SUBTASK.

(2)

The TASK and SUBTASK numbers, once assigned, will not be changed or reused.

(3)

An index of TASK and SUBTASK numbers used in this publication is located behind the Appendixes.

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ENGINE MANUAL 131-9[B]

UP552142

Figure INTRO-3. Elements of a TASK or SUBTASK Number

EFFECTIVITY ALL

(4)

TASK is a complete set of instructions needed to complete a total work assignment, i.e., REPAIR 0001. The TASK will usually be composed of supporting SUBTASKS necessary to perform that procedure.

(5)

SUBTASK level assignments are individual steps necessary to complete the particular work assignment(s) defined by the TASK.

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ENGINE MANUAL 131-9[B] B.

UP552142

C.

Composition and Elements of TASK and SUBTASK Numbers. (Refer to Figure INTRO-3.) (1)

The numbering system is an expansion of the ATA three element numbering system. The number has seven elements. The first five elements are necessary for each TASK or SUBTASK. The sixth and seventh elements are applied only when necessary.

(2)

Each element of the TASK or SUBTASK number will be separate from the next by a dash (-). One space will be used between the word TASK or SUBTASK and the following elements.

(3)

Elements 1, 2 and 3 will identify the ATA Chapter-Section-Subject number of the page block that is to be tasked out.

(4)

Element 4 defines the maintenance function being performed. This element is a three position element. The third position is zero filled when further definition is not required. If required, the manufacturer will use the Numbers 1 through 9 or Letters A through Z, excluding the Letters I and O. Refer to Paragraphs C and D for a complete list and description of all functions.

(5)

Element 5 supplies a unique identification for each TASK or SUBTASK number which are similarly numbered through the first four elements. (a)

TASKS must be numbered from 801 through 999.

(b)

SUBTASKS must be numbered from 001 through 800.

(6)

Element 6 is a three position alphanumeric element used for identification of differences in configurations, methods or techniques.

(7)

Element 7 is reserved for airline use to relate their own locally generated instructions.

TASK and SUBTASK Function Codes.

FUNCTION CODE

DESCRIPTION

000

REMOVAL AND DISASSEMBLY

010

Remove Engine

020

Remove Engine Modular Sections

030

Disassemble Engine Modular Sections

040

Disassemble Engine Subassemblies

050

Remove Accessory/Power Plant Components

060

Disassemble Accessory

070

Disassemble Accessory Subassembly

080

Remove Engine Test Equipment

090

Disassemble Support Equipment

100

CLEANING

110

Chemical

120

Abrasive

130

Ultrasonic

140

Mechanical

150

Unassigned

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

DESCRIPTION

160

Miscellaneous

170

Foam/Water Wash

180

Testing of Solutions

190

Unassigned

200

INSPECTION

210

Check

220

Visual/Dimensional/Grading

230

Penetrant

240

Magnetic

250

Eddy Current

260

X-Ray

270

Ultrasonic

280

Special

290

Unassigned

300

REPAIR

310

Welding and Brazing

320

Machining

330

Stripping and Plating

340

Plasma and Flame Spraying

350

Miscellaneous Repairs

360

Bonding and Molding

370

Heat Treating

380

Surface Treating

390

Machine Riveting and Flaring

400

ASSEMBLY AND INSTALLATION

410

Install Engine

420

Install Engine Modular Sections

430

Assemble Engine Modular Sections

440

Assemble Engine Subassemblies

450

Install Accessory/Power Plant Components

460

Assemble Accessory

470

Assemble Accessory Subassembly

480

Install Engine Test Equipment

490

Assemble Support Equipment

500

MATERIAL HANDLING

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

DESCRIPTION

510

Shipping

520

Receiving

530

Packing

540

Unpacking

550

Storage

560

Marshalling/Positioning

570

Engine Ferry/Pod Maintenance

580-590

Unassigned

600

SERVICING/PRESERVING/LUBRICATING

610

Servicing

620

Preserving

630

Depreserving

640

Lubricating

650-690

Unassigned

700

FUNCTIONAL TESTING

710

Oil Flow

720

Air Flow

730

Fuel Flow

740

Water Flow

750

Electrical

760

Engine

770

Accessory

780

Pressure Check

790

Leak Check

800-990

MISCELLANEOUS

810

Fault Isolation

820

Adjusting/Aligning/Calibrating

830

Rigging

840

Service Bulletin Incorporation

850

Part Number Change/Reidentification

860-870

Unassigned

880

Approved Vendor Processes

890

Airline Maintenance Program

900

Unassigned

910

Special Equipment Maintenance

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

DESCRIPTION

920

Standard Equipment Maintenance

930

Tool Fabrication

940-980

Unassigned

990

Illustration, Tables, Front Matter

UP552142

D.

TASK and SUBTASK Function Code Definitions.

FUNCTION CODE

FUNCTION TITLE/DEFINITION

000

REMOVAL AND DISASSEMBLY

010

REMOVE ENGINE. Engine removal is defined as removal of the engine from a workstand, transport dolly, test stand, etc. It also applies to removing the power plant from an aircraft.

020

REMOVE ENGINE MODULAR SECTIONS. This is the first echelon of engine disassembly which consists of sectionalization of the engine into primary modular sections. Modular sections are identified by the third element of the ATA number when the modular sections are removed from the engine.

030

DISASEMBLE ENGINE MODULAR SECTIONS. This is the second echelon of engine disassembly which consists of the disassembly of engine modular sections into subassemblies after the modular sections have been removed from the engine. Engine modular section designations appear in the second element of the ATA number for this echelon of disassembly.

040

DISASSEMBLE ENGINE SUBASSEMBLIES. This is the third echelon of disassembly which consists of disassembly of subassemblies to the piece part level. The subassemblies are identified by the third element of the ATA number.

050

REMOVE ACCESSORY/POWER PLANT COMPONENTS. This consists of removing individual accessory/power plant components from either installed or uninstalled engines.

060

DISASSEMBLE ACCESSORY. This involves disassembly of accessories into subassemblies.

070

DISASSEMBLE ACCESSORY SUBASSEMBLY. This consists of disassembly of accessory subassemblies into piece parts.

080

REMOVE ENGINE TEST EQUIPMENT. This consists of removing equipment and instrumentation after engine test.

090

DISASSEMBLE SUPPORT EQUIPMENT. Disassembly of support equipment applies to any disassembly required to maintain support equipment.

100

CLEANING

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ENGINE MANUAL 131-9[B] FUNCTION CODE

FUNCTION TITLE/DEFINITION

110

CHEMICAL. Chemical cleaning is defined as the removal of surface deposits from a part by use of a chemical cleaning agent. The chemical agent dissolves or loosens the deposit which is washed or rinsed away after a soaking period. Also included is power flushing with a chemical agent.

120

ABRASIVE. Abrasive cleaning consists of the removal of surface deposits from a part by wet or dry particle impingement.

130

ULTRASONIC. Ultrasonic cleaning refers to the removal of surface deposits and entrapped material by use of high frequency sound waves to produce cavitation at the surface of the part. Cleaning is performed in a liquid bath that transmits the sound energy and keeps the removed material in suspension.

140

MECHANICAL. Mechanical cleaning involves the use of a brush, felt bob, sandpaper or other hand (or machining) action to remove surface deposits from a part.

150

UNASSIGNED.

160

MISCELLANEOUS. Miscellaneous cleaning consists of the removal of deposits from small passages with a compressed air blast, miscellaneous hand cleaning and various combinations of cleaning procedures.

170

FOAM/WATER WASH. Foam/water wash includes removal of post emulsified fluorescent penetrant via an agitated water wash, automatic spray rinse or an aqueous remover aerated to produce a foam.

180

TESTING OF SOLUTIONS. Testing of solutions includes tests used to assist in identifying certain materials by determining the presence or absence of known constituents electrochemically.

190

UNASSIGNED.

200

INSPECTION

210

CHECK. A check inspection is a thorough visual examination of engines, engine systems, subsystems, components and/or parts, to detect structural failure, deterioration or damage; and to determine the need for corrective maintenance. For example: items such as engine exterior surfaces, rotor and stator assemblies, blades and vanes, control systems, linkages, accessory components, tubing, electrical wiring and connections, safety wiring, fasteners, clamps, etc., are inspected to verify the existence of proper conditions and acceptability for continued service. Check TASKS are usually performed with the engine in the static state and may include the use of borescope equipment. The check function for engine application is similar to the periodic visual inspections performed on engine-airframe combinations.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

FUNCTION TITLE/DEFINITION

220

VISUAL/DIMENSIONAL/GRADING. A visual/dimensional inspection is a comparison of the dimensions and material conditions of parts, subassemblies or assemblies with the specifications. The specifications are contained in technical manuals and/or blueprints, to detect deviations from established standard and limits; for the purpose of determining the acceptability for continued service, repair, or need to discard the item being inspected. A visual/dimensional inspection function code is also required to verify that proper corrective maintenance has been accomplished. Although some visual/dimensional inspection TASKS or SUBTASKS may not require measurements, the complete spectrum or visual/ dimensional TASKS or SUBTASKS requires a variety of precision measuring equipment to determine items such as runout, concentricity, flatness, parallelism, harness, squareness, thickness, clearness, angularity, diameters, radii, depth, etc.

230

PENETRANT. This type of inspection refers to the fluorescent penetrant examination of parts to detect surface cracks.

240

MAGNETIC. Magnetic inspection is defined as the magnetic particle examination of parts to detect surface cracks in magnetic materials.

250

EDDY CURRENT. Eddy current inspection consists of examining for subsurface cracks, porosity, inclusions or other non-homogeneous material structure by use of high frequency electromagnetic wave equipment. Parts are scanned and compared to similar parts or test specimens having known material defects.

260

X-RAY. X-ray inspection involves examining for subsurface cracks, porosity, inclusions or other non-homogeneous material structure by passing X-ray through a part and recording an image on photographic film.

270

ULTRASONIC. Ultrasonic inspection involves examining for subsurface cracks, porosity or other non-homogeneous material structure by use of contact pulse echo ultrasonic techniques.

280

SPECIAL. Special inspection refers to any special examination required as a result of abnormal operation, a special inspection to determine integrity for continued operation in service or qualitative analysis.

290

UNASSIGNED.

300

REPAIR

310

WELDING AND BRAZING. Welding and brazing refer to the joining by fusion welding, resistance welding, spot welding, furnace brazing, torch brazing, induction brazing, soldering, electron beam welding, plasma arc welding, etc. This category includes hard facing.

320

MACHINING. Machining consists of processing to obtain a desired shape or finish by grinding, lathe turning, boring, reaming, broaching, milling, machine drilling, machine lapping, honing, sizing, machine polishing, machine buffing, machine cutting, electrochemical machining (ECM) electrodischarge machining (EDM), roll forming, stamping, machine punching, blanking, etc.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

FUNCTION TITLE/DEFINITION

330

STRIPPING AND PLATING. Stripping and plating refer to removing or applying a metallic coating on the surface of a part by mechanical, chemical or electrical means. Plating of chromium, cadmium, tin, nickel, silver, etc., to build up the size of a part or to provide surface protection. Masking or waxing prior to plating and anodizing are included.

340

PLASMA AND FLAME SPRAYING. Plasma and flame spraying consist of the application of a protective coating to a part by feeding a powder into an ionized gas stream. The powder is melted and propelled onto the surface being coated. Flame spraying uses a fuel-oxygen flame to melt and propel metal onto the surface of parts to build up the size or provide surface protection.

350

MISCELLANEOUS REPAIRS. Miscellaneous repair consists of repairing parts by hand cutting, hand drilling, hand polishing, hand grinding, hand lapping, hand riveting, blending, cutting or routing out materials by hand, cutting and fitting patches burring, planing, hand sanding, hand sawing, scraping, emery cloth, hand recambering of vanes, stop drilling, hand tapping, installing helical coil inserts, heating and chilling of parts, etc. This function is also used to identify miscellaneous disassembly and assembly procedures required to accomplish repairs.

360

BONDING AND MOLDING. Bonding and Molding refer to the joining of parts with an adhesive, cementing material or fusible material. Included are silicone rubber bonding and molding, adhesive bonding, fiberglassing, rubber molding, and curing of bonding and molding materials.

370

HEAT TREATING. Heat treating refers to the controlled heating and cooling of a material to get the desired physical property. It includes annealing, tempering, quenching, stress relieving, solution heat treat, etc.

380

SURFACE TREATING. Surface treating is defined as treating the surface of a material by painting, varnishing, graphite varnishing, aluminizing, SermeTel or teflon coating, zinc chromate priming, Fel-Pro coating, tumble finishing, shot peening, glass bead peening, etc. Baking of surface treating materials is included.

390

MACHINE RIVETING AND FLARING. Mechanical machine riveting and flaring refer to the joining of parts by inserting a rivet through matching holes in parts, and deforming or flaring the plain end to form another head, locking the members together.

400

ASSEMBLY AND INSTALLATION

410

INSTALL ENGINE. This includes installation of the engine into a workstand, transport dolly, test stand, etc. It also applies to installing the power plant on an aircraft.

420

INSTALL ENGINE MODULAR SECTIONS. This is the third echelon of engine assembly which consists of assembly of the modular sections into a complete engine assembly. The modular sections are identified by the third element of the ATA number.

430

ASSEMBLE ENGINE MODULAR SECTIONS. This is the second echelon of engine assembly which consists of assembly of subassemblies into modular sections. The engine modular section is identified by the second element of the ATA number.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

FUNCTION TITLE/DEFINITION

440

ASSEMBLE ENGINE SUBASSEMBLIES. This is the first echelon of assembly which consists of the maximum assembly of the piece parts to the subassembly level required to assemble modular sections. The subassemblies are identified by the third element of the ATA number.

450

INSTALL ACCESSORY/POWER PLANT COMPONENTS. This consists of installing individual accessory/power plant components on either installed or uninstalled engines.

460

ASSEMBLE ACCESSORY. This consists of assembly of accessory components.

470

ASSEMBLE ACCESSORY SUBASSEMBLY. This includes assembly of accessory component subassemblies.

480

INSTALL ENGINE TEST EQUIPMENT. This consists of installing equipment and instrumentation required for engine test.

490

ASSEMBLE SUPPORT EQUIPMENT. This applies to any assembly required to maintain support equipment.

500

MATERIAL HANDLING

510

SHIPPING. Shipping is defined as the movement of any part, subassembly, assembly, engine modular section or engine from the time it is packaged, until it reaches its intended destination.

520

RECEIVING. Receiving is defined as the receipt activity for any incoming part, subassembly, assembly, engine modular section or engine.

530

PACKING. Packing consists of installing parts, subassemblies, modules, modular sections or engines in shipping containers.

540

UNPACKING. Unpacking is defined as the removal of parts, subassemblies, modules, modular sections or engines from shipping containers.

550

STORAGE. Storage is defined as the safekeeping of any part, subassembly, module, engine modular section or engine until required for use.

560

MARSHALLING/POSITIONING. Marshalling refers to the collecting of individual parts, subassemblies, engine modular sections and accessories prior to release for assembly. Positioning refers to movement from one fixed state to another.

570

ENGINE FERRY/POD MAINTENANCE. Engine ferry/pod maintenance pertains to performing necessary preparations before and after transporting an engine by aircraft ferry method.

580

UNASSIGNED.

590

UNASSIGNED.

600

SERVICING/PRESERVING/LUBRICATING

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

FUNCTION TITLE/DEFINITION

610

SERVICING. Servicing is defined as that maintenance action required to sustain a unit or system in proper operating status.

620

PRESERVING. Preserving pertains to preparing a part, subassembly, engine modular section or engine for safekeeping from decomposition or deterioration. This includes preparing for storage by applying a preservative layer to, and desiccants in, engine hardware.

630

DEPRESERVING. Depreserving pertains to removing the preservative layer and/or desiccants from the part, subassembly, assembly, engine section, or engine in preparation for installation or operation.

640

LUBRICATING. Lubricating is defined as applying oil, grease, or dry film type lubricant on moving parts in order to reduce friction or wear, or to cool the item.

650

UNASSIGNED.

660

UNASSIGNED.

670

UNASSIGNED.

680

UNASSIGNED.

690

UNASSIGNED.

700

FUNCTIONAL TESTING

710

OIL FLOW. Oil flow testing is defined as measuring the flow of oil through engine components under specific conditions.

720

AIR FLOW. Air flow testing is defined as measuring the flow of air through an engine component or compartment under specific conditions.

730

FUEL FLOW. Fuel flow testing is defined by function checks and flow measurement of the part or system being tested.

740

WATER FLOW. Water flow testing involves both function checks and flow measurements through the part, component or system being tested.

750

ELECTRICAL. Electrical testing pertains to functional checks of the electrical system or component as well as the measurement of systems parameters such as resistance or power drain.

760

ENGINE. Engine testing involves the operation of an engine to establish systems function or operation under specific conditions to measure performance.

770

ACCESSORY. Accessory testing pertains to testing an accessory to make sure proper operation or function.

780

PRESSURE CHECK. Pressure check testing establishes the ability of a normally pressurized component or system to operate properly.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

FUNCTION TITLE/DEFINITION

790

LEAK CHECK. Leak check testing determines the ability of a component or system to operate without leaking.

800

MISCELLANEOUS

810

FAULT ISOLATION. Fault isolation consists of the following procedures. Operating an engine at constant thrust lever or identical EPR to locate the prime suspect deficient system. Operating an improperly functioning system or component in order to locate the cause of malfunction; or performing a series of prescribed checks to isolate a failed part or component.

820

ADJUSTING/ALIGNING/CALIBRATING. Adjusting, aligning, calibrating consists of making a physical correction to make sure proper placement or operation/testing of a system or component.

830

RIGGING. Rigging pertains to hooking-up, arranging or adjusting a component or accessory linkage for proper system operation.

840

SERVICE BULLETIN INCORPORATION. Service bulletin incorporation pertains to performing the work specified in the manufacturer's service bulletin. This provides for identification of modification TASKS at the TASK level with SUBTASKS recognizing any functional changes (e.g. chemical, visual/dimensional, cleaning, machining, etc.) necessary to incorporate the service bulletin.

850

PART NUMBER CHANGE/REIDENTIFICATION. Re-identify pertains to change of part number, application of part number by transfer, engrave repair number, etc.

860

UNASSIGNED.

870

UNASSIGNED.

880

APPROVED VENDOR PROCESSES. The approved process may be proprietary and controlled by a particular manufacturer or be non-proprietary and approved for application by conforming vendors.

890

AIRLINE MAINTENANCE PROGRAM (CUSTOMER USE).

900

UNASSIGNED.

910

SPECIAL EQUIPMENT MAINTENANCE. This permits identification of tasks required to maintain special support equipment.

920

STANDARD EQUIPMENT MAINTENANCE. This permits identification of tasks required to maintain standard support equipment.

930

TOOL FABRICATION. This function consists of fabricating any tool for which procedures to fabricate are contained in the Engine Manual.

940

UNASSIGNED.

950

UNASSIGNED.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] FUNCTION CODE

FUNCTION TITLE/DEFINITION

960

UNASSIGNED.

970

UNASSIGNED.

980

UNASSIGNED.

990

ILLUSTRATIONS, TABLES AND FRONT MATTER. This provides a unique number for data retrieval which cannot be obtained by a TASK or SUBTASK number.

3.

Customer Support A.

Honeywell Aerospace Online Technical Publications Website (1)

B.

-

To download or see publications online

-

To order a publication

-

To tell Honeywell of a possible data error in a publication.

Honeywell Aerospace Contact Team (1)

4.

Go to the Honeywell Online Technical Publications Website at (www.myaerospace.com).

If you do not have access to the Honeywell Technical Publications Website, or if you need to speak to personnel about non-Technical Publication matters, the Honeywell Aerospace Global Customer Care Center gives 24/7 customer service to Air Transport & Regional, Business & General Aviation, and Defense & Space customers around the globe. -

Telephone: 800-601-3099 (Toll Free U.S.A./Canada)

-

Telephone: 602-365-3099 (International).

References A.

Honeywell/Vendor Publications (1)

The publication title or model number, part number, publication number, and type of publications applicable to the unit are shown in Table INTRO-4.

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Table INTRO-4. Applicable Publications List Nomenclature

PN

Publication Number

Type

Pneumatic and Shaft Power Gas Turbine Engine

3800702-1

49-26-85 49-26-93 49-26-97

IRM IPC MM

Standard Practices Manual

-

20-00-02/70-00-01

SPM

Starter/Generator

28B545-7/-9

24-21-14

CMM/IPL

Wiring Harness Assembly

3888449-1/-2

49-11-01 (V64816) 49-11-12 (VH0N89)

CMM/IPL CMM/IPL

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table INTRO-4. Applicable Publications List (Cont) Nomenclature

PN

Publication Number

Type

Wiring Harness Assembly

3888448-1/-2

49-11-03 (V64816) 49-11-11 (VH0N89)

CMM/IPL CMM/IPL

Model CU-C1 Auxiliary Power Unit Fuel Control

441921-4/-5

49-30-99

CMM/IPL

Start Power Unit

1151984-261 1152464-265

49-40-04 49-40-08

CMM/IPL CMM/IPL

Start Converter Unit

1152426-245

49-40-06 49-40-07

CMM IPC

Start Converter Unit

1152466-250

49-40-09 49-40-10

CMM CMM/IPL

Ignition Exciter

3888058-7

49-41-01

CMM/IPL

Ignition Exciter

3888058-5 WE3888439-1

49-41-09

CMM/IPL

Ignition Cable Assembly

3876132-12

49-41-19

CMM/IPL

Servoactuator Assembly

3886188-2

49-50-07

CMM/IPL

Three and One-Half Inch Diameter APU Bleed Air Valve

3291214-2

49-52-29

CMM/IPL

3.0 Inch Diameter Surge Control Valve

3291238-2

49-52-31

CMM/IPL

Data Memory Module

3876287-1

49-60-65

CMM/IPL

CCC-Large Controller

70720860-1

49-61-15

CMM/IPL

Auxiliary Power Unit Controller

2118966-222

49-61-62

CMM

Auxiliary Power Unit Controller

2118966-221

49-61-64

IPC

Lube Module

4131020-3

49-90-57

CMM/IPL

Oil Level Sensor

3876298-3

49-91-60

CMM/IPL

Temperature Control Valve

160550-1

49-94-30

CMM/IPL

Oil Cooler

160564-1/-2

49-94-32

CMM/IPL

B.

Other Publications

UP552142

(1)

EFFECTIVITY ALL

These publications are standard references. Check for latest version of publication. -

The United States GPO Style Manual (available at http://www.gpo.gov/fdsys/pkg/GPOSTYLEMANUAL- 2008/content-detail.html)

-

IEEE Std 260.1, Standard Letter Symbols for Units of Measurement (available from the American National Standards Institute at http://www.ansi.org)

-

ASME Y14.38, Abbreviations for Use on Drawings and Related Documents (available from the American National Standards Institute at http://www.ansi.org)

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ENGINE MANUAL 131-9[B]

5.

-

ASME Y14.5, Dimensioning and Tolerancing (available from the American National Standards Institute at http://www.ansi.org)

-

ANSI/IEEE Std 91, Graphic Symbols for Logic Functions (available from the American National Standards Institute at http://www.ansi.org)

-

CAGE codes and manufacturers' addresses are available at https://cage.dla.mil.

-

IEEE 315/ANSI Y32.2, Graphic Symbols for Electrical and Electronics Diagrams (available from the American National Standards Institute at http://www.ansi.org)

-

MIL-HDBK-263, Electrostatic Discharge Control Handbook for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices) (Metric) (available from any military standards database)

-

MIL-STD-1686, Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices) (Metric) (available from any military standards database).

Acronyms and Abbreviations A.

General (1)

The abbreviations are used in agreement with ASME Y14.38.

(2)

Acronyms and non-standard abbreviations used in this publication are as follows:

UP552142

Table INTRO-5. List of Acronyms and Abbreviations Term

Full Term

Assy

Assembly

ATA

Air Transport Association

BAV

Bleed air valve

DP

Delta pressure sensor

DMM

Data memory module

EGT

Exhaust gas temperature

ECU

Electronic control unit

FCU

Fuel control unit

IGVA

Inlet guide vane actuator

LOP

Low oil pressure

JEMTOSS

Jet engine maintenance task oriented support system

PT

Total pressure sensor

P2

Inlet pressure sensor

SCU

Start converter unit

SCV

Surge control valve

SPU

Start power unit

T2

Inlet temperature sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 6.

Process Verification A.

Verification Data (1)

Honeywell does a verification of these technical instructions by performance or by simulation of the necessary procedures. Performance shows that the procedures were checked by the use of the manual. Simulation shows that the applicable personnel looked at the procedure in the manual and that the procedure is technically correct. The dates of verification for this manual are given in Table INTRO-6. Table INTRO-6. Verification Data

Section

Method

Date

Testing and Fault Isolation

N/A

16 Apr 1997

Disassembly

N/A

14 Apr 1997

Assembly

N/A

15 Apr 1997

Engineering Technical Review

N/A

18 Dec 2019

7.

Geometric Tolerance A.

Symbols

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EFFECTIVITY ALL

If applicable, geometric symbols are used on illustrations in Inspection and Repair tasks of the manual. Refer to Figure INTRO-4.

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ENGINE MANUAL 131-9[B]

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Figure INTRO-4. (Sheet 1 of 2) Geometric Tolerance Symbols

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

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Figure INTRO-4. (Sheet 2 of 2) Geometric Tolerance Symbols

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 8.

Standard Definitions

UP552142

A.

(1)

Load/driven compressor, engine compressor and turbine section fully disassembled.

(2)

Compressor impellers/rotors, turbine rotors/disks and tie shaft inspected per IRM Zero-time Check.

(3)

Gearbox repaired as necessary.

(4)

LRU’s (components) repaired as necessary.

(5)

APU tested to highest performance standard.

B.

"REPAIRED" (applicable to end unit, as noted on Regulatory Airworthiness Tag/8130): Considered continue-time. Any visit NOT an overhaul. Exposed parts checked to the CONTINUE-TIME CHECK section, repaired as necessary to continue-time check limits or REPAIR section limits where applicable, and tested to Light/Medium Repair (continue-time) criteria.

C.

"END UNIT": Term applied to assemblies at the aircraft level; i.e., engines, APU, and LRUs that are shipped and installed as assemblies on the airplane. End units have functional (bench) test requirements (refer to definition of functional/bench test and operational test).

D.

"LINE-REPLACEABLE UNIT (LRU)": Component replaceable at the aircraft level (i.e., has aircraft maintenance manual removal/installation instructions). For engines and APUs, typically refers to control system components that are replaced without removal of the engine/APU.

E.

"REPAIR" (FAA definition): Work performed that does not have to completely conform to applicable manuals, drawings, specifications, etc.

F.

"REWORK" (FAA definition): Work performed that completely conforms to applicable manuals, drawings, specifications, etc.

G.

"REFURBISHED": Term reserved for bearings only, indicating a bearing has been inspected and reworked by an approved certified bearing restoration facility, thus the bearing is in a "zero-time" condition.

H.

"DEPTH OF REPAIR" (end unit or module): Light, Medium or Heavy Repair.

I.

"LIGHT/MEDIUM/HEAVY REPAIR": Depth of repair at end unit or module level.

J.

"HARD-TIME": Fixed interval (hour or cycles) of service life which the end unit cannot exceed on-wing and cannot be shipped as serviceable without resetting the interval. Requires end unit removal from the aircraft at or prior to achieving the maximum hours or cycles.

K.

"SOFT-TIME": Fixed interval (hour or cycles) of service life which applies only when the end unit is received into a repair facility, but once received cannot be shipped without resetting the interval by the prescribed maintenance action without operator approval.

L.

"ON-CONDITION": Maintenance philosophy based on repetitive checks/tests to determine the condition of the end unit with regard to continued serviceability (corrective action taken as determined by the end unit condition).

M.

"PRIMARY FAILURE": Shop finding that caused the end unit to be removed and returned to the shop.

N.

"SECONDARY FAILURE": Shop finding that did not relate to the end unit reason for removal/return.

O.

"VISUAL CHECK": Check without the aid of a microscope or non-destructive test (FPI, magnetic resonance, radiographic, eddy current, etc). Up to 10X magnification is optional.

EFFECTIVITY ALL

"OVERHAULED".

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9.

P.

"COSMETIC DEFECT": Defect found that would not affect end unit build, test, or in-service operation.

Q.

"FUNCTIONAL DEFECT": Defect found that would affect end unit build, test, or in-service operation.

R.

"FUNCTIONAL (BENCH) TEST": Term applied to components/LRUs of an engine/APU to indicate testing conducted on a test bench (i.e., not on the engine/APU) to verify function as stipulated by the end unit CMM or next higher assembly CMM or IRM. Successful completion of testing indicates unit serviceability ("inspected", "adjusted", "repaired", or "overhauled" depending on work accomplished).

S.

"OPERATIONAL TEST": Term applied to components/LRUs of an engine/APU to indicate testing conducted on the engine/APU. Successful completion of testing indicates component/unit serviceability for continue-time on the next higher assembly it was tested on (only).

T.

"PREDICTIVE (PERFORMANCE) TREND MONITORING (PTM)": On-wing data collection to assess engine/APU condition and trended to determine if engine/APU should be removed prior to being inoperative. Considered a "scheduled" removal.

Rotating Group Life Limited Components A.

Check Requirements and Interval. (1)

B.

Refer to Table INTRO-7 for check requirements and check requirement intervals.

Rotating Group Life Limited Components. (1)

This section contains information on rotating group life limited components, which includes cycle definition, cycle monitoring and component marking. Table INTRO-7. Rotating Group Life Limited Components

First Stage Axial Turbine Disk Disk Part Number

Ref. Turbine Rotor Assy Part Number

Disk Life Limit (Cycles)*

3840161-1

3840160-5

30,000

N/A

30,000

N/A

Check Interval

Remarks

3840160-8 3840302-1

3840160-7 3840303-1

N/A^

3840310-3

30,000

N/A

N/A^

3840310-4

30,000

N/A

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Second Stage Turbine Rotor Rotor Part Number

Ref. Turbine Rotor Assy Part Number

N/A^

3840165-4

EFFECTIVITY ALL

Rotor Life Limit Check Interval (Cycles)* 10,000

N/A

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Remarks Refer to SB 131-49-8052 for serial numbers.

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3840165-4

30,000

N/A

3840165-9

30,000

Refer to SB 131-49-8091.

The 30,000 cycle limit applies to 3840165-4 turbine rotors not listed in SB 131-49-8052.

N/A

N/A

Turbine Shaft Shaft Part Number

Shaft Life Limit (Cycles)*

3822504-3

N/A

Remarks

30,000

Engine Compressor Impeller Impeller Life Limit (Cycles)*

Impeller Part Number 3822391-6

N/A

Remarks

30,000

*All above parts are serialized. ^Blades are not removable. The life limit applies to the Rotor Assembly Part Number. (2)

Cycle Definition. One cycle equals an attempted start reaching 95 percent (RPM) and subsequent shutdown. Cycles are monitored on the Data Memory Module (DMM).

(3)

Monitoring Cycles. (a)

Accurate engine records, log books and LLP cards should be used for tracking cycles on Life Limited Parts.

(b)

Some Life Limited Parts may have operating cycles marked on the part using the format below. This procedure is no longer recommended. Example:

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A part that has been through repair twice since new, once at 800 cycles and once again at an additional 1,700 cycles will be marked “X.8.17.” The total accumulated cycles are 2,500. At the next repair after 1,500 additional cycles of service, the part will be identified with another 15, for a complete cycles code marking of “X.8.17.15.”

EFFECTIVITY ALL

(c)

To prevent confusion with proper cycle tracking on parts, cycles marked on a part should either match the actual accumulated cycles documented in the engine records (LLP Card) or be obscured using the process shown in Step (d).

(d)

Obscure the area using Electrochemical Etch per AS478, Type 7A1 or Standard Practices Manual (SPM) 20-00-02/70-00-01. A complete masking of the area or the use of standard type (i.e. XXXXX) is recommended.

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Blank Page

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LIST OF EFFECTIVE PAGES Subheading and Page

F F F F F F F F

Date

List of Effective Pages LEP-1 18 Dec 2019 LEP-2 18 Dec 2019 LEP-3 18 Dec 2019 LEP-4 18 Dec 2019 LEP-5 18 Dec 2019 LEP-6 18 Dec 2019 LEP-7 18 Dec 2019 LEP-8 18 Dec 2019 LEP-9 18 Dec 2019 LEP-10 18 Dec 2019 LEP-11 18 Dec 2019 LEP-12 18 Dec 2019 Table of Contents TC-1 18 Dec 2019 TC-2 18 Dec 2019 TC-3 18 Dec 2019 TC-4 18 Dec 2019 49-20-00 SYSTEMS DESCRIPTION SECTION 1 18 Dec 2019 2 * 18 Dec 2019 3 18 Dec 2019 4 18 Dec 2019 5 18 Dec 2019 6 18 Dec 2019 7 18 Dec 2019 8 18 Dec 2019 9 18 Dec 2019 10 18 Dec 2019 11 18 Dec 2019 12 18 Dec 2019 13/14 18 Dec 2019 15/16 18 Dec 2019 17/18 18 Dec 2019 19/20 18 Dec 2019 21/22 * 18 Dec 2019 23/24 * 18 Dec 2019 25/26 18 Dec 2019 27/28 18 Dec 2019 29 18 Dec 2019 30 18 Dec 2019

Subheading and Page

49-20-00 APU - FAULT ISOLATION 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

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LIST OF EFFECTIVE PAGES (Cont) Subheading and Page

1042 1043 1044 1045 1046 1047 1048 1049 1050 1051 1052 1053 1054 1055 1056 1057 1058 1059 1060 1061 1062 1063 1064 1065 1066 1067 1068 1069 1070 1071 1072 1073 1074 1075 1076 1077 1078 1079 1080 1081 1082 1083 1084 1085

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

Subheading and Page

1086 1087 1088 1089 1090 1091 1092 1093 1094 1095 1096 1097 1098 1099 1100 1101 1102 1103 1104 1105 1106 1107 1108 1109 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119 1120 1121 1122 1123 1124 1125 1126 1127 1128 1129

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

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1130 1131 1132 1133 1134 1135 1136 1137 1138 1139 1140 1141 1142 1143 1144 1145 1146 1147 1148 1149 1150 1151 1152 1153 1154 1155 1156 1157 1158 1159 1160 1161 1162 1163 1164 1165 1166 1167 1168 1169 1170 1171 1172 1173

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

Subheading and Page

1174 1175 1176 1177 1178 1179 1180 1181 1182 1183 1184 1185 1186 1187 1188 1189 1190 1191 1192 1193 1194 1195 1196 1197 1198 1199 1200 1201 1202 1203 1204 1205 1206 1207 1208 1209 1210 1211 1212 1213 1214 1215 1216 1217

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

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1218 1219 1220 1221 1222 1223 1224 1225 1226 1227 1228 1229 1230 1231 1232 1233 1234 1235 1236 1237 1238 1239 1240 1241 1242 1243 1244 1245 1246 1247 1248 1249 1250 1251 1252 1253 1254 1255 1256 1257 1258 1259 1260 1261

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

Subheading and Page

1262 1263 1264 1265 1266 1267 1268 1269 1270 1271 1272 1273 1274 1275 1276 1277 1278 1279 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 1290 1291 1292 1293 1294 1295 1296 1297 1298 1299 1300 1301 1302 1303 1304 1305

Date

* *

* *

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

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1306 1307 1308 1309 1310 1311 1312 1313 1314 1315 1316 1317 1318 1319 1320 1321 1322 1323 1324 1325 1326 1327 1328 1329 1330 1331 1332 1333 1334 1335 1336 1337 1338 1339 1340 1341 1342 1343 1344 1345 1346 1347 1348 1349

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

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Subheading and Page

Date

1350 18 Dec 1351 18 Dec 1352 18 Dec 1353 18 Dec 1354 18 Dec 1355 18 Dec 1356 18 Dec 1357 18 Dec 1358 18 Dec 1359 18 Dec 1360 18 Dec 1361 18 Dec 1362 18 Dec 1363 18 Dec 1364 18 Dec 49-20-00 GENERAL REMOVAL-01 3001 18 Dec 3002 18 Dec 3003 18 Dec 3004 18 Dec 49-20-00 PLUMBING AND ELECTRICAL INSTALLATION REMOVAL-02 3001 18 Dec 3002 18 Dec 3003 18 Dec 3004 18 Dec 3005 18 Dec 3006 18 Dec 3007 18 Dec 3008 18 Dec 3009 18 Dec 3010 18 Dec 3011 18 Dec 3012 18 Dec 3013 18 Dec 3014 18 Dec 3015 18 Dec 3016 18 Dec 3017 18 Dec 3018 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

2019 2019 2019 2019

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

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Date

3019 18 Dec 2019 3020 18 Dec 2019 49-20-00 STARTER/GENERATOR REMOVAL-03 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 LOW OIL PRESSURE (LOP) SWITCH REMOVAL-04 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 OIL LEVEL SENSOR REMOVAL-05 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 FUEL CONTROL UNIT (FCU) REMOVAL-06 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 LUBE MODULE REMOVAL-07 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 DATA MEMORY MODULE (DMM) REMOVAL-08 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019

Subheading and Page

Date

3004 18 Dec 2019 49-20-00 BLEED DUCT REMOVAL-09 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 BLEED AIR VALVE (BAV) REMOVAL-10 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 COMPRESSOR DISCHARGE DUCT REMOVAL-11 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 TOTAL PRESSURE PROBE ASSEMBLY REMOVAL-12 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 SURGE CONTROL VALVE (SCV) REMOVAL-13 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 SURGE DUCT REMOVAL-14 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019

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Date

3004 18 Dec 2019 49-20-00 SPEED SENSOR REMOVAL-15 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 INLET PRESSURE SENSOR (P2) REMOVAL-16 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 TOTAL PRESSURE SENSOR (PT) REMOVAL-17 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 DIFFERENTIAL PRESSURE SENSOR (DP) REMOVAL-18 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 INLET TEMPERATURE SENSOR (T2) REMOVAL-19 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 IGNITER PLUG REMOVAL-20 3001 18 Dec 2019 3002 18 Dec 2019

Subheading and Page

Date

3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 IGNITER PLUG LEAD REMOVAL-21 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 IGNITION UNIT REMOVAL-22 3001 * 18 Dec 2019 3002 * 18 Dec 2019 3003 * 18 Dec 2019 3004 * 18 Dec 2019 3005 * 18 Dec 2019 3006 18 Dec 2019 49-20-00 EXHAUST GAS TEMPERATURE (EGT) THERMOCOUPLE REMOVAL-23 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 COMBUSTOR CASE DRAIN PLUG REMOVAL-24 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 INLET GUIDE VANE ACTUATOR (IGVA) REMOVAL-25 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019

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Date

49-20-00 ACCESS DOOR REMOVAL-26 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 IDENTIFICATION PLATE REMOVAL-27 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 FUEL MANIFOLD ASSEMBLY REMOVAL-28 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 OIL COOLER REMOVAL-29 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 TEMPERATURE CONTROL VALVE REMOVAL-30 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 UPPER AND LOWER INLET DUCT REMOVAL-31 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019

Subheading and Page

Date

49-20-00 GEARBOX ASSEMBLY REMOVAL-32 3001 18 Dec 2019 3002 18 Dec 2019 3003 18 Dec 2019 3004 18 Dec 2019 49-20-00 GENERAL INSTALLATION-01 4001 18 Dec 2019 4002 18 Dec 2019 49-20-00 FUEL MANIFOLD ASSEMBLY INSTALLATION-02 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 ACCESS DOOR INSTALLATION-03 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 INLET GUIDE VANE ACTUATOR (IGVA) INSTALLATION-04 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 UPPER AND LOWER INLET DUCT INSTALLATION-05 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019

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Date

49-20-00 DIFFERENTIAL PRESSURE SENSOR (DP) INSTALLATION-06 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 TOTAL PRESSURE SENSOR (PT) INSTALLATION-07 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 INLET PRESSURE SENSOR (P2) INSTALLATION-08 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 INLET TEMPERATURE SENSOR (T2) INSTALLATION-09 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 SPEED SENSOR INSTALLATION-10 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 OIL COOLER INSTALLATION-11 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019

Subheading and Page

Date

4004 18 Dec 2019 49-20-00 EXHAUST GAS TEMPERATURE (EGT) THERMOCOUPLE INSTALLATION-12 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 GEARBOX ASSEMBLY INSTALLATION-13 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 LUBE MODULE INSTALLATION-14 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 TEMPERATURE CONTROL VALVE INSTALLATION-15 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 OIL LEVEL SENSOR INSTALLATION-16 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 LOW OIL PRESSURE (LOP) SWITCH INSTALLATION-17 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019

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Date

4004 18 Dec 2019 49-20-00 FUEL CONTROL UNIT (FCU) INSTALLATION-18 4001 18 Dec 2019 4002 18 Dec 2019 4003 * 18 Dec 2019 4004 18 Dec 2019 49-20-00 STARTER/GENERATOR INSTALLATION-19 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 DATA MEMORY MODULE (DMM) INSTALLATION-20 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 TOTAL PRESSURE PROBE ASSEMBLY INSTALLATION-21 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 SURGE CONTROL VALVE (SCV) INSTALLATION-22 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 COMPRESSOR DISCHARGE DUCT INSTALLATION-23 4001 18 Dec 2019

Subheading and Page

Date

4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 BLEED AIR VALVE (BAV) INSTALLATION-24 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 BLEED DUCT ASSEMBLY INSTALLATION-25 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 SURGE DUCT ASSEMBLY INSTALLATION-26 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 IGNITER PLUG INSTALLATION-27 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 IGNITION UNIT INSTALLATION-28 4001 18 Dec 2019 4002 * 18 Dec 2019 4003 * 18 Dec 2019 4004 * 18 Dec 2019 4005 * 18 Dec 2019 4006 18 Dec 2019 49-20-00 IGNITER PLUG LEAD INSTALLATION-29 4001 18 Dec 2019

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Date

4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 COMBUSTOR CASE DRAIN PLUG INSTALLATION-30 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 49-20-00 PLUMBING AND ELECTRICAL INSTALLATION INSTALLATION-31 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019 4005 18 Dec 2019 4006 18 Dec 2019 4007 18 Dec 2019 4008 18 Dec 2019 4009 18 Dec 2019 4010 18 Dec 2019 4011 18 Dec 2019 4012 18 Dec 2019 4013 18 Dec 2019 4014 18 Dec 2019 4015 18 Dec 2019 4016 18 Dec 2019 4017 18 Dec 2019 4018 18 Dec 2019 4019 18 Dec 2019 4020 18 Dec 2019 4021 18 Dec 2019 4022 18 Dec 2019 49-20-00 IDENTIFICATION PLATE INSTALLATION-32 4001 18 Dec 2019 4002 18 Dec 2019 4003 18 Dec 2019 4004 18 Dec 2019

Subheading and Page

49-20-00 FINAL INSTALLATION-33 4001 4002 49-20-00 APU CLEANING-01 6001 * 6002 49-20-00 CHECK 8001 8002 49-20-00 REPAIR 9001 9002 49-20-00 APU SERVICING-01 11001 11002 11003 11004 11005 11006 11007 11008 49-20-00 APU STORAGE-01 12001 12002 12003 12004 49-20-00 APU STORAGE-02 12001 12002

Date

18 Dec 2019 18 Dec 2019

18 Dec 2019 18 Dec 2019

18 Dec 2019 18 Dec 2019

18 Dec 2019 18 Dec 2019

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019

18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019

18 Dec 2019 18 Dec 2019

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ENGINE MANUAL 131-9[B]

LIST OF EFFECTIVE PAGES (Cont) Subheading and Page

49-20-00 APU - TESTING 13001 13002 13003 13004 13005 13006 13007 13008 13009 13010 13011 13012 13013 13014 13015 13016 13017 13018 13019 13020 13021 13022 13023 13024 13025 13026 13027 13028 13029 13030 13031 13032 13033 13034 13035 13036 13037 13038 13039 13040 13041

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

Subheading and Page

13042 13043 13044 13045 13046 13047 13048 13049 13050 13051 13052 13053 13054 13055 13056 13057 13058

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

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ENGINE MANUAL 131-9[B]

TABLE OF CONTENTS CHAPTER - 49

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Title

Page

49-20-00 - ENGINE ASSEMBLY .....................................................................................................

1

49-20-00 - SYSTEMS DESCRIPTION SECTION ...................................................................

1

49-20-00 - APU - FAULT ISOLATION ....................................................................................

1001

49-20-00 - GENERAL REMOVAL-01 ......................................................................................

3001

49-20-00 - PLUMBING AND ELECTRICAL INSTALLATION REMOVAL-02 ..........................

3001

49-20-00 - STARTER/GENERATOR REMOVAL-03 ..............................................................

3001

49-20-00 - LOW OIL PRESSURE (LOP) SWITCH REMOVAL-04 .........................................

3001

49-20-00 - OIL LEVEL SENSOR REMOVAL-05 .....................................................................

3001

49-20-00 - FUEL CONTROL UNIT (FCU) REMOVAL-06 .......................................................

3001

49-20-00 - LUBE MODULE REMOVAL-07 .............................................................................

3001

49-20-00 - DATA MEMORY MODULE (DMM) REMOVAL-08 ................................................

3001

49-20-00 - BLEED DUCT REMOVAL-09 ................................................................................

3001

49-20-00 - BLEED AIR VALVE (BAV) REMOVAL-10 .............................................................

3001

49-20-00 - COMPRESSOR DISCHARGE DUCT REMOVAL-11 ............................................

3001

49-20-00 - TOTAL PRESSURE PROBE ASSEMBLY REMOVAL-12 .....................................

3001

49-20-00 - SURGE CONTROL VALVE (SCV) REMOVAL-13 ................................................

3001

49-20-00 - SURGE DUCT REMOVAL-14 ...............................................................................

3001

49-20-00 - SPEED SENSOR REMOVAL-15 ..........................................................................

3001

49-20-00 - INLET PRESSURE SENSOR (P2) REMOVAL-16 ................................................

3001

49-20-00 - TOTAL PRESSURE SENSOR (PT) REMOVAL-17 ..............................................

3001

49-20-00 - DIFFERENTIAL PRESSURE SENSOR (DP) REMOVAL-18 ................................

3001

49-20-00 - INLET TEMPERATURE SENSOR (T2) REMOVAL-19 .........................................

3001

49-20-00 - IGNITER PLUG REMOVAL-20 .............................................................................

3001

49-20-00 - IGNITER PLUG LEAD REMOVAL-21 ...................................................................

3001

49-20-00 - IGNITION UNIT REMOVAL-22 ..............................................................................

3001

49-20-00 - EXHAUST GAS TEMPERATURE (EGT) THERMOCOUPLE REMOVAL-23 .......

3001

49-20-00 - COMBUSTOR CASE DRAIN PLUG REMOVAL-24 ..............................................

3001

49-20-00 - INLET GUIDE VANE ACTUATOR (IGVA) REMOVAL-25 .....................................

3001

49-20-00 - ACCESS DOOR REMOVAL-26 ............................................................................

3001

49-20-00 - IDENTIFICATION PLATE REMOVAL-27 ..............................................................

3001

49-20-00 - FUEL MANIFOLD ASSEMBLY REMOVAL-28 ......................................................

3001

49-20-00 - OIL COOLER REMOVAL-29 .................................................................................

3001

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TABLE OF CONTENTS (Cont) CHAPTER - 49 (Cont)

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Title

Page 49-20-00 - TEMPERATURE CONTROL VALVE REMOVAL-30 .............................................

3001

49-20-00 - UPPER AND LOWER INLET DUCT REMOVAL-31 ..............................................

3001

49-20-00 - GEARBOX ASSEMBLY REMOVAL-32 .................................................................

3001

49-20-00 - GENERAL INSTALLATION-01 ..............................................................................

4001

49-20-00 - FUEL MANIFOLD ASSEMBLY INSTALLATION-02 ..............................................

4001

49-20-00 - ACCESS DOOR INSTALLATION-03 ....................................................................

4001

49-20-00 - INLET GUIDE VANE ACTUATOR (IGVA) INSTALLATION-04 .............................

4001

49-20-00 - UPPER AND LOWER INLET DUCT INSTALLATION-05 ......................................

4001

49-20-00 - DIFFERENTIAL PRESSURE SENSOR (DP) INSTALLATION-06 ........................

4001

49-20-00 - TOTAL PRESSURE SENSOR (PT) INSTALLATION-07 ......................................

4001

49-20-00 - INLET PRESSURE SENSOR (P2) INSTALLATION-08 ........................................

4001

49-20-00 - INLET TEMPERATURE SENSOR (T2) INSTALLATION-09 .................................

4001

49-20-00 - SPEED SENSOR INSTALLATION-10 ...................................................................

4001

49-20-00 - OIL COOLER INSTALLATION-11 .........................................................................

4001

49-20-00 - EXHAUST GAS TEMPERATURE (EGT) THERMOCOUPLE INSTALLATION-12 .....

4001

49-20-00 - GEARBOX ASSEMBLY INSTALLATION-13 .........................................................

4001

49-20-00 - LUBE MODULE INSTALLATION-14 .....................................................................

4001

49-20-00 - TEMPERATURE CONTROL VALVE INSTALLATION-15 .....................................

4001

49-20-00 - OIL LEVEL SENSOR INSTALLATION-16 .............................................................

4001

49-20-00 - LOW OIL PRESSURE (LOP) SWITCH INSTALLATION-17 .................................

4001

49-20-00 - FUEL CONTROL UNIT (FCU) INSTALLATION-18 ...............................................

4001

49-20-00 - STARTER/GENERATOR INSTALLATION-19 ......................................................

4001

49-20-00 - DATA MEMORY MODULE (DMM) INSTALLATION-20 ........................................

4001

49-20-00 - TOTAL PRESSURE PROBE ASSEMBLY INSTALLATION-21 .............................

4001

49-20-00 - SURGE CONTROL VALVE (SCV) INSTALLATION-22 ........................................

4001

49-20-00 - COMPRESSOR DISCHARGE DUCT INSTALLATION-23 ....................................

4001

49-20-00 - BLEED AIR VALVE (BAV) INSTALLATION-24 .....................................................

4001

49-20-00 - BLEED DUCT ASSEMBLY INSTALLATION-25 ....................................................

4001

49-20-00 - SURGE DUCT ASSEMBLY INSTALLATION-26 ...................................................

4001

49-20-00 - IGNITER PLUG INSTALLATION-27 ......................................................................

4001

49-20-00 - IGNITION UNIT INSTALLATION-28 ......................................................................

4001

49-20-00 - IGNITER PLUG LEAD INSTALLATION-29 ...........................................................

4001

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TABLE OF CONTENTS (Cont) CHAPTER - 49 (Cont)

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Title

Page 49-20-00 - COMBUSTOR CASE DRAIN PLUG INSTALLATION-30 ......................................

4001

49-20-00 - PLUMBING AND ELECTRICAL INSTALLATION INSTALLATION-31 ..................

4001

49-20-00 - IDENTIFICATION PLATE INSTALLATION-32 ......................................................

4001

49-20-00 - FINAL INSTALLATION-33 .....................................................................................

4001

49-20-00 - APU CLEANING-01 ...............................................................................................

6001

49-20-00 - CHECK ..................................................................................................................

8001

49-20-00 - REPAIR .................................................................................................................

9001

49-20-00 - APU SERVICING-01 .............................................................................................

11001

49-20-00 - APU STORAGE-01 ...............................................................................................

12001

49-20-00 - APU STORAGE-02 ...............................................................................................

12001

49-20-00 - APU - TESTING ....................................................................................................

13001

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

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ENGINE MANUAL 131-9[B]

SYSTEMS DESCRIPTION SECTION 1.

Introduction The gas turbine auxiliary power unit (APU) is a self-contained power unit designed for airborne auxiliary power. The APU provides electrical power for driving airplane electrical accessories, provides pneumatic bleed-air power for starting main engines and for airplane cabin air-conditioning and pressurization and provides cooling air for APU lubricating oil and for the APU enclosure.

2.

General Description The physical operational characteristics of the engine are listed in Table 1. Approved lubricating oil is found in Table 2. Approved fuel is found in Table 3.

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Table 1. Leading Particulars Total APU Weight

399.7 lb (181.3 KG)

Rated Output Shaft Power

96 KW (continuous)

Rated Output Shaft Speed

48800 RPM

Maximum Turbine Exhaust Gas

1070°F (577°C) at sea level, standard day Temperature at Rated Output

Maximum Allowable Speed

53875 RPM

Maximum Oil Consumption Rate

8 cm³/hour

Oil Pressure Limits

67.5 ±7.5 PSIG (466 ±52 KPA)(nominal) 30 to 40 PSIG (207 to 276 kPa)(automatic LOP shutdown)

Usable Oil Capacity

Total sump capacity 5.56 quarts (5.26 liters) Approximately 1.78 quarts (1.68 liters) depletion to minimum oil quantity signal. Approximately 4.8 quarts (4.5 liters) depletion to automatic shutdown.

Frequency of Oil Change

No oil change required

Frequency of Oil Filter Change

A Delta P indicator is provided to indicate when oil filter change is required.

Oil

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

Fuel

Refer to Table 3 for list of acceptable fuels.

Minimum Fuel Inlet Pressure

10 PSIG (20.36 Hg) for starting and operation

Fuel Filter

25 micron filter

Frequency of Fuel Filter Change

3500 hrs or 3 yrs, whichever comes first

APU Power Supply (Start Power Unit)

28 VDC, 500 amperes (max.) or 200 VAC line to line, 3 phase, 400 Hz, 30 amperes (max.)

APU Power Supply (Start Converter Unit)

28 VDC, 8 amperes (max.)

ECU Power Supply

28 VDC, 8 amperes (max.)

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ENGINE MANUAL 131-9[B] Table 2. Approved Lubricating Oil Ambient Temperature Approved Oil Brand Name

Minimum

Maximum

Minimum

Maximum

Refer to Service Bulletin 49-7933 Table 3. Approved Fuels Fuel

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Refer to Service Bulletin 49-8252

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ENGINE MANUAL 131-9[B]

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Figure 1. APU Internal Features (Typical)

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ENGINE MANUAL 131-9[B] The APU system includes the APU with its line replaceable units (LRU’s) and remotely located support equipment. The APU has the following features. -

A direct driven gearbox. The gearbox is directly driven by the turbines, is modular and supplies mounts for the APU accessories and starter/generator.

-

A load compressor. The load compressor is a single stage centrifugal compressor.

-

An engine compressor. The engine compressor is a single stage centrifugal compressor.

-

A turbine section. The turbine section is a two-stage axial turbine with a reverse flow annular combustion section. The load compressor, engine compressor and the turbines are connected together with a single shaft.

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Figure 1 shows the APU internal components and their locations.

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ENGINE MANUAL 131-9[B]

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Figure 2. APU External Features

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ENGINE MANUAL 131-9[B] The APU has LRU’s that are easy to service, remove and replace at line level. The LRU’s include the following. -

APU wiring harness

-

Bleed air valve

-

Combustor drain valve

-

Data memory module

-

Delta pressure sensor

-

Exhaust gas temperature thermocouples

-

Engine speed sensor (monopole)

-

Fuel control unit and filter

-

Fuel flow divider

-

Fuel manifolds

-

Fuel nozzles

-

Generator wiring harness

-

Igniter plug lead

-

Igniter plug

-

Ignition unit

-

Inlet guide vane actuator

-

Inlet pressure sensor

-

Inlet temperature sensor

-

Low oil pressure switch

-

Lube oil fill, check and drain

-

Lube module with filters

-

Magnetic drain plug

-

Oil cooler

-

Oil level sensor

-

Oil temperature sensor

-

Speed sensor

-

Starter-generator

-

Surge control valve

-

(Oil) temperature control valve

-

Total pressure probe assembly

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Figure 2 and Figure 3 shows detailed APU external components locations.

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ENGINE MANUAL 131-9[B]

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Figure 3. (Sheet 1 of 2) APU External Features

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ENGINE MANUAL 131-9[B]

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Figure 3. (Sheet 2 of 2) APU External Features

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ENGINE MANUAL 131-9[B] The following APU support equipment is remotely located from the APU. -

Electronic control unit (ECU).

-

Start converter unit (SCU).

-

Start power unit (SPU).

APU Start Sequencing The APU is started by a RUN signal, followed by a momentary START signal, transmitted from the airplane to the Electronic Control Unit (ECU) from the APU start switch. The ECU then energizes its internal power supply and commands the APU inlet door to open. During the time it takes for the APU inlet door to open, the ECU performs an automatic prestart built-in-test equipment (BITE) check and also monitors all input commands. After the BITE check is completed and receipt of the APU DOOR OPEN signal from the position switch, the ECU transmits a signal to the start converter unit (SCU). The SCU then applies 115-Volts, 400-Hz ac power, if available, or converts 28 VDC to AC and applies it to the starter-generator. The starter-generator applies torque to the gear train, which in turn increases the speed of the APU rotating group. As the APU shaft begins to turn, both speed signals generated by the dual-circuited speed sensor are transmitted to the ECU. When the APU has reached seven-percent speed, the ECU energizes the fuel solenoid valve and commands the fuel control unit (FCU) torque motor (T/M) to deliver fuel flow for ignition. The ignition unit causes the igniter to spark at a rate necessary to ignite the atomized fuel being delivered by the FCU. When light-off occurs the FCU T/M signal is switched from light-off schedule to the timed-acceleration speed control loop. At APU light-off, two thermocouple assemblies positioned in the combustion exhaust gas path see a temperature rise and send these values to the ECU on a continuous basis. After light-off, the ECU continues to monitor APU speed, and inlet air and exhaust gas temperatures, and limits fuel delivery to keep operation at safe turbine temperatures under all inlet temperature and altitude conditions. After ignition, the starter continues to accelerate the APU faster than the reference ramp. During this time, a minimum fuel flow keeps a continuous combustion. When the actual APU acceleration rate slows to become equal to the reference ramp acceleration, then the integrator is reset so that the reference speed equals the actual speed, which gives a smooth transition from starter-generator assistance to combustion power. When combustion becomes the primary source of power, APU speed is controlled through fuel flow rate feedback from the resolver flow meter in the FCU. Governing action occurs when the actual speed (N) is compared against the speed reference set point (NREF): if N is less than the reference, the resulting error is amplified and added to the T/M current to increase APU speed. The ECU de-energizes the starter-generator at 70 percent APU speed.

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The speed reference increases according to the speed reference ramp schedule. This schedule varies with altitude so that the APU starts in the specified time at high altitudes, and starts faster at low-altitude and normal-ambient conditions where turbine inlet temperature (T4) is moderate. The speed reference also increases more quickly at higher APU speeds, where the APU is capable of faster acceleration with reduced turbine inlet temperature.

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ENGINE MANUAL 131-9[B] At 95 percent speed, the timed-acceleration logic is no longer used, and the on-speed governor control loop assumes control of APU speed. The "easy-up" logic gives a speed set-point rate of four percent per second to ease the APU up from 95 to 100 percent speed. Two seconds after speed exceeds 95 percent, the ECU sends the APU ready-to-load (RTL) signals to the airplane, indicating that generator and pneumatic power are available. The on-speed governor loop keeps a constant APU speed under varying load conditions. Governing is electronically made by the digital APU ECU. The ECU uses proportional-plus-integral (P+I) logic to prevent steady-state speed errors and keep transient speed changes inside specification limits. The ECU gives closed-loop APU speed control at governed speed by monitoring speed and modulating fuel flow. Speed is sensed by one speed sensor and two speed-conditioning circuits, with fail-safe logic contained in the ECU. The single sensor gives two redundant speed signals. Speed is compared with a 100 percent reference and the error signal is acted on by the P+I control logic. The output of this logic is limited by maximum and minimum schedules that prevent power section surge and combustor blowout, respectively, subsequent to large step changes in generator load. The control current to the FCU T/M is updated every 20 milliseconds. Closed-loop control of fuel flow is active. It increases the speed of response of fuel flow during generator loading and unloading, and helps apply the minimum and maximum fuel flow limits more accurately. Shutdown

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Normal APU shutdown is specified in the following sequence of events. (a)

A normal APU shutdown is started from the cockpit by switching the APU master switch to the OFF position which in turn causes the 28-Vdc OFF signal to replace the 28-VDC ON signal in the ECU. The ECU removes the READY TO LOAD (RTL) signal immediately.

(b)

The ECU starts a 60-second cool-down timer as soon as it receives the "Closed" signal from the bleed air valve (BAV). This could happen before a normal APU shutdown is commanded.

(c)

If the APU master switch OFF signal is received while the BAV is "Open", the ECU begins pneumatic unloading by closing the inlet guide vanes (IGV) and the BAV and opening the surge control valve (SCV) and starts the 60-second cool-down time delay. The APU then continues to complete the entire cool-down cycle. If the APU master switch OFF signal is received after the completion of the cool-down timer started in Step (b) above, the APU is shutdown immediately.

(d)

If the APU master switch OFF signal is received before completion of the time delay started in (a) above, the APU will shutdown at completion of the cool-down time delay in progress.

(e)

At the end of the cool-down cycle, the ECU supplies a frequency input to the overspeed shutdown circuitry to simulate a overspeed condition. In response, the fuel solenoid closes and the APU shuts down as it would for an actual overspeed shutdown. In this mode, however, no overspeed shutdown is recorded by the APU. After the overspeed protection circuit is checked, the ECU attempts to keep speed at 100 percent by modulating the fuel flow. If the ECU is able to keep speed at 100 percent, it would indicate that the fuel solenoid failed in the open position. If the ECU sees a fuel solenoid failure in this manner, it will reduce the FCU T/M current to zero to make sure the APU is shutdown.

(f)

During APU rolldown, the ECU continues to function and keep signals to the airplane circuits. The IGVs are positioned at 22 degrees until the APU has rolled down to 20 percent, at which point the IGVs are closed to 15 degrees. An APU restart may be given at any time after speed has dropped below seven percent.

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ENGINE MANUAL 131-9[B] Inlet Guide Vane (IGV) Control System The load compressor inlet guide vane (IGV) control system positions the load compressor IGVs to meet necessary airplane pneumatic loads, protect the APU from overtemperature, and limit bleed duct pressure in situations where the APU could make more than maximum allowable duct pressure. Airplane mode select logic commands the IGV position. The IGV position is set by means of the hydraulic actuator. Two outer loops limit EGT (T5) trim and bleed-pressure, in this sequence. The logic for these two outer loops can reduce the IGV position set point if T5 or bleed pressure becomes greater than each of their set point. If an electrical overload occurs, the IGVs are immediately closed to prevent generator underfrequency, then slowly and continuously allowed to return to their original position. During an APU start, the IGVs are held at 15 degrees open to remove pneumatic load from the load compressor. Surge Control System The foundation of the surge control system is a hydraulically actuated (fuel powered) electrically piloted surge control valve (SCV) with a two-stage servovalve and a linear variable differential transformer (LVDT) that gives feedback on valve position. The surge control system prevents load compressor surge for all service modes, altitudes, inlet temperatures and airplane airflow. The system keeps a minimum load compressor discharge corrected flow (Wc) by opening the surge control valve (SCV) when little or no airflow is necessary for the airplane. Surge is prevented by control of the load compressor Wc to keep it at or above a limit, or set point. The Wc set point is a function of inlet temperature (T2), IGV position, and airplane selected mode. The ECU commands the SCV position loop to keep Wc at or above the set point. Wc is measured by a total pressure (PT) probe at the scroll discharge and static pressure (PS) ports in the load compressor diffuser. The signals for PT and PS are transmitted to the ECU by sensors. The flow sensor gives a Delta P/PT signal that is a function of Wc. A lookup table in the ECU uses the known characteristics of the flow sensor to convert Delta P/PT back into Wc. The control logic generates the Wc error by subtracting the measured Wc from Wc setpoint. A lead-lag filter and P+I controller then act on the Wc error to command the SCV position. The P+I controller provides zero steady-state flow error. The surge control logic is updated every 5 milliseconds. The SCV position control loop is an inner loop in the airflow control loop. The SCV position command comes from the airflow control loop software. The proportional controller for the SCV position loop is a analog electronics device, and controls the current to a T/M. The T/M controls the flow of high pressure fuel to the hydraulic cylinder, which, through a mechanical linkage, drives the SCV butterfly. A linear variable differential transformer (LVDT) senses the position of the butterfly shaft, which provides the position measurement for the controller. Electronic Control Unit (ECU) The APU ECU is a full-authority digital electronic control that gives complete APU speed and temperature control during start and on-speed operation. The ECU has an energy storage module that gives power to the rest of the ECU for up to 50 milliseconds if there is a dc power interruption. The ECU has key software tests that give nearly perfect fault detection and isolation to the LRU level. Fault information and APU status data are available on the control display unit (CDU) in the cockpit.

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The ECU contains the necessary electronic hardware and software to operate the 131-9[B] APU in the airplane. This operation includes APU start, run, and load order of succession, as well as modifications of these modes that results from airplane parameters that change. EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] The ECU features BITE technology as follows:

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3.

-

Open- and short-circuit and signal-invalid tests on all speed, temperature, position, and pressure signals.

-

Voltage, current, and overcurrent signals on all outputs to detect open, short, or failed ECU drivers on any ECU output.

-

Various internal self-test and monitoring features to detect and isolate ECU and LRU faults. These tests are as follows: •

Central processor unit (CPU) instruction test.

•

Temporary results and computational storage memory (RAM) sum test.

•

Nonvolatile memory for storage of shutdown and fault records (EEPROM) voting logic test.

•

Monitoring of power-supply-voltage hardware.

•

CPU monitoring of power-supply and reference voltages using logic tests to isolate faults.

•

Self-test of internal and external CPU watchdog timers, conducted during alternate APU shutdowns.

•

Self-test of hardware overspeed circuit, conducted during alternate APU shutdowns.

•

Transmitter-to-receiver wraparound test of the ARINC 429 data bus.

•

CPU self-test to determine execution time of foreground and background tasks.

•

Extensive LRU fault isolation.

Training Information Points A.

The APU oil cooler air inlet side should always be kept clean to make sure air can pass through to keep the oil in temperature limits.

B.

The drain mast is examined for leakage. If leakage is found, the tell-tail witness drains are opened to isolate the leakage source. (Refer to Figure 7.)

C.

Approved oil is added to the gearbox oil sump through the oil filler housing.

D.

The oil level sight glass is visually examined to see the oil level in the gearbox oil sump.

E.

The magnetic chip collector is examined for metal pieces to see if there is possible engine damage.

F.

The magnetic chip collector and plug are removed to drain oil from the gearbox oil sump.

G.

The air-oil separator plug is removed to insert a tool to turn the APU rotating group for hot section inspection.

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ENGINE MANUAL 131-9[B]

Figure 4. Lubrication System Schematic

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ENGINE MANUAL 131-9[B]

Figure 5. Pneumatic System Schematic

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ENGINE MANUAL 131-9[B]

Figure 6. Fuel System Schematic

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ENGINE MANUAL 131-9[B]

Figure 7. Vent and Drain System Schematic

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ENGINE MANUAL 131-9[B]

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

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Figure 8. (Sheet 2 of 2) Wiring Diagram Schematic

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ENGINE MANUAL 131-9[B]

Figure 9. (Sheet 1 of 2) Start System Schematic

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ENGINE MANUAL 131-9[B]

Figure 9. (Sheet 2 of 2) Start System Schematic

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ENGINE MANUAL 131-9[B]

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ENGINE MANUAL 131-9[B]

APU - FAULT ISOLATION TASK 49-20-00-810-801 1.

General A.

Electronic Control Unit (ECU). The electronic control unit (ECU) is a full-authority digital controller. It has full authority over APU starts, acceleration, governed speed load conditions, temperature limits and normal and protective shutdowns. The electronic control unit (ECU) also has BITE capability designed to decrease time in troubleshooting problems the APU can have. The electronic control unit (ECU) includes control-related features as follows:

B.

-

Full-authority fuel control operation

-

Software-computed inlet guide vane positioning with direct hardware Closed-loop vane control

-

Software-computed surge control valve positioning with direct hardware Closed-loop valve control

Built-In-Test-Equipment (BITE). The APU BITE includes hardware and software that finds and sends fault data of the APU system and interfacing airplane systems. The primary purpose of BITE is to be an aid to maintenance troubleshooting and planning. Faults are sent to the test cell PC monitor via the RS 232 data bus. Each of the possible faults that can be found has a unique name and corresponds to a specific symptom. The test cell PC monitor shows the symptom and fault that was found.

C.

Fault Detection. Each fault has detection logic to make sure that the specified limits for a specified time are met. The detection logic is executed continuously for most faults. Not all BITE faults can be found all the time. There will be times when a BITE fault can only be found in one of the BITE modes that follow:

D.

-

Continuous - when the electronic control unit (ECU) is powered,

-

Power-up - immediately after electronic control unit (ECU) power-up,

-

Power-down - immediately before electronic control unit (ECU) power-down,

-

Test - during the test mode which follows power-up and rolldown to 7% speed,

-

Start - during APU start-up,

-

Onspeed - during onspeed operation,

-

Shutdown - during APU rolldown.

Fault Clearing.

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The electronic control unit (ECU) continuously transmits the condition of all the possible BITE faults to the PC monitor. The electronic control unit (ECU) keeps a record on the condition of all BITE faults even after power is removed and applied again. After the cause of the fault has been repaired or replaced, the fault can be removed by running the APU in the mode that the fault was initially found in.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] After an LRU has been replaced, an APU start, bleed load applied and a shutdown must be done. Refer to Paragraph 4. Then examine the PC monitor to make sure the fault has been removed. E.

Fault Tolerance and Alternate Values. Each BITE fault can cause other control logic to use different values for unsatisfactory sensors or special control procedures that must be done.

F.

EICAS Messages. Some faults cause one or more displays to be shown on the EICAS APU page. These displays supply dispatchability data to the flight crew.

G.

Auto Shutdowns. The APU will be shutdown automatically if a hazardous condition is found by the electronic control unit (ECU). Like the BITE faults, some of these hazardous conditions can only be found during certain modes. If an auto-shutdown is found before the APU is started, the start will be prevented. An auto-shutdown can be removed when the APU Master switch is turned to the OFF position.

2.

Special Tools, Fixtures and Equipment A.

Table 1001 shows the special tools, fixtures and equipment needed for fault isolation. Table 1001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Electronic Control Unit (ECU)

To monitor the APU operation and generates fuel 2118966-221 metering valve position commands for APU acceleration 2118966-222 and on-speed governing.

Start Converter Unit

Change incoming power to necessary power for start power unit.

1152426-245 1152466-250

Start Power Unit

Provide necessary power to APU starter/generator to provide torque to the APU rotating group for APU start.

1151984-261 1152464-265

3.

Equipment and Materials A.

Table 1002 shows the equipment and materials needed for fault isolation. Table 1002. Equipment and Materials

Equipment/Materials

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NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Test cell

Commercially available

Test cell APU master control panel

Commercially available

Test cell APU PC monitor

Commercially available

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 4.

Procedure

SUBTASK 49-20-00-810-001 A.

Fault Isolation. Off-wing fault isolation starts with a review of the airplane log, a full inspection of the operating and non-operating APU, and an inspection of the PC monitor for APU faults. The APU fault isolation test procedures are limited to electronic control unit (ECU) power-up (Ref. B.), starting (Ref. C.), operating and shutdown (Ref. D.) of the APU. For faults found on the PC monitor, find the corresponding maintenance message in the Fault Isolation Manual (Ref. SUBTASK49-20-00-810-007) and follow the corrective procedures. Table 1003 and Table 1004 for corrective procedures. For all other faults use Table 1005 through Table 1013. The fault isolation tables are as follows: Table 1003

APU Fault Detected Isolation

Table 1004

APU Auto-shutdown Isolation

Table 1005

Fluid Leak Isolation

Table 1006

Fumes in APU Bleed Air Isolation

Table 1007

High Oil Consumption Isolation

Table 1008

High Vibration Isolation

Table 1009

Inability to Load Isolation

Table 1010

Load Compressor Surge Isolation

Table 1011

Poor Load Compressor Performance Isolation

Table 1012

Starting Problems Isolation

Table 1013

Unusual Noise Isolation

The fault isolation tables identify the test, trouble, probable cause and the correction. The probable causes are shown in order of decreasing probability. The trouble column shows the APU fault shown on the PC monitor. The BITE Maintenance Messages are given in SUBTASK49-20-00-810-007.

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Table 1003. APU Fault Detected Isolation TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

ECU POWER-UP, APU START, APU OPERATION, OR APU SHUTDOWN

APU FAULT DETECTED

MANY

DO THE APU BITE CHECK PROCEDURE. (Ref. SUBTASK49-20-00-810-007)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table 1004. APU Auto-shutdown Isolation TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

ECU POWER-UP, APU START, APU OPERATION, OR APU SHUTDOWN

AUTO SHUTDOWN

APU/ECU

DO THE APU BITE CHECK PROCEDURES. (Ref. SUBTASK49-20-00-810-007)

NO FUEL

EXAMINE FUEL SUPPLY.

APU

EXAMINE APU FOR ROTATION. DO MAGNETIC CHIP COLLECTOR ISOLATION PROCEDURE.

WIRING

REPAIR/REPLACE WIRING.

Table 1005. Fluid Leak Isolation TEST

TROUBLE

PROBABLE CAUSE

EXTERNAL LEAK CHECK

EXTERNAL FLUID LEAKAGE DAMAGED REPAIR/REPLACE COMPONENTS, TUBES AND TIGHTEN FITTINGS AS COMPONENTS, NECESSARY. TUBES, PACKINGS OR LOOSE FITTINGS.

DRAIN MAST LEAK CHECK

OIL LEAKAGE FROM FUEL CONTROL UNIT, SURGE CONTROL VALVE AND INLET GUIDE VANE (IV) ACTUATOR

FUEL CONTROL UNIT EXAMINE FUEL CONTROL UNIT WITNESS DRAIN. IF OIL IS FOUND, REPLACE FUEL CONTROL UNIT.

FUEL LEAKAGE FROM FUEL INLET GUIDE VANE CONTROL UNIT, SURGE (IGV) ACTUATOR CONTROL VALVE AND INLET GUIDE VANE (IGV) ACTUATOR

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SURGE CONTROL VALVE

EFFECTIVITY ALL

CORRECTION

EXAMINE INLET GUIDE VANE (IGV) ACTUATOR WITNESS DRAIN. IF FUEL IS FOUND, OPEN DRAIN THEN START AND OPERATE THE APU. IF LEAKAGE IS MORE THAN 1/3 cm³ PER HOUR, REPLACE THE INLET GUIDE VANE (IGV) ACTUATOR. EXAMINE SURGE CONTROL VALVE WITNESS DRAIN. IF FUEL IS FOUND, OPEN DRAIN THEN START AND OPERATE THE APU. IF LEAKAGE IS MORE THAN 1/3 cm³ PER HOUR, REPLACE THE SURGE CONTROL VALVE.

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ENGINE MANUAL 131-9[B] Table 1005. Fluid Leak Isolation (Cont) TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

FUEL CONTROL UNIT EXAMINE FUEL CONTROL UNIT WITNESS DRAIN. IF FUEL IS FOUND, OPEN DRAIN THEN START AND OPERATE THE APU. IF LEAKAGE IS MORE THAN 1/3 cm³ PER HOUR, REPLACE THE FUEL CONTROL UNIT. BEARING CAVITY DRAIN OIL LEAKAGE

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BLEED AIR DISCHARGE DUCT INSPECTION

EFFECTIVITY ALL

DAMAGED BEARING EXAMINE BEARING WITNESS SHAFT SEAL DRAIN TO FIND THE DAMAGED SEAL AND DO THE MAGNETIC CHIP COLLECTOR FAULT ISOLATION PROCEDURE. IF OIL LEAKAGE IS MORE THAN 10 DROPS PER HOUR, REMOVE THE APU FOR DISASSEMBLY AND INSPECTION.

COMBUSTOR PLENUM COMBUSTOR DRAIN FUEL LEAKAGE PLENUM DRAIN DURING A SHUTDOWN OR UNSATISFACTORY START

REPLACE THE COMBUSTOR DRAIN VALVE.

EDUCTOR/EDUCTOR ADAPTER DRAIN OIL LEAKAGE

GEARBOX AIR/OIL SEPARATOR

MOVE APU EXHAUST DUCT AFT. EXAMINE THE GEARBOX VENT LINE FOR OIL. IF OIL IS FOUND, LOOK AT THE GEARBOX OIL LEVEL. IF OIL LEVEL IS CORRECT, REMOVE APU FOR REPLACEMENT OF GEARBOX AIR/OIL SEPARATOR.

AIR/OIL COOLER

MOVE APU EXHAUST DUCT AFT. EXAMINE THE EDUCTOR HOUSING FOR OIL AROUND AIR/OIL COOLER. IF OIL IS FOUND, REPLACE THE AIR/OIL COOLER.

DAMAGED TURBINE BEARING SUMP SEAL

DO THE MAGNETIC CHIP COLLECTOR FAULT ISOLATION PROCEDURE. IF LEAKAGE IS MORE THAN 10 DROPS PER HOUR, REMOVE THE APU FOR DISASSEMBLY AND INSPECTION.

OIL IN BLEED AIR DISCHARGE

OPENING BETWEEN REMOVE APU FOR DISASSEMBLY LOAD COMPRESSOR AND INSPECTION. AND GEARBOX

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ENGINE MANUAL 131-9[B] Table 1006. Fumes in APU Bleed Air Isolation TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

APU OPERATION

FUMES IN APU BLEED AIR

FLUID ENTERED APU EXAMINE INLET FOR FLUIDS. INLET CLEAN INLET. APU FLUIDS (OIL) IN REMOVE APU FOR DISASSEMBLY INLET AND INSPECTION. UNWANTED MATERIAL IN INLET

REMOVE UNWANTED MATERIAL FROM INLET.

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Table 1007. High Oil Consumption Isolation TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

EXTERNAL LEAK CHECK

EXTERNAL OIL LEAKAGE

DAMAGED COMPONENTS, TUBES, PACKINGS OR LOOSE FITTINGS

REPLACE DAMAGED COMPONENTS. REPAIR TUBES, REPLACE PACKINGS, OR TIGHTEN FITTINGS AS NECESSARY.

DRAIN MAST LEAK CHECK

OIL LEAKAGE FROM FUEL CONTROL UNIT, SURGE CONTROL VALVE AND INLET GUIDE VANE (IGV) ACTUATOR

FUEL CONTROL UNIT

REPLACE FUEL CONTROL UNIT.

COMPRESSOR BEARING CAVITY DRAIN OIL LEAKAGE

DAMAGED BEARING DO THE MAGNETIC CHIP SHAFT SEAL COLLECTOR FAULT ISOLATION PROCEDURE. IF OIL LEAKAGE IS MORE THAN 10 DROPS PER HOUR, REMOVE THE APU FOR DISASSEMBLY AND INSPECTION.

EDUCTOR/EDUCTOR ADAPTER DRAIN OIL LEAKAGE

GEARBOX OVER SERVICE GEARBOX TO THE SERVICED WITH OIL CORRECT OIL LEVEL.

EFFECTIVITY ALL

GEARBOX AIR/OIL SEPARATOR

MOVE APU EXHAUST DUCT AFT. EXAMINE THE GEARBOX VENT LINE FOR OIL. IF OIL IS FOUND, REMOVE APU FOR REPLACEMENT OF GEARBOX AIR/OIL SEPARATOR.

AIR/OIL COOLER

MOVE APU EXHAUST DUCT AFT. EXAMINE THE EDUCTOR HOUSING FOR OIL AROUND AIR/OIL COOLER. IF OIL IS FOUND, REPLACE THE AIR/ OIL COOLER.

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ENGINE MANUAL 131-9[B] Table 1007. High Oil Consumption Isolation (Cont) TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

DAMAGED TURBINE DO THE MAGNETIC CHIP BEARING SUMP COLLECTOR FAULT ISOLATION SEAL PROCEDURE. IF LEAKAGE IS MORE THAN 10 DROPS PER HOUR, REMOVE THE APU FOR DISASSEMBLY AND INSPECTION. BLEED AIR DISCHARGE DUCT INSPECTION

OIL IN DISCHARGE BLEED AIR

OIL LEAKAGE REMOVE APU FOR DISASSEMBLY BETWEEN GEARBOX AND INSPECTION. AND LOAD COMPRESSOR

Table 1008. High Vibration Isolation TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

ECU POWER-UP, APU START, APU OPERATION, OR APU SHUTDOWN

APU FAULT FOUND

MANY

DO THE APU BITE CHECK PROCEDURES.

APU START, APU OPERATION, OR APU SHUTDOWN

HIGH VIBRATION

UNWANTED MATERIAL IN INLET

EXAMINE INLET FOR UNWANTED MATERIAL.

INSTALLATION

EXAMINE/REPAIR/REPLACE INSTALLATION EQUIPMENT (MOUNTS, VIBRATION ISOLATORS, WIRING ETC.)

GENERATOR

DO THE MAGNETIC CHIP COLLECTOR FAULT ISOLATION PROCEDURE. REPLACE GENERATOR.

APU

DO THE MAGNETIC CHIP COLLECTOR FAULT ISOLATION PROCEDURE.

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EXAMINE/BORESCOPE APU FOR DAMAGE. REMOVE APU FOR DISASSEMBLY IF NECESSARY.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table 1009. Inability to Load Isolation TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

ECU POWER-UP, APU START, APU OPERATION, OR APU SHUTDOWN

APU FAULT FOUND

APU/ECU

DO THE APU BITE CHECK PROCEDURES.

APU OPERATION

INABILITY TO LOAD APU

INLET BLOCKAGE

EXAMINE INLET FOR BLOCKAGE AND REMOVE AS NECESSARY.

APU INTERNAL COMPONENTS

DO THE MAGNETIC CHIP COLLECTOR FAULT ISOLATION PROCEDURE.

GENERATOR CONTROL UNIT

RESET/REPLACE GENERATOR CONTROL UNIT.

GENERATOR

REPLACE GENERATOR.

INABILITY TO LOAD APU - ELECTRICAL

INSTALLATION WIRING EXAMINE/REPAIR INSTALLATION WIRING/HOOKUP.

INABILITY TO LOAD APU - PNEUMATIC

FUEL CONTROL UNIT

REPLACE FUEL CONTROL UNIT.

APU WIRE HARNESS

REPAIR/REPLACE APU WIRE HARNESS.

BLEED DUCT BLOCKAGE

EXAMINE BLEED AIR DUCT FOR ANY BLOCKAGE, UNWANTED MATERIAL, AND POSSIBLE CLOSED VALVES.

INSTALLATION WIRING EXAMINE/REPAIR INSTALLATION WIRING/HOOKUP. FUEL CONTROL UNIT

REPLACE FUEL CONTROL UNIT.

IGV POSITION CUTBACK BECAUSE OF HIGH EXHAUST GAS TEMPERATURE (EGT)

EXAMINE EXHAUST GAS TEMPERATURE (EGT) FOR OPERATING CONDITIONS. IF HIGH, EXAMINE EGT PROBES FOR FAILURE. IF PROBES OK, REMOVE APU FOR DISASSEMBLY AND INSPECTION AS NECESSARY.

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Table 1010. Load Compressor Surge Isolation TEST

TROUBLE

APU START, APU OPERATION, OR APU SHUTDOWN

LOAD COMPRESSOR APU FAULT SURGE

EFFECTIVITY ALL

PROBABLE CAUSE

CORRECTION DO THE APU BITE CHECK PROCEDURES. EXAMINE/ BORESCOPE APU FOR DAMAGE. IF DAMAGE IS FOUND, REMOVE APU FOR DISASSEMBLY.

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ENGINE MANUAL 131-9[B] Table 1010. Load Compressor Surge Isolation (Cont) TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

BLEED DUCT BLOCKAGE

EXAMINE BLEED DUCT FOR ANY BLOCKAGE, UNWANTED MATERIAL AND POSSIBLE CLOSED VALVES. EXAMINE/BORESCOPE APU FOR DAMAGE. IF DAMAGE IS FOUND, REMOVE APU FOR DISASSEMBLY AND INSPECTION.

SURGE CONTROL VALVE

EXAMINE SURGE CONTROL VALVE HYDRAULIC LINES FOR BLOCKAGE. REPLACE LINES/REMOVE BLOCKAGE AS NECESSARY. EXAMINE/BORESCOPE APU FOR DAMAGE. IF DAMAGE IS FOUND, REMOVE APU FOR DISASSEMBLY. REPLACE SURGE CONTROL VALVE EXAMINE/BORESCOPE APU FOR DAMAGE. IF DAMAGE IS FOUND, REMOVE APU FOR DISASSEMBLY.

APU WIRE HARNESS

REPAIR/REPLACE APU WIRE HARNESS. EXAMINE/BORESCOPE APU FOR DAMAGE. IF DAMAGE IS FOUND, REMOVE APU FOR DISASSEMBLY.

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Table 1011. Poor Load Compressor Performance Isolation TEST

TROUBLE

PROBABLE CAUSE

APU OPERATION

LOW BLEED PRESSURE

TEST CELL DO TEST CELL FAULT ISOLATION COMPONENT FAILURE PROCEDURES.

EFFECTIVITY ALL

CORRECTION

APU COMPONENT FAILURE

DO THE APU BITE CHECK PROCEDURES.

INLET BLOCKAGE

EXAMINE INLET FOR BLOCKAGE. REMOVE AS NECESSARY.

INCORRECT IGV POSITION

MANUALLY EXAMINE THAT IGVs ARE ADJUSTED CORRECTLY IN THE CLOSED POSITION. ADJUST AS NECESSARY.

IGV POSITION CUTBACK BECAUSE OF HIGH EXHAUST GAS TEMPERATURE (EGT)

EXAMINE EXHAUST GAS TEMPERATURE (EGT) FOR OPERATING CONDITIONS. IF HIGH, EXAMINE EGT PROBES FOR FAILURE. IF PROBES OK, REMOVE APU FOR DISASSEMBLY AND INSPECTION AS NECESSARY.

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ENGINE MANUAL 131-9[B] Table 1011. Poor Load Compressor Performance Isolation (Cont) TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

WIRING

EXAMINE/REPAIR APU WIRE HARNESS.

FLUCTUATING DUCT TEST CELL DO TEST CELL FAULT ISOLATION PRESSURE COMPONENT FAILURE PROCEDURES. APU COMPONENT FAILURE

DO THE APU BITE CHECK PROCEDURES.

Table 1012. Starting Problems Isolation TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

ECU POWER-UP, APU START, APU OPERATION, OR APU SHUTDOWN

APU FAULT FOUND

MANY

DO THE APU BITE CHECK PROCEDURES.

APU START

NO ACCELERATION

STARTING POWER SUPPLY

EXAMINE APU INSTALLATION AND HOOKUP. (PNEUMATIC SUPPLY, ELECTRIC OR BATTERY POWER)

INSTALLATION WIRING

EXAMINE INSTALLATION WIRING HOOKUP.

NO IGNITION

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HARD OR SLOW START

EFFECTIVITY ALL

DAMAGED IGNITER EXAMINE AND REPLACE IGNITER PLUGS OR IGNITION PLUGS AND/OR IGNITION LEADS. LEADS FUEL SUPPLY

EXAMINE FUEL SUPPLY AND TYPE TO APU.

INCORRECT OIL TYPE

EXAMINE OIL TYPE FOR OPERATING CONDITIONS. REPLACE AS NECESSARY.

STARTING POWER SUPPLY

EXAMINE APU INSTALLATION AND HOOKUP. (PNEUMATIC SUPPLY, ELECTRIC OR BATTERY POWER)

APU INLET BLOCKAGE

EXAMINE INLET FOR BLOCKAGE AND UNWANTED MATERIAL.

INSTALLATION WIRING

EXAMINE INSTALLATION WIRING HOOKUP.

FUEL SUPPLY

EXAMINE FUEL SUPPLY AND TYPE TO APU.

GEARBOX

DO MAGNETIC CHIP COLLECTOR FAULT ISOLATION PROCEDURE.

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ENGINE MANUAL 131-9[B] Table 1012. Starting Problems Isolation (Cont) TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

APU

DO MAGNETIC CHIP COLLECTOR FAULT ISOLATION PROCEDURE.

INLET PRESSURE SENSOR

DO THE APU BITE CHECK PROCEDURES.

Table 1013. Unusual Noise Isolation TEST

TROUBLE

PROBABLE CAUSE

CORRECTION

APU START, APU OPERATION, OR APU SHUTDOWN

LOUD WHISTLE WHEN ECS OR MES IS COMMANDED, OR WHEN THE APU GOES TO READY-TO-LOAD

LOAD COMPRESSOR DE-WHISTLERS NOT INSTALLED OR DAMAGED

EXAMINE INLET GUIDE VANES FOR DE-WHISTLERS. REMOVE APU FOR DISASSEMBLY AND INSPECTION IF NECESSARY.

DAMAGE LOAD COMPRESSOR BLADES

EXAMINE LOAD COMPRESSOR IMPELLER FOR DAMAGE. REMOVE APU FOR DISASSEMBLY AND INSPECTION IF NECESSARY.

UNWANTED MATERIAL IN INLET

REMOVE UNWANTED MATERIAL FROM INLET. EXAMINE APU FOR DAMAGE. REMOVE APU FOR DISASSEMBLY AND INSPECTION IF NECESSARY.

LOUD WHISTLE OR DAMAGED POWER SCREECH DURING ALL SECTION FIRST MODES OF APU IMPELLER BLADES OPERATION.

EXAMINE FIRST COMPRESSOR IMPELLER FOR DAMAGED BLADES. REMOVE APU FOR DISASSEMBLY AND INSPECTION IF NECESSARY.

UNWANTED MATERIAL IN INLET

REMOVE UNWANTED MATERIAL FROM INLET. EXAMINE APU FOR DAMAGE. REMOVE APU FOR DISASSEMBLY AND INSPECTION IF NECESSARY.

SURGING, POPPING, OR BANGING NOISE

GRINDING, RUBBING, OR SCRAPING NOISE

LOAD COMPRESSOR DO LOAD COMPRESSOR SURGE SURGE FAULT ISOLATION PROCEDURES. POWER SECTION COMPRESSOR SURGE

REPLACE FUEL CONTROL UNIT. EXAMINE APU FOR DAMAGE. REMOVE APU FOR DISASSEMBLY AND INSPECTION IF NECESSARY.

APU

DO MAGNETIC CHIP COLLECTOR FAULT ISOLATION PROCEDURE.

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EXAMINE/BORESCOPE APU FOR DAMAGE. REMOVE APU FOR DISASSEMBLY AND INSPECTION.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] SUBTASK 49-20-00-810-002 B.

Electronic control unit (ECU) power-up. (Refer to Figure 1001.) (1)

Install the APU operating program into the PC monitor.

(2)

Set the Master on switch to ON.

(3)

Set the Run switch to RUN.

SUBTASK 49-20-00-810-003 C.

APU starting. (Refer to Figure 1001.) (1)

Set the Master on switch to ON.

(2)

Set the Run switch to RUN.

(3)

Push the Start switch momentarily.

SUBTASK 49-20-00-810-004 D.

APU shutdown. (Refer to Figure 1001.) (1)

Set the inlet guide vanes to the closed position with the PC monitor.

(2)

Remove the electrical load.

(3)

Set the Run switch to STOP.

SUBTASK 49-20-00-810-005 E.

Electronic control unit (ECU) BITE check.

UP552142

(1)

EFFECTIVITY ALL

Type "CONTROL B" on the PC monitor keyboard.

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ENGINE MANUAL 131-9[B] SUBTASK 49-20-00-810-006

UP552142

F.

EFFECTIVITY ALL

APU loading. (1)

Electrically load APU.

(2)

Set the inlet guide vanes to the correct open position with the PC monitor.

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ENGINE MANUAL 131-9[B]

Figure 1001. Test Cell APU Master Control Panel 5.

Fault Isolation Procedures MAINTENANCE MESSAGE: 49-11019 ( LOSS_OF_DC_POWER_COND ) A.

Description: The ECU sets a bit in the EEPROM indicating an orderly termination of the software's "control mode" whenever a stop switch is received or an auto-shutdown occurs. On every box power-up the bit is examined; if it is not set, then the previous run was terminated by a power loss, not by a stop switch or an auto-shutdown. Power losses of less than 50 ms will not cause shutdown (though they can cause blowout and re-light). When the ECU powers up, it first examines if the RAM is valid. If so, the power interruption must have been short, and the control software execution is picked up where it left off. Longer power interrupts where the RAM is lost will trigger this fault. If the fault is triggered, and the speed is greater than 7%, the fault lamp will illuminate in addition to the fault being stored. If the speed is less than 7% at the time of detection, the fault lamp will not illuminate, and cycling the APU on/off switch is not necessary to permit normal operation.

B.

Fault isolation procedure. (1)

Examine test cell wiring. (a)

(2)

Replace APU Electronic Control Unit (ECU). (AMM Task)

UP552142

(a)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B]

UP552142

(3)

EFFECTIVITY ALL

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-11021 ( FIRE_COCKPIT_HANDLE_COND ) A.

Description: The APU fire switch, on the engine and APU fire control panel was pulled. The Electronic Control Unit receives or has received this input from the APU fire switch. The APU fire switch, is also referred to as the fire handle.

B.

Fault isolation procedure. (1)

(2)

Reset the following. (AMM TASK) -

fire cockpit handle

-

remote handle

-

fire detection system

Examine test cell wiring. (a)

(3)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-11023 ( FIRE_REMOTE_HANDLE_COND ) A.

Description: The APU remote fire switch, on the remote APU control panel, was pulled. The Electronic Control Unit receives or has received this input from the APU remote fire switch. The APU remote fire switch is also referred to as the remote fire handle.

B.

Fault isolation procedure. (1)

Reset the cockpit fire handle to the stowed position.

(2)

Examine test cell wiring. (a)

(3)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-11024 ( FIRE_DETECTION_SYS_COND ) A.

Description: The engine and APU fire detection module, senses a fire problem in the APU compartment. The Electronic Control Unit receives or has received this input from the engine and APU fire detection module.

B.

Fault isolation procedure. (1)

Do an operational examination of the APU fire detection system.

(2)

Examine test cell wiring. (a)

(3)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-15003 ( DOOR_CLOSED_AFTER_OPENING_COND ) A.

Description: If the door open switch transitions from "open" to "not fully open" after the APU speed has become greater than 7%, the shutdown will occur.

B.

Fault isolation procedure. (1)

(2)

(3)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Evaluate the air inlet door position switch and inlet door actuator. (a)

Rig/replace inlet door switch. (AMM Task)

(b)

Rig/replace inlet door actuator. (AMM Task)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-15004 ( DOOR_FAILED_TO_OPEN_COND ) A.

Description: If the door switch (which is read only by the ECU) does not read open within 30 seconds after being commanded to open, the shutdown must occur.

B.

Fault isolation procedure. (1)

(2)

(3)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Evaluate the air inlet door position switch and inlet door actuator. (a)

Rig/replace inlet door switch. (AMM Task)

(b)

Rig/replace inlet door actuator. (AMM Task)

Examine test cell wiring. (a)

(4)

Replace the inlet door actuator. (AMM Task) (a)

(5)

UP552142

ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

EFFECTIVITY

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

(6)

Evaluate APU fuel shutoff valve. (BOEING)

(7)

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-21015 ( OVERTEMPERATURE_ONSPEED_COND ) A.

Description: This shutdown is active during onspeed and essential modes only and occurs if the calculated turbine inlet temperature (T4) is greater than the 2200°F (1204°C) shutdown limit for one second. T4 is calculated from the higher of the two EGT signals. The open-loop IGV schedules normally keep the T4 below 2050°F (1121°C). The second level of defense against high T4 is the T4 trim control loop, which trims back the IGVs to limit T4 to the 2050°F (1121°C) set-point. The third defense is the T4 bleed shutoff function, which latches the IGVs closed if the calculated T4 is greater than 2060°F (1126°C) for 15 seconds, 2130°F (1165°C) for six seconds, or 2160°F (1183°C) for one second. The last defense, if closing the IGVs does not lower the EGT to within limits, is this auto-shutdown, which occurs in non-essential mode if T4 is greater than 2200°F (1204°C) for one second.

B.

Fault isolation procedure. (1)

(2)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Examine for APU internal damage (a)

Inspect Magnetic Chip Collector. (AMM Task) NOTE:

(b) (3)

Examine APU inlet plenum for blockage. (AMM TASK)

(6)

Replace the EGT1 thermocouple. (AMM Task)

(7)

(8)

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

(10)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(9)

Do the repair confirmation at the end of this task.

Replace the EGT2 thermocouple. (AMM Task) (a)

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

UP552142

Do the repair confirmation at the end of this task.

(5)

(a)

ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

EFFECTIVITY

Make sure that the APU rotates freely. (AMM Task)

Examine IGV linkage. (AMM Task) (a)

(4)

If collector is OK, continue without starting APU.

Start APU, apply electrical load and bleed air. (AMM Task)

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UP552142

ENGINE MANUAL 131-9[B]

EFFECTIVITY ALL

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-21235 ( BLEED_SHUTOFF_T4_HIGH ) A.

Description: If the calculated T4 reaches a certain value, bleed air is disabled to protect the APU and permit generator load.

B.

Fault isolation procedure. (1)

Look at CDU for the following associated faults. -

49-52190 (IGV_POS_VS_CMD_NEG).

-

49-61185 (IGV_SHORTED_DRIVER).

(a)

Follow applicable FIM task.

(b)

Do the repair confirmation at the end of this task.

(2)

Examine APU inlet plenum for blockage. (AMM TASK)

(3)

Examine IGV linkage. (AMM Task) (a)

(4)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(5)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace T2 sensor. (AMM Task) (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU, apply electrical load and bleed air.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Examine CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31001 ( APU_FUEL_VALVE_NOT_CLOSED_COND ) A.

Description: This test determines whether the APU fuel valve on the airplane has closed. The monitored time is just short of the time to log the inlet door not closed fault to prevent the logging of that fault, since this one will log first. If the APU fuel valve does not close within the monitor time, door driver faults can be associated with this shutdown. The faults that can be associated are listed in the associated faults column below.

B.

Fault isolation procedure. (1)

(2)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(3)

Examine APU fuel shutoff valve. (BOEING)

(4)

Replace APU Electronic Control Unit (ECU). (AMM Task)

UP552142

(a)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

(5)

Replace APU fuel shutoff valve. (AMM Task).

(6)

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31014 ( OVERSPEED_COND ) A.

Description: The APU primary overspeed protection is handled by redundant ECU hardware overspeed circuits with each circuit reading a different monopole and commanding the solenoid and the torque motor. The hardware circuits trip based on the difference in speed when the speed exceeds the 106% limit. The hardware circuits handle the shutdown independent of the software; the software monitors the bits "HARDWARE_OS_1" and "HARDWARE_OS_2" , which indicate that the hardware has shut down the engine. The software overspeed trip point is also 106%. On a real overspeed, either channel of hardware or software can trip first.

B.

Fault isolation procedure. (1)

(2)

(3)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Examine for APU inlet for flammable contaminants. (a)

(4)

Replace the Fuel Control Unit. (AMM Task) (a)

(5)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace the speed sensor. (AMM Task) (a)

(7)

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU, apply electrical load and bleed air. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31016 ( OVERTEMPERATURE_START_COND ) A.

Description: This shutdown is active during startup only and occurs if T5 exceeds the calculated fuel flow cut-back temperature setpoint (which is based on speed, T2, and P2) by more than 125°F (52°C) for two seconds.

B.

Fault isolation procedure. (1)

(2)

(3)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Inspect the APU inlet. (a)

Examine the APU inlet duct through the inlet door for sign of obstruction or flammable materials.

(b)

Remove the access panel on the APU plenum.

(c)

Examine the APU inlet plenum for sign of obstruction or flammable materials.

(d)

Do the repair confirmation at the end of this task.

Examine for APU internal damage. (a)

Inspect Magnetic Chip Collector. (AMM Task) NOTE:

(b)

(4)

(a)

(a)

UP552142

ALL

2

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

The APU can have a normal start on the ground and fail a start in the air if the proper ambient corrections are not made. Do the repair confirmation at the end of this task.

The APU can have a normal start on the ground and fail a start in the air if the proper ambient corrections are not made. Do the repair confirmation at the end of this task.

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

EFFECTIVITY

Replace APU.

Replace P2 sensor. (AMM Task) NOTE:

(7)

1

Replace T2 sensor. (AMM Task) NOTE:

(6)

Make sure that the APU rotates freely. (AMM Task)

Replace the Fuel Control Unit. (AMM Task) (a)

(5)

If collector is OK, continue without starting APU.

Do repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (8)

Replace APU Start Power Unit (SPU). (AMM Task) (a)

(9)

Replace the EGT1 thermocouple. (AMM Task) (a)

(10)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

(13)

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(12)

Do the repair confirmation at the end of this task.

Replace the EGT2 thermocouple. (AMM Task) (a)

(11)

Do repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31018 ( UNDERSPEED_COND ) A.

Description: This shutdown is meant to provide an orderly shutoff of fuel if the APU shuts down or drops in speed while the on-speed governor is working. If the speed drops below 85% and is still decreasing for 10 seconds, the shutdown occurs (the condition of speed less than the set-point is included so that the shutdown won't occur if the speed set-point is decreased for performance testing). The speed governor holds the APU speed between 98% and 102% during any application or removal of electrical load up to the full generator rating.

B.

Fault isolation procedure. (1)

(2)

(3)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

(5)

Do a general visual inspection of the APU fuel system. (a)

Correct any problems found.

(b)

Do the repair confirmation at the end of this task.

Examine airplane fuel system. (BOEING) (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Examine for APU internal damage. (a)

Inspect Magnetic Chip Collector. (AMM Task) NOTE:

(b) (7)

(8)

UP552142

ALL

Make sure that the APU rotates freely. (AMM Task)

Inspect the APU inlet. (a)

Examine the APU inlet duct through the inlet door for sign of obstruction or flammable materials.

(b)

Remove the access panel on the APU plenum.

(c)

Examine the APU inlet plenum for sign of obstruction or flammable materials.

(d)

Do the repair confirmation at the end of this task.

Replace the Fuel Control Unit. (AMM Task) (a)

EFFECTIVITY

If collector is OK, continue without starting APU.

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (9)

Replace P2 sensor. (AMM Task) (a)

(10)

Replace T2 sensor. (AMM Task) (a)

(11)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

(12)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31159 ( WF_RESOLVER_EXC_HI_GROUNDED ) A.

Description: An ac excitation voltage is continuously applied to the resolver. The excitation circuit furnishes a BITE voltage and a voltage related to current to the software. If the voltage is low and the current is not present then the high side is shorted to ground or the driver is open. In normal operation the voltage reads 1.0 to 1.8 V, including temperature and component variations, providing good margin from nuisance trips. The position signal is invalid if this fault occurs.

B.

Fault isolation procedure. (1)

(2)

Examine APU wiring harness. (a)

Replace APU wiring harness if necessary.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Disconnect electrical connector P22 at APU/FCU interface.

2

Test continuity as follows: Connector Number: P22 Test across LRU pins: 1 to 2 Necessary value: >100K ohms

(c)

3

Replace the FCU.

4

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 13 to 26

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(3)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic control Box (ECB). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31160 ( WF_RESOLVER_EXC_OPEN ) A.

Description: An ac excitation voltage is continuously applied to the resolver. The excitation circuit furnishes a BITE voltage and a voltage related to current to the software. If the voltage bit is high and the current is not present then the resolver has opened. In normal operation the voltage reads 1.0 to 1.8 V, including temperature and component variations, providing good margin from nuisance trips. The position signal is invalid if this fault occurs.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU resolver continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 3 Necessary value: <200 ohms

(c)

2

Replace the FCU.

3

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 12 to 26 Necessary value: <200 ohms

UP552142

3

EFFECTIVITY ALL

Replace wire harness.

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ENGINE MANUAL 131-9[B] 4 (3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31161 ( WF_RESOLVER_EXC_SHORT ) A.

Description: An ac excitation voltage is continuously applied to the resolver. The excitation circuit furnishes a BITE voltage and a voltage related to current to the software. If the voltage bit is low and the current is present then the resolver driver circuit has a short. The position signal is invalid if this fault occurs.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU resolver continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 3 Necessary value: >30 ohms

2

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 1 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P22 Test across LRU pins: 3 to 1

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

4

Replace the FCU.

5

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (c)

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 12 to 26 Necessary value: >30 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 12 to 13 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 26 to 13 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

5

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31162 ( WF_RESOLVER_FCU ) A.

Description: An ac excitation voltage is continuously applied to the resolver. The excitation circuit furnishes a BITE voltage and a voltage related to current to the software. If the voltage bit is normal with the driver energized and the current is not present then the low side of the resolver circuit is shorted. The position signal is invalid if this fault occurs.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU resolver continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 3 to 1 Necessary value: >100K ohms

(c)

2

Replace the FCU.

3

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 12 to 13

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31163 ( FUEL_SOL_FAILED_ON ) A.

Description: This test is run on every normal shutdown (commanded by stop switch) at the end of onspeed mode, while the normal speed control is working After the overspeed circuit is tested, by setting the test frequency to zero, engine speed is monitored for proper rolldown as a result of the fuel solenoid hardware clamp (fuel solenoid valve commanded closed). If after 10.0 seconds the APU speed has not fallen 10%, the fault is set and the shutdown sequence continues by clamping the fuel torque motor to 0 ma. This fault can only be tested on shutdown. If detected, the fault stays TRUE until the test can be run again on the next shutdown. The occurrence of this fault will not permit the APU To start. If powered from the CDU, the APU can be started to make sure corrective procedure.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Replace the Fuel Control Unit. (a)

(3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU.

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31164 ( FUEL_SOL_OPEN ) A.

Description: The fuel solenoid driver circuit furnishes a bit voltage to the software that is an indication of the current flowing through the fuel solenoid circuit. Under normal conditions, the current flow will be 700 ma if the solenoid is open, the current flow is less than 0.1 ma. An open circuit condition causes no fuel flow to the APU and a speed droop, no flame, or no acceleration auto-shutdown that results from this fault this fault will be associated with the appropriate auto-shutdown.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 8 to 9 Necessary value: <80 ohms

(c)

2

Replace the FCU.

3

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 27 to 42 Necessary value: <80 ohms

UP552142

3

EFFECTIVITY ALL

Replace wire harness.

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ENGINE MANUAL 131-9[B] 4 (3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31165 A.

Description:

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do FCU continuity/resistance examination. 1

Check continuity as follows: Connector Number: P22 Test across LRU pins: 4 to 5 Specified value: <200 ohms

(c)

2

Replace the FCU. (AMM Task)

3

Do the repair confirmation at the end of this task.

Examine FCU continuity at APU/firewall interface. 1

Disconnect connector P2 at APU/firewall interface.

2

Check continuity as follows: Connector Number: P2/D10436 Test across pins: 28 to 29 Specified value: <200 ohms

UP552142

(3)

EFFECTIVITY ALL

3

Replace wire harness. (AMM Task)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31166 ( FUEL_SOL_SHORT ) A.

Description: The fuel solenoid driver circuitry supplies a signal that shows the current flow of the driver. If the current signal shows > 0.9 A, the driver is turned off. The highest expected current with no failures is approximately 0.9 A (including component tolerance, solenoid temp. variation, and box power supply variation). Overcurrent to fuel solenoid can be detected while solenoid is turned on. An actual short will probably cause the solenoid to close, shutting off fuel to the APU, which will lead to an UNDERSPEED , No Flame, or No Acceleration auto-shutdown. If an overcurrent is found, the driver must be turned off immediately. After one second, the driver will be enabled.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU resolver continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 8 to 9 Necessary value: >10 ohms

2

Test continuity as follows: Connector Number: P22 Test across LRU pins: 8 to 1 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P22 Test across LRU pins: 9 to 1

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(c)

4

Replace the FCU.

5

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 27 to 42 Necessary value: >10 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 27 to 13 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 42 to 13 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

5

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31167 ( FUEL_TEMP_GND_SHORT ) A.

Description: The RTD conditioner circuit supplies a bit voltage to the software, which shows the voltage at the positive side of the RTD. If this signal is less than the limit, the fault is tripped The normal operating range is 2.53 ±0.18 VDC. The value of the bit voltage with a short to ground at the RTD is 0.5 VDC maximum.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 1 to 4 Necessary value: >100K ohms

2

Test continuity as follows: Connector Number: P22 Test across LRU pins: 1 to 5 Necessary value: >100K ohms

(c)

3

Replace the FCU.

4

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436

UP552142

Test across pins: 13 to 28 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: >100K ohms 3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 13 to 29 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31168 ( FUEL_TEMP_HIGH ) A.

Description: Because an open circuit is an infinite resistance, it looks like an infinite temperature. The highest possible temperature in operation is approximately 325°F (163°C). Conditioner circuit range is -107 to 548°F (-77 to 286°C) setting the BITE limit at 500°F (260°C) is low enough to make sure that the conditioner can always read the BITE limit without saturating.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 4 to 5 Necessary value: <200 ohms

(c)

2

Replace the FCU.

3

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 28 to 29

UP552142

Necessary value: <200 ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31169 ( FUEL_TEMP_LOW ) A.

Description: The near zero resistance of a short circuit looks like a very low temperature. Lowest possible temperature in operation is approximately -65°F (-54°C). Conditioner circuit range is -107 to 548°F (-77 to 286°C). The bite limit set at -100°F (-73°C) makes sure the conditioner can always read limit without saturating and supplies good margin (17°F (-8.3°C)) to prevent nuisance indications (precision is better than ±12°F (±6.6°C). A two-second make sure time permits this fault to be included in the power-up test sequence and is longer than needed to filter out electrical noise.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 4 to 5 Necessary value: >72 ohms

(c)

2

Replace the FCU.

3

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 28 to 29

UP552142

Necessary value: >72 ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31170 ( FTM_DRIVENSIDE_GROUNDED ) A.

Description: The test determines the value of the voltage and current BIT signals. A low voltage value and a low current value causes the fault to log and shows the driven side of the torque motor is grounded. The torque motor driver side grounded failure will cause no fuel flow to the APU and a no flame, no acceleration or underspeed shutdown.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 1 to 7 Necessary value: >100K ohms

(c)

2

Replace the FCU.

3

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 3 to 13 Necessary value: >100K ohms

(d)

Replace wire harness.

UP552142

1

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31171 ( FUEL_FLOW_VS_CMD ) A.

Description: The fault is detectable when fuel pump speed is high enough to make sure reliable fuel flow feedback (n> 7% will suffice; n> 20% in logic supplies margin). The fault is true when the actual fuel flow differs from the commanded fuel flow by 40 lb/hr (18 Kg/hr) for five sec. The control loop has an integral term that brings the error to zero, with a settling time of less than 0.5 second, to provide a substantial margin for nuisance indications. The make sure time is set shorter for this loop because a stuck metering valve can cause a speed droop or overspeed auto-shutdown, and it is desirable to have this fault occur before the shutdown for troubleshooting. This fault is inhibited by resolver position sensing faults or torque motor driver faults to prevent multiple fault messages.

B.

Fault isolation procedure. (1)

Replace the Fuel Control Unit. (a)

(2)

Examine test cell fuel system. (a)

(3)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Evaluate the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do FCU continuity/resistance check. 1

Check continuity as follows: Connector Number: P22 Test across LRU pins: 6 to 7 Specified value: <100 ohms

(c)

2

Replace the FCU. (AMM Task)

3

Do the repair confirmation at the end of this task.

Examine FCU continuity at APU/firewall interface. 1

Disconnect connector P2 at APU/firewall interface.

2

Check continuity as follows:

UP552142

Connector Number: P2/D10436 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across pins: 3 to 24 Specified value: <100 ohms

(4)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(6)

Replace wire harness. (AMM Task)

Replace APU Electronic Control Unit (ECU). (a)

(5)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31172 ( FUEL_TM_OPEN ) A.

Description: For this test, the fuel torque motor is commanded to 125 ma. The ECU measures both the torque motor drive current and the voltage across the torque motor load. If the current is low and the voltage is high, then the torque motor is failed open. An open torque motor will stop fuel flow to APU that results in a no flame, no acceleration, or underspeed auto-shutdown.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 6 to 7 Necessary value: <100 ohms

(c)

2

Replace the FCU.

3

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 3 to 24

UP552142

Necessary value: <100 ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31173 ( FUEL_TM_SHORT ) A.

Description: For this test, the fuel torque motor is commanded to 125 ma. The ECU measures both the torque motor drive current and the voltage across the torque motor load if the fuel torque motor voltage bits low and the current is normal, the torque motor failure is a short circuit. A short circuit will cause no fuel to APU and a speed droop, no flame, or no acceleration auto-shutdown.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 6 to 7 Necessary value: >20 ohms

(c)

2

Replace the FCU.

3

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 5 to 7

UP552142

Necessary value: >20 ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31175 ( WF_RESOLVER_SEC_BAD ) A.

Description: An ac excitation voltage is continuously applied to the resolver. The ac excitation is a trapezoidal wave form. The excitation circuitry supplies two voltages to the software which indicate the resolver sine and cosine values. Using the trigonometric identity that (sin²) + (cos²) = 1, the proper secondary operation can be evaluated. The equation is (K*A*sin) + (K*A*cos). The constant K for a sine wave is 0.492 ± 10% (from the fuel resolver specification). The constant K for the trapezoidal wave is 0.556 (based on Vrms calculations). The constant A is the amplitude of the excitation reference from ground (5V/2). At 0 degrees: The nominal value is (0.55*65/2) 2 = 1.932. The minimum "in range" value is (0.5*4.7/2) 2 = 1.380. The maximum "in range" value is (0.606*5.3/2) = 2.579. The position signal is invalid if this fault occurs.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the FCU electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a fuel control unit continuity/resistance test. 1

Test continuity as follows: Connector Number: P22 Test across LRU pins: 10 to 12 Necessary value: 30 to 200 ohms

2

Test continuity as follows: Connector Number: P22 Test across LRU pins: 11 to 12 Necessary value: 30 to 200 ohms

3

Test continuity as follows:

UP552142

Connector Number: P22

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across LRU pins: 10 to 1 Necessary value: >100K ohms 4

Test continuity as follows: Connector Number: P22 Test across LRU pins: 11 to 1 Necessary value: >100K ohms

(c)

5

Replace the FCU.

6

Do the repair confirmation at the end of this task.

Test fuel control unit continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across LRU pins: 25 to 4 Necessary value: 30 to 200 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across LRU pins: 11 to 4 Necessary value: 30 to 200 ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across LRU pins: 25 to 13 Necessary value: >100K ohms

5

Test continuity as follows: Connector Number: P2/D10436 Test across LRU pins: 11 to 13 Necessary value: >100K ohms

(3)

UP552142

ALL

7

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

EFFECTIVITY

Replace wire harness.

Examine test cell wiring. (a)

(4)

6

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (5)

Replace the Fuel Control Unit. (a)

UP552142

(6)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31294 ( FLOW_DIVIDER_SOL_ON_OC ) A.

Description: The ECU circuit supplies an overcurrent discrete bit, which shows the software must turnoff the driver. The highest expected current with no failures is 2.0 A (including aircraft component tolerance, temp variation, and aircraft power supply variation). The nominal overcurrent trip point is 4.0 Adc. The fault detects an overcurrent in the flow divider solenoid when the ECU driver is turned on. If this failure is detected, it is possible to have a no flame shutdown at altitude.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel flow divider solenoid. (a)

(b)

Examine the fuel flow divider solenoid electrical connector. 1

Disconnect electrical connector P23 from the fuel flow divider solenoid.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a fuel flow divider solenoid continuity/resistance test. 1

Test continuity as follows: Connector Number: P23 Test across LRU pins: 1 to 2 Necessary value: >10 ohms

2

Test continuity as follows: Connector Number: P23 Test across LRU pins: 1 to 3 Necessary value: >100K ohms

UP552142

(c)

EFFECTIVITY ALL

3

Replace the solenoid.

4

Do the repair confirmation at the end of this task.

Test fuel flow divider solenoid continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P3/10434 Test across pins: 25 to 26 Necessary value: >10 ohms 3

Test continuity as follows: Connector Number: P3/10434 Test across pins: 25 to 27 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-31295 ( FLOW_DIVIDER_SOL_OPEN ) A.

Description: The driver voltage BITE circuit supplies a voltage to the software that is a rescaled value of the voltage across the start relay output terminals (i.e., the voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is within 4.6 to 11.0 VDC, the fault is set. This test is performed while the driver is turned off. While the driver is turned off, the high side is normally pulled to less than 4.0 VDC by the start relay. If the circuit is open while the driver is off, the high side is pulled to greater than 4.6 VDC as measured by a resistor network. If this failure is detected, it is possible to have a no flame shutdown at altitude.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel flow divider solenoid. (a)

(b)

Examine the fuel flow divider solenoid electrical connector. 1

Disconnect electrical connector P23 from the fuel flow divider solenoid.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a fuel flow divider solenoid continuity/resistance test. 1

Test continuity as follows: Connector Number: P23 Test across LRU pins: 1 to 2 Necessary value: <80 ohms

(c)

2

Replace the solenoid.

3

Do the repair confirmation at the end of this task.

Test fuel flow divider solenoid continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P3/D10434

UP552142

Test across pins: 25 to 26

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: <80 ohms

(3)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41010 ( NO_ACCEL_COND ) A.

Description: This shutdown occurs when the APU acceleration drops to nearly zero or less for 12.5 seconds during a start if light-off occurred (failure to light-off is detected by the NO_FLAME shutdown). On normal starts the APU acceleration stays above 1%/s throughout the start. This shutdown aborts starts in order to limit the starter rotation time and battery consumption for any one start attempt.

B.

Fault isolation procedure. (1)

(2)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Examine airplane APU battery and electrical generation system. (BOEING) (a)

(3)

(4)

(5)

Inspect the APU inlet. (a)

Examine the APU inlet duct through the inlet door for sign of obstruction or flammable materials.

(b)

Remove the access panel on the APU plenum.

(c)

Examine the APU inlet plenum for sign of obstruction or flammable materials.

(d)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU fuel system. (a)

Correct any problems found.

(b)

Do the repair confirmation at the end of this task.

Replace the Fuel Control Unit. (AMM Task) (a)

(6)

(8)

(a)

Replace the APU. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Replace T2 sensor. (AMM Task)

UP552142

ALL

Do the repair confirmation at the end of this task.

Replace P2 sensor. (AMM Task) (a)

EFFECTIVITY

Do the repair confirmation at the end of this task.

Examine IGV actuator linkage and APU IGV assembly for binding or damage. (AMM Task)

(a) (9)

Do the repair confirmation at the end of this task.

Replace the Fuel Flow Divider. (AMM Task) (a)

(7)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (10)

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

(11)

Replace APU Start Power Unit (SPU). (AMM Task) (a)

(12)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

(17)

Do the repair confirmation at the end of this task.

Replace Starter/Generator. (AMM Task) (a)

(16)

Do the repair confirmation at the end of this task.

Replace the EGT2 thermocouple. (AMM Task) (a)

(15)

Do the repair confirmation at the end of this task.

Replace the EGT1 thermocouple. (AMM Task) (a)

(14)

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(13)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41011 ( NO_FLAME_COND ) A.

Description: This auto shutdown occurs when the fuel solenoid is commanded on (normally at 7% speed) and the flag "LITE_OFF" is not true for 20 seconds. The flag "LITE_OFF" is set when EGT increases by 300°F (149°C) at low altitude (500°F (260°C) at high altitude). On normal starts the APU lites off within a few seconds from the time the solenoid is turned on.

B.

Fault isolation procedure. (1)

(2)

(3)

(4)

(5)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Inspect the APU inlet. (a)

Examine the APU inlet duct through the inlet door for sign of obstruction or flammable materials.

(b)

Remove the access panel on the APU plenum.

(c)

Examine the APU inlet plenum for sign of obstruction or flammable materials.

(d)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU fuel system. (a)

Correct any problems found.

(b)

Do the repair confirmation at the end of this task.

Replace Ignition Plug. (AMM Task) (a)

(6)

Replace Ignition Plug Lead. (AMM Task) (a)

(7)

UP552142

ALL

Do the repair confirmation at the end of this task.

Evaluate the FCU. (a)

EFFECTIVITY

Do the repair confirmation at the end of this task.

Examine test cell fuel system. (BOEING) (a)

(9)

Do the repair confirmation at the end of this task.

Replace Ignition Unit. (AMM Task) (a)

(8)

Do the repair confirmation at the end of this task.

Remove the FCU. (AMM Task)

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ENGINE MANUAL 131-9[B] (b)

(c)

Evaluate the lube cluster. 1

Remove the end cap from the air/oil separator.

2

Use a socket and ratchet on the shaft for the starter generator to turn the APU.

3

Turn the socket counterclockwise, forward facing aft.

4

Make sure the lube cluster turns.

5

Replace the lube cluster.

6

Do the repair confirmation at the end of this task.

Replace the Fuel Control Unit. (AMM Task) 1

(10)

Replace P2 sensor. (AMM Task) NOTE: (a)

(11)

(a)

UP552142

EFFECTIVITY ALL

The APU can have a normal start on the ground and fail a start in the air if the proper ambient corrections are not made. Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

(14)

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(13)

The APU can have a normal start on the ground and fail a start in the air if the proper ambient corrections are not made.

Replace T2 sensor. (AMM Task) NOTE:

(12)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU, apply electrical load and bleed air. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41012 ( NO_SPEED_COND ) A.

Description: This shutdown occurs when the APU fails to reach 7% speed (which is when fuel and igniters are turned on) during a start. This shutdown is separated from the "normal" no acceleration shutdown because this shutdown means that the APU did not rotate when the starter was commanded on. This shutdown limits start time to minimize battery consumption for any one start attempt.

B.

Fault isolation procedure. (1)

(2)

(3)

Examine CDU fault history screen for any associated faults. (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Examine for APU internal damage. (a)

Inspect Magnetic Chip Collector. (AMM Task) NOTE:

(b)

(4)

UP552142

ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

EFFECTIVITY

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(9)

2

Examine airplane APU battery and electrical generation system. (BOEING) (a)

(8)

Replace APU.

Replace Starter/Generator. (AMM Task) (a)

(7)

1

Replace APU Start Power Unit (SPU). (AMM Task) (a)

(6)

Make sure that the APU rotates freely. (AMM Task)

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

(5)

If collector is OK, continue without starting APU.

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B]

UP552142

(10)

EFFECTIVITY ALL

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41180 ( IGNITER_ON_OC ) A.

Description: The ECU ignition unit drive circuitry furnishes an overcurrent discrete bit, which turns off the driver. If this bit is active, the ignition unit is turned off and the overcurrent shows true. The bit shows an overcurrent condition only when the driver is turned on. The highest expected current with no failures is about 8.0 A (including component tolerance, ignition unit temperature variation, and ECU power supply variation). The nominal overcurrent trip point is 12 A including tolerances, providing large margin from nuisance prevention. Detects overcurrent to ignition unit during starting. An actual short will probably prevent ignition and APU starting; a NO_FLAME auto-shutdown can occur. If an overcurrent is found, the driver will be turned off after one second, the driver will be enabled.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the ignition unit. (a)

(b)

Examine the ignition unit electrical connector. 1

Disconnect electrical connector P13 from the ignition unit

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do an ignition unit continuity/resistance test. 1

Disconnect electrical connector P13 from the ignition unit.

2

Test continuity as follows: Connector Number: P13 Test across LRU pins: A to B Necessary value: >10 ohms

3

Test continuity as follows: Connector Number: P13 Test across LRU pins: B to C

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

4

Replace the ignition unit.

5

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (c)

Test ignition unit continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P3/10434 Test across pins: 16 to 17 Necessary value: >10 ohms

3

Test continuity as follows: Connector Number: P3/10434 Test across pins: 6 to 17 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41181 ( IGNITER_OPEN ) A.

Description: The ignition unit voltage BITE circuit furnishes a BIT voltage to the software that is a rescaled value of the voltage across the ignition unit (i.e., the ignition unit voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is outside the valid range, the fault is set. This test is run while the driver is turned off. While the driver is off, the high side is normally pulled to 0 V by the low resistance of a correctly operating ignition unit. If the ignition unit is open, the high side is pulled to between 4 and 11.0 VDC by a resistor network. A real open can result in an unsuccessful start attempt; a NO_FLAME auto-shutdown can occur.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the ignition unit. (a)

(b)

Examine the ignition unit electrical connector. 1

Disconnect electrical connector P13 from the ignition unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do an ignition unit continuity/resistance test. 1

Disconnect electrical connector P13 from the ignition unit.

2

Test continuity as follows: Connector Number: P13 Test across LRU pins: A to B Necessary value: <80 ohms

(c)

3

Replace the ignition unit.

4

Do the repair confirmation at the end of this task.

Test ignition unit continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P3/D10434

UP552142

Test across pins: 16 to 17 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: <80 ohms

(3)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41244 ( GENERATOR_ROTATE_DIODE_SHORT ) A.

Description: The voltage regulator monitors the current output to the exciter field. A high ripple in the field current whenever there is a shorted rotating diode in the generator the voltage regulator detects the ripple and produces a discrete signal the voltage regulator sets a fail flag whenever there is a shorted rotating diode failure. This signal is sent to the supervisory control. The supervisory control sets the GEN_SRD flag whenever the shorted rotating diode fail flag is set. The start converter unit will latch the fault and abort the generate mode by disconnecting the PMG to the voltage regulator.

B.

Fault isolation procedure. (1)

Make an analysis of the Generator. (a)

(2)

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

UP552142

(3)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Apply electrical load to APU generator. (AMM Task)

(c)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41245 ( GENERATOR_UNDER_VOLTAGE ) A.

Description: The voltage regulator sets the generator fail flag and sends it to the supervisory control. The voltage regulator commands full output and there is an under voltage flag from the automatic generator control unit. The supervisory control sets the GEN_UV flag whenever the generator fail flag is set. The start converter unit will latch this fault. The start converter unit will wait for the automatic generator control unit to terminate the generate mode. When VR_ENABLE flag is deactivated, the voltage regulator will open the relay disconnecting PMG to the voltage regulator.

B.

Fault isolation procedure. (1)

(2)

Do an examination of the APU wiring harness. (a)

Replace wiring harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the Starter-Generator excitation circuit. (a)

(b)

Examine the Starter-Generator electrical connector. 1

Disconnect electrical connector P6 from the Starter-Generator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a Starter-Generator continuity/resistance test. 1

Disconnect electrical connector P6 from the Starter-Generator.

2

Test continuity as follows: Connector Number: P6 Test across LRU pins: 5 to 7 Necessary value: 2 to 10 ohms

3

Test continuity as follows: Connector Number: P6 Test across LRU pins: 5 to connector shell

UP552142

Necessary value: > 100K ohms

EFFECTIVITY ALL

4

Replace the ignition unit.

5

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (c)

Do a Starter-Generator at APU/Test Cell interface. 1

Disconnect electrical connector P4 from APU/Test Cell interface.

2

Test continuity as follows: Connector Number: P4/D11118 Test across pins: 6 to 8 Necessary value: 2 to 10 ohms

3

Test continuity as follows: Connector Number: P4/D11118 Test across pins: 6 to 19 Necessary value: >100K ohms

(3)

Replace the ignition unit.

5

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Evaluate the starter-generator terminals. (a)

(b)

Examine the starter-generator phase terminals. 1

Examine the terminal connections, fasteners, and insulators for contamination and damage.

2

Clean terminals.

3

Replace starter-generator.

4

Do the repair confirmation at the end of this task.

Do starter-generator terminal continuity/resistance check. 1

Check continuity as follows: Connector Number: TB1 Test across terminals: T1 to N Specified value: <5 ohms

2

Check continuity as follows: Connector Number: TB1 Test across terminals: T2 to N Specified value: <5 ohms

3

Check continuity as follows:

UP552142

Connector Number: TB1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across terminals: T3 to N Specified value: <5 ohms

(5)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Start Converter Unit (SCU). (a)

(7)

Replace the starter-generator.

Replace APU Generator. (AMM Task) (a)

(6)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Apply electrical load to APU generator.

(c)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41246 ( SCU_BAD_CMD ) A.

Description: If the voltage enable signal is >XX VDC and the start enable signal is >XX VDC. Then the supervisory control sets the SCU_AN_CMD flag. The starter generator rotation is greater than 75 % of the rated speed and the ECU fails to remove the start enable signal, then the supervisory control sets the SCU_AN_CMD flag. The start converter unit will sense reverse windmilling in the starter generator. If the starter generator reverse windmilling is greater than 5 % of the generator speed and the ECU commands a start, then the supervisory control sets the SCU_AN_CMD flag. The start converter unit will not "START" and revert into the "GENERATE" state until the anomaly is removed.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the APU start system. (a)

Do an APU normal start. (AMM Task)

(b)

Do the following procedure if the APU starts normally and supplies electric power normally.

(c)

(d)

(3)

UP552142

ALL

Replace the Start Control Unit (SCU). (AMM Task)

2

Do the repair confirmation at the end of this task.

Do the following procedure if the APU will not start. 1

Replace the APU generator Control Unit (AGCU). (AMM Task)

2

Do the repair confirmation at the end of this task.

Do the following procedure if the APU rolls as soon as the APU master switch is placed in the ON position. 1

Replace the ECU. (AMM Task)

2

Do the repair confirmation at the end of this task.

Evaluate the test cell wiring. (a)

EFFECTIVITY

1

Do the following procedure if the APU will not start. 1

Determine source of inadvertent 28 VDC Voltage Regulator Enable signal.

2

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (b)

UP552142

(4)

EFFECTIVITY ALL

Do the following procedure if the APU starts and supplies electric power normally, but MM 49-41246 persists. 1

Determine source of inadvertent 28 VDC Start Enable signal.

2

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Apply electrical load to APU generator. (AMM Task)

(c)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41247 ( SCU_INTERLOCK_RELAY ) A.

Description: The start converter unit sends a 28 VDC signal through the APIR auxiliary contact in the start converter unit this auxiliary contact is normally closed when the main contact is closed. The start converter unit can monitor the state of the APIR by monitoring the aux. contact. When the start converter unit senses the APIR is closed during the generate mode or opened during the start mode, the supervisory control sets the SCU_APIR flag. The start converter unit will inhibit start or generate depending on the command. This fault will not be latched.

B.

Fault isolation procedure. (1)

Make an analysis of the Start Converter Unit. (a)

(2)

Do the repair confirmation at the end of this task.

Evaluate the airplane Auxiliary Power Breaker (APB). (a)

(b)

Examine the APB electrical connector. 1

Disconnect electrical connector D11114C from the APB.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do continuity/resistance check. 1

Disconnect electrical connector D11114C.

2

Check continuity as follows: Necessary value D11114C Test across contact: 58 to 59 Specified value: <5 ohms

(3)

UP552142

EFFECTIVITY ALL

Check test cell wiring for open circuit.

4

Check test cell APB for open circuit.

5

Do the repair confirmation at the end of this task.

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Apply electrical load to APU generator. (AMM Task)

(c)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41248 ( SCU_INTERNAL_FAILURE ) A.

Description: The exciter power supply will monitor failures caused by transient overcurrent, transient over voltage, and out-of-tolerance in voltage supply. Whenever any of these failures occur, the exciter power supply fault flag will be set. The supervisory control will set the SCU_INT_FAIL flag. The start converter unit will still attempt to supply exciter power under foldback conditions.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Evaluate the APU Starter/Generator (S/G) field excitation circuit. (a)

(b)

Examine the S/G electrical connector. 1

Disconnect electrical connector P6 from the S/G.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do S/G excitation continuity/resistance check. 1

Disconnect electrical connector P6 at S/G interface.

2

Check continuity as follows: Connector Number: P6 Test across LRU pins: 5 to 7 Specified value: 2 to 10 ohms

(c)

3

Replace the S/G. (AMM Task)

4

Do the repair confirmation at the end of this task.

Check S/G excitation continuity at APU/firewall interface. 1

Disconnect connector P4 at APU/firewall interface.

2

Check continuity as follows: Connector Number: P4/D11118 Test across harness pins: 6 to 8 Specified value: 2 to 10 ohms

UP552142

3 EFFECTIVITY ALL

Replace S/G wire harness. (AMM Task)

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ENGINE MANUAL 131-9[B] 4 (3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41249 ( SCU_LO_BATTERY_POWER ) A.

Description: The dc/ac inverter monitors the battery voltage level. If the battery voltage falls below 18 V and the air/ground signal is disabled, the dc/ac inverter sets the dc/dc PWR FOLDBACK flag. If the battery voltage falls below 20 V and the air/ground signal is enabled, the dc/ac inverter sets the dc/dc PWR FOLDBACK flag. The dc/ac will decrease its output to prevent a battery depletion. The start converter unit sets the SCU_LO_BAT_PWR flag whenever the dc/dc PWR FOLDBACK flag is set.

B.

Fault isolation procedure. (1)

Examine cell APU battery and electrical generation system. (a)

(2)

Examine test cell wiring. (a)

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

(5)

Do the repair confirmation at the end of this task.

Replace APU Start Power Unit (SPU). (AMM Task) (a)

(4)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU using DC power only. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41250 ( SCU_OVERCURRENT ) A.

Description: The dc/ac supplies a BITE voltage (voltage across the switching device) that shows when the device is conducting. Under normal operating condition, when the device is conducting this voltage is <XX V. If the driver circuit commands the device ON XX microseconds later this voltage is >XX V, then an overcurrent condition has occurred. The dc/ac inverter will set a device overcurrent flag and send it to the supervisory controls. The dc/ac inverter monitors the 3-phase output current. When this current is more than XX peak, the dc/ac inverter will set the load overcurrent flag and send it to the supervisory controls. Exciter power supply control attempts to maintain a constant current through the starter generator winding, if the output impedance drops due to a failure the output voltage will drop below a nominal value. When this occurs the exciter power supply set the exciter power supply low impedance flag and the start converter will set the SCU_OCURNT flag. The supervisory control sets the SCU_OCURNT flag whenever the device overcurrent flag, load overcurrent flag, or exciter fault flag is set the start converter unit will still attempt to start under foldback conditions.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the starter-generator terminals. (a)

(b)

Examine the starter-generator phase terminals. 1

Examine the terminal connections, fasteners, and insulators for contamination and damage.

2

Clean terminals.

3

Replace starter-generator.

4

Do the repair confirmation at the end of this task.

Do starter-generator terminal continuity/resistance check. 1

Check continuity as follows: Connector Number: TB1 Test across terminals: T1 to structural ground Specified value: >100K ohms

2

Check continuity as follows: Connector Number: TB1 Test across terminals: T2 to structural ground

UP552142

Specified value: >100K ohm EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 3

Check continuity as follows: Connector Number: TB1 Test across terminals: T3 to structural ground Specified value: >100K ohms

(3)

4

Replace the starter-generator. (AMM Task)

5

Do the repair confirmation at the end of this task.

Evaluate the starter-generator phase cables. (a)

(b)

Examine the starter-generator phase terminals at the SCU. 1

Examine the terminal connections, fasteners, and insulators for contamination and damage.

2

Clean/repair terminals.

3

Do the repair confirmation at the end of this task.

Do starter-generator phase cable continuity/resistance check. 1

Disconnect the three phase cable leads from the SCU at TB2.

2

Check continuity as follows: Connector Number: TB2 Test across terminals: E1 to structural ground Specified value: >100K ohms

3

Check continuity as follows: Connector Number: TB2 Test across terminals: E2 to structural ground Specified value: >100K ohms

4

Check continuity as follows: Connector Number: TB2 Test across terminals: E3 to structural ground Specified value: >100K ohms

(4)

UP552142

ALL

Repair/replace the applicable starter-generator phase cable assembly. (AMM Task)

6

Do the repair confirmation at the end of this task.

Replace APU Generator. (AMM Task) (a)

EFFECTIVITY

5

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (5)

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

UP552142

(6)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41251 ( SCU_OVERTEMPERATURE ) A.

Description: The supervisory control supplies a constant current across the temp sensor. As temperature changes, so does the sensor resistance, and the start converter monitors the change in the voltage. A window comparator identifies when the voltage is more than the specified limit the supervisory control sets the SCU_OVTMP flag whenever the voltage in any of the three sensors is more than the specified limit, and the start converter unit will stop rotation of the APU shaft. The start converter unit will continuously monitor the temperature. When the overtemperature condition is removed, the start converter unit will re-enable the deactivated module.

B.

Fault isolation procedure. (1)

(2)

(3)

Look for associated fault: Refer to 49-41256 (SPU_SCU_FAN_POWER). (a)

Follow the applicable FIM Task.

(b)

Do the repair confirmation at the end of this task.

Evaluate Start Converter Unit. (a)

See CDU Fault History to determine if multiple APU start attempts had been made before fault appearing (as could occur during other APU system troubleshooting), thus indicating temporary SCU overheating.

(b)

Wait for 15 minutes (minimum) following the last start attempt to permit SCU to cool.

(c)

Do the repair confirmation at the end of this task.

Replace APU Start Converter Unit (SCU). (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41252 ( SCU_VOLTAGE_REGULATOR ) A.

Description: The voltage regulator sets the voltage regulator fail flag and sends it to the start converter whenever: - The voltage regulator commands full output and there is an OV flag from the AGCU. - The voltage regulator commands minimum output, there is a voltage regulator enable, and there is a UV flag from the AGE. The supervisory control sets the SCU_VREG flag whenever the voltage regulator fail flag is set the start converter unit will latch this fault. The start converter unit will wait for the AGCU to terminate the generate mode. When VR_ENABLE flag is deactivated, the voltage regulator will open the relay disconnecting PMG to the voltage regulator.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

(3)

Evaluate the AGCU. (a)

(4)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Evaluate the starter-generator terminals. (a)

(b)

Examine the starter-generator phase terminals. 1

Examine the terminal connections, fasteners, and insulators for contamination and damage.

2

Clean terminals.

3

Replace starter-generator.

4

Do the repair confirmation at the end of this task.

Do starter-generator terminal continuity/resistance check. 1

Check continuity as follows: Connector Number: TB1 Test across terminals: T1 to structural ground Specified value: >100K ohms

2

Check continuity as follows: Connector Number: TB1 Test across terminals: T2 to structural ground

UP552142

Specified value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 3

Check continuity as follows: Connector Number: TB1 Test across terminals: T3 to structural ground Specified value: >100K ohms

(5)

4

Replace the starter-generator. (AMM Task)

5

Do the repair confirmation at the end of this task.

Evaluate the starter-generator phase cables. (a)

(b)

Examine the starter-generator phase terminals at the SCU. 1

Examine the terminal connections, fasteners, and insulators for contamination and damage.

2

Clean/repair terminals.

3

Do the repair confirmation at the end of this task.

Do starter-generator phase cable continuity/resistance check. 1

Disconnect the three phase cable leads from the SCU at TB2.

2

Check continuity as follows: Connector Number: TB2 Test across terminals: E1 to structural ground Specified value: >100K ohms

3

Check continuity as follows: Connector Number: TB2 Test across terminals: E2 to structural ground Specified value: >100K ohms

4

Check continuity as follows: Connector Number: TB2 Test across terminals: E3 to structural ground Specified value: >100K ohms

UP552142

(6)

EFFECTIVITY ALL

5

Repair/replace the applicable starter-generator phase cable assembly. (AMM Task)

6

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Apply electrical load to APU generator. (AMM Task)

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ENGINE MANUAL 131-9[B]

UP552142

(c)

EFFECTIVITY ALL

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41253 (SPU_INTERNAL_FAILURE) A.

Description: The start converter monitors the dc link voltage and the ac input to the ac/dc converter. An ac/dc failure flag is set if the start converter detects no dc link voltage, normal ac input to the ac/dc, and the ac/dc enable signal is ON. The dc/dc converter sets the dc/dc BITE flag and sends it to the start converter when: - 200 ms have elapsed since the unit was enabled and DC input is normal: - One or more power modules have failed. The dc/dc converter sets the dc/dc FTO flag and send it to the start converter whenever: - 200 ms have elapsed since the dc/dc Enable signal changed from OFF to ON: - The converter output voltage is below 250 volts DC; and Converter input voltage is within normal range. The supervisory control sets the SPU_INT_FAIL flag whenever the ac/dc failure flag, dc/dc FTO flag, or dc/dc BITE flag is set the start converter unit will latch this fault the start converter unit will attempt to circumvent the fault to restart.

B.

Fault isolation procedure. (1)

Replace APU Start Power Unit (SPU). (AMM Task) (a)

(2)

Do the repair confirmation at the end of this task.

Evaluate the Start Power Unit (SPU) input power. (a)

Remove the SPU from the mounting rack.

(b)

Examine the SPU input power electrical connector.

(c)

1

Disconnect electrical connector D11478B.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Examine the voltage at the connector as follows: 1

Disconnect electrical connector D11478B.

2

Examine the voltage at the connector as follows: Connector Number: D11478B Test across sockets: 5 to 6 Specified value: >190 Vac

3

Examine the voltage at the connector as follows: Connector Number: D11478B Test across sockets: 6 to 7 Specified value: >190 Vac

UP552142

4

EFFECTIVITY ALL

Repair airplane wiring. (AMM Task)

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ENGINE MANUAL 131-9[B] 5

UP552142

(3)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41254 ( SPU_OVERCURRENT ) A.

Description: The dc/dc converter will limit the output current to XX A. The dc/dc current limit flag will be set when this condition occurs. The start converter will set the SPU_OCURNT flag. The dc/dc will still attempt to supply power under foldback conditions.

B.

Fault isolation procedures (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the APU start system. (a)

Do an APU normal start. (AMM Task)

(b)

Do the following procedure if the APU will not start.

(c)

(3)

1

Replace the APU generator. (AMM Task)

2

Do the repair confirmation at the end of this task.

Do the following procedure if the APU starts and supplies electric power normally, but MM 49-41254 persists. 1

Replace the Start Converter Unit (SCU). (AMM Task)

2

Do the repair confirmation at the end of this task.

Evaluate the APU Starter/Generator (S/G) field excitation circuit. (a)

(b)

Examine the S/G electrical connector. 1

Disconnect electrical connector P6 from the S/G.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do S/G excitation continuity/resistance check. 1

Disconnect electrical connector P6 at S/G interface.

2

Check continuity as follows: Connector Number: P6 Test across LRU pins: 5 to 7

UP552142

Specified value: 2 to 10 ohms

EFFECTIVITY ALL

3

Replace the S/G. (AMM Task)

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (c)

Examine S/G excitation continuity at APU/firewall interface. 1

Disconnect connector P4 at APU/firewall interface.

2

Check continuity as follows: Connector Number: P4/D11118 Test across harness pins: 6 to 8 Specified value: 2 to 10 ohms

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

(7)

4

Replace APU Generator. (AMM Task) (a)

(6)

Replace S/G wire harness. (AMM Task)

Examine test cell wiring. (a)

(5)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41255 ( SPU_OVERTEMPERATURE ) A.

Description: The start converter supplies a constant current across the temperature sensor. As temperature changes so does the sensor resistance. The start converter monitors the change in the voltage. A window comparator identifies when the voltage is more than the specified limit. The supervisory control sets the SPU_OVTMP flag whenever the voltage in any of the three sensors is more than the specified limit. The start converter unit will continuously monitor the temperature. When the overtemp condition is removed, the start converter unit will re-enable the deactivated module.

B.

Fault isolation procedure. (1)

(2)

(3)

Look for associated fault: - 49-41256 (SPU_SCU_FAN_POWER) (a)

Follow the applicable FIM Task.

(b)

Do the repair confirmation at the end of this task.

Evaluate Start Converter Unit. (a)

Consult CDU Fault History to determine if multiple APU start attempts had been made before appearing (as could occur during other APU system troubleshooting), thus indicating temporary SCU overheating.

(b)

Wait for 15 minutes (minimum) following the last start attempt to permit SCU to cool.

(c)

Do the repair confirmation at the end of this task.

Replace APU Start Power Unit (SPU). (AMM Task) (a)

(4)

Replace APU Start Converter Unit (SCU). (AMM Task) (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41256 ( SPU_SCU_FAN_POWER ) A.

Description: The start converter senses the input voltage to the SPU and start converter unit fans. The supervisory control sets the SPU/SCU_FAN_PWR flag whenever the SPU and start converter unit fan voltage level is below XX V.

B.

Fault isolation procedure. (1)

Make an analysis of the Aircraft Standby Power Supply. (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41266 (START_COMMAND_ON_OC) A.

Description: The ECU start relay circuit supplies an over current discrete bit, which shows the software must turn off the driver. The highest expected current with no failures is 2.0 A (including aircraft component tolerance, temp variation, and aircraft power supply variation). The nominal overcurrent trip point is 4.0 Adc. The fault detects an overcurrent in the start relay circuit when the ECU driver is turned on.

B.

Fault isolation procedure. (1)

Make an analysis of the Start Relay. (a)

(2)

(3)

Make an analysis of the wiring. (a)

Examine wiring for contamination.

(b)

Perform any necessary continuity examinations on the wiring.

(c)

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41267 ( START_COMMAND_OPEN ) A.

Description: The SCU supplies 4 BITE lines to the ECU. When the SCU is not on-line or powered, all lines are pulled down (logical 0). When an APU start is initiated, the SCU is expected to respond with valid BITE information or all logical 1s which shows no faults found.

B.

Fault isolation procedure. (1)

Make an analysis of the Start Converter Unit. (a)

(2)

(3)

Make an analysis of the wiring (a)

Examine wiring for contamination.

(b)

Perform any necessary continuity examination on the wiring.

(c)

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41297 ( DC_DC_FAILURE ) A.

Description: The dc/dc converter sets the dc/dc BITE flag and sends it to the start converter when: - 200 ms have elapsed since the unit was enabled and DC input is normal. One or more power modules have failed. The dc/dc converter sets the dc/dc FTO flag and sends it to the start converter whenever: - 200 ms have elapsed since the dc/dc Enable signal changed from OFF to ON; - The converter output voltage is below 250 V DC; - Converter input voltage is within normal range.

B.

Fault isolation procedure. (1)

Make an analysis of the Start Power Unit. (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Move the Master Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-41298 ( PMG_FAILURE ) A.

Description: The Voltage Regulator uses the PMG input to generate a PMG speed signal. This signal is representative of the frequency of the PMG signal. If the VR Enable is ON and the PMG speed shows a speed < 75% of the generator rated speed then the SC will set the PMG_FAIL flag. The SCU will latch and annunciate the fault. The APU will not carry electrical load, however will be capable of starting and carrying pneumatic load.

B.

Fault isolation procedure. (1)

Make an analysis of the Generator. (a)

(2)

UP552142

(3)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Make an analysis of the wiring. (a)

Examine wiring for contamination.

(b)

Perform any necessary continuity examination on the wiring.

(c)

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Load APU Generator to confirm repair.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52017 ( REVERSE_FLOW1_COND ) A.

Description: This shutdown occurs when the load compressor discharge corrected flow is less than 0.4 lb/s for six seconds and typically can only happen when both the airplane check valve and the APU bleed air valve fail simultaneously. After the condition corrected flow < 0.4 lb/s has been TRUE for one second, the ECU commands the bleed valve closed (if not already closed) in an attempt to stop the reverse flow. Because the slowest closing time for the bleed valve is four seconds, at most five seconds after the condition corrected flow < 0.4 lb/s condition becomes TRUE, the bleed valve must have closed and reverse flow stopped. If the corrected flow < 0.4 lb/s still persists, this shutdown is declared six seconds following the initial occurrence of corrected flow < 0.4 lb/s. An up/down counter is used to count up to six seconds due to the noisy nature of the load compressor flow sensor signal. The logic also requires the condition PT/P2 > 2 to be TRUE. This is to make sure that the load compressor is operating in the normal range of the flow sensor curve. For each P/PT (the flow sensor signal), there are two possible values of corrected flow one in the normal operating range and the other much higher. If the load compressor is operating at the "much higher" flow, the flow sensor signal must not be misinterpreted as indicating a reverse flow condition (hence, the need to monitor for PT/P2 > 2).

B.

Fault isolation procedures. (1)

(2)

Look for associated faults: -

49-52236 (BLEED_VALVE_POS_SW_FAILED)

-

49-61279 (SCVTM_SHORTED_POS_D)

-

49-52284 (SCV_POS_VS_CMD)

(a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Inspect the APU inlet. (a)

Examine the APU inlet duct through the inlet door for sign of obstruction or flammable materials.

(b)

Remove the access panel on the APU plenum.

(c)

Examine the APU inlet plenum for sign of obstruction or flammable materials.

(d)

Do the repair confirmation at the end of this task.

(3)

Examine IGV actuator linkage and APU IGV assembly for binding or damage. (AMM Task)

(4)

Replace the SCV. (AMM Task) (a)

(5)

Examine the APU bleed check valve. (BOEING)

(6)

Replace delta pressure sensor. (AMM Task)

UP552142

(a)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (7)

Replace total pressure sensor. (AMM Task) (a)

(8)

Purge the flow sensor lines. (AMM Task) (a)

(9)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(11)

Do the repair confirmation at the of this task.

Examine the flow sensor assembly and associated lines. (AMM Task) (a)

(10)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU and apply bleed air. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52102 ( PT_SENSOR ) A.

Description: A bit signal that shows the common-mode output voltage of the balanced-bridge sensor (normally 5 VDC) is used for this fault. A value < 4.83 VDC shows an open sensor, excitation (+) lead open, signal (+) lead open, or short to ground, all of which will result in 0.0 V excitation. A value greater than 5.18 VDC shows an open excitation (-) lead, which will result in 10.0 VDC common-mode this pressure measurement is used in calculating corrected flow for the surge control system.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the total pressure sensor (PT). (a)

(b)

Examine the PT electrical connector. 1

Disconnect electrical connector P19 from the PT sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the PT sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P19 at APU/DP sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 8 to 20

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 5

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 20 to 21 Necessary value: >100K ohms

6

Install a jumper across sockets 3 and 4 at the total pressure sensor connector P19 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Necessary value: <10 ohms

(d)

8

Replace wire harness.

9

Do the repair confirmation at the end of this task.

Examine the PT sensor excitation wiring harness. 1

Power up the ECU.

2

Disconnect the electrical connector P19 from the PT sensor.

3

Test the voltage at the harness as follows: Connector Number: P19 Test across pins: 1 to 2 Necessary value: 9.7 to 10.3 volts DC

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace the PT excitation wiring harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52183 ( IGV_EXC_OPEN ) A.

Description: This fault is set when there is an open in the linear variable differential transformer (LVDT) excitation circuit. An excitation voltage is applied continuously to the LVDT in the inlet guide vane (IGV) actuator. An open in the LVDT excitation circuit and a loss of the position signal shows the voltage is more than 2.5 VDC and the current is less than 3 mA. With the loss of the position signal, the position of the inlet guide vanes is fully closed and APU bleed air is not available during the APU operation.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do IGV actuator continuity/resistance examination. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Check continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 6 Specified value: <300 ohms

(c)

3

Replace the IGV actuator. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine IGV actuator continuity at APU/firewall interface. 1

Disconnect connector P2 at APU/firewall interface.

2

Examine continuity as follows: Connector Number: P2/D10436 Test across harness pins: 15 to 30 Specified value: <300 ohms

UP552142

3 EFFECTIVITY ALL

Replace wire harness. (AMM Task)

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ENGINE MANUAL 131-9[B] 4 (3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52186 ( IGV_EXC_LO_GROUNDED ) A.

Description: The ac excitation voltage is continuously applied to the LVDT. The excitation circuit furnishes a BITE voltage and a measurement related to the current to the software. If the voltage is normal when the current is not present, then the low side of the LVDT primary is grounded. The position signal is invalid if this fault occurs. With a loss of position signal, the actuator can only be controlled to either end-stop. Electric operation is unaffected.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a IGV actuator continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 6 to 10 Necessary value: >100K ohms

(c)

3

Replace the IGV actuator.

4

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 14 to 30 Necessary value: >100K ohms

UP552142

3

EFFECTIVITY ALL

Replace wire harness.

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ENGINE MANUAL 131-9[B] 4 (3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52187 ( IGV_EXC_SHORT ) A.

Description: The ac excitation voltage is continuously applied to the LVDT. The excitation circuit furnishes a BITE voltage and a measurement related to the current to the software. If current is present and the voltage is low, then the LVDT primary circuit is failed shorted. The position signal is invalid if this fault occurs. With loss of position signal, the actuator can only be controlled to either end-stop. Electric operation is unaffected.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a IGV actuator continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 6 Necessary value: >50 ohms

(c)

3

Replace the IGV actuator.

4

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 15 to 30 Necessary value: >50 ohms

UP552142

3

EFFECTIVITY ALL

Replace wire harness.

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ENGINE MANUAL 131-9[B] 4 (3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52188 ( SCV_EXC_OPEN ) A.

Description: An ac excitation voltage is continuously applied to the LVDT. The excitation circuitry supplies voltages to the software which indicate the amplitude of the excitation voltage and the current flow through the circuit. If the voltage is high and the current is low, then the LVDT circuits open. The position signal is invalid if this fault occurs.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a SCV continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 4 to 5 Necessary value: <100 ohms

(c)

3

Replace the SCV.

4

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 9 to 22

UP552142

Necessary value: <100 ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52189 ( IGV_LVDT_CT_OPEN ) A.

Description: The LVDT demodulator circuit furnishes two bit voltage signals that indicate the peak voltages developed across the center tapped coils of the LVDT secondary windings. If these voltages do not meet the limits, then the fault is set. If the excitation is OK, then the fault shows an open secondary center-tap. The position signal is invalid if this fault occurs. With loss of position signal, the actuator can only be controlled to either end-stop.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a IGV actuator continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 2 to 5 Necessary value: 10 to 100 ohms

3

Test continuity as follows: Connector Number: P17 Test across LRU pins: 2 to 3 Necessary value: 10 to 100 ohms

4

Test continuity as follows: Connector Number: P17 Test across LRU pins: 3 to 10

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(c)

5

Replace the IGV actuator.

6

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 6 to 16 Necessary value: 10 to 100 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 16 to 31 Necessary value: 10 to 100 ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 14 to 31 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

5

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52190 ( IGV_POS_VS_CMD_NEG ) A.

Description: Fault is detectable when fuel pump speed is high enough to make sure enough hydraulic power to move the IGV actuator. The fault is true when position error is more than 10% stroke for 20 seconds. The control loop has a high proportional gain term that brings error to nearly zero, with settling time less than 0.5 second IGV position is still known so surge control system will work. Depending on what position the vanes indicate, pneumatic power can be available. If IGVs are stuck open, high altitude starting or electric load capability can be impaired. The LVDT fail flag inhibits recognition of this fault in case of LVDT failures. The IGV torque motor fail flag inhibits the fault in case of IGV Torque motor driver failure.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator, linkage, and APU IGV assembly. (a)

(b)

(3)

Test IGV fuel supply and return lines for damage, leakage, or restrictions.

2

Repair or replace defective fuel lines as necessary.

3

Do the repair confirmation at the end of this task.

Test IGV actuator linkage and APU IGV assembly for binding or damage. 1

Replace the APU.

2

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

1

Replace the Inlet Guide Vane Actuator. (a)

(4)

Do a general visual inspection of the IGV actuator.

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator torque motor/wiring. (a)

Do a IGV actuator torque motor continuity examination. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 4 to 10

UP552142

Necessary value: >100K ohms EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(b)

3

Replace IGV actuator.

4

Do the repair confirmation at the end of this task.

Test IGV actuator torque motor continuity at APU/test cell interface. 1

Disconnect Connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 5 to 14 Necessary value: >100K ohms

(6)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the APU. (a)

(8)

Replace wire harness.

Examine test cell wiring. (a)

(7)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU and apply bleed air.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52191 ( IGV_POS_VS_CMD_POS ) A.

Description: Fault is detectable when fuel pump speed is high enough to make sure hydraulic pressure to move the IGV actuator. The fault is true when position error’s more than 10% stroke for 20 seconds. The control loop has a high proportional gain term that brings the error to nearly zero, with a settling time less than 0.5 second. IGV position is still known so surge control system will work. Depending on what position the vanes indicate, pneumatic power can be available. If IGVs are stuck open, high altitude starting or electric load capability can be impaired. The LVDT fail flag inhibits this fault in case of LVDT failures. The IGV Torque motor fail flag inhibits the fault in case of IGV torque motor driver failure.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator, linkage, and APU IGV assembly. (a)

(b)

(3)

Test IGV fuel supply and return lines for damage, leakage, or restrictions.

2

Repair or replace defective fuel lines as necessary.

3

Do the repair confirmation at the end of this task.

Test IGV actuator linkage and APU IGV assembly for binding or damage. 1

Replace the APU.

2

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(5)

1

Replace the Inlet Guide Vane Actuator. (AMM Task) (a)

(4)

Do a general visual inspection of the IGV actuator.

Do the repair confirmation at the end of this task.

Evaluate the IGV actuator torque motor/wiring. (a)

Do IGV actuator torque motor continuity examination. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Examine continuity as follows: Connector Number: P17

UP552142

Test across LRU pins: 4 to 10 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Specified value: >100K ohms

(b)

3

Replace IGV actuator. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine IGV actuator torque motor continuity at APU/firewall interface. 1

Disconnect Connector P2 at APU/firewall interface.

2

Examine continuity as follows: Connector Number: P2/D10436 Test across harness pins: 5 to 14 Specified value: >100K ohms

(6)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

(8)

Replace wire harness. (AMM Task)

Examination test cell wiring. (a)

(7)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU and apply bleed air. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52192 ( IGV_VA_OPEN ) A.

Description: The LVDT demodulator circuit furnishes two bit voltage signals that indicate the peak voltages developed across the center tapped coils of the LVDT secondary windings. If this voltage is less than the limit, then the fault is set. If the excitation is OK, then the shows an open or short on a secondary coil. The position signal is invalid if this fault occurs. With loss of position signal, can only control actuator to either end-stop.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a IGV actuator continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 2 to 5 Necessary value: 10 to 100 ohms

3

Test continuity as follows: Connector Number: P17 Test across LRU pins: 2 to 3 Necessary value: 10 to 100 ohms

4

Test continuity as follows: Connector Number: P17 Test across LRU pins: 3 to 10

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(c)

5

Replace the IGV actuator.

6

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 6 to 16 Necessary value: 10 to 100 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 16 to 31 Necessary value: 10 to 100 ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 14 to 31 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

5

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52193 (IGV_VB_OPEN) A.

Description: The LVDT demodulator circuit furnishes two bit voltage signals that indicate the peak voltages developed across the center tapped coils of the LVDT secondary windings. If this voltage is less than the limit, then the fault is set. If the excitation is OK, then the fault shows an open of the primary or an open or short on a secondary coil B. The position signal is invalid if this fault occurs. With loss of position signal, can only control actuator to either end-stop.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a IGV actuator continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 2 to 5 Necessary value: 10 to 100 ohms

3

Test continuity as follows: Connector Number: P17 Test across LRU pins: 2 to 3 Necessary value: 10 to 100 ohms

4

Test continuity as follows: Connector Number: P17 Test across LRU pins: 3 to 10

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(c)

5

Replace the IGV actuator.

6

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 6 to 16 Necessary value: 10 to 100 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 16 to 31 Necessary value: 10 to 100 ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 14 to 31 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

5

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52194 ( IGVTM_OPEN ) A.

Description: For this test, the IGV actuator torque motor is commanded to 60 mA to make sure full scale output. The ECU measures both the torque motor drive current and the that results voltage across the torque motor load. If the voltage bit is high and the current bit is low, the load is open. A open torque motor circuit will remove the ability to open the vanes, but IGV position will still be known from the LVDT. The torque motor driver flag inhibits the position fault to prevent multiple fault messages.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 4 to 7 Necessary value: <100 ohms

(c)

3

Replace the IGV actuator.

4

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 1 to 5

UP552142

Necessary value: <100 ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(3)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52195 ( IGVTM_SHORT ) A.

Description: For this test, the IGV actuator torque motor is commanded to 60 mA to insure maximum output. The ECU measures both the torque motor drive current and the resulting voltage across the torque motor load. If the current is normal and the voltage bit is low, then the load is shorted. A shorted torque motor will remove the ability to open the vanes, but IGV position will still be known from the LVDT. The torque motor failed flag inhibits the position fault to prevent multiple fault messages.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 4 to 7 Necessary value: >15 ohms

(c)

3

Replace the IGV actuator.

4

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 1 to 5

UP552142

Necessary value: >15 ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(3)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52196 ( IGVTM_DRIVENSIDE_GROUNDED ) A.

Description: The test determines the value of the voltage and current BIT signals. A low voltage value and a low current value causes the fault to log and shows the driven side of the torque motor is grounded.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 7 to 10 Necessary value: >100K ohms

(c)

3

Replace the IGV actuator.

4

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 1 to 14

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52219 ( P2_DIFF_AC_P2 ) A.

Description: This test is designed to detect a P2 sensor that differs from the valued received from the test cell via ARINC label AC_P2. If the absolute value of the difference is greater than the prescribed value, the test fails. A failed test could indicate a "frozen " sensor or a sensor that has drifted from the correct value.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the inlet pressure (P2) sensor. (a)

(b)

Examine the P2 sensor electrical connector. 1

Disconnect electrical connector P18 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the P2 sensor. (AMM Task) 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P18 at APU/P2 sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Necessary value: >100K

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 25 Necessary value: >100K

5

Test continuity as follows: Connector Number: P2/D10912

UP552142

Test across pins: 24 to 25 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: >100K 6

Install a jumper across sockets 3 and 4 at the P2 sensor connector P18 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Necessary value: <10 ohms

(3)

UP552142

EFFECTIVITY ALL

9

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

8

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52221 ( P2_HIGH ) A.

Description: If P2 reads above the test limit, the fault is set. Maximum possible reading of P2 at sea level is 16.8 psia (115.83 kPa), including maximum mach number, plus two percent tolerance for the sensor and ECU. BIT limit at 18 psia (124.11 kPa) has extra margin at sea level but no extra margin at -2000 ft altitude, maximum mach number. Conditioner circuit range -1.75 to 23.6 psia (-12.07 to 162.72 kPa) will permit the BITE limit to be read. A short to ground in the measurement (-) lead will result in a high (+5 VDC) differential voltage at the sensor input to the ECU, which will cause a saturated maximum reading.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the inlet pressure (P2) sensor. (a)

(b)

Examine the P2 sensor electrical connector. 1

Disconnect electrical connector P18 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the P2 sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P18 at APU/P2 sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Necessary value: >100K

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 25 Necessary value: >100K

UP552142

5 EFFECTIVITY ALL

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P2/D10912 Test across pins: 24 to 25 Necessary value: >100K 6

Install a jumper across sockets 3 and 4 at the P2 sensor connector P18 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Necessary value: <10 ohms

(3)

UP552142

EFFECTIVITY ALL

9

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

8

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52222 ( P2_LOW ) A.

Description: If P2 reads below the test limit, the fault is set. Minimum possible P2 reading in operation is 1.96 psia (13.51 kPa) at 43,000 ft altitude, minimum mach, - 2% sensor and ECU tolerance, providing margin from nuisance trips. Conditioner circuit range is -3.0 to 20.0 psia (-20.68 to 137.90 kPa) so BITE limit can be read without saturating.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the inlet pressure (P2) sensor. (a)

(b)

Examine the P2 sensor electrical connector. 1

Disconnect electrical connector P18 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the P2 sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P18 at APU/P2 sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Necessary value: >100K

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 25 Necessary value: >100K

5

Test continuity as follows: Connector Number: P2/D10912

UP552142

Test across pins: 24 to 25

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: >100K 6

Install a jumper across sockets 3 and 4 at the P2 sensor connector P18 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Necessary value P1/D10912 Test across pins: 11 to 24 Necessary value: <10 ohms

(3)

UP552142

EFFECTIVITY ALL

9

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

8

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52236 ( BLEED_VALVE_POS_SW_FAILED ) A.

Description: The bleed valve position switch must indicate BAV not open (contacts closed) when bleed air is not selected. If the bleed valve shows open when bleed is not selected, the test fails.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the BAV. (a)

(b)

(c)

Examine the BAV electrical connector. 1

Disconnect electrical connector P10 from the switch.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a general visual inspection of the BAV. 1

Examine the visual indicator to make sure valve is closed.

2

Replace the BAV.

3

Do the repair confirmation at the end of this task.

Do a continuity test as follows: 1

Disconnect connector P10 at the APU/BAV interface.

2

Test continuity as follows: Connector Number: P10 Test across LRU pins: 3 to 4 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P10 Test across LRU pins: 4 to 5

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

4

Replace the BAV.

5

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (d)

Test continuity at the APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P3/D10434 Test across pins: 3 to 4 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P3/D10434 Test across pins: 3 to 6 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

5

Replace the Bleed Air Valve. (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Make sure that the master switch has been off for a minimum of five minutes.

(c)

Move the Master Switch to the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52237 ( BLEED_VALVE_SOL_OPEN ) A.

Description: The bleed control valve solenoid voltage BITE circuit furnishes a BIT voltage to the software that is a rescaled value of the voltage across the bleed control valve solenoid (i.e., the bleed control valve solenoid voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is outside the valid range, the fault is set. This test is run while the driver is turned off. While the driver is off, the high side is normally pulled to 0 V by the low resistance of a correctly operating bleed control valve solenoid. If the bleed control valve solenoid circuit is open, the high side is pulled to between 4.59 and 8.50 VDC by a resistor network.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the BAV. (a)

(b)

Examine the bleed air valve electrical connector. 1

Disconnect electrical connector P10 from the bleed air valve.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a BAV solenoid continuity/resistance test. 1

Disconnect connector P10 at the APU/BAV interface.

2

Test continuity as follows: Connector Number: P10 Test across LRU pins: 1 to 2 Necessary value: <80 ohms

(c)

3

Replace the BAV.

4

Do the repair confirmation at the end of this task.

Test continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P3/D10434

UP552142

Test across pins: 1 to 5 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: <80 ohms

(3)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position and APU is not running.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52238 ( BLEED_VALVE_FAILURE ) A.

Description: This test looks to see that when the bleed valve is commanded to open, the valve shows that it has opened. The bleed valve open signal will go true if the bleed switch has not failed.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the BAV and wiring. (a)

(b)

Examine the BAV electrical connector. 1

Disconnect electrical connector P10 from the BAV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the BAV. 1

(c)

Do the repair confirmation at the end of this task.

Test the continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Disconnect connector P10 at the BAV.

3

Install a jumper across sockets 3 and 4 at BAV connector P10 on the APU harness side.

4

Test continuity at the test cell connector as follows: Connector Number: P3/D10434 Test across pins: 3 to 4 Necessary value: <10 ohms

(3)

UP552142

ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

EFFECTIVITY

Replace wire harness.

Examine test cell wiring. (a)

(4)

5

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B]

UP552142

(5)

EFFECTIVITY ALL

Do a repair confirmation as follows: (a)

Start APU and apply bleed air.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52240 ( BLEED_VALVE_SOL_ON_OC ) A.

Description: The ECU bleed valve solenoid circuit furnishes an overcurrent discrete bit, which shows the driver is in an overcurrent state. The software reads the status of the bit and turns off the driver. The fault detects an overcurrent in the bleed valve solenoid circuit when the ECU driver is turned on. If an overcurrent is found, the driver will be turned off. After one second, the driver will be enabled.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the BAV solenoid. (a)

(b)

Examine the BAV electrical connector. 1

Disconnect electrical connector P10 from the BAV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a BAV solenoid continuity/resistance test. 1

Disconnect connector P10 at the APU/BAV interface.

2

Test continuity as follows: Connector Number: P10 Test across LRU pins: 1 to 2 Necessary value: >20 ohms

3

Test continuity as follows: Connector Number: P10 Test across LRU pins: 1 to 5 Necessary value: >100K ohms

UP552142

(c)

EFFECTIVITY ALL

4

Replace the BAV.

5

Do the repair confirmation at the end of this task.

Test continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P3/D10434 Test across pins: 1 to 5 Necessary value: >20 ohms 3

Test continuity as follows: Connector Number: P3/D10434 Test across pins: 5 to Structural Ground Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52269 ( REVFLO_BLEED_OFF ) A.

Description: As a reverse flow condition occurs, bleed air is disabled in an attempt to prevent the occurrence of a reverse flow shutdown.

B.

Fault isolation procedure. (1)

(2)

(3)

(4)

(5)

Look for associated faults: -

49-52270 (DELTAP_DRIFT_STATIC)

-

49-52272 (DELTAP_LOW_RUN)

-

49-52276 (SCVTM_OPEN_NEG_D)

-

49-52279 (SCVTM_SHORTED_POS_D)

-

49-52284 (SCV_POS_VS_CMD)

-

49-52289 (PT_HIGH_DRIFT)

-

49-52290 (PT_HIGH_RUN)

(a)

Follow the applicable FIM task.

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU inlet plenum and surge ducting. (a)

Remove blockage/correct findings.

(b)

Do the repair confirmation at the end of this task.

Examine IGV actuator linkage and APU IGV assembly for binding or damage. (AMM Task) (a)

Replace the APU. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the SCV.

UP552142

(a)

EFFECTIVITY ALL

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (b)

Replace the SCV. (AMM Task) 1

(c)

Do the repair confirmation at the end of this task.

Examine SCV continuity at APU/firewall interface. 1

Disconnect connector P2 at APU/firewall interface.

2

Examine continuity as follows: Connector Number: P2/D10436 Test across harness pins: 7 to 8 Specified value: >100K ohms

(6)

3

Replace wire harness. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

Do the repair confirmation at the end of this task.

(7)

Examine the APU bleed check valve. (BOEING)

(8)

Evaluate the delta pressure (DP) sensor. (a)

(b)

Examine the DP sensor electrical connector. 1

Disconnect electrical connector P20 from the DP sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the DP sensor. (AMM Task) 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/firewall interface. 1

Disconnect electrical connector P1 at APU/firewall interface.

2

Disconnect electrical connector P20 at APU/DP sensor interface.

3

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Specified value: >100K ohms

4

Examine continuity as follows: Connector Number: P1/D10912

UP552142

Test across pins: 9 to 22

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Specified value: >100K ohms 5

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 22 to 23 Specified value: >100K ohms

6

Install a jumper across sockets 3 and 4 at the delta pressure sensor connector P20 on the APU harness side.

7

Examine continuity on the harness at the firewall as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Specified value: <10 ohms

(9)

Replace wire harness. (AMM Task)

9

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(10)

8

Do the repair confirmation at the end of this task.

Evaluate the total pressure (PT) sensor. (a)

(b)

Examine the PT electrical connector. 1

Disconnect electrical connector P19 from the PT sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the PT sensor. (AMM Task) 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/firewall interface. 1

Disconnect electrical connector P1 at APU/firewall interface.

2

Disconnect electrical connector P19 at APU/PT sensor interface.

3

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Specified value: >100K

UP552142

4

EFFECTIVITY ALL

Examine continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P1/D10912 Test across pins: 8 to 20 Specified value: >100K 5

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 20 to 21 Specified value: >100K

6

Install a jumper across sockets 3 and 4 at the PT sensor connector P19 on the APU harness side.

7

Examine continuity on the harness at the firewall as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Specified value: <10 ohms

(d)

8

Replace wire harness. (AMM Task)

9

Do the repair confirmation at the end of this task.

Examine the PT sensor excitation wiring harness. 1

Power up the ECU.

2

Disconnect the electrical connector P19 from the PT sensor.

3

Examine the voltage at the harness as follows: Connector Number: P19 Test across pins: 1 to 2 Specified value: 9.7 to 10.3 volts DC

(11)

UP552142

ALL

Do the repair confirmation at the of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the APU wire harness. (AMM Task) (a)

EFFECTIVITY

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(14)

5

Examine the flow sensor assembly and associated lines. (AMM Task) (a)

(13)

Replace the PT excitation wiring harness.

Purge the flow sensor lines. (AMM Task) (a)

(12)

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B]

UP552142

(15)

EFFECTIVITY ALL

Do a repair confirmation as follows: (a)

Start APU and apply bleed air. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52270 ( DELTAP_DRIFT_STATIC ) A.

Description: When the engine is less than 7% speed and the offset reads above the test limit, the fault is set. The actual DELTA P static pressure will be 0 psig. This pressure measurement is used in calculating corrected flow for the surge control system.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the delta pressure sensor (DP). (a)

(b)

Examine the DP electrical connector. 1

Disconnect electrical connector P20 from the DP sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the DP sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P20 at APU/DP sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 22 Necessary value: >100K ohms

5

Test continuity as follows: Connector Number: P1/D10912

UP552142

Test across pins: 22 to 23

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: >100K ohms 6

Install a jumper across sockets 3 and 4 at the delta pressure sensor connector P20 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Necessary value: <10 ohms

(3)

Replace wire harness.

9

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

8

Do the repair confirmation at the end of this task.

Evaluate the pressure sensor excitation wiring. (a)

Examine the test cell wiring at the APU/firewall interface. 1

Power up the ECU.

2

Disconnect electrical connector P1/D10912.

3

Examine the voltage at the connector as follows: Connector Number: P1 Test across sockets: 2 to 10 Specified value: 9.7 to 10.3 volts DC

(b)

4

Repair airplane wiring. (AMM Task)

5

Do the repair confirmation at the end of this task.

Examine APU wiring harness excitation voltage. 1

Disconnect the electrical connector P20 from the DP sensor.

2

Examine the voltage at the harness as follows: Connector Number: P20 Test across sockets: 1 to 2 Specified value: 9.7 to 10.3 volts DC

(5)

UP552142

ALL

Replace the APU wiring harness.

4

Do the repair confirmation at the end of this task.

Purge the flow sensor lines. (AMM Task) (a)

EFFECTIVITY

3

Do the repair confirmation at the of this task.

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ENGINE MANUAL 131-9[B] (6)

Examine the flow sensor assembly and associated lines. (AMM Task) (a)

(7)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(8)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position, and APU is not running.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52271 ( DELTA_P_HIGH_RUN ) A.

Description: This test measures the value of DP during a run. If the value of pressure value is too high, the test fails. Failure of the test shows a DP sensor that has drifted to cause this out of range condition. Normal values of DP are expected to be below 25 psia (172.37 kPa).

B.

Fault isolation procedure. (1)

(2)

(3)

Look for associated fault: - 49-52270 (DELTAP_DRIFT_STATIC) (a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the delta pressure sensor (DP). (a)

(b)

Examine the DP electrical connector. 1

Disconnect electrical connector P20 from the DP sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the DP sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/firewall interface. 1

Disconnect electrical connector P1 at APU/firewall interface.

2

Disconnect electrical connector P20 at APU/DP sensor interface.

3

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Specified value: >100K ohms

4

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 22 Specified value: >100K ohms

UP552142

5 EFFECTIVITY ALL

Examine continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P1/D10912 Test across pins: 22 to 23 Specified value: >100K ohms 6

Install a jumper across sockets 3 and 4 at the delta pressure sensor connector P20 on the APU harness side.

7

Examine continuity on the harness at the firewall as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Specified value: <10 ohms

(4)

Replace wire harness. (AMM Task)

9

Do the repair confirmation at the end of this task.

Purge the flow sensor lines. (a)

(5)

8

Do the repair confirmation at the of this task.

Evaluate the pressure sensor excitation wiring. (a)

Examine the test cell wiring at the APU/firewall interface. 1

Power up the ECU.

2

Disconnect electrical connector P1/D10912.

3

Examine the voltage at the connector as follows: Connector Number: P1 Test across sockets: 2 to 10 Specified value: 9.7 to 10.3 volts DC

(b)

4

Repair test cell wiring. (AMM Task)

5

Do the repair confirmation at the end of this task.

Examine APU wiring harness excitation voltage. 1

Disconnect the electrical connector P20 from the DP sensor.

2

Examine the voltage at the harness as follows: Connector Number: P20 Test across sockets: 1 to 2

UP552142

Specified value: 9.7 to 10.3 volts DC

EFFECTIVITY ALL

3

Replace the APU wiring harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (6)

Purge the flow sensor lines. (AMM Task) (a)

(7)

Examine the flow sensor assembly and associated lines. (AMM Task) (a)

(8)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(9)

Do the repair confirmation at the of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU and apply bleed air. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52272 ( DELTAP_LOW_RUN ) A.

Description: When the engine is greater than 95% speed and DP reads below the test limit, the fault is set. The actual DELTA P when n > 95% speed can be 0 psid. Subtracting 2% Tolerance of sensor and ECU gives -0.8 psid (-172.37 kPa) as the lowest possible reading during normal operation. This pressure measurement is used in calculating corrected flow for the surge control system. A low reading results in operation further from surge and lower bleed pressure.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the delta pressure sensor (DP). (a)

(b)

Examine the DP electrical connector. 1

Disconnect electrical connector P20 from the DP sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the DP sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P20 at APU/DP sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 22 Necessary value: >100K ohms

5

Test continuity as follows:

UP552142

Connector Number: P1/D10912

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across pins: 22 to 23 Necessary value: >100K ohms 6

Install a jumper across sockets 3 and 4 at the delta pressure sensor connector P20 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Necessary value: <10 ohms

(d)

8

Replace wire harness.

9

Do the repair confirmation at the end of this task.

Examine the DP sensor excitation wiring harness. 1

Power up the ECU.

2

Disconnect the electrical connector P20 from the DP sensor.

3

Test the voltage at the harness as follows: Connector Number: P20 Test across pins: 1 to 2 Necessary value: 9.7 to 10.3 volts DC

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(7)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(6)

5

Examine the flow sensor assembly and associated lines for looseness and damage. (a)

(5)

Replace the DP excitation wiring harness.

Purge the flow sensor lines. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU and apply bleed air.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52273 ( DELTA_P_SENSOR ) A.

Description: A bit signal that shows the common-mode output voltage of the balanced-bridge sensor (normally 5 VDC) is used for this fault. A value < 4.83 VDC shows an open sensor, excitation (+) lead open, signal (+) lead open, or short to ground, all of which will result in 0.0 V excitation. A value greater than 5.18 VDC shows an open excitation (-) lead, which will result in 10.0 VDC common-mode this pressure measurement is used in calculating corrected flow for the surge control system.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the delta pressure sensor (DP). (a)

(b)

Examine the DP electrical connector. 1

Disconnect electrical connector P20 from the DP sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the DP sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P20 at APU/DP sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 22

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 5

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 22 to 23 Necessary value: >100K ohms

6

Install a jumper across sockets 3 and 4 at the delta pressure sensor connector P20 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Necessary value: <10 ohms

(d)

8

Replace wire harness.

9

Do the repair confirmation at the end of this task.

Examine the DP sensor excitation wiring harness. 1

Power up the ECU.

2

Disconnect the electrical connector P20 from the DP sensor.

3

Test the voltage at the harness as follows: Connector Number: P20 Test across pins: 1 to 2 Necessary value: 9.7 to 10.3 volts DC

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace the DP excitation wiring harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52280 ( SCVTM_DRIVENSIDE_GROUNDED ) A.

Description: The test determines the value of the voltage and current BIT signals. A low voltage value and a low current value causes the fault to log and shows the driven side of the torque motor is grounded.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 7 to 9 Necessary value: >100K ohms

(c)

3

Replace the SCV.

4

Do the repair confirmation at the end of this task.

Test SCV actuator continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 7 to 8

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52281 ( SCV_LVDT_CT_OPEN ) A.

Description: The LVDT demodulator circuit furnishes two bit voltage signals that indicate the peak voltages developed across the center tapped coils of the LVDT secondary windings. If these voltages do not meet the limits, then the fault is set. If the excitation is OK, then the fault shows an open secondary center-tap the position signal is invalid if this fault occurs. With loss of position signal, the actuator can only be controlled to either end-stop.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a SCV continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 1 to 2 Necessary value: 50 to 200 ohms

3

Test continuity as follows: Connector Number: P9 Test across LRU pins: 2 to 3 Necessary value: 50 to 200 ohms

4

Test continuity as follows: Connector Number: P9 Test across LRU pins: 1 to 9 Necessary value: >100K ohms

UP552142

5

EFFECTIVITY ALL

Replace the SCV.

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ENGINE MANUAL 131-9[B] 6 (c)

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 10 to 23 Necessary value: 50 to 200 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 2 to 10 Necessary value: 50 to 200 ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 7 to 23 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

5

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52282 ( SCV_EXC_SHORT ) A.

Description: The ac excitation voltage is continuously applied to the LVDT. The excitation circuit furnishes a BITE voltage and a voltage measurement related to current to the software. If current is present and the voltage is low then the LVDT primary circuit is failed shorted. The position signal is invalid if this fault occurs. With loss of position signal, the actuator can only be controlled to either end-stop. Electric operation is unaffected. A failed surge valve position flag causes the position fault to be disabled.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a SCV continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 4 to 5 Necessary value: >20 ohms

(c)

3

Replace the SCV.

4

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 9 to 22

UP552142

Necessary value: >20 ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(3)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52283 ( SCV_EXC_LO_GROUNDED ) A.

Description: The ac excitation voltage is continuously applied to the LVDT. The excitation circuit furnishes a BITE voltage and a voltage measurement related to current to the software. If the voltage bits normal when current not present, then the low side of the LVDT primary is grounded.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a SCV continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 5 to 9 Necessary value: >100K ohms

(c)

3

Replace the SCV.

4

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 7 to 22

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52284 ( SCV_POS_VS_CMD ) A.

Description: Fault is detectable when fuel pump speed is high enough to make sure adequate fuel pressure to move the SCV. Fault is true when position error is more than 10°F (-12°C) for 20 seconds. With a stuck surge control valve, the APU system surge margin cannot be controlled. This fault causes the fault tolerance logic to monitor corrected flow and turn off the bleed system (command inlet guide vanes closed and surge control valve open) if it approaches surge. The surge valve can not be moved anyway, but closing the IGVs will lessen the severity of possible surge.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

Do a SCV torque motor continuity check. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 8 to 9 Necessary value: >100K ohms

3 (b)

Do the repair confirmation at the end of this task.

Test SCV torque motor continuity at APU/test cell interface. 1

Disconnect Connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 7 to 21 Necessary value: >100K ohms

(3)

UP552142

ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a general visual inspection of the SCV. (a)

EFFECTIVITY

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Examine SCV fuel supply and return lines for damage, leakage, or restrictions.

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ENGINE MANUAL 131-9[B]

(5)

(b)

Repair or replace defective fuel lines as necessary.

(c)

Do the repair confirmation at the end of this task.

Replace the SCV. (a)

(6)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(7)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU and apply bleed air.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52285 ( SCV_VA_OPEN ) A.

Description: The LVDT demodulator circuit furnishes two-bit voltage signals that indicate the peak voltages developed across the center tapped coils of the LVDT secondary windings. If these voltages are less than the limits, then the fault is set. If the excitation is OK, then this shows an open of the primary or an open or short on a secondary coil. The position signal is invalid if this fault occurs. With loss of position signal, the actuator can only be controlled to either end-stop.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a SCV continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 1 to 2 Necessary value: 50 to 200 ohms

3

Test continuity as follows: Connector Number: P9 Test across LRU pins: 2 to 3 Necessary value: 50 to 200 ohms

4

Test continuity as follows: Connector Number: P9 Test across LRU pins: 1 to 9

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(c)

5

Replace the SCV.

6

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 10 to 23 Necessary value: 50 to 200 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 2 to 10 Necessary value: 50 to 200 ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 7 to 23 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

5

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52286 ( SCV_VB_OPEN ) A.

Description: The LVDT demodulator circuit furnishes two-bit voltage signals that indicate the peak voltages developed across the center tapped coils of the LVDT secondary windings. If this voltage is less than the limit, then the fault is set. If the excitation is OK, then the fault shows an open of the primary or an open or short on a secondary coil. The position signal is invalid if this fault occurs. With loss of position signal, then actuator can only be controlled to either end-stop.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a SCV continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 1 to 2 Necessary value: 50 to 200 ohms

3

Test continuity as follows: Connector Number: P9 Test across LRU pins: 2 to 3 Necessary value: 50 to 200 ohms

4

Test continuity as follows: Connector Number: P9 Test across LRU pins: 1 to 9

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

(c)

5

Replace the SCV.

6

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 10 to 23 Necessary value: 50 to 200 ohms

3

Test continuity as follows: Connector Number: P2/D10436 Test across harness pins: 2 to 10 Necessary value: 50 to 200 ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 7 to 23 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

6

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(5)

Replace wire harness.

Replace APU Electronic Control Unit (ECU). (a)

(4)

5

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52287 ( SCVTM_OPEN_CIRCUIT ) A.

Description: For this test, the surge control valve torque motor is commanded to 40 mA. The ECU measures both the torque motor drive current and the voltage across the torque motor load. If the values are not correct, the test fails. An open positive torque motor winding will remove the ability to close the valve, which will cause a low APU bleed pressure.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 7 to 8 Necessary value: <80 ohms

(c)

3

Replace the SCV.

4

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 8 to 21 Necessary value: <80 ohms

UP552142

3

EFFECTIVITY ALL

Replace wire harness.

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ENGINE MANUAL 131-9[B] 4 (3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52288 ( SCVTM_SHORT_CIRCUIT ) A.

Description: For this test, the SCV Torque motor is commanded to 40 mA. The ECU measures both the torque motor drive current and the voltage across the torque motor load. If the values are not correct, the test fails.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity/resistance test. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 7 to 8 Necessary value: >10 ohms

(c)

3

Replace the SCV.

4

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P2 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 8 to 21

UP552142

Necessary value: >10 ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52289 ( PT_HIGH_DRIFT ) A.

Description: When the engine is less than 7% speed and the offset reads above the test limit, the fault is set. This pressure measurement is used in calculating corrected flow for the surge control system.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the total pressure (PT) sensor. (a)

(b)

Examine the PT electrical connector. 1

Disconnect electrical connector P19 from the PT sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the PT sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P19 at APU/PT sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Necessary value: >100K

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 8 to 20 Necessary value: >100K

5

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 20 to 21

UP552142

Necessary value: >100K EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 6

Install a jumper across sockets 3 and 4 at the PT sensor connector P19 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Necessary value: <10 ohms

(d)

8

Replace wire harness.

9

Do the repair confirmation at the end of this task.

Examine the PT sensor excitation wiring harness. 1

Power up the ECU.

2

Disconnect the electrical connector P19 from the PT sensor.

3

Test the voltage at the harness as follows: Connector Number: P19 Test across pins: 1 to 2 Necessary value: 9.7 to 10.3 volts DC

(3)

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the of this task.

Examine the flow sensor assembly and associated lines for looseness and damage. (a)

(5)

Replace the PT excitation wiring harness.

Purge the flow sensor lines. (a)

(4)

4

Do the repair confirmation at the end of this task.

Make an analysis of the inlet pressure (P2) sensor. (a)

(b)

Examine the P2 sensor electrical connector. 1

Disconnect electrical connector P18 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the P2 sensor. (AMM Task) 1

(c)

Examine wiring harness continuity at APU/test cell interface.

UP552142

1

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Disconnect electrical connector P1 at APU/test cell interface.

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ENGINE MANUAL 131-9[B] 2

Disconnect electrical connector P18 at APU/P2 sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Necessary value: >100K

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 25 Necessary value: >100K

5

Test continuity as follows: Connector Number: P2/D10912 Test across pins: 24 to 25 Necessary value: >100K

6

Install a jumper across sockets 3 and 4 at the P2 sensor connector P18 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Necessary value: <10 ohms

(6)

UP552142

EFFECTIVITY ALL

9

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(8)

Replace wire harness.

Examine test cell wiring. (a)

(7)

8

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position, and APU is not running.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52290 ( PT_HIGH_RUN ) A.

Description: When the engine is greater than 95% speed and pressure reads above the test limit, the fault is set. This pressure measurement is used in calculating corrected flow for the surge control system.

B.

Fault isolation procedure. (1)

Look for associated faults: 49-52289 (PT_HIGH_DRIFT)

(2)

(3)

(a)

Follow the applicable FIM task.

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the total pressure (PT) sensor. (a)

(b)

Examine the PT electrical connector. 1

Disconnect electrical connector P19 from the PT sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the PT sensor. 1

(4)

Replace APU Electronic Control Unit (ECU). (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Evaluate the APU and test cell PT sensor wiring. (a)

Examine continuity as follows: 1

Connector Number: P19 Test across plug sockets: 3 to structural ground Specified value: >100K ohms

2

Connector Number: P1/D10912 Test across firewall sockets: 8 to structural ground

UP552142

Specified value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

(6)

EFFECTIVITY ALL

3

Replace applicable wire harness. (AMM Task)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU and apply bleed air.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52291 ( PT_LOW_RUN ) A.

Description: When the engine is greater than 50% speed and PT reads below the test limit, the fault is set. The minimum possible PT in operation is 2.82 PSIA (19.44 kPa) at 43k ft, minimum mach number. Minus two percent sensor and ECU tolerance gives 0.7 PSIA (4.83 kPa), providing margin from nuisance trips. BITE limit is within the conditioner circuit range, -8.75 to 118.0 PSIA (-60.33 to 813.58 kPa). This pressure measurement is used in calculating corrected flow for the surge control system.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the total pressure (PT) sensor. (a)

(b)

Examine the PT electrical connector. 1

Disconnect electrical connector P19 from the PT sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the PT sensor. 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P1 at APU/test cell interface.

2

Disconnect electrical connector P19 at APU/PT sensor interface.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Necessary value: >100K

4

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 8 to 20 Necessary value: >100K

5

Test continuity as follows:

UP552142

Connector Number: P1/D10912 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across pins: 20 to 21 Necessary value: >100K 6

Install a jumper across sockets 3 and 4 at the PT sensor connector P19 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Necessary value: <10 ohms

(d)

8

Replace wire harness.

9

Do the repair confirmation at the end of this task.

Examine the PT sensor excitation wiring harness. 1

Power up the ECU.

2

Disconnect the electrical connector P19 from the PT sensor.

3

Test the voltage at the harness as follows: Connector Number: P19 Test across pins: 1 to 2 Necessary value: 9.7 to 10.3 volts DC

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace the PT excitation wiring harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU.

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Look at CDU APU Current Status screen to make sure fault cleared.

(f)

Select the Ground Report Page (5R) and make sure fault has not reoccurred.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52292 ( BLEED_SHUT_OFF_RV ) A.

Description: As a reverse flow condition occurs, bleed air is disabled in an attempt to prevent the occurrence of a reverse flow shutdown.

B.

Fault isolation procedure. (1)

(2)

(3)

(4)

(5)

Look for associated faults: -

49-52270 (DELTAP_DRIFT_STATIC)

-

49-52272 (DELTAP_LOW_RUN)

-

49-52276 (SCVTM_OPEN_NEG_D)

-

49-52279 (SCVTM_SHORTED_POS_D)

-

49-52284 (SCV_POS_VS_CMD)

-

49-52289 (PT_HIGH_DRIFT)

-

49-52290 (PT_HIGH_RUN)

(a)

Follow the applicable FIM task.

(b)

Do the repair confirmation at the end of this task.

Inspect the APU inlet. (a)

Examine the APU inlet duct through the inlet door for signs of obstruction or flammable materials.

(b)

Remove the access panel on the APU plenum.

(c)

Examine the APU inlet plenum for sign of obstruction or flammable materials.

(d)

Do the repair confirmation at the end of this task.

Examine IGV actuator linkage and APU IGV assembly for binding or damage. (AMM Task) (a)

Replace the APU. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the SCV.

UP552142

(a)

EFFECTIVITY ALL

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

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ENGINE MANUAL 131-9[B]

(b)

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the SCV. (AMM Task) 1

(c)

Do the repair confirmation at the end of this task.

Examine SCV continuity at APU/firewall interface. 1

Disconnect connector P2 at APU/firewall interface.

2

Examine continuity as follows: Connector Number: P2/D10436 Test across harness pins: 7 to 8 Specified value: >100K ohms

(6)

3

Replace wire harness. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

Do the repair confirmation at the end of this task.

(7)

Examine the APU bleed check valve. (BOEING)

(8)

Evaluate the delta pressure (DP) sensor. (a)

(b)

Examine the DP sensor electrical connector. 1

Disconnect electrical connector P20 from the DP sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the DP sensor. (AMM Task) 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/firewall interface. 1

Disconnect electrical connector P1 at APU/firewall interface.

2

Disconnect electrical connector P20 at APU/DP sensor interface.

3

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Specified value: >100K ohms

UP552142

4

EFFECTIVITY ALL

Examine continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P1/D10912 Test across pins: 9 to 22 Specified value: >100K ohms 5

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 22 to 23 Specified value: >100K ohms

6

Install a jumper across sockets 3 and 4 at the delta pressure sensor connector P20 on the APU harness side.

7

Examine continuity on the harness at the firewall as follows: Connector Number: P1/D10912 Test across pins: 9 to 23 Specified value: <10 ohms

(9)

8

Replace wire harness. (AMM Task)

9

Do the repair confirmation at the end of this task.

Evaluate the total pressure (PT) sensor. (a)

(b)

Examine the PT electrical connector. 1

Disconnect electrical connector P19 from the PT sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the PT sensor. (AMM Task) 1

(c)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/firewall interface. 1

Disconnect electrical connector P1 at APU/firewall interface.

2

Disconnect electrical connector P19 at APU/PT sensor interface.

3

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Specified value: >100K

UP552142

4

EFFECTIVITY ALL

Examine continuity as follows:

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ENGINE MANUAL 131-9[B] >Connector Number: 1/D10912 Test across pins: 8 to 20 Specified value: >100K 5

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 20 to 21 Specified value: >100K

6

Install a jumper across sockets 3 and 4 at the PT sensor connector P19 on the APU harness side.

7

Examine continuity on the harness at the firewall as follows: Connector Number: P1/D10912 Test across pins: 8 to 21 Specified value: <10 ohms

(d)

8

Replace wire harness. (AMM Task)

9

Do the repair confirmation at the end of this task.

Examine the PT sensor excitation wiring harness. 1

Power up the ECU.

2

Disconnect the electrical connector P19 from the PT sensor.

3

Examine the voltage at the harness as follows: Connector Number: P19 Test across pins: 1 to 2 Specified value: 9.7 to 10.3 volts DC

(10)

UP552142

ALL

Do the repair confirmation at the of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the APU wire harness. (AMM Task) (a)

EFFECTIVITY

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(13)

5

Examine the flow sensor assembly and associated lines. (AMM Task) (a)

(12)

Replace the PT excitation wiring harness.

Purge the flow sensor lines. (AMM Task) (a)

(11)

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B]

UP552142

(14)

EFFECTIVITY ALL

Do a repair confirmation as follows: (a)

Start APU and apply bleed air. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52301 ( IGV_EXC_HI_GROUNDED ) A.

Description: This fault is set when there is an open or short to ground in the high side driver of the linear variable differential transformer (LVDT) for the IGV actuator. An excitation voltage is applied continuously to the LVDT. An open or short to ground in the high side driver of the LVDT circuit and a loss of the position signal shows the voltage is less than 0.8 VDC and the current is less than 3 mA. With the loss of the position signal, the position of the inlet guide vanes is fully closed. If this failure occurs, the APU bleed air is not available during the APU operation.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do continuity/resistance check. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Examine continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 10 Specified value: >100K ohms

(c)

3

Replace the IGV actuator. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine IGV actuator continuity at APU/firewall interface. 1

Disconnect connector P2 at APU/firewall interface.

2

Examine continuity as follows: Connector Number: P2/D10436 Test across pins: 14 to 15 Specified value: >100K ohms

UP552142

3 EFFECTIVITY ALL

Replace wire harness. (AMM Task)

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ENGINE MANUAL 131-9[B] 4 (3)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52302 ( SCV_EXC_HI_GROUNDED ) A.

Description: This fault is set when there is an open or short to ground in the high side driver circuit of the linear variable differential transformer (LVDT) in the surge control valve. An excitation voltage is applied continuously to the LVDT. An open or short to ground in the high side driver circuit of the LVDT and a loss of the position signal shows the voltage is less than 0.8 VDC and the current is less than 3 mA. With the loss of the position signal, the position of the surge control valve is fully open. If this failure occurs, low or no APU bleed air is available during the APU operation.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the SCV. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do continuity/resistance check. 1

Disconnect electrical connector P9 at APU/SCV interface.

2

Examine continuity as follows: Connector Number: P9 Test across LRU pins: 4 to 9 Specified value: >100K ohms

(c)

3

Replace the SCV. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine SCV continuity at APU/firewall interface. 1

Disconnect connector P2 at APU/firewall interface.

2

Examine continuity as follows: Connector Number: P2/D10436 Test across pins: 7 to 22 Specified value: >100K ohms

UP552142

3 EFFECTIVITY ALL

Replace wire harness. (AMM Task)

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ENGINE MANUAL 131-9[B] 4 (3)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-52303 ( P2_SENSOR ) A.

Description: This fault is set when there is an open or short to ground in the inlet pressure sensor circuit. The electronic control unit does a check of the voltage across the balanced bridge of the inlet pressure sensor. An open or short to ground in the inlet pressure sensor circuit shows the voltage is less than 2.0 VDC. If this failure occurs, the air data for the inlet pressure sensor is replaced with the corrected air data from the airplane and continues the APU operation. An APU start and operation problem at altitude can occur.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the inlet pressure (P2) sensor. (a)

(b)

Examine the P2 sensor electrical connector. 1

Disconnect electrical connector P18 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the P2 sensor. (AMM Task) 1

(c)

aDo the repair confirmation at the end of this task.

Examine wiring harness continuity at APU/firewall interface. 1

Disconnect electrical connector P1 at APU/firewall interface.

2

Disconnect electrical connector P18 at APU/P2 sensor interface.

3

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Specified value: >100K

4

Examine continuity as follows: Connector Number: P1/D10912 Test across pins: 11 to 25 Specified value: >100K

5

Examine continuity as follows:

UP552142

Connector Number: P2/D10912 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across pins: 24 to 25 Specified value: >100K 6

Install a jumper across sockets 3 and 4 at the P2 sensor connector P18 on the APU harness side.

7

Examine continuity on the harness at the firewall as follows: Connector Number: P1/D10912 Test across pins: 11 to 24 Specified value: <10 ohms

(3)

8

Replace wire harness. (AMM Task)

9

Do the repair confirmation at the end of this task.

Evaluate the pressure sensor excitation wiring. (a)

Examine the test cell wiring at the APU/firewall interface. 1

Power up the ECU.

2

Disconnect electrical connector P1/D10912.

3

Examine the voltage at the connector as follows: Connector Number: P1 Test across sockets: 2 to 10 Specified value: 9.7 to 10.3 volts DC

(b)

4

Repair airplane wiring. (AMM Task)

5

Do the repair confirmation at the end of this task.

Examine APU wiring harness excitation voltage. 1

Disconnect the electrical connector P20 from the DP sensor.

2

Examine the voltage at the harness as follows: Connector Number: P20 Test across sockets: 1 to 2 Specified value: 9.7 to 10.3 volts DC

(4)

UP552142

ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

EFFECTIVITY

Replace the APU wiring harness.

Examine test cell wiring. (a)

(5)

3

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B]

UP552142

(6)

EFFECTIVITY ALL

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Examine CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-60304 ( OIL_QUANTITY_SWITCH ) A.

Description:

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the oil level switch. (a)

(b)

Examine the oil level switch electrical connector. 1

Disconnect electrical connector P16 from the OLS.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do continuity/resistance check. 1

Examine the gearbox sight glass to make sure that the oil level is below the LOQ mark (APU OFF). Drain oil to below LOQ mark.

2

Examine continuity as follows: Connector Number: P16 Test across LRU pins: 1 to 5 Specified value: <10 ohms

(c)

3

Replace the OLS. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine OLS continuity at APU/firewall interface. 1

Disconnect connector P3 at APU/firewall interface.

2

Examine continuity as follows: Connector Number: P3/D10434 Test across pins: 19 to 22 Specified value <10 ohms

(3)

UP552142

ALL

Replace wire harness. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

EFFECTIVITY

3

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (4)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61025 ( SENSOR_FAILURE_COND ) A.

Description: This APU protective shutdown occurs when there is a problem with the inlet temperature sensor, or the oil temperature sensor. The problem is a loss of the temperature indications from one of the two temperature sensors. If the inlet temperature sensor does not send the APU inlet temperature indications to the electronic control unit, the APU will operate with degraded exhaust temperature control. If the oil temperature sensor does not send the oil temperature indications to the electronic control unit, the APU will operate with no high oil temperature protection. This APU protective shutdown does not occur during flight operations.

B.

Fault isolation procedure. (1)

(2)

(3)

Examine the CDU Fault History screen for associated faults: -

49-61136 (V10_BUFF_BAD)

-

49-61223 (T2_GND_SHORT)

-

49-61224 (T2_HIGH)

-

49-61225 (T2_LOW)

-

49-94228 (T OIL_GND_SHORT)

-

49-94229 (T OIL_HIGH)

-

49-94230 (T OIL_LOW)

(a)

Follow the applicable FIM.

(b)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Replace P2 sensor. (AMM Task) (a)

(4)

Replace the oil temperature sensor. (AMM Task) (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Evaluate the pressure sensor excitation wiring. (a)

Examine the airplane wiring at the APU/firewall interface. 1

Power up the ECU.

2

Disconnect electrical connector P1/D10912.

3

Examine the voltage at the connector as follows: Connector Number: P1

UP552142

Test across sockets: 2 to 10

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Specified value: 9.7 to 10.3 volts DC

(b)

4

Repair airplane wiring. (AMM Task)

5

Do the repair confirmation at the end of this task.

Examine APU wiring harness excitation voltage. 1

Disconnect the electrical connector P20 from the DP sensor.

2

Examine the voltage at the harness as follows: Connector Number: P20 Test across sockets: 1 to 2 Specified value: 9.7 to 10.3 volts DC

(6)

UP552142

EFFECTIVITY ALL

4

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(8)

Replace the APU wiring harness.

Examine test cell wiring. (a)

(7)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61106 ( DMM_POWER_OPEN_D ) A.

Description: The DMM driver circuit furnishes a bit voltage to the software that is a re-scaled value of the voltage across the DMM output terminals (i.e., the voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is less than 7.0 VDC, then fault is set. This test is run while the driver is turned on. While the driver is on, the high side is driven to approximately 27 VDC (10.5 VDC with minimum box power). If the driver is open (failed off), the high side is pulled to less than 3.3 VDC by the input impedance of the DMM. Software monitoring of the ECU input voltage will prevent DMM power turn on if ECU DMM power is greater 32 VDC. An open driver circuit results in the loss of DMM operation. The DMM is attached to the APU and is used to store usage statistics, health monitoring, and life usage information for the core APU, as well as IGV bias information, which is set at engine ATP. The DMM cannot be read or written to if this fault occurs.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Make sure that the master switch has been off for a minimum of five minutes.

(c)

Move the Master Switch to the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61107 ( DMM_POWER_SHORT_D ) A.

Description: The ECU DMM driver circuit furnishes a bit voltage to the software that is a rescaled value of the voltage across the DMM output terminals (i.e., the voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is greater than or equal to 11.0 VDC while the driver is turned off, the fault is set. The voltage is normally pulled to less than 3.3 VDC when the driver is turned off due to the power input section of the DMM. There is substantial margin to prevent nuisance indications. If the driver is failed-on, the high side is driven to about 27 VDC (with a minimum value of approximately 11.0 VDC with minimum ECU power), providing reliable detection. The DMM is attached to the APU and is used to store usage statistics, health monitoring, and life usage information for the core APU, as well as IGV bias information, which is set at engine ATP.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the DMM electrical connector. (a)

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P2 at APU/test cell interface.

2

Disconnect electrical connector P11 at APU/DMM interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 18 Necessary value: > 100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 32 Necessary value: > 100K ohms

(3)

Examine test cell wiring. (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61108 ( DMM_WRAP_ECU ) A.

Description: During the DMM power_up wrap test the ECU processor input buffer is read to determine the status of the DMM transmit and receive circuits. If the buffer shows a fault inside the ECU, DMM ECU wrap flag is set and DMM_WRAP_ECU is declared. Power is applied to the DMM at least one second before this test is run to permit the DMM power tests to complete and inhibit this test if power is failed. NOTE:

B.

The ECU and DMM must not be replaced at the same time or the data will be lost.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the DMM. (a)

(b)

Examine the DMM electrical connector. 1

Disconnect electrical connector P11 from the DMM.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace DMM (AMM TASK). 1

(3)

Do the repair confirmation at the end of this task.

Examine wiring harness continuity at test cell. (a)

Examine wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P2 at APU/test cell interface.

2

Disconnect electrical connector P11 at APU/DMM interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 19 Necessary value: > 100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 35 Necessary value: > 100K ohms

UP552142

5

EFFECTIVITY ALL

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P2/D10436 Test across pins: 19 to 35 Necessary value: > 100K ohms 6

Install a jumper across sockets 8 and 9 at the DMM connector P11 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 19 to 35 Necessary value: < 10 ohms

8

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 34 Necessary value: > 100K ohms

9

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 33 Necessary value: > 100K ohms

10

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 33 to 34 Necessary value: > 100K ohms

11

Install a jumper across sockets 10 and 11 at the DMM connector P11 on the APU harness side.

12

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 33 to 34 Necessary value: < 10K ohms

13

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 20 Necessary value: > 100K ohms

UP552142

14

EFFECTIVITY ALL

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P2/D10436 Test across pins: 17 to 36 Necessary value: > 100K ohms 15

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 20 to 36 Necessary value: > 100K ohms

16

Install a jumper across sockets 6 and 7 at the DMM connector P11 on the APU harness side.

17

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 20 to 36 Necessary value: < 10 ohms

18 (4)

Examine test cell wiring. (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Make sure that the master switch has been off for a minimum of two seconds.

(c)

Move the Master Switch to the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61109 ( ATOD_CONVERSION ) A.

Description: The ECU analog to digital converter is monitored after the initiation of an analog signal conversion command. If the conversion does not complete, the analog signal conversions necessary to operate and control the APU do not occur. The make sure time of 60 ms relates to the typical conversion time of 35 µs, preventing false trips and providing reliable detection of the fault. During each 20 ms period, failures of any conversion to complete during that 20 ms loop causes the fault to count up three consecutive counts sets the fault.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61110 ( BAD_INTERRUPT ) A.

Description: The ECU hardware and software provide for detecting unexpected interrupts. If an unexpected interrupt occurs, the ECU interrupt service handler can detect and report the condition. The ECU hardware design precludes nuisance occurrences of this fault, and experience shows that this type of fault does not have nuisance trips. Occurrence of multiple bad interrupts means something is seriously wrong with the controller and APU control steps can be unpredictable.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61111 ( BOOTSTRAP_ROM ) A.

Description: At each power-up the EPROM containing the bootstrap software is checked. Failure of the test causes this fault. This test is performed by the operational software (OPS), which reports this fault via ARINC. Some bootstrap ROM failures will prevent the bootstrap code from executing enough to transfer control to the OPS. Those faults will not result in this fault report but will cause the ECU to be unresponsive.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Move the Master Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61112 ( CJC_BAD ) A.

Description: CJC loss could cause significant EGT errors, but a substitute value of CJC = 100°F (38°C) will permit operation with minimal error. If the failure is real, it will subtract from the EGT Temperature measurement making the ECU believe that EGT is lower than actual. This will prevent the ECU from trimming back the IGVs or reducing fuel in case of high combined electrical and pneumatic loads, which could potentially damage the APU. An open circuit is an infinite resistance, so it looks like an infinite temperature. The highest possible temperature in operation is around 210F (99°C). Conditioner circuit range is -92°F to 291°F (-69 to 144°C). BITE limit at 260°F (126°C) is low enough to make sure that the conditioner can always read the BITE limit without saturating and supplies large margin from nuisance indications. The two second make sure time permits this fault to be included in the power-up test sequence and is much longer than needed to filter out electrical noise.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61113 ( CPU_FAILED ) A.

Description: Once at power-up of the ECU, a variety of checks are performed on the ECU 1750A processor. The tests include the internal processor built-in-test and a suite of typical processor operations. Failure of any test triggers this fault. Processor failures can result in the box locking up or can result in unpredictable control effects.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Move the Master Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61114 ( EEPROM_WRITE ) A.

Description: Each time the EEPROM memory is written, the data are read back and tested. If a mismatch occurs, the test is repeated three times and a new location is selected. If no memory locations are available, the fault is set. EEPROM is used only for fault storage and DMM backup. Failures of EEPROM do not affect engine operation.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1210 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61115 ( FIXED_OVERFLOW ) A.

Description: The ECU is equipped to detect and report on fixed-point overflow conditions. An overflow could happen if a counter were incremented endlessly, for example the software design is intended to prevent occurrences of overflows. If this fault occurs, the bad data will probably be quickly overwritten with no significant effect, but there is also a significant chance of unpredictable control steps.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1211 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61116 ( FLOAT_OVERFLOW ) A.

Description: The ECU is equipped to detect and report on floating point overflow conditions. An overflow could happen if a divide by zero were performed as part of the APU control algorithms, for example the software design is intended to prevent occurrences of overflows. If this fault occurs, the bad data will probably be quickly overwritten with no significant effect, but there is also a significant chance of unpredictable control steps.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1212 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61117 ( GAIN_C_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1213 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61118 ( GAIN_D_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61119 ( GND_0_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1215 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61120 ( GND_0_BIP_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61121 ( GND_2_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1217 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61122 ( IO_GND_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1218 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61123 ( IO_GND_BIP_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1219 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61124 ( MMU_PAGE_REGISTERS ) A.

Description: The ECU memory is accessed via the memory management unit (MMU). Memory access is done by writing address data to the registers. At ECU power-up, the memory management unit is written to and the information is then read back to make sure correct operation. A RAM failure can have no noticeable effect on APU operation, but it also has a significant chance of which will cause a unpredictable control steps.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Move the Master Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1220 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61125 ( POWERUP_RAM ) A.

Description: At each ECU power-up, two ram memory tests are performed: The address test, which writes a non-repeating pattern through the entire RAM address range. This pattern is then read back and tested. Stuck bits test, which writes a set of patterns (5555h, AAAAh, FFFFh, and 0000h), make sure all adjacent RAM bits are functioning properly. A RAM failure can have no noticeable effect on APU operation, but it also has a significant chance of which will cause a unpredictable control steps.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Move the Master Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61126 ( PS_5V_UNDER_VOLTAGE ) A.

Description: The ECU is equipped with a hardware watchdog timer that is refreshed periodically by the software (as a function of the real-time scheduling executive). If the timer is not refreshed, the ECU output drive circuits are reset, providing for a safe APU shutdown. The watchdog circuit also includes a function that monitors the +5 VDC supply to the digital electronics. If the supply falls below specified level, this circuit holds the processor in reset until (or if) the supply comes back. This +5 VDC monitor function of the watchdog circuit is tested at each power-up by purposely simulating an under voltage condition to the watchdog circuit. Failure of the circuit to reset the processor triggers this fault. With this failure the CPU can be permitted to function outside of its valid operating range.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61127 ( PSIO_GND_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1223 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61128 ( PSIO_GND_BIP_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1224 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61129 ( PSIO_REF_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1225 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61130 ( REALTIME_10 ) A.

Description: The ECU scheduling executive monitors each of the software real-time execution loops for proper completion. Before scheduling any particular loop to begin execution, the loop is monitored for having completed its last scheduled execution. If the loop has not completed execution, some fault condition in the ECU hardware and/or software has occurred. The software design and the timing margin specifications are both intended to preclude timing overflow. If timing overflow occurs, APU control can be unpredictable.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61131 ( REALTIME_1SEC ) A.

Description: The ECU scheduling executive monitors each of the software real-time execution loops for proper completion. Before scheduling any particular loop to begin execution, the loop is monitored for having completed its last scheduled execution. If the loop has not completed execution, some fault condition in the ECU hardware and/or software has occurred. The software design and the timing margin specifications are both intended to preclude timing overflow. If timing overflow occurs, APU control can be unpredictable.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61132 ( REALTIME_20 ) A.

Description: The ECU scheduling executive monitors each of the software real-time execution loops for proper completion. Before scheduling any particular loop to begin execution, the loop is monitored for having completed its last scheduled execution. If the loop has not completed execution, some fault condition in the ECU hardware and/or software has occurred. The software design and the timing margin specifications are both intended to preclude timing overflow. If timing overflow occurs, APU control can be unpredictable.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). NOTE: (a)

UP552142

(2)

EFFECTIVITY ALL

Return ECU to Honeywell Engines. Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61133 ( REALTIME_200 ) A.

Description: The ECU scheduling executive monitors each of the software real-time execution loops for proper completion. Before scheduling any particular loop to begin execution, the loop is monitored for having completed its last scheduled execution. If the loop has not completed execution, some fault condition in the ECU hardware and/or software has occurred. The software design and the timing margin specifications are both intended to preclude timing overflow. If timing overflow occurs, APU control can be unpredictable.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). NOTE: (a)

UP552142

(2)

EFFECTIVITY ALL

Return ECU to Honeywell Engines. Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61134 ( REALTIME_5 ) A.

Description: The ECU scheduling executive monitors each of the software real-time execution loops for proper completion. Before scheduling any particular loop to begin execution, the loop is monitored for having completed its last scheduled execution. If the loop has not completed execution, some fault condition in the ECU hardware and/or software has occurred. The software design and the timing margin specifications are both intended to preclude timing overflow. If timing overflow occurs, APU control can be unpredictable.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

FAULT ISOLATION Page 1230 18 Dec 2019

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61135 ( REALTIME_5SEC ) A.

Description: The ECU scheduling executive monitors each of the software real-time execution loops for proper completion. Before scheduling any particular loop to begin execution, the loop is monitored for having completed its last scheduled execution. If the loop has not completed execution, some fault condition in the ECU hardware and/or software has occurred. The software design and the timing margin specifications are both intended to preclude timing overflow. If timing overflow occurs, APU control can be unpredictable.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). NOTE: (a)

UP552142

(2)

EFFECTIVITY ALL

Return ECU to Honeywell Engines. Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61136 ( V10_BUFF_BAD ) A.

Description: The +10.0 VDC internal reference is used for RTD conditioners, IGV and SCV position loop offsets and miscellaneous internal references. Various other malfunctions, as well as possible performance degradation, are possible if this failure occurs.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61137 ( V10_REF_BAD ) A.

Description: The ECU analog to digital converter is equipped with scaling resistors that are used to scale the analog signal inputs such as exhaust gas temperature and pressures. To make sure that the scaling values are correct, these resistor networks are range-checked using reference voltages. If any reference voltage is not in the correct range, the analog conversion of signals associated with the particular faulty reference will not be correctly converted. The limits are set to prevent nuisance trips in normal operation, including production tolerances, specified temperature variations and extra margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61138 ( V15_BAD ) A.

Description: The +15 VDC internal ECU supplies power to the analog input conditioning circuitry and output drivers. More than +15 VDC shows power supply failure and will result in additional power dissipation in conditioning/driver circuits. In normal operation this voltage is a maximum of +15.7 VDC. If the failure occurs, APU control can be unpredictable. NOTE:

B.

This fault can be logged with a gain or offset fault.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61139 ( V5_BAD ) A.

Description: The +5 VDC internal power supply supplies power for all digital logic. In normal operation, it will be a maximum of +5.25 VDC. The power sequencer hardware turns off the box at +5.35 VDC. This fault is only tripped if the power sequencer does not work. The threshold for this fault is set at the highest value where proper digital circuit operation can be maintained. If the +5 VDC supply goes out of range, the box will probably become inoperative. If the supply stays high enough to trip this fault but not high enough to disable the microprocessor, the control steps will be unpredictable and the APU must be shut down.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61140 ( VBIAS_BAD ) A.

Description: The Vbias supply floats on the +28 VDC input and is used for FET gate drive on high side discrete drivers. It is nominally +15 VDC and is controlled by a 5% zener reference. Occurrence of this fault results in greater probability of damage to the solenoid drive transistors in the ECU.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61141 ( VM10_BAD ) A.

Description: The -10.0 VDC internal reference is used for RTD conditioners, IGV and SCV position loop offsets and miscellaneous internal references. It is generated from the master reference through a buffer with matched precision resistor networks for gain setting and therefore has a tolerance of 10 mV. Various other malfunctions, as well as possible performance degradation, are possible if this failure occurs.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61142 ( VM15_BAD ) A.

Description: The 15 VDC internal ECU supplies power analog conditioning circuitry and output drivers. Although analog integrated circuits tolerate inputs below -10.0 VDC, circuits can saturate at -13 VDC. If this failure occurs, APU control can be unpredictable. NOTE:

B.

This fault can be logged with a gain or offset fault.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61143 ( WD_COUNTER ) A.

Description: The ECU is equipped with a hardware watchdog timer that is refreshed periodically by the software (as a function of the real-time scheduling executive). If the timer is not refreshed, the ECU output drive circuits are reset, providing for a safe APU shutdown. This test is performed continuously and verifies that the counter circuit is counting toward expiration.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61144 ( WD_FAILED_TO_TIMEOUT ) A.

Description: The ECU is equipped with a hardware watchdog timer that is refreshed periodically by the software (as a function of the real-time scheduling executive). If the timer is not refreshed, the ECU output drive circuits are reset, providing for a orderly APU shutdown. This circuit is tested for proper operation by purposely permitting the timer to expire during the test mode and measuring the expiration time. Occurrence of this fault shows a failure of the watchdog timer system, which itself is used only to test the software. The APU will operate normally with watchdog timer that cannot time-out.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for 2 seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61145 ( WD_TIMEOUT_OCCURRED ) A.

Description: The ECU is equipped with a hardware watchdog timer that is refreshed periodically by the software (as a function of the real-time scheduling executive). If the timer is not refreshed once, the ECU output drive circuits are turned off and the processor is reset. If there is a second consecutive time-out, power is removed from the drivers, providing for a safe APU shutdown, and the fault lamp is illuminated. If this fault occurs, a hardware condition has caused the watchdog timer to expire sooner than programmed or a software condition has prevented the real-time executive from scheduling the timer refresh task (and probably also preventing execution of the engine controls). This fault will be detected and reported immediately following the reset of the software in the case of a single time-out.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that the APU is not running.

(b)

Move the Master Switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61150 ( FUEL_DISABLE_FAIL ) A.

Description: This fault tests whether the fuel disable logic functions properly. If the fuel torque motor shows low current with the disable clamp set or the fuel torque motor shows a current value with the disable clamp not set the test fails.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61151 ( FUEL_SOL_HIGH_CURRENT ) A.

Description: This test shows a failed ECU driver PWM circuit when the current is outside the constant current control value.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61152 ( FUEL_SOL_SHORT_D ) A.

Description: The fuel solenoid driver circuit furnishes a voltage to the software that is a rescaled value of the voltage across the output terminals (i.e., the voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is greater than or equal to 7.3 VDC while the driver is turned off and there is at least a current path, the fault is set the current is monitored to make sure an open load will not cause this fault. With the driver turned off, the voltage is normally pulled to 0 VDC by the low resistance of the correctly operating solenoid. If the driver is failed-on, the high side is driven to about 27 VDC (with a value of approximately 14.5 VDC with minimum ECU power).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61153 ( FUEL_TM_OPEN_D ) A.

Description: The fuel torque motor is commanded to 125 ma. The ECU measures both the torque motor drive current and the that results voltage across the torque motor load ). If the fuel torque motor voltage bits low and the current is low, the torque motor driver is failed open. The typical reading for a torque motor operating correctly is fuel torque motor = 125 ma ±1% and fuel torque motor voltage bit = 3.4 to 19.9 VDC. An open torque motor will stop fuel flow to APU that results in a NO_FLAME, NO_ACCEL, or UNDERSPEED auto-shutdown.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61154 ( LOADSHED_OPEN_D ) A.

Description: The loadshed driver circuit furnishes a BITE voltage to the software that is a reconstruction of the voltage across the circuit. (i.e., the voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is too high, the fault is set. This test is run while the driver is turned on. While the driver is on, the low side is normally driven to 0 VDC. If the driver is open (failed off), the low side is pulled to 28 VDC (minimum of approximately 15.8 VDC with 16.0 VDC test cell circuit power) since the load is not pulled to ground. The driver will be turned on in test mode long enough to for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61155 ( LOADSHED_SHORT_D ) A.

Description: The loadshed driver circuit furnishes an indication of the circuit current flow to the software. If the circuit shows current flow with the driver turned off, the test fails. This test is run while the driver is turned off. While the driver is off, the low side is driven to 28 VDC since the circuit is not pulled to ground. If the circuit is shorted (failed on), the low side is pulled to 0.0 VDC and the normal circuit current flow is shown (greater than 2.75 ma and less than 10 ma).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Examine test cell wiring. (a)

UP552142

(3)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61156 ( WD_TO_FUEL_SOL_CLAMP ) A.

Description: The ECU is equipped with a hardware watchdog timer that is refreshed periodically by the software (as a function of the real-time scheduling executive). If the timer is not refreshed, the ECU output drive circuits are reset, providing for a safe APU shutdown. This circuit is tested for proper operation by purposely permitting the timer to expire during the test mode and reading the voltage output to the fuel solenoid to test that the solenoid was clamped off. With the driver clamped off, the voltage will read 0 v, so the BITE limit has sufficient margin. If the clamp function fails, the BIT voltage will read about 27 VDC (13 VDC with minimum box power) and will trip the fault. Occurrence of this fault shows a failure of the watchdog timer system, which itself is used only to test the software. The APU will operate normally with a failed watchdog timer.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61157 ( WD_TO_FUELTM_CLAMP ) A.

Description: The ECU is equipped with a hardware watchdog timer that is refreshed periodically by the software (as a function of the real-time scheduling executive). If the timer is not refreshed, the ECU output drive circuits are reset, providing for a safe APU shutdown. This circuit is tested for proper operation by purposely permitting the timer to expire during the test mode and reading the voltage output to the fuel torque motor to test that it was clamped off. With the driver clamped off, the fuel torque motor current wrap will read zero ma. If the clamp function fails, fuel torque motor current wrap will read 30 ma and will trip the fault. Occurrence of this fault shows a failure of the watchdog timer system, which is used to test that the software is in control. The APU will operate normally with a watchdog timer that fails to clamp the fuel torque motor.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the APU harness/FCU Torque motor wiring. (a)

(b)

Examine the FCU electrical connector. 1

Disconnect electrical connector P22 from the FCU.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Examine FCU torque motor wiring. 1

Disconnect electrical connector P22 at APU/FCU interface.

2

Make sure that the APU Master Switch is in the OFF position.

3

Test current at the harness plug as follows: Connector Number: P22 Test across sockets: 6 to 7 Necessary value: < 0.5 VDC

(3)

UP552142

ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

EFFECTIVITY

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Display CDU APU Current Status screen.

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UP552142

ENGINE MANUAL 131-9[B]

EFFECTIVITY ALL

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61158 ( WF_RESOLVER_EXC_DRIVER_HI ) A.

Description: An ac excitation voltage is continuously applied to the resolver. The excitation circuit furnishes a BITE voltage and a voltage related to current to the software. If the voltage is high and the current is present then the driver is shorted. In normal operation the voltage reads 1.0 to 1.8V, including temperature and component variations, providing good margin from nuisance trips. The position signal is invalid if this fault occurs.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the fuel control unit. (a)

(b)

Examine the fuel control unit electrical connector. 1

Disconnect electrical connector P22 from the fuel control unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a FCU continuity/resistance test. 1

Disconnect electrical connector P22 at APU/FCU interface.

2

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 7 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 6 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 8 Necessary value: >100K ohms

UP552142

5

EFFECTIVITY ALL

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P22 Test across LRU pins: 2 to 9 Necessary value: >100K ohms 6

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 10 Necessary value: >100K ohms

7

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 12 Necessary value: >100K ohms

8

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 11 Necessary value: >100K ohms

9

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 4 Necessary value: >100K ohms

10

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 5 Necessary value: >100K ohms

11

Test continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 1 Necessary value: >100K ohms

12

Examine continuity as follows: Connector Number: P22 Test across LRU pins: 2 to 3 Necessary value: >30 ohms

UP552142

13 EFFECTIVITY ALL

Replace the FCU.

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ENGINE MANUAL 131-9[B] 14 (c)

Do the repair confirmation at the end of this task.

Test FCU continuity at APU/test cell interface. 1

Disconnect electrical connector P22 at APU/FCU interface.

2

Disconnect connector P2 at APU/test cell interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 3 to 26 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 24 to 26 Necessary value: >100K ohms

5

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 26 to 27 Necessary value: >100K ohms

6

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 26 to 42 Necessary value: >100K ohms

7

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 12 to 26 Necessary value: >100K ohms

8

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 25 to 26 Necessary value: >100K ohms

9

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 4 to 26

UP552142

Necessary value: >100K ohms EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 10

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 11 to 26 Necessary value: >100K ohms

11

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 26 to 28 Necessary value: >100K ohms

12

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 26 to 29 Necessary value: >100K ohms

13

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 13 to 26 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness.

15

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

14

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61165 ( FUEL_SOL_OPEN_D ) A.

Description: The fuel solenoid driver circuit furnishes a bit voltage to the software that is a re-scaled value of the voltage across the output terminals (i.e. The voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is less than 4.0 VDC while the driver is turned on, the fault is set. With the driver on, the output is driven to about 27 VDC (14.5 VDC with minimum box power). If the driver is open (failed off) the output is pulled to zero VDC by the low resistance of the solenoid. An open driver circuit will cause no fuel flow to APU, that results in a speed droop, no flame, or no acceleration auto-shutdown.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61174 ( FUELTM_SHORT_D ) A.

Description: For this test, 0 ma is commanded. The ECU reads the torque motor drive current . If fuel torque motor current > 20 ma, the driver is shorted. The reading with no failures must be 0 ma. A driver short causes full fuel flow that can cause an overtemperature or NO_FLAME shutdown during a start or an overspeed auto-shutdown if onspeed when failure occurred. If this fault occurs during a start, there is a chance of turbine damage.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the APU harness/FCU wiring. (a)

(b)

Examine the FCU electrical connector. 1

Disconnect electrical connector P22 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Test FCU wiring. 1

Make sure that the APU master switch is in the OFF position.

2

Disconnect electrical connector P22 at APU/FCU interface.

3

Look for presence of voltage at the harness plug as follows: Connector Number: P22 Test across sockets: 6 to 7 Necessary value: < 0.5 VDC

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness.

5

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61176 ( LOADSHED_ON_OC ) A.

Description: The ECU loadshed driver circuit furnishes a current indication determine the current flow in the loadshed circuit. The expected current with no failures is less than 10 ma (including aircraft component tolerance, temp variation, and aircraft power supply variation). If an overcurrent is found, the driver must be turned off immediately. After one second, the driver will be enabled. The driver will be turned on in test mode long enough to for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

(2)

Make an analysis of the bus power control circuit bar. (a)

Replace the bus power control circuit bar.

(b)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(3)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61177 ( LOADSHED_OPEN ) A.

Description: This test shows that the expected load for the loadshed circuit is not present. The fault is detected when the voltage bit shows a low voltage ( the driver is turned on) and the current bit shows there is no current flow. Because, the test is done only when the driver is turned on, the interaction of test cell testing of the circuit will not cause false trips. The driver will be turned on in test mode long enough to for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

(2)

Make an analysis of the bus power control circuit bar. (a)

Replace the bus power control circuit bar.

(b)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(3)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(4)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61178 ( IGNITER_OPEN_D ) A.

Description: The ECU ignition unit voltage BITE circuit furnishes a voltage to the software that is a rescaled value of the voltage across the ignition unit (i.e., The ignition unit volt is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is less than 4.0 VDC, the fault is set. This test is run while the driver is turned on. While the driver is on, the high side is normally driven to about 27 VDC (13 VDC with minimum ECU power). If the driver is open (failed off) the high side is pulled to 0.0 VDC by the low resistance of the solenoid. A real open driver will result in a NO_FLAME auto-shutdown.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61179 ( IGNITER_SHORT_D ) A.

Description: The ECU ignition unit voltage BITE circuit furnishes a voltage to the software that is a rescaled value of the voltage across the ignition unit (i.e., The voltage is scaled down by a resistor network, goes through the analog to digital converter and is then scaled back up in software). If the voltage bit is greater than or equal to 11.0 VDC with the driver off, the fault is set. This test is run while the driver is turned off and the voltage is normally pulled to 0.0 VDC by the low resistance of a correctly operating ignition unit. If the driver is failed on, the high side is driven to about 27 VDC (with a minimum value around 13 VDC with minimum ECU power).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the APU harness/igniter unit wiring. (a)

(b)

Examine the igniter unit electrical connector. 1

Disconnect electrical connector P13 from igniter unit.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Test igniter unit wiring. 1

Make sure that the APU master switch is in the OFF position.

2

Disconnect electrical connector P13 at APU/igniter unit interface.

3

Look for presence of voltage at the harness plug as follows: Connector Number: P13 Test across sockets: A to B Necessary value: <0.5 VDC

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness.

5

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61182 ( IGV_EXC_ECU ) A.

Description: The ac excitation voltage is continuously applied to the LVDT. The excitation circuit furnishes a BITE voltage and a voltage related to current to the software. If the voltage is high and the current is present then the driver is shorted. The position signal is invalid if this fault occurs. With loss of position signal, the actuator can only be controlled to either end-stop. Electric operation is unaffected.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a IGV actuator continuity/resistance test. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Test continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 4 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 7 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 5 Necessary value: >100K ohms

5

Test continuity as follows:

UP552142

Connector Number: P17

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across LRU pins: 1 to 2 Necessary value: >100K ohms 6

Test continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 3 Necessary value: >100K ohms

7

Test continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 10 Necessary value: >100K ohms

(c)

8

Replace the IGV actuator.

9

Do the repair confirmation at the end of this task.

Test IGV actuator continuity at APU/test cell interface. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Disconnect connector P2 at APU/test cell interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 5 to 15 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 1 to 15 Necessary value: >100K ohms

5

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 15 to 30 Necessary value: >100K ohms

6

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 6 to 15 Necessary value: >100K ohms

UP552142

7 EFFECTIVITY ALL

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P2/D10436 Test across pins: 15 to 16 Necessary value: >100K ohms 8

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 15 to 31 Necessary value: >100K ohms

9

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 14 to 15 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness.

11

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

10

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61183 A.

Description:

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Evaluate the IGV actuator. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do IGV actuator continuity/resistance check. 1

Disconnect connector P17 at the APU/IGV actuator interface.

2

Examine continuity as follows: Connector Number: P17 Test across LRU pins: 1 to 6 Specified value: <300 ohms

(c)

3

Replace the IGV actuator. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine IGV actuator continuity at APU/firewall interface. 1

Disconnect connector P2 at APU/firewall interface.

2

Examine continuity as follows: Connector Number: P2/D10436 Test across harness pins: 15 to 30 Specified value: <300 ohms

(3)

UP552142

ALL

Replace wire harness. (AMM Task)

4

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

EFFECTIVITY

3

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (4)

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61184 ( IGVTM_OPEN_DRIVER ) A.

Description: For this test, the IGV actuator torque motor is commanded to 64 ma to establish an output value. The ECU measures the torque motor drive current (via sense resistor). For an open driver condition there will be no current BIT indication and the voltage bit will be low.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61185 ( IGVTM_SHORTED_DRIVER ) A.

Description: For this test, the IGV actuator torque motor is commanded to 0 ma to insure no current output. The ECU measures the torque motor drive current. If the value of the current is greater than 20 ma with the torque motor commanded off, the test fails.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the APU harness/ IGV actuator wiring. (a)

(b)

Examine the IGV actuator electrical connector. 1

Disconnect electrical connector P17 from the IGV actuator.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Test IGV actuator wiring. 1

Disconnect electrical connector P17 at APU/IGV actuator interface.

2

Look for presence of voltage at the harness plug as follows: Connector Number: P17 Test across sockets: 4 to 7 Necessary value: <0.5 VDC

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness.

4

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61197 ( APU_FAULT_OPEN_D ) A.

Description: The APU fault circuit furnishes a bit voltage to the software that is a reconstruction of the voltage across the circuit, (i.e., The APU fault volt is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is too high, the fault is set. This test is run while the driver is turned on. While the driver is on, the low side is normally driven to 0 VDC. If the driver is open (failed off), the low side is pulled to 28 VDC (minimum voltage of approximately 15.8 VDC with 16.0 VDC test cell circuit power) since the load is not pulled to ground. The driver will be turned on in test mode long enough to for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61198 ( APU_FAULT_SHORT_D ) A.

Description: The APU fault BITE circuit furnishes an indication of the circuit current flow to the software. If the circuit shows current flow with the driver turned off, the test fails. This test is run while the driver is turned off. While the driver is off, the low side is driven to 28 VDC since the circuit is not pulled to ground. If the circuit is shorted (failed on), the low side is pulled to 0.0 VDC, and the normal circuit current flow is shown (greater than 40 ma).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61199 ( LOP_INDICATOR_OPEN_D ) A.

Description: The LOP Indicator driver circuit furnishes a voltage to the software that is a reconstruction of the voltage across the circuit. (i.e., the voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is too high, the fault is set. This test is run while the driver is turned on. While the driver is on, the low side is normally driven to 0 VDC. If the driver is open (failed off), the low side is pulled to 28 VDC (minimum voltage of approximately 15.8 VDC with 16.0 VDC test cell circuit power) since the load is not pulled to ground. The driver will be turned on in test mode long enough for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61200 ( LOP_INDICATOR_SHORT_D ) A.

Description: The LOP indicator driver circuit furnishes an indication of the circuit current flow to the software. If the circuit shows current flow with the driver turned off, the test fails. This test is run while the driver is turned off. While the driver is off, the low side is driven to 28 VDC since the circuit is not pulled to ground. If the circuit is shorted (failed on), the low side is pulled to 0.0 VDC and the normal circuit current flow is shown (greater than 40 ma).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61201 ( MAINT_INDICATOR_OPEN_D ) A.

Description: The maintenance indicator driver circuit furnishes a bit voltage to the software that is a reconstruction of the voltage across the circuit (i.e., the voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is too high, the fault is set. This test is run while the driver is turned on. While the driver is on, the low side is normally driven to 0 VDC. If the driver is open (failed off), the low side is pulled to 28 VDC (minimum voltage of approximately 15.8 VDC with 16.0 VDC test cell circuit power) since the load is not pulled to ground. The driver will be turned on in test mode long enough for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61202 ( MAINT_INDICATOR_SHORT_D ) A.

Description: The maintenance indicator driver circuit furnishes an indication of the circuit current flow to the software. If the circuit shows current flow with the driver turned off, the test fails. This test is run while the driver is turned off. While the driver is off, the low side is driven to 28 VDC since the circuit is not pulled to ground. If the circuit is shorted (failed on), the low side is pulled to 0.0 VDC and the normal circuit current flow is shown (greater than 40 ma).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61203 ( OVERSPEED_IND_OPEN_D ) A.

Description: The overspeed indicator driver circuit furnishes a bit voltage to the software that is a reconstruction of the voltage across the circuit. (i.e., The APU fault volt is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage is too high, the fault is set. This test is run while the driver is turned on. While the driver is on, the low side is normally driven to 0 VDC. If the driver is open (failed off), the low side is pulled to 28 VDC (minimum voltage of approximately 15.8 VDC with 16.0 VDC test cell circuit power) since the load is not pulled to ground.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61204 ( OVERSPEED_IND_SHORT_D ) A.

Description: The overspeed indicator driver circuit furnishes an indication of the circuit current flow to the software. If the circuit shows current flow with the driver turned off, the test fails. This test is run while the driver is turned off. While the driver is off, the low side is driven to 28 VDC since the circuit is not pulled to ground. If the circuit is shorted (failed on), the low side is pulled to 0.0 VDC and the normal circuit current flow is shown (greater than 40 ma).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61210 ( DOOR_CLOSE_OPEN_D ) A.

Description: The ECU door close driver voltage BITE circuit furnishes a BIT voltage to the software that is a rescaled value of the voltage across the door close actuator (i.e., the door close actuator voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is less than 4.0 VDC, the fault is set. This test is run while the driver is turned on. While the driver is on, the high side is driven to about 27 VDC (14.5 VDC with minimum ECU power). If the driver is open (failed off), the high side is pulled to 0.0 VDC by the low resistance of the actuator.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61211 ( DOOR_CLOSE_SHORT_D ) A.

Description: The ECU door close driver voltage BITE circuit furnishes a voltage to the software that is are scaled value of the voltage across the door close driver output (i.e., the door close driver voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is greater than or equal to 8.0 VDC with the driver off, the fault is set. This test is run while the driver is turned off and the voltage is normally pulled to 0.0 VDC by the low resistance of a correctly operating door close actuator. If the driver is failed on, the high side is driven to about 27 VDC (with a minimum value around 13 VDC with minimum ECU power).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Examine test cell wiring. (a)

UP552142

(3)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61212 ( DOOR_OPEN_OPEN_D ) A.

Description: The ECU door open driver voltage BITE circuit furnishes a BIT voltage to the software that is a rescaled value of the voltage across the door open actuator (i.e., the door open actuator voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is less than 4.0 VDC, the fault is set. This test is run while the driver is turned on. While the driver is on, the high side is driven to about 27 VDC (14.5 VDC with minimum ECU power). If the driver is open (failed off), the high side is pulled to 0.0 VDC by the low resistance of the actuator.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61213 ( DOOR_OPEN_SHORT_D ) A.

Description: This failure causes the door open driver to be on continuously the ECU ignition unit voltage BITE circuit furnishes a voltage to the software that is a rescaled value of the voltage across the out-put of the door open driver (i.e., The door open driver voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is greater than or equal to 4.0 VDC with the driver off, the fault is set. This test is run while the driver is turned off and the voltage is normally pulled to 0.0 VDC by the low resistance of a correctly operating ignition unit. If the driver is failed on, the high side is driven to about 27 VDC (with a minimum value around 13 VDC with minimum ECU power).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Examine test cell wiring. (a)

UP552142

(3)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61220 ( PRESS_EXC_FAIL ) A.

Description: The software reads 2 bit voltages: The voltage bit shows the level of the dc excitation voltage (normally 10 VDC) applied to the pressure sensor. The current bit is a voltage that shows the excitation current. When the current bit shows a normal load is present (prevent an open load from which will cause a fault) and the voltage is output must indicate 10.0 V ± 0.1 V if the driver is working. A ± 0.2 V limit make sure adequate margin.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61223 ( T2_GND_SHORT ) A.

Description: Start flow is theta corrected. The RTD conditioner circuit supplies a BIT voltage to the software, which shows the voltage at the positive side of the RTD. If this signal is less than the limit, the fault is tripped. Starting schedules are modified by T-2.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the inlet temperature (T2) sensor. (a)

(b)

Examine the T2 sensor electrical connector. 1

Disconnect electrical connector P21 from the T2 sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a T2 sensor continuity/resistance test. 1

Test continuity as follows: Connector Number: P21 Test across LRU pins: A to GND (connector shell) Necessary value: >100K ohms

2

Test continuity as follows: Connector Number: P21 Test across LRU pins: B to GND (connector shell) Necessary value: >100K ohms

(c)

3

Replace the T2 sensor.

4

Do the repair confirmation at the end of this task.

Test T2 sensor continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 4 to 13

UP552142

Necessary value: >100K ohms EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 4 to 14 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61224 ( T2_HIGH ) A.

Description: Because open circuit is an infinite resistance, it looks like an infinite temperature. The highest expected temperature in operation is around 325°F (163°C). Conditioner circuit range is -107 to 548°F (-77° to 287°C). Starting schedules are modified by T2.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the inlet temperature (T2) sensor. (a)

(b)

Examine the T2 sensor electrical connector. 1

Disconnect electrical connector P21 from the T2 sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a T2 sensor continuity/resistance test. 1

Test continuity as follows: Connector Number: P21 Test across LRU pins: A to B Necessary value: <200 ohms

(c)

2

Replace the T2 sensor.

3

Do the repair confirmation at the end of this task.

Test T2 sensor continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 13 to 14 Necessary value: <200 ohms

(3) UP552142

ALL

Replace wire harness.

4

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

EFFECTIVITY

3

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61225 ( T2_LOW ) A.

Description: The near-zero resistance of a short circuit looks like a very low temperature. Lowest expected temperature in operation is around -65°F (-54°C). Conditioner circuit range is -107 to 548°F (-77 to 287°C). Startup schedules are modified by T2.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the inlet temperature (T2) sensor. (a)

(b)

Examine the T2 sensor electrical connector. 1

Disconnect electrical connector P21 from the T2 sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a T2 sensor continuity/resistance test. 1

Disconnect electrical connector P21 from the T2 sensor.

2

Test continuity as follows: Connector Number: P21 Test across LRU pins: A to B Necessary value: >72 ohms

(c)

3

Replace the T2 sensor.

4

Do the repair confirmation at the end of this task.

Test FCU T2 sensor continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 13 to 14

UP552142

Necessary value: >72 ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61231 ( OS1_CIRCUIT ) A.

Description: This test in run in test mode and at the end of onspeed mode (while the normal speed control is working). Upon receipt of a test command by the processor, the overspeed circuit selects a 0% test frequency to its input. If the output of the overspeed circuit does not indicate overspeed, within ( 3.0 / (speed frequency at which the test command was issued)) ± 0.2 ms, the fault is set. If the fuel solenoid command does not get removed as shown by a fuel solenoid current of less than 0.1A, the fault is also set. When the fault occurs, the overspeed flag is set to indicate a loss of one channel of overspeed protection (both overspeed circuits failed causes an auto-shutdown for loss of overspeed protection). If this fault is logged, the second overspeed channel test is to be done as the primary overspeed test.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU.

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Look at CDU APU Current Status screen to make sure fault cleared.

(f)

Select the Ground Report Page (5R) and make sure fault has not reoccurred.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61232 (OS1_LATCH) A.

Description: The overspeed circuit is designed to latch the overspeed indication output if the overspeed condition is removed. Failure of the overspeed indication to remain latched after the overspeed circuit test command is removed results in this fault.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU.

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Look at CDU APU Current Status screen to make sure fault cleared.

(f)

Select the Ground Report Page (5R) and make sure fault has not reoccurred.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61233 (OS2_CIRCUIT) A.

Description: This test is run in test mode and at the end of onspeed mode (while the normal speed control is working). Upon receipt of a test command by the processor, the overspeed circuit selects a 0% test frequency to its input. If the output of the overspeed circuit does not indicate overspeed, within (3.0 / (speed frequency at which the test command was issued)) ± 0.2 ms, the fault is set. If the fuel solenoid command does not get removed as shown by a fuel solenoid current of less than 0.1A, the fault is also set. When the fault occurs, the overspeed fail flag is set to indicate a loss of one channel of overspeed protection (both overspeeds failed causes an auto-shutdown for loss of overspeed protection). If this test is logged, the first overspeed channel test is to be done as the primary overspeed test.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU.

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Look at CDU APU Current Status screen to make sure fault cleared.

(f)

Select the Ground Report Page (5R) and make sure fault has not reoccurred.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61234 ( OS2_LATCH ) A.

Description: The overspeed circuit is designed to latch the overspeed indication output if the overspeed condition is removed. Failure of the overspeed indication to remain latched after the overspeed circuit test command is removed results in this fault.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU.

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Look at CDU APU Current Status screen to make sure fault cleared.

(f)

Select the Ground Report Page (5R) and make sure fault has not reoccurred.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61239 ( BLEED_VALVE_OPEN_D ) A.

Description: The ECU bleed control valve solenoid BITE circuit furnishes a voltage to the software that is a rescaled value of the voltage across the bleed control valve solenoid (i.e., The bleed control valve solenoid voltage is scaled down by a resistor network, goes through the analog to digital converter and is then scaled back up in software). If the voltage bit is low with the driver on, the driver is open. This test is run while the driver is turned on and the voltage is normally driven to about 27 VDC (with a minimum value around 13 VDC with minimum ECU power). If the driver is failed open, the high side is driven to 0.0 VDC by the low resistance of a correctly operating bleed control valve solenoid.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61241 ( BLEED_VALVE_SOL_SHORT_D ) A.

Description: The ECU bleed control valve solenoid voltage BITE circuit furnishes a voltage to the software that is a rescaled value of the voltage across the bleed control valve solenoid (i.e., The bleed control valve voltage is scaled down by a resistor network, goes through the analog to digital converter and is then scaled back up in software). If the voltage bit is greater than or equal to 14.6 VDC with the driver off, the fault is set. This test is run while the driver is turned off and the voltage is normally pulled to 0.0 VDC by the low resistance of a correctly operating bleed control solenoid valve. If the driver is failed on, the high side is driven to about 27 VDC (with a minimum value around 13 VDC with minimum ECU power). The APU Bleed valve will always be open.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Evaluate the APU harness/bleed air valve wiring. (a)

(b)

Examine the bleed air valve unit electrical connector. 1

Disconnect electrical connector P10 from the bleed air valve.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Examine APU wiring. 1

Make sure that the APU master switch is in the OFF position.

2

Disconnect electrical connector P10 at APU/LRU interface.

3

Examine for presence of voltage at the harness plug as follows: Connector Number: P10 Test across sockets: 1 to 2 Specified value: <0.5 VDC

(3)

UP552142

ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

EFFECTIVITY

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Make sure that APU Master Switch is in the ON position.

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ENGINE MANUAL 131-9[B]

UP552142

(b)

EFFECTIVITY ALL

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61242 ( READY_TO_LOAD_OPEN_D ) A.

Description: The ECU ready to load voltage driver circuit furnishes a voltage to the software that is a rescaled value of the voltage across the ready to load relay (i.e., The voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is less than the limit with the driver on, the fault is set. This test is run while the driver is turned on. If the driver is open, the high side will indicate 0.0 VDC instead of the normal 27 VDC (with a minimum value around 13 VDC with minimum ECU power).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61243 ( READY_TO_LOAD_SHORT_D ) A.

Description: The ECU ready to load voltage BITE circuit furnishes a voltage to the software that is a rescaled value of the voltage across the ready to load relay (i.e., The voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is greater than or equal to 14.6 VDC with the driver off, the fault is set. This test is run while the driver is turned off and the voltage is normally pulled to 0.0 VDC by the low resistance of a correctly operating ready to load circuit. If the driver is failed on, the high side is driven to about 27 VDC (with a minimum value around 13 VDC with minimum ECU power).

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Examine test cell wiring. (a)

UP552142

(3)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61257 ( FTOD1 ) A.

Description: The ECU frequency-to-digital (FtoD) conversion hardware is equipped to read a standard frequency reference. This known reference frequency is read through each channel of the speed conversion hardware and monitored for precision. By reading the known reference frequency through all speed converter channels during each test mode (at power-up and rolldown), the conversion reference and all speed channels are tested. Monopole #1 signal is read through FtoD #1 and monopole #2 signal is read through FtoD #2. The reference frequencies are shared with the overspeed protection circuits. FtoD #1 and FtoD #2 failures cause erroneous speed signal inputs to the software for engine control, but do not affect the operation of the hardware overspeed protection system.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61258 ( FTOD2 ) A.

Description: The ECU frequency-to-digital (FtoD) conversion hardware is equipped to read a standard frequency reference. This known reference frequency is read through each channel of the speed conversion hardware and monitored for precision. By reading the known reference frequency through all speed converter channels during each test mode (at power-up and rolldown), the conversion reference and all speed channels are tested. Monopole #1 signal is read through FtoD #1 and monopole #2 signal is read through FtoD #2. The reference frequencies are shared with the overspeed protection circuits. FtoD #1 and FtoD #2 failures cause erroneous speed signal inputs to the software for engine control, but do not affect the operation of the hardware overspeed protection system.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61259 ( SPD1_OPEN ) A.

Description: The monopole input circuit furnishes a bit voltage to the software, which shows the dc level of the voltage at the monopole. If this voltage bit signal is greater than 10 VDC, the monopole is failed open. The circuit supplies a 15 VDC pull-up applied to the analog to digital input in the case of an open monopole. The maximum value for the BIT voltage during normal operation is 9.3 VDC. An open monopole will cause the BIT voltage to be pulled up to 15 VDC, which will guarantee 10 VDC reading from the analog to digital. The test is run with a 20 ms update and is tripped by six consecutive out-of-range readings. Since quick detection has safety relevance, this fault has a short detection time, but experience shows that nuisance trips will not occur.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the speed sensor monopole 1. (a)

(b)

Examine the speed sensor monopole 1 electrical connector. 1

Disconnect electrical connector P12 from the speed sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a speed sensor monopole 1 continuity/resistance test. 1

Test continuity as follows: Connector Number: P12 Test across LRU pins: 1 to 2 Necessary value: <50 ohms

(c)

2

Replace the speed sensor.

3

Do the repair confirmation at the end of this task.

Test speed sensor monopole 1 continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows:

UP552142

Connector Number: P1/D10912

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across harness pins: 18 to 19 Necessary value: <50 ohms

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

4

Replace the speed sensor. (AMM Task) (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61260 ( SPD1_THRSH_CHK ) A.

Description: This test compares the speed (or period) of the high and low threshold signals from the same monopole. Each monopole has 2 conditioning (squaring) circuits - one with a low threshold and one with a high threshold. If monopole output amplitude decreases steadily, the high threshold conditioner will stop being triggered by the sine wave, that results in a long time period per cycle and a slow measured speed. This type of signal deterioration is the dominant failure mode for monopoles. Only the low threshold signals are used for control and overspeed detection, so the APU still has two speed inputs and two redundant channels of overspeed protection even when this fault exists.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the speed sensor monopole 1. (a)

(b)

Examine the speed sensor monopole 1 electrical connector. 1

Disconnect electrical connector P12 from the speed sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the speed sensor. 1

(c)

Do the repair confirmation at the end of this task.

Test speed sensor monopole 1 continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across harness pins: 7 to 18 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P1/D10912 Test across harness pins: 7 to 19

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

4

Replace wire harness.

5

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace the speed sensor. (AMM Task) (a)

(5)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61261 ( SPD1_XCHECK ) A.

Description: The speed controller works on the higher of SPEED1LO and SPEED2LO (the LO shows the output of the low threshold monopole conditioner). A gradual degradation of a monopole will first cause the low threshold signal to disagree with the high threshold signal, triggering the speed threshold check fault. If the problem were fixed following that fault, then this fault will never occur.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Examine speed sensor monopole 1 wire harness continuity at APU/firewall interface. (a)

Disconnect connector P1 at APU/firewall interface.

(b)

Examine continuity as follows: Connector Number: P1/D10912 Test across harness pins: 7 to 18 Specified value: >100K ohms

(c)

Examine continuity as follows: Connector Number: P1/D10912 Test across harness pins: 7 to 19 Specified value: >100K ohms

(3)

(d)

Replace wire harness. (AMM Task)

(e)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

Replace the speed sensor. (AMM Task) (a)

(5)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU. (AMM Task)

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

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ENGINE MANUAL 131-9[B]

UP552142

(d)

EFFECTIVITY ALL

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61262 ( SPD2_OPEN ) A.

Description: The monopole input circuit furnishes a bit voltage to the software, which shows the dc level of the voltage at the monopole. If this voltage bit signal is greater than 10 VDC, the monopole is failed open. The circuit supplies a 15 VDC pull-up applied to the analog to digital input in the case of an open monopole. The nominal value for the BIT voltage during normal operation is 7.5 VDC, with a max. of 8.4 VDC including tolerances, which will prevent nuisance trips. An open monopole will cause the BIT voltage to be pulled up to 15 VDC, which will guarantee 10 VDC reading from the analog to digital. The test is run with a 20 ms update and is tripped by six consecutive out-of-range readings. Since quick detection has safety relevance, this fault has a short detection time, but experience shows that nuisance trips will not occur.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the speed sensor monopole 2. (a)

(b)

Examine the speed sensor monopole 2 electrical connector. 1

Disconnect electrical connector P12 from the speed sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a speed sensor monopole 2 continuity/resistance test. 1

Test continuity as follows: Connector Number: P12 Test across LRU pins: 3 to 4 Necessary value: <50 ohms

UP552142

(c)

EFFECTIVITY ALL

2

Replace the speed sensor.

3

Do the repair confirmation at the end of this task.

Test speed sensor monopole 2 continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P1/D10912 Test across harness pins: 12 to 26 Necessary value: <50 ohms

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

4

Replace the speed sensor. (AMM Task) (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61263 ( SPD2_THRSH_CHK ) A.

Description: This test compares the speed (or period) of the high and low threshold signals from the same monopole. Each monopole has 2 conditioning (squaring) circuits - one with a low threshold and one with a high threshold. If monopole output amplitude decreases steadily, the high threshold conditioner will stop being triggered by the sine wave, that results in a long time period per cycle and a slow measured speed. This type of signal deterioration is the dominant failure mode for monopoles. The 5% difference test has a factor of 50 margin from nuisance indications since the speed measurement precision is about ±0.1%. Only the low threshold signals are used for control and overspeed detection, so the APU still has 2 speed inputs and two redundant channels of overspeed protection even when this fault exists.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the speed sensor monopole 2. (a)

(b)

Examine the speed sensor monopole two electrical connector. 1

Disconnect electrical connector P12 from the speed sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace the speed sensor. 1

(c)

Do the repair confirmation at the end of this task.

Test speed sensor monopole two continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across harness pins: 12 to 27 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P1/D10912 Test across harness pins: 26 to 27 Necessary value: >100K ohms

UP552142

4

EFFECTIVITY ALL

Replace wire harness.

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ENGINE MANUAL 131-9[B] 5 (3)

Examine test cell wiring. (a)

(4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

Do the repair confirmation at the end of this task.

Replace the speed sensor. (AMM Task) (a)

(5)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61264 ( SPD2_XCHECK ) A.

Description: Speed precision is actually about ±0.1%, so a speed disagreement of 5% has a factor of 50 margin from nuisance indications. The speed controller works on the higher of speed 1 and speed 2 low threshold monopole conditioners. A gradual degradation of a monopole will first cause the low threshold signal to disagree with the high threshold signal, triggering the speed threshold check fault. If the problem were fixed following that fault, then this fault will never occur.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness. (AMM Task)

(b)

Do the repair confirmation at the end of this task.

Test speed sensor monopole 2 wire harness continuity at APU/test cell interface. (a)

Disconnect connector P1 at APU/test cell interface.

(b)

Test continuity as follows: Connector Number: P1/D10912 Test across harness pins: 12 to 27 Necessary value: >100K ohms

(c)

Test continuity as follows: Connector Number: P1/D10912 Test across harness pins: 26 to 27 Necessary value: >100K ohms

(3)

(d)

Replace wire harness.

(e)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

Replace the speed sensor. (AMM Task) (a)

(5)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

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ENGINE MANUAL 131-9[B]

UP552142

(d)

EFFECTIVITY ALL

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61265 ( START_COMMAND_SHORT_D ) A.

Description: The start relay driver circuit furnishes a voltage to the software that is a rescaled value of the voltage across the output terminals (i.e., The voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is greater than 11.0 VDC while the driver is off, the fault is set. With the driver is off, the voltage must read less than 3.33 VDC. If the driver is shorted (failed on), the voltage will read greater than 14.6 VDC.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Examine test cell wiring. (a)

UP552142

(3)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61268 ( START_COMMAND_OPEN_D ) A.

Description: The start relay driver circuit supplies a bit voltage to the software that is a reconstruction of the voltage across the output terminals (i.e., The voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). This test is run while the driver is turned on. With the driver on, the voltage is normally 28 VDC (around 14.5 VDC with 16.0 VDC test cell circuit power). If the driver is open (failed off), the voltage is less than 3.33 VDC. If this failure is detected, the starter will not be energized and the subsequent NOSPEED shutdown will be logged.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61274 ( SCV_DAC_FAILURE ) A.

Description: The SCV digital-to-analog converter must indicate a value proportional to the command set for the test. If the DAC output is stuck low the surge valve will be closed that results in no surge protection.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61275 ( SCV_EXC_ECU ) A.

Description: The ac excitation voltage is continuously applied to the LVDT. The excitation circuit furnishes a BITE voltage and a voltage measurement related to current to the software. If the voltage bit is high and current is present then the driver is shorted. The position signal is invalid if this fault occurs. With loss of position signal, the actuator can only be controlled to either end-stop. Electric operation is unaffected. A failed surge position flag causes the fault tolerance logic to monitor the corrected flow area and latch the SCV fully open if the corrected flow approaches surge while in bleed air mode. While not in bleed air mode, the SCV is held open anyway.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Make an analysis of the SCV actuator. (a)

(b)

Examine the SCV electrical connector. 1

Disconnect electrical connector P9 from the SCV.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a SCV continuity/resistance test. 1

Disconnect connector P9 at the APU/SCV interface.

2

Test continuity as follows: Connector Number: P9 Test across LRU pins: 4 to 8 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P9 Test across LRU pins: 4 to 7 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P9 Test across LRU pins: 1 to 4

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 5

Test continuity as follows: Connector Number: P9 Test across LRU pins: 2 to 4 Necessary value: >100K ohms

6

Test continuity as follows: Connector Number: P9 Test across LRU pins: 3 to 4 Necessary value: >100K ohms

7

Test continuity as follows: Connector Number: P9 Test across LRU pins: 4 to 9 Necessary value: >100K ohms

(c)

8

Replace the SCV.

9

Do the repair confirmation at the end of this task.

Test SCV continuity at APU/test cell interface. 1

Disconnect connector P9 at the APU/SCV actuator interface.

2

Disconnect connector P2 at APU/test cell interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 21 to 22 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 8 to 22 Necessary value: >100K ohms

5

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 9 to 22 Necessary value: >100K ohms

6

Test continuity as follows: Connector Number: P2/D10436

UP552142

Test across pins: 22 to 23 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: >100K ohms 7

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 10 to 22 Necessary value: >100K ohms

8

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 2 to 22 Necessary value: >100K ohms

9

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 7 to 22 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness.

11

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

10

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61276 ( SCVTM_OPEN_NEG_D ) A.

Description: For this test, the SCV torque motor is commanded to -20 ma. The ECU measures the torque motor drive current via a sense resistor. If the current is not within the expected range, then the driver has failed. A failed negative torque motor driver will decrease the maximum opening rate of the valve, which will make the APU more likely to surge in pneumatic transients.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61277 ( SCVTM_OPEN_POS_D ) A.

Description: For this test, the SCV torque motor is commanded to 40 ma. The ECU measures the torque motor drive current via a sense resistor. If the current is not within the expected range, then the driver has failed the typical current reading for a torque motor operating correctly is 40 ma. The reading for a failed driver circuit current will be 0 ma. A failed positive torque motor driver will remove the ability to close the valve, which will cause a low bleed pressure.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61278 ( SCVTM_SHORTED_NEG_D ) A.

Description: The test expects the current output for the torque motor driver to be 0.0 ma when there is no commanded current to the driver. If the current shown by the current wrap signal is more than the limit with no current commanded, the test fails.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Evaluate the APU harness/surge control valve wiring. (a)

(b)

Examine the surge control valve electrical connector. 1

Disconnect electrical connector P9 from the surge control valve.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Examine APU wiring. 1

Make sure that the APU master switch is in the OFF position.

2

Disconnect electrical connector P9 at APU/LRU interface.

3

Examine for presence of voltage at the harness plug as follows: Connector Number: P9 Test across sockets: 7 to 8 Specified value: <0.5 VDC

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness.

5

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61279 ( SCVTM_SHORTED_POS_D ) A.

Description: The test expects the current output for the torque motor driver to be 0.0 ma when there is no commanded current to the driver. If the current shown by the current wrap signal is more than the limit with no current commanded, the test fails.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Evaluate the APU harness/surge control valve wiring. (a)

(b)

Examine the surge control valve electrical connector. 1

Disconnect electrical connector P9 from the surge control valve.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Examine APU wiring. 1

Make sure that the APU master switch is in the OFF position.

2

Disconnect electrical connector P9 at APU/LRU interface.

3

Examine for presence of voltage at the harness plug as follows: Connector Number: P9 Test across sockets: 7 to 8 Specified value: <0.5 VDC

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness. (AMM Task)

5

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61293 ( FLOW_DIVIDER_SOL_SHORT_D ) A.

Description: The driver circuit furnishes a voltage to the software that is a rescaled value of the voltage across the output terminals (i.e., The voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). If the voltage bit is greater than 11.0 VDC while the driver is off, the fault is set. With the driver is off, the voltage must read less than 3.33 VDC. If the driver is shorted (failed on), the voltage will read greater than 11.0 VDC.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

(2)

Do the repair confirmation at the end of this task.

Evaluate the APU harness/flow divider solenoid wiring. (a)

(b)

Examine the flow divider solenoid electrical connector. 1

Disconnect electrical connector P23 from the flow divider solenoid.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Examine APU wiring. 1

Make sure that the APU master switch is in the OFF position.

2

Disconnect electrical connector P23 at APU/LRU interface.

3

Examine for presence of voltage at the harness plug as follows: Connector Number: P23 Test across sockets: 1 to 2 Specified va: <0.5 VDC

(3)

UP552142

EFFECTIVITY ALL

Replace wire harness.

5

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-61296 ( FLOW_DIVIDER_SOL_OPEN_D ) A.

Description: The driver circuit supplies a bit voltage to the software that is a reconstruction of the voltage across the output terminals (i.e., The voltage is scaled down by a resistor network, goes through the analog to digital converter, and is then scaled back up in software). This test is run while the driver is turned on. With the driver on, the voltage is normally 28 VDC (around 14.5 VDC with 16.0 VDC test cell circuit power). If the driver is open (failed off), the voltage is less than 3.33 VDC. If this failure is detected, it is possible to have a no flame shutdown at altitude.

B.

Fault isolation procedure. (1)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(2)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-71146 ( EGT1_DIFF ) A.

Description: Fault is logged when the two EGT signals disagree by more than 150°F (66°C) for 10 seconds. Experience shows EGTs read within 30°F (-1°C) of each other while APU is on-speed. During startup, larger differences occur, so this fault is not detectable with N < 95%.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the EGT1 thermocouple. (a)

Test EGT1 thermocouple continuity at APU. 1

Disconnect wire harness connections from EGT1 terminals.

2

Test continuity as follows: Test across terminals: chromel to alumel Necessary value: <20 ohms

3

Test continuity as follows: Test across terminals: chromel to grounded EGT1 mount flange Necessary value: >100K ohms

4

Test continuity as follows: Test across terminals: alumel to grounded EGT1 mount flange Necessary value: >100K ohms

(b)

5

Replace the EGT1 thermocouple.

6

Do the repair confirmation at the end of this task.

Test EGT1 thermocouple continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Disconnect wire harness connections from EGT1 terminals.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 1 to 5 Necessary value: >100K ohms

4

Test continuity as follows:

UP552142

Connector Number: P1/D10912

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across LRU pins: 1 to 7 Necessary value: >100K ohms 5

Test continuity as follows: Connector Number: P1/D10912 Test across LRU pins: 5 to 7 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the APU. (a)

(8)

Do the repair confirmation at the end of this task.

Replace the EGT2 thermocouple. (a)

(7)

Do the repair confirmation at the end of this task.

Replace the EGT1 thermocouple. (a)

(6)

7

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

6

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU, apply electrical load and bleed air.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-71147 ( EGT1_OPEN ) A.

Description: EGT1 less than -200°F (-129°C) for an open thermocouple. An open circuit is the dominant failure mode.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the EGT1 thermocouple. (a)

Test EGT1 thermocouple continuity at APU. 1

Test continuity of as follows: Test across two terminals: chromel to alumel Necessary value: <20 ohms

(b)

2

Replace the EGT1 thermocouple.

3

Do the repair confirmation at the end of this task.

Test EGT1 thermocouple continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 1 to 5 Necessary value: <20 ohms

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the EGT1 thermocouple. (a)

(6)

4

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-71148 ( EGT2_OPEN ) A.

Description: EGT2 less than -200°F (-129°C) for an open thermocouple. An open circuit is the dominant failure mode.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the EGT2 thermocouple. (a)

Test EGT2 thermocouple continuity at APU. 1

Test continuity of as follows: Test across two terminals: chromel to alumel Necessary value: <20 ohms

(b)

2

Replace the EGT2 thermocouple.

3

Do the repair confirmation at the end of this task.

Test EGT2 thermocouple continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 15 to 16 Necessary value: <20 ohms

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the EGT2 thermocouple. (a)

(6)

4

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

3

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-71149 ( EGT2_DIFF ) A.

Description: The fault is logged when the two EGT signals disagree by more than 150°F (66°C) for 10 seconds. The lower signal is the most likely cause since there are no known failure modes that make EGT read high. Experience shows the EGT signals read within 30°F (-1°C) of each other while the APU is on-speed. During startup, larger differences occur, so this fault is not detectable with N < 95%.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the EGT2 thermocouple. (a)

Test EGT2 thermocouple continuity at APU. 1

Disconnect wire harness connections from EGT2 terminals.

2

Test continuity as follows: Test across terminals: chromel to alumel Necessary value: <20 ohms

3

Test continuity as follows: Test across terminals: chromel to grounded EGT2 mount flange Necessary value: >100k ohms

4

Test continuity as follows: Test across terminals: alumel to grounded EGT2 mount flange Necessary value: >100k ohms

(b)

5

Replace the EGT2 thermocouple.

6

Do the repair confirmation at the end of this task.

Test EGT2 thermocouple continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Disconnect wire harness connection from one EGT2 terminal.

3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 15 to 16 Necessary value: >100K ohms

UP552142

4

EFFECTIVITY ALL

Test continuity as follows:

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ENGINE MANUAL 131-9[B] Connector Number: P1/D10912 Test across LRU pins: 7 to 15 Necessary value: >100K ohms 5

Test continuity as follows: Connector Number: P1/D10912 Test across LRU pins: 7 to 16 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace the APU. (a)

(7)

Do the repair confirmation at the end of this task.

Replace the EGT2 thermocouple. (a)

(6)

7

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

6

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Start APU, apply electrical load and bleed air.

(b)

Shut down APU.

(c)

Make sure that APU Master Switch is in the ON position.

(d)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72101 ( DMM_POWER_ON_OC ) A.

Description: The DMM drive circuitry furnishes an overcurrent discrete bit to the software that shows the need to turn off the driver. The expected current is 45.0 ma - 100.0 ma. The nominal overcurrent trip point is 300 ma including tolerances, providing a large margin from nuisance prevention. Detects overcurrent to DMM while it is turned on (during power-up and rolldown). The DMM is attached to the APU and is used to store usage statistics, health monitoring, and life usage information for the core APU, as well as IGV bias information, which is set at engine ATP. The DMM cannot be read or written to if this fault occurs. Note: the ECU and DMM must not be replaced at the same time or the data will be lost. Also, DMM must always be replaced with a newly-initialized unit. If an overcurrent is found, the driver will be turned off. After one second, the driver will be enabled.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

(3)

Do the repair confirmation at the end of this task.

Make an analysis of wiring harness. (a)

Test wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P2 at APU/test cell interface.

2

Disconnect electrical connector P11 at APU/DMM interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 18 Necessary value: >100K

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 32 Necessary value: >100K

5

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 18 to 32

UP552142

Necessary value: >100K

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] (4)

Make an analysis of the DMM. (a)

(b)

(5)

UP552142

EFFECTIVITY ALL

1

Disconnect electrical connector P11 from the DMM.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace DMM. 1

Do the repair confirmation at the end of this task.

2

If the fault has not cleared reinstall the DMM removed in the steps above.

Replace APU Electronic Control Unit (ECU). (a)

(6)

Examine the DMM electrical connector.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72103 ( DMM_READ_FAIL ) A.

Description: Tests the value of the APU serial number stored in the DMM. If the data does not match, or the APU serial number is invalid, or the data cannot be read correctly, the test fails.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the DMM. (a)

(b)

(3)

Examine the DMM electrical connector. 1

Disconnect electrical connector P11 from the DMM.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace DMM. (AMM TASK) 1

Do the repair confirmation at the end of this task.

2

If the fault has not cleared reinstall the DMM removed in the steps above.

Make an analysis of wiring harness. (a)

Test wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P2 at APU/test cell interface.

2

Disconnect electrical connector P11 at APU/DMM interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 19 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 35 Necessary value: >100K ohms

5

Test continuity as follows:

UP552142

Connector Number: P2/D10436 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across pins: 19 to 35 Necessary value: >100K ohms 6

Install a jumper across sockets 8 and 9 at the DMM connector P11 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 19 to 35 Necessary value: <10 ohms

8

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 34 Necessary value: >100K ohms

9

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 33 Necessary value: >100K ohms

10

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 33 to 34 Necessary value: >100K ohms

11

Install a jumper across sockets 10 and 11 at the DMM connector P11 on the APU harness side.

12

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 33 to 34 Necessary value: <10K ohms

13

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 20 Necessary value: >100K ohms

14

Test continuity as follows:

UP552142

Connector Number: P2/D10436

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across pins: 17 to 36 Necessary value: >100K ohms 15

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 20 to 36 Necessary value: >100K ohms

16

Install a jumper across sockets 6 and 7 at the DMM connector P11 on the APU harness side.

17

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 20 to 36 Necessary value: <10 ohms

18 (4)

Examine test cell wiring. (a)

(5)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72104 ( DMM_WRAP_FAIL ) A.

Description: During the DMM power_up wrap test the ECU processor input buffer is read to determine the status of the DMM transmit and receive circuits. If the buffer shows a fault outside of the ECU, DMM_WRAP is set. Power is applied to the DMM at least 1 second before this test is run to permit the DMM_POWER tests to complete and inhibit this test if power is failed. NOTE:

B.

The ECU and DMM must not be replaced at the same time or the data will be lost. Also, DMM must always be replaced with a newly-initialized unit.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the DMM. (a)

(b)

(3)

Examine the DMM electrical connector. 1

Disconnect electrical connector P11 from the DMM.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace. 1

Do the repair confirmation at the end of this task.

2

If the fault has not cleared reinstall the DMM removed in the steps above.

Make an analysis of wiring harness. (a)

Test wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P2 at APU/test cell interface.

2

Disconnect electrical connector P11 at APU/DMM interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 19 Necessary value: >100K ohms

4

Test continuity as follows:

UP552142

Test across pins: 17 to 35 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: >100K ohms 5

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 19 to 35 Necessary value: >100K ohms

6

Install a jumper across sockets 8 and 9 at the DMM connector P11 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 19 to 35 Necessary value: <10 ohms

8

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 34 Necessary value: >100K ohms

9

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 33 Necessary value: >100K ohms

10

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 33 to 34 Necessary value: >100K ohms

11

Install a jumper across sockets 10 and 11 at the DMM connector P11 on the APU harness side.

12

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 33 to 34 Necessary value: <10K ohms

13

Test continuity as follows: Connector Number: P2/D10436

UP552142

Test across pins: 17 to 20

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: >100K ohms 14

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 36 Necessary value: >100K ohms

15

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 20 to 36 Necessary value: >100K ohms

16

Install a jumper across sockets 6 and 7 at the DMM connector P11 on the APU Harness side.

17

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 20 to 36 Necessary value: <10 ohms

18 (4)

Examine test cell wiring. (a)

(5)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72105 ( DMM_WRITE_FAIL ) A.

Description: The test checks the value of the APU serial number, hours, minutes or cycles. If the data does not match the written value, the test fails.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the DMM. (a)

(b)

(3)

Examine the DMM electrical connector. 1

Disconnect electrical connector P11 from the DMM.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace DMM. 1

Do the repair confirmation at the end of this task.

2

If the fault has not cleared reinstall the DMM removed in the steps above.

Make an analysis of wiring harness. (a)

Test wiring harness continuity at APU/test cell interface. 1

Disconnect electrical connector P2 at APU/test cell interface.

2

Disconnect electrical connector P11 at APU/DMM interface.

3

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 19 Necessary value: >100K ohms

4

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 35 Necessary value: >100K ohms

5

Test continuity as follows:

UP552142

Connector Number: P2/D10436 EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across pins: 19 to 35 Necessary value: >100K ohms 6

Install a jumper across sockets 8 and 9 at the DMM connector P11 on the APU harness side.

7

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 19 to 35 Necessary value: <10 ohms

8

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 34 Necessary value: >100K ohms

9

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 33 Necessary value: >100K ohms

10

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 33 to 34 Necessary value: >100K ohms

11

Install a jumper across sockets 10 and 11 at the DMM connector P11 on the APU harness side.

12

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 33 to 34 Necessary value: <10K ohms

13

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 17 to 20 Necessary value: >100K ohms

14

Test continuity as follows:

UP552142

Connector Number: P2/D10436

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Test across pins: 17 to 36 Necessary value: >100K ohms 15

Test continuity as follows: Connector Number: P2/D10436 Test across pins: 20 to 36 Necessary value: >100K ohms

16

Install a jumper across sockets 6 and 7 at the DMM connector P11 on the APU harness side.

17

Test continuity on the harness at the test cell as follows: Connector Number: P2/D10436 Test across pins: 20 to 36 Necessary value: <10 ohms

18 (4)

Examine test cell wiring. (a)

(5)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72205 ( APU_FAULT_ON_OC ) A.

Description: The APU fault driver circuit furnishes a current indication that is used to turn off the driver. The expected current with no failures is 80 mA. The nominal overcurrent trip point is 200 mA dc. The fault detects an overcurrent in the APU fault circuit when the ECU driver is turned on. If an overcurrent is found, the driver will be turned off. After one second, the driver will be enabled. The driver will be turned on in test mode long enough to for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

Examine test cell wiring. (a)

(2)

Make an analysis of test cell components. (a)

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(4)

Do the repair confirmation at the end of this task.

Do this repair confirmation task: 1

Power up controller.

2

Pull FIRE Handle to energize fault light.

3

Verified Fault cleared from APU current status CDU page.

4

Do repair confirmation task at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72206 ( LOP_INDICATOR_ON_OC ) A.

Description: The ECU lop indicator driver circuit furnishes a current indication that is used to turn off the driver. The expected current with no failures is 80 mA (including aircraft component tolerance, temp variation, and aircraft power supply variation). The nominal overcurrent trip point is 200 mA dc. The fault detects an overcurrent in the "LOP" indicator circuit when the ECU driver is turned on. If an overcurrent is found, the driver will be turned off. After one second, the driver will be enabled. The driver will be turned on in test mode long enough to for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

Examine test cell wiring. (a)

(2)

Make an analysis of test cell components. (a)

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(4)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU.

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72207 ( MAINT_INDICATOR_ON_OC ) A.

Description: The ECU maintenance indicator driver circuit furnishes a current indication that is used to turn off the driver. The expected current with no failures is 80 mA. The nominal overcurrent trip point is 200 mA dc. The fault detects an overcurrent in the "MAINTENANCE" indicator circuit when the ECU driver is turned on. If an overcurrent is found, the driver will be turned off. After one second, the driver will be enabled. The driver will be turned on in test mode long enough to for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

Examine test cell wiring. (a)

(2)

Make an analysis of test cell components. (a)

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(4)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72208 ( OVERSPEED_IND_ON_OC ) A.

Description: The ECU overspeed indicator driver circuit furnishes a current indication that is used to turn off the driver. The expected current with no failures is 80 mA. The nominal overcurrent trip point is 200 mA dc. The fault detects an overcurrent in the "OVERSPEED" indicator circuit when the ECU driver is turned on. If an overcurrent is found, the driver will be turned off. After one second, the driver will be enabled. The driver will be turned on in test mode long enough to for the test to pass or fail only when powered from the CDU.

B.

Fault isolation procedure. (1)

Examine test cell wiring. (a)

(2)

Make an analysis of test cell components. (a)

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(4)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-72209 ( READY_TO_LOAD_ON_OC ) A.

Description: The ECU ready to load driver circuit furnishes an overcurrent discrete bit that shows the driver has exceeded the overcurrent threshold the highest expected current with no failures is 3A. The nominal overcurrent trip point is 6A. The fault detects overcurrent in the ready to load circuit when the ECU driver is turned on. If an overcurrent is found, the driver must be turned off. After one second, the driver will be enabled.

B.

Fault isolation procedure. (1)

Examine test cell wiring. (a)

(2)

Make an analysis of test cell components. (a)

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(4)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CUD APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-74105 A.

Description:

B.

Fault isolation procedure. (1)

Evaluate the DMM. (a)

UP552142

(b)

EFFECTIVITY ALL

Examine the DMM electrical connector. 1

Disconnect electrical connector P11 from the DMM.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Replace DMM. (AMM TASK) 1

Do the repair confirmation at the end of this task.

2

If the fault has not cleared reinstall the DMM removed in the steps above.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-90601 A.

Description:

B.

Fault isolation procedure.

UP552142

(1)

EFFECTIVITY ALL

Evaluate plumbing for leakage source. (a)

Open fuel control witness drain and inspect for oil leakage.

(b)

Replace fuel control unit if leakage is seen.

(c)

Do the repair confirmation at the end of this task.

(d)

Open surge control value witness drain and inspect for oil leakage.

(e)

Replace surge control value if oil is present.

(f)

Do the repair confirmation at the end of this task.

(g)

Open surge control value witness drain and inspect for oil leakage.

(h)

Replace surge control value if oil is present.

(i)

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-91005 ( HIGH_OIL_TEMP_COND ) A.

Description: This shutdown occurs if the oil temperature reads higher than 312°F (156°C) for 10 seconds. The cooling system has sufficient margin to prevent high oil temperature, especially in normal conditions. If the oil temp sensor is failed, 60°F (16°C) is substituted for oil temperature, essentially disabling this shutdown.

B.

Fault isolation procedure. (1)

Inspect APU oil cooler. (AMM Task) (a)

(2)

Inspect the eductor oil cooler inlet. (AMM Task) (a)

(3)

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Examine for APU internal damage. (a)

Inspect Magnetic Chip Collector. (AMM Task) NOTE:

(b) (4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

(9)

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(8)

Do the repair confirmation at the end of this task.

Replace Hot Oil Temperature sensor. (AMM Task) (a)

(7)

Do the repair confirmation at end of this task.

Replace Starter/Generator. (AMM Task) (a)

(6)

Make sure that the APU rotates freely. (AMM Task)

Replace oil Temperature Control Valve. (AMM Task) (a)

(5)

If collector is OK, continue without starting APU.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Select Page 2 of CDU input monitoring pages.

(d)

Run APU with full load until oil temperature stabilizes. (AMM Task)

(e)

Make sure the oil temperature is less than 250°F (121°C).

(f)

Shut down APU. (AMM Task)

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-91006 ( INLET_OVERHEAT_COND ) A.

Description: This shutdown occurs if the inlet temperature reads higher than 350°F (177°C) for 3 seconds.

B.

Fault isolation procedure. (1)

Do the following steps to insure there is no signs of an inlet fire: (a)

Remove the access panel on the APU plenum.

(b)

Examine the inner side of the inlet plenum for fire damage.

(c)

Inspect the APU inlet duct through the inlet door for fire damage.

(d)

If there is no signs of fire damage, then continue. NOTE:

(2)

Replace T2 sensor. (AMM Task) (a)

(3)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(4)

If fire damage is evident replace APU. (AMM Task)

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Shut down APU.

(d)

Make sure that APU Master Switch is in the ON position.

(e)

Make sure CDU APU Current Status screen fault is cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-91007 ( LOP_COND ) A.

Description: This shutdown occurs after SPD95U if low oil pressure is indicated for 20 seconds. Oil pressure is normally high before reaching 95% speed. The 20 second time for this shutdown is necessary by the ECU specification. Also operation at negative Gs, for up to 10 seconds, is necessary without shutdown. Hence a 20-second monitor time is used.

B.

Fault isolation procedures. (1)

(2)

Examine for maintenance messages. (a)

Move APU master switch to the OFF position for two seconds then to the ON position.

(b)

Examine CDU APU current status screen for maintenance message: - 49-94226 (LOPSW_OPEN)

-

- 49-91227 (OIL_QUANTITY_LOW)

(c)

Follow the applicable FIM task.

(d)

Do the repair confirmation at the end of this task.

Make sure oil level on APU oil level sight glass. (AMM Task) (a)

(3)

-

Do the repair confirmation at end of this task.

Examine for APU internal damage. (a)

Inspect Magnetic Chip Collector. (AMM Task) NOTE:

(b) (4)

UP552142

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Replace the APU. (AMM Task) (a)

(8)

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(7)

Do the repair confirmation at the end of this task.

Replace Lube module. (AMM Task) (a)

(6)

Make sure that the APU rotates freely. (AMM Task)

Replace the LOP switch. (AMM Task) (a)

(5)

If collector is OK, continue without starting APU.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

(c)

Select Page 2 of CDU input monitoring pages.

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UP552142

ENGINE MANUAL 131-9[B]

EFFECTIVITY ALL

(d)

Run APU with full load until oil temperature stabilizes. (AMM Task)

(e)

Make sure the oil temperature is less than 250°F (121°C).

(f)

Shut down APU. (AMM Task)

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-91227 ( OIL_QUANTITY_LOW ) A.

Description: This test shows that the APU oil quantity is low. If LOQMNTDIS is true MAINT_ACT is not set and the flight deck effect is "NO FLIGHT DECK LIGHT".

B.

Fault isolation procedure. (1)

APU oil level. (a)

With APU off, examine APU oil level on sight glass. (AMM Task)

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

(2)

(3)

(b)

Add oil to fill the APU sump.

(c)

Do the repair confirmation at the end of this task.

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the oil level switch. (a)

(b)

Examine the OLS electrical connector. 1

Disconnect electrical connector P16 from the OLS.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity/resistance test. 1

Make sure that the oil level is above the add mark on the sight glass.

2

Test continuity as follows: Connector Number: P16 Test across LRU pins: 1 to 2 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P16

UP552142

Test across LRU pins: 2 to 12

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Necessary value: >100K ohms

(c)

4

Replace the OLS.

5

Do the repair confirmation at the end of this task.

Test OLS continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P3/D10434 Test across pins: 9 to 19 Necessary value: >100K ohms

3

Test continuity as follows: Connector Number: P3/D10434 Test across pins: 9 to 6 Necessary value: >100K ohms

(4)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(6)

Replace wire harness.

Examine test cell wiring. (a)

(5)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-94022 ( CLOGGED_OIL_FILTER_COND ) A.

Description: The ECU receives a hardware switch input indicating an impending bypass of the starter/ generator oil filter. If this condition is true for five seconds with the Oil Temperature being greater than 100°F (38°C) and the airplane is on the ground (main engines have been off for at least 90 seconds), an APU auto-shutdown is initiated.

B.

Fault isolation procedures. (1)

Examine for APU internal damage. (a)

Inspect Magnetic Chip Collector. (AMM Task) NOTE:

(b) (2)

Make sure that the APU rotates freely. (AMM Task)

Evaluate starter/generator oil filter. (a)

Replace starter/generator oil filter. (AMM Task)

(b)

Do a general visual examination of the lube system filter delta P indicator.

(c) (3)

1

If filter delta P indicator is extended continue.

2

Replace lube system oil filter. (AMM TASK)

Do the repair confirmation at the end of this task.

Look for maintenance messages. (a)

Move APU master switch to the OFF position for two seconds then to the ON position.

(b)

Examine CDU APU current status screen for maintenance message: -

(4)

Follow the applicable FIM.

(d)

Do the repair confirmation at the end of this task.

Examine test cell wiring.

UP552142

EFFECTIVITY ALL

Do the repair confirmation at end of this task.

Replace APU Electronic Control Unit (ECU). (AMM Task) (a)

(7)

Do the repair confirmation at the end of this task.

Replace SG Impending Bypass Switch. (AMM Task) (a)

(6)

49-94300 (OIL_FILTER_SW_FAILED)

(c)

(a) (5)

If collector is OK, continue without starting APU.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU. (AMM Task)

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UP552142

ENGINE MANUAL 131-9[B]

EFFECTIVITY ALL

(c)

Select Page 2 of CDU input monitoring pages.

(d)

Run APU with full load until oil temperature stabilizes. (AMM Task)

(e)

Make sure the oil temperature is less than 250°F (121°C).

(f)

Shut down APU. (AMM Task)

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-94226 ( LOPSW_OPEN ) A.

Description: The LOP switch is a normally closed switch. This means when the APU is not running, there is no oil pressure and the switch must be closed or "short". Before engine operation, if the switch shows "open", then there is an open in the circuit or the switch is stuck open.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the LOP switch. (a)

(b)

Examine the LOP switch electrical connector. 1

Disconnect electrical connector P14 from the LOP switch.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity test as follows: 1

Test continuity as follows: Connector Number: P14 Test across LRU pins: 1 to 2 Necessary value: <10 ohms

(c)

2

Replace the LOP switch.

3

Do the repair confirmation at the end of this task.

Test LOP switch continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P3/D10434 Test across pins: 11 to 12 Necessary value: <10 ohms

(3) UP552142

ALL

Replace wire harness.

4

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

EFFECTIVITY

3

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for two seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-94228 ( TOIL_GND_SHORT ) A.

Description: The RTD conditioner circuit supplies a BIT voltage to the software, which shows the voltage at the positive side of the RTD. If this signal is less than the limit, the fault is tripped.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the oil temperature sensor. (a)

(b)

Examine the oil temperature sensor electrical connector. 1

Disconnect electrical connector P15 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a sensor continuity/resistance test. 1

Test continuity as follows: Connector Number: P15 Test across LRU pins: A to connector shell Necessary value: >100K ohms

2

Test continuity as follows: Connector Number: P15 Test across LRU pins: B to connector shell Necessary value: >100K ohms

(c)

3

Replace the sensor.

4

Do the repair confirmation at the end of this task.

Test continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 34 to 35

UP552142

Necessary value: >100K ohms

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 3

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 35 to 36 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-94229 ( TOIL_HIGH ) A.

Description: Because an open circuit is an infinite resistance, it looks like an infinite temperature. The highest possible operating temperature is limited to 290°F (143°C). Conditioner circuit range is -107 to 548°F (-77 to 287°C).

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the oil temperature sensor. (a)

(b)

Examine the oil temperature sensor electrical connector. 1

Disconnect electrical connector P15 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a sensor continuity/resistance test. 1

Test continuity as follows: Connector Number: P15 Test across LRU pins: A to B Necessary value: <200 ohms

(c)

2

Replace the oil temperature sensor.

3

Do the repair confirmation at the end of this task.

Test continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 34 to 36 Necessary value: <200 ohms

(3) UP552142

ALL

Replace wire harness.

4

Do the repair confirmation at the end of this task.

Examine test cell wiring. (a)

EFFECTIVITY

3

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-94230 ( TOIL_LOW ) A.

Description: The near-zero resistance of a short circuit looks like a very low temperature. Lowest possible temperature in operation is around -65°F (-54°C). Conditioner circuit range is -107 to 548°F (-77 to 287°C). The BITE limit at -100°F (-73°C) makes sure that the conditioner can always read the value without saturating a short to ground could cause an out-of-range reading, so the ground short fault inhibits this one.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the oil temperature sensor. (a)

(b)

Examine the oil temperature sensor electrical connector. 1

Disconnect electrical connector P15 from the sensor.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a sensor continuity/resistance test. 1

Test continuity as follows: Connector Number: P15 Test across LRU pins: A to B Necessary value: >60 ohms

(c)

2

Replace the oil temperature sensor.

3

Do the repair confirmation at the end of this task.

Test continuity at APU/test cell interface. 1

Disconnect connector P1 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P1/D10912 Test across pins: 34 to 36

UP552142

Necessary value: >60 ohms

EFFECTIVITY ALL

3

Replace wire harness.

4

Do the repair confirmation at the end of this task.

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ENGINE MANUAL 131-9[B] (3)

Examine test cell wiring. (a)

(4)

Replace APU Electronic Control Unit (ECU). (a)

UP552142

(5)

EFFECTIVITY ALL

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Make sure that APU Master Switch is in the ON position.

(b)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-94299 ( OIL_FILTER_CLOGGED ) A.

Description: A hardware discrete input to the ECU shows an impending bypass of the starter generator oil filter. If the filter is bypassed and the bypass switch is not failed and oil temperature is greater than 100°F (38°C) and the APU is running, the oil filter will only be bypassed when the filter is clogged.

B.

Fault isolation procedure. (1)

Make an analysis of starter/generator oil filter. (a)

Replace starter/generator oil filter.

(b)

Do a general visual examination of the lube system filter delta P indicator.

(c) (2)

1

If filter delta P indicator is extended continue.

2

Replace lube system oil filter.

Do the repair confirmation at the end of this task.

Look for maintenance messages. (a)

Move APU master switch to the OFF position for two seconds then to the ON position.

(b)

Look at CDU APU current status screen for maintenance message: - 49-94300 (OIL_FILTER_SW_FAILED).

UP552142

(3)

EFFECTIVITY ALL

(c)

Follow the applicable FIM.

(d)

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Start APU.

(c)

Select Page 2 of CDU input monitoring pages.

(d)

Run APU with full load until oil temperature stabilizes.

(e)

Make sure the oil temperature is less than 250°F (121°C).

(f)

Shut down APU.

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ENGINE MANUAL 131-9[B] MAINTENANCE MESSAGE: 49-94300 ( OIL_FILTER_SW_FAILED ) A.

Description: A hardware discrete input to the ECU shows an impending bypass of the starter generator oil filter. When the APU is not running, this switch must be electrically open. If an electrical ground is detected, the switch is failed.

B.

Fault isolation procedure. (1)

(2)

Do a general visual inspection of the APU wiring harness. (a)

Replace wire harness.

(b)

Do the repair confirmation at the end of this task.

Make an analysis of the starter/generator impending bypass switch. (a)

(b)

Examine the switch electrical connector. 1

Disconnect electrical connector P24 from the switch.

2

Examine the electrical connector plug and receptacle for contamination and damage.

3

Repair/clean connector.

4

Do the repair confirmation at the end of this task.

Do a continuity test as follows: 1

Test continuity as follows: Connector Number: P24 Test across LRU pins: 1 to 2 Necessary value: >100K ohms

2

Test continuity as follows: Connector Number: P24 Test across LRU pins: 1 to 3 Necessary value: >100K ohms

(c)

3

Replace the impeding bypass switch.

4

Do the repair confirmation at the end of this task.

Test impending bypass switch continuity at APU/test cell interface. 1

Disconnect connector P3 at APU/test cell interface.

2

Test continuity as follows: Connector Number: P3/D10434 Test across pins: 13 to 29

UP552142

Necessary value: >100K ohms EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 3

Test continuity as follows: Connector Number: P3/D10434 Test across pins: 14 to 29 Necessary value: >100K ohms

(3)

UP552142

EFFECTIVITY ALL

5

Do the repair confirmation at the end of this task.

Do the repair confirmation at the end of this task.

Replace APU Electronic Control Unit (ECU). (a)

(5)

Replace wire harness.

Examine test cell wiring. (a)

(4)

4

Do the repair confirmation at the end of this task.

Do a repair confirmation as follows: (a)

Display CDU APU Current Status screen.

(b)

Move the APU Master Switch to the OFF position for 2 seconds, minimum, then move the switch to the ON position.

(c)

Look at CDU APU Current Status screen to make sure fault cleared.

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ENGINE MANUAL 131-9[B]

GENERAL REMOVAL-01 TASK 49-20-00-000-801 1.

General A.

This section contains procedures to prepare the APU for the removal of accessory components and the separation of the modules.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

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

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

E.

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

F.

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

Special Tools, Fixtures and Equipment

2.

A.

Table 3001 shows the special tools, fixtures and equipment needed for preparation of the APU for removal of the accessory components. Table 3001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Use

Equivalent tools, fixtures and equipment can be used.

Cart Assembly

Includes PN 834990-1 engine stand/cart, PN 834895-1 Interface Mount, PN 834892-2 and PN 834892-3 Aft Mount arm, PN 834898-1 Support Arm, PN 834894-1 Adjustable Mount.

Lifting Adapter

Used with hoist to lift the APU out of shipping carton 834888-1 and place into portable engine stand/cart.

Bleed Duct Support

Component of PN 834892-1. Support APU forward end and bleed duct in PN 834990-1 portable engine stand/cart.

Adjustable Mount

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Part No. 834892-1

834894-1

Bleed Duct Support

Component of PN 834894-1.Support APU bleed duct 834894-5 in PN 834943-1 portable engine stand/cart.

Interface Bolts

Component of PN 834892-1. Adapt APU mounts to aft mount arms and support arm (3 necessary).

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

834895-1

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ENGINE MANUAL 131-9[B] Table 3001. Special Tools, Fixtures and Equipment (Cont) Nomenclature

Use

Aft Mount Arm

Component of PN 834892-1. Adapt engine assembly 834892-2 into portable engine stand/cart (right aft engine mount).

Aft Mount Arm

Component of PN 834892-1. Adapt engine assembly 834892-3 into portable engine stand/cart (left aft engine mount).

Support Arm

Component of PN 834892-1. Support engine assembly 834898-1 on forward right side in portable engine stand/cart.

Portable Engine

Component of PN 834892-1. Build stand and test cart for APU.

Stand/Cart 3.

Part No.

834990-1

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-540-001 A.

Remove the APU from the shipping container. (1)

Remove hardware that attaches the APU to the shipping container, crate, skid or other support.

(2)

Attach PN 834888-1 lifting adapter to the APU lifting brackets.

(3)

Remove the APU from the shipping container with PN 834888-1 lifting adapter.

SUBTASK 49-20-00-410-001

UP552142

B.

EFFECTIVITY ALL

Install the APU in the PN 834990-1 portable engine stand/cart. (1)

Install PN 834895-1 interface bolts on the APU aft mounts and forward right mount.

(2)

Attach PN 834892-2 aft mount arm to the PN 834895-1 interface bolt on the APU right aft mount.

(3)

Attach PN 834892-3 aft mount arm to the PN 834895-1 interface bolt on the APU left aft mount.

(4)

Install PN 834898-1 support arm on the PN 834990-1 portable engine stand/cart with the support arm attaching hole inboard in relation to the portable engine stand/cart.

(5)

Install APU in PN 834990-1 portable engine stand/cart as follows: (a)

Position the APU in the PN 834990-1 portable engine stand/cart with the APU forward right side next to the portable engine stand/cart support arm.

(b)

Attach the PN 834892-2 and PN 834892-3 aft mount arms to the PN 834895-1 interface bolts on the APU aft mounts.

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ENGINE MANUAL 131-9[B] (c)

Attach the PN 834898-1 forward support arm to the PN 834895-1 interface bolt on the forward right APU mount.

(6)

Remove PN 834888-1 lifting adapter from the APU.

(7)

Use a protractor mounted on the DMM mount pad to adjust the APU forward end down by 11.5 degrees and tighten PN 834898-1 forward support arm to keep APU at this angle.

(8)

Attach the PN 834894-5 bleed duct support to the bleed duct.

SUBTASK 49-20-00-600-001

UP552142

C.

EFFECTIVITY ALL

Drain the oil if necessary. (Refer to SERVICING 01).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

PLUMBING AND ELECTRICAL INSTALLATION REMOVAL-02 TASK 49-20-00-050-801 1.

2.

General A.

This section contains procedures for removal of the plumbing and electrical installation.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

D.

Make a record of the quantities and thickness of the washers. This will help when the part is installed.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-002 A.

Remove the plumbing and electrical installation. WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENERGIZED AND GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT TERMINAL.

UP552142

(1)

EFFECTIVITY ALL

Remove components of plumbing and electrical installation (Figure 3001 through Figure 3009) and replace as necessary in accordance with good shop practice. During removal, write the routing of wiring, tubing and hoses, and manner of attaching clamps for reference at assembly. Plumbing fittings, lines, and wiring harness connectors and terminals, must be tagged as removed to help in assembly.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 5A. WIRING HARNESS-BRANCHED (IPC FIG. 2)

240. TUBE-FUEL SUPPLY

45. TUBE ASSEMBLY

250. TUBE ASSEMBLY

70. SPACER

260. TUBE ASSEMBLY

205. NUT SELF-LOCKING

265. PLATE DRAIN MAST

215. WASHER

270. SEAL

225. NUT-ATTACHED WASHER

285. CLAMP TUBE

230. TAPE

340. PACKING

UP552142

235A. HARNESS-GENERATOR

EFFECTIVITY ALL

385. BOLT

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3002. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3002 30. TUBE-GEARBOX VENT (IPC FIG. 2)

215. WASHER

90. BOLT

225. NUT-ATTACHED WASHER

110. CLAMP-COOLER TUBES

230. TAPE

115. GROMMET

335. PACKING

120. GROMMET -COOLER TUBES

355. CLAMP-HINGED

130. GROMMET

360. CLAMP-HINGED

135. PACKING

365. BRACKET-GENERATOR FILTER

205. NUT

370. BRACKET-VENT-TUBE

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3003. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3003 10. TUBE-COOLER RETURN (IPC FIG. 2)

170. PACKING

15. TUBE-COOLER SUPPLY

180. PACKING

20. TUBE-AFT BRG RETURN

195. ADAPTER-ORIFICED TUBE

- 20A. TUBE-AFT BRG RETURN (POST SB 131-49-7597) 25. TUBE-AFT BRG SUPPLY

UP552142

- 25A. TUBE-AFT BRG SUPPLY (POST SB 131-49-7597)

215. WASHER 225. NUT-ATTACHED WASHER

35. TUBE-IGV SUPPLY

230. TAPE

40. TUBE-IGV RETURN

275. GASKET

45. TUBE-LRU FUEL DRAIN

300. CLAMP-QUAD-TUBE

60. TUBE-MANIFOLD SUPPLY

315. CLAMP-HARN-4TH-MNT

65. ADAPTER

360. CLAMP-HINGED

80. REDUCER-ADAPTER

375. CLAMP-LOOP

85. CLAMP-MAIN HARNESS

380. CLAMP-LOOP

90. BOLT

390. CLAMP

115. GROMMET

410. CLAMP

120. GROMMET

420. BRACKET (POST SB 131-49-7597)

130. GROMMET

425. GROMMET (POST SB 131-49-7597)

135. PACKING

430. NUT (POST SB 131-49-7597)

155. PACKING

-. ITEM NOT ILLUSTRATED

EFFECTIVITY ALL

205. NUT

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3004. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3004 50. TUBE-P TOTAL

180. PACKING

55. TUBE-P STATIC (IPC FIG. 2)

185. PACKING

90. BOLT

230. TAPE

120. GROMMET

245. TUBE

170. PACKING

285. CLAMP

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3005. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3005 90. BOLT (IPC FIG. 2)

205. NUT

95. CLAMP-BAV TO GRBX

230. TAPE

100. CLAMP-GRBX/HARNESS

295. CLAMP-GRBX-HARN/TUBE

170. PACKING

305. CLAMP-COMB-TO-HARN

175. PACKING

320. CLAMP-HARN-NR-IGV

180. PACKING

350. CLAMP-LOOP

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3006. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3006 50. TUBE-P TOTAL (IPC FIG. 2)

210. FLOW DIVIDER

65. ADAPTER

215. WASHER

70. SPACER

220. UNION-FLARED

75. ADAPTER

230. TAPE

90. BOLT

250. TUBE-EDUCTOR DRAIN

105. PACKING

255. TUBE-DUCT DRAIN

115. GROMMET

260. TUBE-SEAL

120. GROMMET

265. PLATE

125. NUT-TUBE

270. GASKET

140. RETAINER

280. FITTING

145. PACKING

290. CLAMP

150. PACKING

325. BOLT

160. PACKING

330. CLAMP

165. PACKING

380. CLAMP

190. PACKING

385. BOLT

200. VALVE-SOLENOID

400. PLATE

UP552142

205. NUT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3007. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3007

UP552142

90. BOLT (IPC FIG. 2) 205. NUT

450. NUT (POST SB 131-49-7902)

375. CLAMP

460. CLAMP-LOOP (POST SB 131-49-7902)

380. CLAMP

470. CLAMP-LOOP (POST SB 131-49-7902)

EFFECTIVITY ALL

440. BOLT (POST SB 131-49-7902)

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3008. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3008 45. FUEL DRAIN TUBE ASSEMBLY (PRE SB 131-49-8023)

500. FUEL DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

485. FCU DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

505. DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

490. SCV DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

510. TEE (POST SB 131-49-8023)

UP552142

495. INLET GUIDE VANE DRAIN TUBE ASSEMBLY (POST 131-SB 49-8023)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3009. Disassemble the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3009 25. GROUND STRAP (IPC FIG. 10)

375. CLAMP

90. BOLT (IPC FIG. 2)

380. CLAMP

UP552142

205. NUT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

STARTER/GENERATOR REMOVAL-03 TASK 49-20-00-050-802 1.

General A.

This section contains procedures for removal of the starter/generator.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

UP552142

SUBTASK 49-20-00-050-003 A.

Turn-off all electrical power to the starter/generator.

B.

Disconnect electrical connectors and cables from the starter/generator. Separate and insulate bare lead-ends from touching each other.

C.

Remove the starter/generator. (Refer to Figure 3001.)

EFFECTIVITY ALL

(1)

Remove nuts with attached washer (10).

(2)

Remove starter/generator (20) from the engine assembly (100).

(3)

Remove seal plate (30) from engine assembly (100).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Starter/Generator

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 10. NUT WITH ATTACHED WASHER (IPC FIG. 3)

UP552142

20. STARTER/GENERATOR

EFFECTIVITY ALL

30. SEAL PLATE 100. ENGINE ASSEMBLY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

LOW OIL PRESSURE (LOP) SWITCH REMOVAL-04 TASK 49-20-00-050-803 1.

General A.

This section contains procedures for removal of the LOP switch.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-004

UP552142

A.

EFFECTIVITY ALL

Remove the LOP switch. (Refer to Figure 3001.) (1)

Remove nut with attached washer (40).

(2)

Remove LOP switch (50) with packing (60) from the engine assembly (100). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of LOP Switch

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 40. NUT WITH ATTACHED WASHER (IPC FIG. 3)

UP552142

50. LOP SWITCH

EFFECTIVITY ALL

60. PACKING 100. ENGINE ASSEMBLY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

OIL LEVEL SENSOR REMOVAL-05 TASK 49-20-00-050-804 1.

General A.

This section contains procedures for removal of the oil level sensor.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-005

UP552142

A.

EFFECTIVITY ALL

Remove the oil level sensor. (Refer to Figure 3001.) (1)

Remove nut (70).

(2)

Remove oil level sensor (80) with packing (90) from the engine assembly (100). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Oil Level Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 70. NUT (IPC FIG. 3)

UP552142

80. OIL LEVEL SENSOR

EFFECTIVITY ALL

90. PACKING 100. ENGINE ASSEMBLY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

FUEL CONTROL UNIT (FCU) REMOVAL-06 TASK 49-20-00-050-805 1.

General A.

This section contains procedures for removal of the FCU.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

Special Tools, Fixtures and Equipment A.

3.

None

Equipment and Materials A.

4.

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

None

Procedure

SUBTASK 49-20-00-050-006 A.

Remove the fuel control unit. (Refer to Figure 3001.) (1)

Put a 2 gallon (8L) container below the fuel control unit (20).

(2)

Remove the coupling clamp (10) from the fuel control unit (20).

WARNING: USE THE CORRECT PERSONAL PROTECTION. FUEL CAN CAUSE SKIN, EYE, AND LUNG DAMAGE. USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (3)

Remove the fuel control unit (20) with packing (30) from the engine assembly (90). Discard packing.

UP552142

NOTE:

EFFECTIVITY ALL

During removal of the fuel control unit, oil from the lube module cavity may drain.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Fuel Control Unit

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3001 10. COUPLING CLAMP (IPC FIG. 4)

30. PACKING

20. FUEL CONTROL UNIT

90. ENGINE ASSEMBLY

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

LUBE MODULE REMOVAL-07 TASK 49-20-00-050-806 1.

General A.

This section contains procedures for removal of the lube module.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-007 A.

Remove the lube module. (Refer to Figure 3001.) (1)

Put a 2 gallon (8 L) container below lube module (40).

(2)

Remove the fuel control unit (FCU). (Refer to REMOVAL 06.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. USE CARE WHEN ENGINE OIL IS DRAINED. HOT OIL CAN CAUSE BAD BURNS.

UP552142

CAUTION:

EFFECTIVITY ALL

THE LUBE MODULE IS A TIGHT FIT. DURING REMOVAL, PULL THE LUBE MODULE CAREFULLY TO PREVENT DAMAGE TO THE LUBE MODULE DRIVE SHAFT.

(3)

Loosen the captive bolts and remove lube module (40) with packing (50) from the engine assembly (90).

(4)

Remove packing (50) from lube module (40). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Lube Module

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 40. LUBE MODULE (IPC FIG. 4)

90. ENGINE ASSEMBLY

UP552142

50. PACKING

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

DATA MEMORY MODULE (DMM) REMOVAL-08 TASK 49-20-00-050-807 1.

2.

General A.

This section contains procedures for removal of the DMM.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-008

UP552142

A.

EFFECTIVITY ALL

Remove the DMM. (Refer to Figure 3001.) (1)

Remove bolts (60) and washers (70).

(2)

Remove the DMM (80) from the engine assembly (90).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of DMM

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3001 60. BOLT (IPC FIG. 4)

80. DMM

70. WASHER

90. ENGINE ASSY

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

BLEED DUCT REMOVAL-09 TASK 49-20-00-050-808 1.

2.

General A.

This section contains procedures for removal of the bleed duct.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-009 A.

Remove the bleed duct assembly. (Refer to Figure 3001.)

UP552142

(1)

EFFECTIVITY ALL

Remove clamps (10), bleed duct (20) and seals (30) from the engine assembly (190).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Bleed Duct

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 10. CLAMP (IPC FIG. 5)

UP552142

20. BLEED DUCT

EFFECTIVITY ALL

30. SEAL 190. ENGINE ASSY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

BLEED AIR VALVE (BAV) REMOVAL-10 TASK 49-20-00-050-809 1.

2.

General A.

This section contains procedures for removal of the bleed air valve.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-010

UP552142

A.

EFFECTIVITY ALL

Remove the bleed air valve. (Refer to Figure 3001.) (1)

Remove the bleed duct. (Refer to REMOVAL 09.)

(2)

Remove clamp (10), bleed air valve (40), and seal (30) from the engine assembly (190).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Bleed Air Valve

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 10. CLAMP (IPC FIG. 5)

UP552142

30. SEAL

EFFECTIVITY ALL

40. BLEED AIR VALVE 190. ENGINE ASSY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

COMPRESSOR DISCHARGE DUCT REMOVAL-11 TASK 49-20-00-050-810 1.

2.

General A.

This section contains procedures for removal of the compressor discharge duct.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-011

UP552142

A.

EFFECTIVITY ALL

Remove the compressor discharge duct. (Refer to Figure 3001.) (1)

Remove the bleed air valve. (Refer to REMOVAL 10.)

(2)

Remove clamp (50).

(3)

Remove bolts (120) and washers (130) from the engine assembly (190).

(4)

Remove compressor discharge duct (140) with packing (150) and attached total pressure probe assembly from the engine assembly (190). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Compressor Discharge Duct

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 10. CLAMP (IPC FIG. 5)

130. WASHER

30. SEAL

140. COMPRESSOR DISCHARGE DUCT

50. CLAMP

150. AIR PACKING

70. SEAL

190. ENGINE ASSY

UP552142

120. BOLT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

TOTAL PRESSURE PROBE ASSEMBLY REMOVAL-12 TASK 49-20-00-050-811 1.

General A.

This section contains procedures for removal of the total pressure probe assembly.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-012

UP552142

A.

EFFECTIVITY ALL

Remove the total pressure probe assembly. (Refer to Figure 3001.) (1)

Remove compressor discharge duct (140) from the engine assembly (190). (Refer to REMOVAL 11.)

(2)

Remove nut (160) and total pressure probe assembly (170) with packing (180) from the compressor discharge duct (140). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Total Pressure Probe Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 140. COMPRESSOR DISCHARGE DUCT (IPC FIG. 5)

180. PACKING

160. NUT

190. ENGINE ASSY

UP552142

170. TOTAL PRESSURE PROBE ASSY

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

SURGE CONTROL VALVE (SCV) REMOVAL-13 TASK 49-20-00-050-812 1.

2.

General A.

This section contains procedures for removal of the surge control valve.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-013

UP552142

A.

EFFECTIVITY ALL

Remove the surge control valve. (Refer to Figure 3001.) (1)

Remove clamps (50).

(2)

Remove surge control valve (60) from the engine assembly.

(3)

Remove seals (70) from the surge control valve (60).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Surge Control Valve

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 50. CLAMP (IPC FIG. 5)

UP552142

60. SURGE CONTROL VALVE

EFFECTIVITY ALL

70. SEAL 190. ENGINE ASSY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

SURGE DUCT REMOVAL-14 TASK 49-20-00-050-813 1.

2.

General A.

This section contains procedures for removal of the surge duct.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-014

UP552142

A.

EFFECTIVITY ALL

Remove the surge duct. (Refer to Figure 3001.) (1)

Remove clamps (10, 50) from the engine assembly (190).

(2)

Remove surge duct (110) from the engine assembly (190).

(3)

Remove seals (30, 70) from the surge duct (110).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Surge Duct

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001

UP552142

10. CLAMP (IPC FIG. 5) 30. SEAL

110. SURGE DUCT

50. CLAMP

190. ENGINE ASSY

EFFECTIVITY ALL

70. SEAL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

SPEED SENSOR REMOVAL-15 TASK 49-20-00- 050-814 1.

2.

General A.

This section contains procedures for removal of the speed sensor.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-015

UP552142

A.

EFFECTIVITY ALL

Remove speed sensor. (Refer to Figure 3001.) (1)

Remove nut (10).

(2)

Remove speed sensor (20) with packing (30, 40) from the engine assembly (160). Discard packings.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Speed Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 10. NUT (IPC FIG. 6) 20. SPEED SENSOR

40. PACKING 160. ENGINE ASSY

UP552142

30. PACKING

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

INLET PRESSURE SENSOR (P2) REMOVAL-16 TASK 49-20-00-050-815 1.

General A.

This section contains procedures for removal of the inlet pressure sensor.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-016

UP552142

A.

EFFECTIVITY ALL

Remove inlet pressure sensor. (Refer to Figure 3001.) (1)

Remove nut (50).

(2)

Remove inlet pressure sensor (60) with attached packing (70) from the engine assembly (160). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Inlet Pressure Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 50. NUT (IPC FIG. 6)

UP552142

60. P2 SENSOR

EFFECTIVITY ALL

70. PACKING 160. ENGINE ASSY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

TOTAL PRESSURE SENSOR (PT) REMOVAL-17 TASK 49-20-00-050-816 1.

General A.

This section contains procedures for removal of the total pressure sensor.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-017

UP552142

A.

EFFECTIVITY ALL

Remove total pressure sensor. (Refer to Figure 3001.) (1)

Remove nut (80).

(2)

Remove total pressure sensor (90) with attached packing (100) from the engine assembly (160). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Total Pressure Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3001 80. NUT (IPC FIG. 6)

100. PACKING

90. TOTAL PRESSURE SENSOR

160. ENGINE ASSY

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

DIFFERENTIAL PRESSURE SENSOR (DP) REMOVAL-18 TASK 49-20-00-050-817 1.

General A.

This section contains procedures for removal of the differential pressure sensor.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-018

UP552142

A.

EFFECTIVITY ALL

Remove differential pressure sensor. (Refer to Figure 3001.) (1)

Remove nut (110).

(2)

Remove differential pressure sensor (120) with attached packings (130, 140) from the engine assembly (160). Discard packings.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Differential Pressure Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 110. NUT (IPC FIG. 6)

140. PACKING

120. DIFFERENTIAL PRESSURE SENSOR

160. ENGINE ASSY

UP552142

130. PACKING

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

INLET TEMPERATURE SENSOR (T2) REMOVAL-19 TASK 49-20-00-050-818 1.

General A.

This section contains procedures for removal of the inlet temperature sensor.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-019 A.

Remove the inlet temperature sensor. (Refer to Figure 3001.)

UP552142

(1)

EFFECTIVITY ALL

Remove inlet temperature sensor (150) and gasket from the engine assembly (160).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Inlet Temperature Sensor (T2)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001

UP552142

150. INLET TEMPERATURE SENSOR (IPC FIG. 6)

EFFECTIVITY ALL

160. ENGINE ASSY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

IGNITER PLUG REMOVAL-20 TASK 49-20-00-050-819 1.

2.

General A.

This section contains procedures for removal of the igniter plug.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-020

UP552142

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

Remove the power input connector from the ignition unit.

B.

Remove igniter plug. (Refer to Figure 3001.)

EFFECTIVITY ALL

(1)

Remove igniter plug lead from the igniter plug (20).

(2)

Remove igniter plug (20) with gasket (30) from the engine assembly (240). Discard gasket.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Igniter Plug and Adapter

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 20. IGNITER PLUG (IPC FIG. 7)

240. ENGINE ASSY

UP552142

30. GASKET

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

IGNITER PLUG LEAD REMOVAL-21 TASK 49-20-00-050-820 1.

2.

General A.

This section contains procedures for removal of the igniter plug lead.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-021 WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENERGIZED AND GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT TERMINAL. A.

Remove the power input connector from the ignition unit.

B.

Remove igniter plug lead. (Refer to Figure 3001.)

UP552142

(1)

EFFECTIVITY ALL

Remove igniter plug lead (10) from the ignition unit and igniter plug.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Igniter Plug Lead

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001

UP552142

10. IGNITER PLUG LEAD (IPC FIG. 7)

EFFECTIVITY ALL

240. ENGINE ASSY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

IGNITION UNIT REMOVAL-22 TASK 49-20-00-050-821 1.

2.

General A.

This section contains procedures for removal of the ignition unit.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-022 WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENERGIZED AND GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT TERMINAL. A.

Remove the power input connector from the ignition unit (70).

B.

(Pre SB 131-49-7527) Remove ignition unit. (Refer to Figure 3001).

UP552142

C.

EFFECTIVITY ALL

(1)

Remove igniter plug lead from the ignition unit (70).

(2)

Remove bolts (40, 50), washers (60), and ignition unit (70) from ignition bracket (100).

(3)

Remove bolts (80) to disconnect ground strap (90) and ignition bracket (100) from the engine assembly (240).

(Post SB 131-49-7527) Remove ignition unit. (Refer to Figure 3002). (1)

Remove igniter plug lead from the ignition unit (70).

(2)

Remove bolt (80) to disconnect ground strap (90).

(3)

Remove bolts (40), washers (60) and ignition unit (70) from the engine assembly (240).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. (Pre SB 131-49-7527) Removal of Ignition Unit

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3001 40. BOLT (IPC FIG. 7)

80. BOLT

50. BOLT

90. GROUND STRAP

60. WASHER

100. IGNITION BRACKET

70. IGNITION UNIT

240. ENGINE ASSY

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3002. (Post SB 131-49-7527) Removal of Ignition Unit

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3002 40. BOLT (IPC FIG. 7)

80. BOLT

60. WASHER

90. GROUND STRAP

UP552142

70. IGNITION UNIT

EFFECTIVITY ALL

240. ENGINE ASSY

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

EXHAUST GAS TEMPERATURE (EGT) THERMOCOUPLE REMOVAL-23 TASK 49-20-00-050-822 1.

2.

General A.

This section contains procedures for removal of the EGT thermocouples.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-023

UP552142

A.

EFFECTIVITY ALL

Remove EGT thermocouples. (Refer to Figure 3001.) (1)

Remove nuts (110).

(2)

Remove EGT thermocouples (120) with gaskets (130) from the engine assembly (240). Discard gaskets.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of EGT Thermocouples

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3001 110. NUT (IPC FIG. 7)

130. GASKET

120. EGT THERMOCOUPLE

240. ENGINE ASSY

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

COMBUSTOR CASE DRAIN PLUG REMOVAL-24 TASK 49-20-00-050-823 1.

2.

General A.

This section contains procedures for removal of the combustor case drain plug.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-024 A.

Remove combustor case drain plug. (Refer to Figure 3001.) (1)

(Pre SB 131-49-7667) Remove plug (140) with gasket (150) from the engine assembly (240). Discard gasket.

UP552142

(Post SB 131-49-7667) Remove lockwire from plug (-140A). Remove plug (-140A) with gasket (150) from the engine assembly (240). Discard gasket.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Combustor Case Drain Plug

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] Key to Figure 3001 140. PLUG (IPC FIG. 7) -140A. PLUG

240. ENGINE ASSY -. ITEM NOT ILLUSTRATED

UP552142

150. GASKET

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

INLET GUIDE VANE ACTUATOR (IGVA) REMOVAL-25 TASK 49-20-00-050-824 1.

General A.

This section contains procedures for removal of the inlet guide vane actuator.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-025

UP552142

A.

EFFECTIVITY ALL

Remove inlet guide vane actuator. (Refer to Figure 3001.) (1)

Loosen bolts (160) and move cover to show clevis assembly.

(2)

Remove clevis bolt and washer securing clevis assembly to rod end (190). (Refer to View A.)

(3)

Remove bolts (160) and washers (170) from the engine assembly (240).

(4)

Remove inlet guide vane actuator (180) from the engine assembly (240).

(5)

Loosely install bolt and washer on clevis assembly.

(6)

Remove rod end (190) from the inlet guide vane actuator (180).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Inlet Guide Vane Actuator

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 160. BOLT (IPC FIG. 7)

190. ROD END

170. WASHER

240. ENGINE ASSY

UP552142

180. INLET GUIDE VANE ACTUATOR

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

ACCESS DOOR REMOVAL-26 TASK 49-20-00-050-825 1.

2.

General A.

This section contains procedures for removal of the access door.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-026

UP552142

A.

EFFECTIVITY ALL

Remove access door. (Refer to Figure 3001.) (1)

Remove bolt (220).

(2)

Loosen the eight latches and remove access door (230) from the engine assembly (240).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Access Door

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 220. BOLT (IPC FIG. 7)

240. ENGINE ASSY

UP552142

230. ACCESS DOOR

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

IDENTIFICATION PLATE REMOVAL-27 TASK 49-20-00-050-826 1.

2.

General A.

This section contains procedures for removal of the identification plate.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-027 A.

Remove the identification plate. (Refer to Figure 3001.) (1)

Remove screws (200) and identification plate (210) from the engine assembly (240).

UP552142

NOTE:

EFFECTIVITY ALL

Do not remove identification plate unless it is damaged or if unreadable.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Identification Plate

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] Key to Figure 3001 200. SCREW (IPC FIG. 7)

240. ENGINE ASSY

UP552142

210. IDENTIFICATION PLATE

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

FUEL MANIFOLD ASSEMBLY REMOVAL-28 TASK 49-20-00-050-827 1.

General A.

This section contains procedures for removal of the fuel manifold assemblies.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-028

UP552142

A.

EFFECTIVITY ALL

Remove the fuel manifold assemblies. (Refer to Figure 3001.) (1)

Disconnect secondary fuel manifold (10) and primary fuel manifold assembly (20) from fuel nozzles on the engine assembly (30).

(2)

Disconnect secondary fuel manifold assembly (10) and primary fuel manifold assembly (20) from flow divider on the engine assembly (30).

(3)

Remove secondary fuel manifold assembly (10) and primary fuel manifold assembly (20) from the engine assembly (30).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Fuel Manifold Assemblies

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B] Key to Figure 3001 10. SECONDARY FUEL MANIFOLD ASSY (IPC FIG. 8)

30. ENGINE ASSY

UP552142

20. PRIMARY FUEL MANIFOLD ASSY

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

OIL COOLER REMOVAL-29 TASK 49-20-00-050-828 1.

General A.

This section contains procedures for removal of the oil cooler.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-029

UP552142

A.

EFFECTIVITY ALL

Remove the oil cooler. (Refer to Figure 3001.) (1)

Loosen captive bolts and remove oil cooler (10) from the engine assembly (80).

(2)

Remove fireshield (50) from oil cooler (10) as follows. (a)

Remove countersunk screws (20) and fireshield (50) from the oil cooler (10).

(b)

Remove screws (30) and fireshield brackets (40) from the fireshield (50).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Oil Cooler

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 3001 10. OIL COOLER (IPC FIG. 9)

40. FIRESHIELD BRACKET

20. COUNTERSUNK SCREW

50. FIRESHIELD

30. SCREW

80. ENGINE ASSY

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TEMPERATURE CONTROL VALVE REMOVAL-30 TASK 49-20-00-050-829 1.

General A.

This section contains procedures for removal of the temperature control valve.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-030

UP552142

A.

EFFECTIVITY ALL

Remove the temperature control valve. (Refer to Figure 3001.) (1)

Remove nuts (60).

(2)

Remove the temperature control valve (70) from the engine assembly (80).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Temperature Control Valve

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 60. NUT (IPC FIG. 9)

80. ENGINE ASSY

UP552142

70. TEMPERATURE CONTROL VALVE

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UPPER AND LOWER INLET DUCT REMOVAL-31 TASK 49-20-00-050-830 1.

2.

General A.

This section contains procedures for removal of the upper and lower inlet ducts.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-050-031

UP552142

A.

EFFECTIVITY ALL

Remove the upper and lower inlet ducts. (Refer to Figure 3001.) (1)

Disconnect bonding straps from flow divider valve, IGV access cover and gearbox assembly.

(2)

Loosen retaining straps and remove upper inlet duct (10) and lower inlet duct (20A) from the engine assembly (30).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Upper and Lower Inlet Duct

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 10. UPPER INLET DUCT (IPC FIG. 10)

30. ENGINE ASSY

UP552142

20A. LOWER INLET DUCT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

GEARBOX ASSEMBLY REMOVAL-32 TASK 49-20-00-020-801 1.

General A.

This section contains procedures for removal of the gearbox assembly.

B.

Do the removal procedures in a dry, bright, clean room.

C.

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

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. D. 2.

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

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Procedure

SUBTASK 49-20-00-020-001

UP552142

A.

EFFECTIVITY ALL

Remove the gearbox assembly. (Refer to Figure 3001.) (1)

Remove nuts (10) and washers (20).

(2)

Remove clamps (95, 100, 285, 295, 320).

(3)

Remove the gearbox assembly (30) with packing (40) from the engine assembly (80). Discard packing.

(4)

Remove quill shaft assembly (50) and packing (60) from the engine assembly (80). Discard packing.

(5)

Remove packing (70) from lubricating nozzle assembly. Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 3001. Removal of Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 3001 10. NUT (IPC FIG. 11)

80. ENGINE ASSEMBLY

20. WASHER

95. BAV TO GEARBOX CLAMP (IPC FIG. 2)

30. GEARBOX ASSY

100. GEARBOX/HARNESS CLAMP

40. PACKING

285. GEARBOX TO VENT CLAMP

50. QUILL SHAFT ASSEMBLY

295. GEARBOX HARNESS/TUBE CLAMP

60. PACKING

320. IGV NR HARNESS CLAMP

UP552142

70. PACKING

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

GENERAL INSTALLATION-01 TASK 49-20-00-400-801 1.

General

2.

A.

This section contains general procedures for installation of accessory components and modules on the APU.

B.

For most of the installation procedures, the APU will be supported by PN 833940-1 engine maintenance stand assembly.

Special Tools, Fixtures and Equipment A.

Table 4001 shows the special tools, fixtures and equipment needed for installation. Table 4001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Cart Assembly

Includes PN 834990-1 engine stand/cart, PN 834895-1 Interface Mount, PN 834892-2 and PN 834892-3 Aft Mount arm, PN 834898-1 Support Arm.

Interface Bolts

Component of PN 834892-1. Adapt APU mounts to aft mount 834895-1 arms and support arm (3 necessary).

Aft Mount Arm

Component of PN 834892-1. Adapt engine assembly into portable engine stand/cart (right aft engine mount).

834892-2

Aft Mount Arm

Component of PN 834892-1. Adapt engine assembly into portable engine stand/cart (left aft engine mount).

834892-3

Lifting Adapter

Used to lift the APU out of shipping carton and place into portable engine stand/cart.

834888-1

Support Arm

Component of PN 834892-1. Support engine assembly on forward right side in portable engine stand/cart.

834898-1

Portable Engine Stand/Cart

Component of PN 834892-1. Build stand and test cart for APU.

834990-1

3.

834892-1

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 5.

Procedure

SUBTASK 49-20-00-410-001

UP552142

A.

EFFECTIVITY ALL

Install the APU on the PN 834990-1 portable engine stand/cart. (1)

Install PN 834895-1 interface bolts on the APU aft mounts and forward right mount.

(2)

Attach PN 834892-2 aft mount arm to the PN 834895-1 interface bolt on the APU right aft mount.

(3)

Attach PN 834892-3 aft mount arm to the PN 834895-1 interface bolt on the APU left aft mount.

(4)

Install PN 834898-1 support arm on the PN 834990-1 portable engine stand/cart with the support arm attaching hole inboard in relation to the portable engine stand/cart.

(5)

Install APU in PN 834990-1 portable engine stand/cart as follows: (a)

Attach PN 834888-1 lifting adapter to the APU lifting brackets.

(b)

Position the APU in the PN 834990-1 portable engine stand/cart with the APU forward right side next to the portable engine stand/cart support arm.

(c)

Attach the PN 834892-2 and PN 834892-3 aft mount arms to the PN 834895-1 interface bolts on the APU aft mounts.

(d)

Attach the PN 834898-1 forward support arm to the PN 834895-1 interface bolt on the forward right APU mount.

(e)

Remove PN 834888-1 lifting adapter from the APU.

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ENGINE MANUAL 131-9[B]

FUEL MANIFOLD ASSEMBLY INSTALLATION-02 TASK 49-20-00-450-802 1.

General A.

This section contains procedures for installation of the fuel manifold assemblies.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Fuel Manifold Assemblies

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. SECONDARY FUEL MANIFOLD ASSY (IPC FIG. 8)

30. ENGINE ASSY

20. PRIMARY FUEL MANIFOLD ASSY 5.

Procedure

SUBTASK 49-20-00-450-002

UP552142

A.

EFFECTIVITY ALL

Install the fuel manifold assembly. (Refer to Figure 4001.) (1)

Install the secondary and primary fuel manifolds assemblies (10, 20) on the engine assembly (30).

(2)

Connect the secondary and primary fuel manifolds assemblies (10, 20) to the fuel nozzles on the engine assembly (30). Tighten fittings to 120 in-lb (13.56 Nm).

(3)

Connect fuel manifolds to flow divider valve. Tighten fittings to 140 in-lb (15.8 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

ACCESS DOOR INSTALLATION-03 TASK 49-20-00-450-803 1.

General A.

This section contains procedures for installation of the access door.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque and tolerance is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Access Door

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 220. BOLT (IPC FIG. 7)

240. ENGINE ASSEMBLY

230. ACCESS DOOR 5.

Procedure

SUBTASK 49-20-00-450-003

UP552142

A.

EFFECTIVITY ALL

Install access door. (Refer to Figure 4001.) (1)

Install the access door (230) on the engine assembly (240) and tighten the eight latches.

(2)

Attach access door lanyard to the engine assembly (240) with bolt (220). Tighten bolt to a torque value of 50 in-lb (5.6 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

INLET GUIDE VANE ACTUATOR (IGVA) INSTALLATION-04 TASK 49-20-00-450-804 1.

General A.

This section contains procedures for installation of the inlet guide vane actuator.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

MIL-PRF-23699) 4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Inlet Guide Vane Actuator

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 160. BOLT (IPC. FIG. 7)

190. ROD END

170. WASHER

240. ENGINE ASSY

180. INLET GUIDE VANE ACTUATOR 5.

Procedure

SUBTASK 49-20-00-450-004

UP552142

A.

EFFECTIVITY ALL

Install inlet guide vane actuator inlet guide vane actuator. (Refer to Figure 4001.) (1)

Rotate cover to access clevis assembly.

(2)

Remove clevis bolt and washer.

(3)

Install rod end (190) on the inlet guide vane actuator (180). Tighten rod end to a torque value of 30 in-lb (3.4 Nm).

(4)

Put inlet guide vane actuator (180) into the engine assembly (240) and position rod end (190) on the clevis assembly. Tighten clevis bolt to a torque value of 50 in-lb (5.6 Nm). (Refer to View A.)

(5)

Install clevis bolt and washer to secure rod end (190) to clevis assembly.

(6)

Push inlet guide vane actuator (180) on to the engine assembly (240) and attach with bolts (160) and washers (170). Tighten bolts to a torque value of 120 in-lb (13.6 Nm).

(7)

Move inlet guide vane clevis access cover closed. Tighten both bolts to a torque value of 50 in-lb (5.6 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UPPER AND LOWER INLET DUCT INSTALLATION-05 TASK 49-20-00-450-805 1.

General A.

This section contains procedures for installation of the upper and lower inlet ducts.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Upper and Lower Inlet Duct

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. UPPER INLET DUCT (IPC FIG. 10) 20. LOWER INLET DUCT

60. NUT (10, IPC FIG. 11)

30. ENGINE ASSEMBLY

-240. BONDING STRAP (30, IPC FIG. 35)

40. NUT (10, IPC FIG. 11)

-250. BONDING STRAP

50. BOLT (10, IPC FIG. 24) 5.

-50. BONDING STRAP (IPC FIG. 34)

-. ITEM NOT ILLUSTRATED

Procedure

SUBTASK 49-20-00-450-005 A.

Install the upper and lower inlet ducts. (Refer to Figure 4001.) CAUTION: (1)

MAKE SURE RUBBER SEAL MATES ON AFT SECTION OF ENGINE.

Install upper and lower inlet ducts (10, 20) on the engine assembly (30).

UP552142

NOTE:

EFFECTIVITY ALL

Make sure the notched upper inlet duct is aligned with guide bolt.

(2)

Attach upper inlet duct (10) retaining straps to the lower inlet duct (20) and tighten to a torque value of 15 in-lb (1.7 Nm).

(3)

Connect lower inlet duct (20) bonding strap (240) at gearbox assembly nut (40) and tighten to a torque value of 100 in-lb (11.3 Nm).

(4)

Connect lower inlet duct (20) bonding strap (250) at IGV access cover bolt (50) and tighten to a torque value of 50 in-lb (5.6 Nm).

(5)

Connect upper inlet duct (10) bonding strap (50) at gearbox assembly nut (60) and tighten to a torque value of 100 in-lb (11.3 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

DIFFERENTIAL PRESSURE SENSOR (DP) INSTALLATION-06 TASK 49-20-00-450-806 1.

General A.

This section contains procedures for installation of the differential pressure sensor.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Equivalent equipment/materials can be used.

UP552142

Oil (MIL-PRF-7808 or MIL-PRF-23699)

EFFECTIVITY ALL

Description/Manufacturer Commercially available

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Differential Pressure Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 110. NUT (IPC FIG. 6)

140. PACKING

120. DIFFERENTIAL PRESSURE SENSOR

160. ENGINE ASSY

130. PACKING 4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience. Table 4002. Parts to be Replaced at Each Installation

Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

130, 140

Packing

1

5.

Procedure

SUBTASK 49-20-00-450-006 A.

Install differential pressure sensor. (Refer to Figure 4001.) WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. (1)

Lubricate new packing (130, 140) with oil.

(2)

Put packing (130, 140) on the differential pressure sensor (120).

(3)

Install differential pressure sensor (120) with installed packing on the engine assembly (160).

UP552142

(a)

EFFECTIVITY ALL

Attach differential pressure sensor (60) to engine assembly (160) with nut (110). Tighten nut to a torque value of 40 in-lb (4.5 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TOTAL PRESSURE SENSOR (PT) INSTALLATION-07 TASK 49-20-00-450-807 1.

General A.

This section contains procedures for installation of the total pressure sensor.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Equivalent equipment/materials can be used.

UP552142

Oil (MIL-PRF-7808 or MIL-PRF-23699)

EFFECTIVITY ALL

Description/Manufacturer Commercially available

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Total Pressure Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001

4.

80. NUT (IPC FIG. 6)

100. PACKING

90. TOTAL PRESSURE SENSOR

160. ENGINE ASSY

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience. Table 4002. Parts to be Replaced at Each Installation

Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

100

Packing

1

5.

Procedure

SUBTASK 49-20-00-450-007 A.

Install total pressure sensor. (Refer to Figure 4001.) WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. (1)

Lubricate new packing (100) with oil.

(2)

Put packing (100) on the total pressure sensor (90).

(3)

Install total pressure sensor (90) with installed packing on the engine assembly (160).

UP552142

(a)

EFFECTIVITY ALL

Attach total pressure sensor (60) to engine assembly (160) with nut (80). Tighten nut to a torque value of 40 in-lb (4.5 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

INLET PRESSURE SENSOR (P2) INSTALLATION-08 TASK 49-20-00-450-808 1.

General A.

This section contains procedures for installation of the inlet pressure sensor.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

UP552142

MIL-PRF-23699)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Inlet Pressure Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 50. NUT (IPC FIG. 6)

70. PACKING

60. INLET PRESSURE SENSOR 4.

160. ENGINE ASSY

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience. Table 4002. Parts to be Replaced at Each Installation

Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

70

Packing

1

5.

Procedure

SUBTASK 49-20-00-450-008 A.

Install inlet pressure sensor. (Refer to Figure 4001.) WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (1)

Lubricate new packing (70) with oil.

(2)

Put packing (70) on the inlet pressure sensor (60).

(3)

Install inlet pressure sensor (60) with installed packing on the engine assembly (160).

UP552142

(a)

EFFECTIVITY ALL

Attach inlet pressure sensor (60) to engine assembly (160) with nut (50). Tighten nut to a torque value of 40 in-lb (4.5 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

INLET TEMPERATURE SENSOR (T2) INSTALLATION-09 TASK 49-20-00-450-809 1.

General A.

This section contains procedures for installation of the inlet temperature sensor.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials Table 4001. Equipment and Materials Equipment/Materials NOTE:

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or MIL-PRF-23699) 4.

Description/Manufacturer Commercially available

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Inlet Temperature Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 150. INLET TEMPERATURE SENSOR (IPC FIG. 6) 5.

160. ENGINE ASSY

Procedure

SUBTASK 49-20-00-450-009

UP552142

A.

EFFECTIVITY ALL

Install the inlet temperature sensor. (Refer to Figure 4001.) (1)

Coat gasket with oil.

(2)

Install gasket on inlet temperature sensor (150).

(3)

Install inlet temperature sensor (150) on the engine assembly (160). Tighten inlet temperature sensor to a torque value of 230 in-lb (26.0 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

SPEED SENSOR INSTALLATION-10 TASK 49-20-00-450-810 1.

General A.

This section contains procedures for installation of the speed sensor.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

MIL-PRF-23699) 4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience.

UP552142

Table 4002. Parts to be Replaced at Each Installation Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

30, 40

Packing

1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Speed Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. NUT (IPC FIG. 6)

40. PACKING

20. SPEED SENSOR

160. ENGINE ASSY

30. PACKING 5.

Procedure

SUBTASK 49-20-00-450-010 A.

Install speed sensor. (Refer to Figure 4001.) WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (1)

Apply a layer of oil to packing (30, 40).

(2)

Install packing (30, 40) on the speed sensor (20).

(3)

Install speed sensor (20) with packing (30, 40) on the engine assembly (160).

UP552142

(a)

EFFECTIVITY ALL

Attach speed sensor (20) to the engine assembly (160) with nut (10). Tighten nut to a torque value of 40 in-lb (4.5 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

OIL COOLER INSTALLATION-11 TASK 49-20-00-450-811 1.

General A.

This section contains procedures for installation of the oil cooler.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Oil Cooler

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001

5.

10. OIL COOLER (IPC FIG. 9)

40. FIRESHIELD BRACKET

20. COUNTERSUNK SCREW

50. FIRESHIELD

30. SCREW

80. ENGINE ASSY

Procedure

SUBTASK 49-20-00-450-011 A.

Install the oil cooler. (Refer to Figure 4001.)

UP552142

(1)

EFFECTIVITY ALL

Install fireshield (50) on the oil cooler (10) as follows: (a)

Install fireshield brackets (40) on the fireshield (50) and attach with screws (30). Do not tighten screws (30) in this step.

(b)

Install fireshield (50) on the oil cooler (10) and attach with countersunk screws (20). Tighten countersunk screws to a torque value of 22 in-lb (2.5 Nm).

(c)

Tighten screws (30) to a torque value of 30 in-lb (3.4 Nm).

(2)

Install oil cooler (10) with assembled fireshield on the engine assembly (80). Make sure oil cooler mounting flange is seated on bottom lip of engine assembly mounting flange.

(3)

Tighten captive bolts on oil cooler to a torque value of 50 in-lb (5.6 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

EXHAUST GAS TEMPERATURE (EGT) THERMOCOUPLE INSTALLATION-12 TASK 49-20-00-450-812 1.

General A.

This section contains procedures for installation of the exhaust gas temperature thermocouples.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials None

4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4001 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience.

UP552142

Table 4001. Parts to be Replaced at Each Installation Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

130

Gasket

1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Exhaust Gas Temperature Thermocouples

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001

5.

110. NUT (IPC FIG. 7)

130. GASKET

120. EGT THERMOCOUPLE

240. ENGINE ASSY

Procedure

SUBTASK 49-20-00-450-012

UP552142

A.

EFFECTIVITY ALL

Install exhaust gas temperature thermocouples. (Refer to Figure 4001.) (1)

Install gasket (130) on the exhaust gas temperature thermocouple (120).

(2)

Install exhaust gas temperature thermocouples (120) with gasket (130) on the engine assembly (240).

(3)

Attach exhaust gas temperature thermocouple to the engine assembly (240) with nuts (110). Tighten nuts to a torque value of 40 in-lb (4.5 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

GEARBOX ASSEMBLY INSTALLATION-13 TASK 49-20-00-420-813 1.

General A.

This section contains procedures for installation of the gearbox assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Corrosion-preventive compound (Braycote 248) (MIL-C-11796, Class 3)

Air BP Lubricants Div, Maple Plaza II, 1 N., 6 Campus Dr, Parsippany, NJ 07054-4406

Moly Lubricant

Deleted

Oil (MIL-PRF-7808 or

Commercially available

MIL-PRF-23699) 4.

Expendable Parts

UP552142

A.

EFFECTIVITY ALL

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. NUT (IPC FIG. 11)

80. ENGINE ASSY

20. WASHER

95. BAV TO GEARBOX CLAMP (IPC FIG. 2)

30. GEARBOX ASSY

100. GEARBOX/HARNESS CLAMP

40. PACKING

285. GEARBOX TO VENT CLAMP

50. QUILL SHAFT ASSY

295. GEARBOX HARNESS/TUBE CLAMP

60. PACKING

320. IGV NR HARNESS CLAMP

70. PACKING Table 4002. Parts to be Replaced at Each Installation Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

40, 60, 70

Packing

1

Table 4003. Check Point Summary Check Point

Operation

Page

10

Visually make sure the gearbox and power section cavities are clean and have no damaged parts.

4004

5.

Procedure

SUBTASK 49-20-00-420-013 A.

Install the gearbox assembly. (Refer to Figure 4001.)

UP552142

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL.

EFFECTIVITY ALL

(1)

Lubricate packings (60, 70) with oil.

(2)

Lubricate packing (40) with corrosion-preventive compound (Braycote 248) (MIL-C-11796, Class 3).

(3)

Install packing (70) on oil jet tube in gearbox assembly (30).

(4)

Install packing (60) on quill shaft assembly (50).

(5)

Install quill shaft assembly (50) with packing in the engine assembly (80).

(6)

Install packing (40) on the engine assembly (80).

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ENGINE MANUAL 131-9[B] WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (7)

Install gearbox assembly (30) on the engine assembly (80). NOTE:

Pre-oil engine duplex bearing before installation of gearbox assembly.

(8)

Install clamps (95, 100, 285, 295, 320) with nuts (10).

(9)

Tighten nuts to a torque value of 100 in-lb (11.3 Nm).

(10)

Install bonding straps with nuts (10). Tighten nuts to a torque value of 100 in-lb (11.3 Nm). Check Point 10:

UP552142

(11)

EFFECTIVITY ALL

Visually make sure the gearbox and power section cavities are clean and have no damaged parts.

Install washers (20) and nuts (10). Tighten nuts to a torque value of 100 in-lb (11.3 Nm).

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ENGINE MANUAL 131-9[B]

LUBE MODULE INSTALLATION-14 TASK 49-20-00-450-814 1.

General A.

This section contains procedures for installation of the lube module.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

UP552142

MIL-PRF-23699)

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 14 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Lube Module

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 40. LUBE MODULE (IPC FIG. 4)

90. ENGINE ASSEMBLY

50. PACKING 4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience. Table 4002. Parts to be Replaced at Each Installation

Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

50

Packing

1

5.

Procedure

SUBTASK 49-20-00-450-014 A.

Install the lube module. (Refer to Figure 4001.) WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (1)

Lubricate new packing (50) with oil.

(2)

Install packing (50) on the lube module (40).

CAUTION:

UP552142

(3)

EFFECTIVITY ALL

OIL LEAKAGE MAY OCCUR BETWEEN LUBE MODULE AND GEARBOX IF LUBE MODULE CAPTIVE BOLTS ARE NOT TIGHTENED IN CORRECT SEQUENCE.

Install lube module (40) with packing (50) on the engine assembly (90) and tighten captive bolts in sequence, as shown in View A, to 120 in-lb (13.6 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TEMPERATURE CONTROL VALVE INSTALLATION-15 TASK 49-20-00-450-815 1.

General A.

This section contains procedures for installation of the temperature control valve.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

MIL-PRF-23699) 4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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INSTALLATION 15 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Temperature Control Valve

EFFECTIVITY ALL

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INSTALLATION 15 Page 4002 18 Dec 2019

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ENGINE MANUAL 131-9[B] Key to Figure 4001 60. NUT (IPC FIG. 9)

80. ENGINE ASSY

70. TEMPERATURE CONTROL VALVE 5.

Procedure

SUBTASK 49-20-00-450-015 A.

Install the temperature control valve. (Refer to Figure 4001.)

UP552142

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

EFFECTIVITY ALL

(1)

Lubricate seal plate packing on the temperature control valve (70) with oil.

(2)

Install temperature valve (70) on the engine assembly (80).

(3)

Install nuts (60) and tighten to a torque value of 40 in-lb (4.5 Nm).

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INSTALLATION 15 Page 4003 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

OIL LEVEL SENSOR INSTALLATION-16 TASK 49-20-00-450-816 1.

General A.

This section contains procedures for installation of the oil level sensor.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

UP552142

MIL-PRF-23699)

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 16 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Oil Level Sensor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 70. NUT (IPC FIG. 3)

90. PACKING

80. OIL LEVEL SENSOR 4.

100. ENGINE ASSY

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience. Table 4002. Parts to be Replaced at Each Installation

Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

90

Packing

1

5.

Procedure

SUBTASK 49-20-00-450-016 A.

Install the oil level sensor. (Refer to Figure 4001.)

UP552142

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

EFFECTIVITY ALL

(1)

Lubricate new packing (90) with oil.

(2)

Put packing (90) on oil level sensor (80).

(3)

Put oil level sensor (80) with packing on the engine assembly (100).

(4)

Install nut (70) and tighten to a torque value of 40 in-lb (4.5 Nm).

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

LOW OIL PRESSURE (LOP) SWITCH INSTALLATION-17 TASK 49-20-00-450-817 1.

General A.

This section contains procedures for installation of the low oil pressure switch.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

MIL-PRF-23699) 4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience.

UP552142

Table 4002. Parts to be Replaced at Each Installation Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

60

Packing

1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Low Oil Pressure Switch

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 17 Page 4002 18 Dec 2019

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ENGINE MANUAL 131-9[B] Key to Figure 4001 40. NUT WITH ATTACHED WASHER (IPC FIG. 3)

60. PACKING

50. LOW OIL PRESSURE SWITCH 5.

100. ENGINE ASSY

Procedure

SUBTASK 49-20-00-450-017 A.

Install the low oil pressure (LOP) switch. (Refer to Figure 4001.)

UP552142

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

EFFECTIVITY ALL

(1)

Lubricate new packing (60) with oil.

(2)

Install packing (60) on low oil pressure switch (50).

(3)

Install low oil pressure switch (50) with packing (60) on the engine assembly (100) and attach with nut with attached washer (40). Tighten nut with attached washer to a torque value of 40 in-lb (4.5 Nm).

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

FUEL CONTROL UNIT (FCU) INSTALLATION-18 TASK 49-20-00-450-818 1.

General A.

This section contains procedures for installation of the fuel control unit (FCU).

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Material/Compound NOTE:

Manufacturer/Description

Equivalent substitutes may be used for listed items.

Grease (Aeroshell No. 17) (MIL-G-21164C)

Shell Oil Co., Aviation Sales Div., P.O. Box 910, Louisiana St., Houston, TX 77252-2463

(Mobil 29) (MIL-G-81827) (Molybdenum-Disulphide)

Mobil Oil Corp., Beaumont Refinery, P.O. Box 3311, Interstate 10, Beaumont, TX 77704

(Royco 13D) (MIL-G-25013)

Anderol Inc., P.O. Box 518, 215 Merry Ln., East Hanover, NJ 07936

Oil (MIL-PRF-7808

Commercially available

Oil

UP552142

or MIL-PRF-23699)

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 18 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Fuel Control Unit

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 18 Page 4002 18 Dec 2019

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ENGINE MANUAL 131-9[B] Key to Figure 4001

4.

10. COUPLING CLAMP (IPC FIG. 4)

30. PACKING

20. FUEL CONTROL UNIT

90. ENGINE ASSY

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience. Table 4002. Parts to be Replaced at Each Installation

Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

30

Packing

1

5.

Procedure

SUBTASK 49-20-00-450-018 A.

Install the fuel control unit (FCU). (Refer to Figure 4001.) (1)

Apply MIL-PRF-23699 or MIL-PRF-7808, lubricating oil to the new packing (30). Install packing on the fuel control unit (20).

(2)

Install coupling clamp (10) on flange of fuel control unit (20). Do not tighten coupling clamp.

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

UP552142

(3)

EFFECTIVITY ALL

THE BELLOWS SHAFT SEAL LIFE CAN DECREASE WITHOUT LUBRICANT.

Lubricate fuel control unit (20). (a)

Make sure the fuel control unit drive shaft points up.

(b)

Fill the cavity between the fuel control unit drive shaft and the bellows shaft seal with 2cc or 40 drops of oil.

(c)

Apply 3 to 4 drops of oil on the fuel control unit drive shaft spline.

(4)

Put fuel control unit (20) over alignment pin on flange of the lube module.

(5)

Put coupling clamp (10) over flanges of fuel control unit (20) and lube module.

(6)

Tighten nut on coupling clamp (10) as follows: (a)

If coupling clamp is PN 234-591-3030, tighten nut to a torque value of 60 in-lb (6.78 Nm).

(b)

If coupling clamp is PN 234-511-9059 (POST SPB GTE1245), tighten nut to a torque value of 20 in-lb (2.26 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

STARTER/GENERATOR INSTALLATION-19 TASK 49-20-00-450-819 1.

General A.

This section contains procedures for installation of the starter/generator.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

MIL-PRF-23699) 4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 19 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Starter/Generator

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 19 Page 4002 18 Dec 2019

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. NUT WITH ATTACHED WASHER (IPC FIG. 3) 20. STARTER/GENERATOR 5.

30. SEAL PLATE 100. ENGINE ASSY

Procedure

SUBTASK 49-20-00-450-019 A.

Install the starter/generator. (Refer to Figure 4001.)

UP552142

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

EFFECTIVITY ALL

(1)

Lubricate seal plate (30) with oil.

(2)

Install seal plate (30) on the engine assembly (100).

(3)

Put nuts with attached washer (10) on starter/generator pad studs. Leave nuts with attached washer loose on studs so starter/generator can be installed and turned to engage studs.

(4)

Install starter/generator (20) on starter/generator pad and rotate starter/generator assembly to engage studs.

(5)

Tighten nuts with attached washer (10) to a torque value of 240 in-lb (27.1 Nm).

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

DATA MEMORY MODULE (DMM) INSTALLATION-20 TASK 49-20-00-450-820 1.

General A.

This section contains procedures for installation of the data memory module.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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INSTALLATION 20 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Data Memory Module

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 20 Page 4002 18 Dec 2019

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ENGINE MANUAL 131-9[B] Key to Figure 4001

5.

60. BOLT (IPC FIG. 4)

80. DATA MEMORY MODULE

70. WASHER

90. ENGINE ASSY

Procedure

SUBTASK 49-20-00-450-020

UP552142

A.

EFFECTIVITY ALL

Install the data memory module. (Refer to Figure 4001.) (1)

Install data memory module (80) on the engine assembly (90).

(2)

Attach data memory module to engine assembly with bolts (60) and washers (70). Tighten bolts to a torque value of 50 in-lb (5.6 Nm).

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 20 Page 4003 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 20 Page 4004 18 Dec 2019

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ENGINE MANUAL 131-9[B]

TOTAL PRESSURE PROBE ASSEMBLY INSTALLATION-21 TASK 49-20-00-450-821 1.

General A.

This section contains procedures for installation of the total pressure probe assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials A.

Table 4001 shows the equipment and materials needed for installation. Table 4001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Oil (MIL-PRF-7808 or

Commercially available

UP552142

MIL-PRF-23699)

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 21 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Total Pressure Probe Assembly

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 21 Page 4002 18 Dec 2019

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ENGINE MANUAL 131-9[B] Key to Figure 4001 140. COMPRESSOR DISCHARGE DUCT (IPC FIG. 5)

180. PACKING

160. NUT

190. ENGINE ASSY

170. TOTAL PRESSURE PROBE ASSY 4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4002 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience. Table 4002. Parts to be Replaced at Each Installation

Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

180

Packing

1

5.

Procedure

SUBTASK 49-20-00-450-021 A.

Install the total pressure probe assembly. (Refer to Figure 4001.) WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (1)

Lubricate packing (180) with oil.

(2)

Install packing (180) on total pressure probe assembly (170).

(3)

Install total pressure probe assembly (170) on the compressor discharge duct (140).

UP552142

(a)

EFFECTIVITY ALL

Attach total pressure probe assembly (170) to compressor discharge duct with nut (160). Tighten nut to a torque value of 40 in-lb (4.5 Nm).

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 21 Page 4003 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 21 Page 4004 18 Dec 2019

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ENGINE MANUAL 131-9[B]

SURGE CONTROL VALVE (SCV) INSTALLATION-22 TASK 49-20-00-450-822 1.

General A.

This section contains procedures for installation of the surge control valve.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 22 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Surge Control Valve

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 22 Page 4002 18 Dec 2019

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ENGINE MANUAL 131-9[B] Key to Figure 4001 50. CLAMP (IPC FIG. 5) -50B. CLAMP

190. ENGINE ASSY

60. SURGE CONTROL VALVE 5.

70. SEAL -. ITEM NOT ILLUSTRATED

Procedure

SUBTASK 49-20-00-450-022 A.

Install the surge control valve. (Refer to Figure 4001.) (1)

Install seal (70) on the compressor discharge duct.

(2)

Install seal (70) on the discharge end of the surge control valve (60).

(3)

(Pre SPB 131-GTE1328) Install surge control valve (60) with clamps (50) on the engine assembly (190).

UP552142

(Post SPB 131-GTE1328) Install surge control valve (60) with clamps (50B) on the engine assembly (190)

EFFECTIVITY ALL

(4)

Align the alignment mark on the surge control valve (60) with the alignment mark on the compressor discharge duct.

(5)

(Pre SPB 131-GTE1328) Tighten clamps (50) to a torque value of 93 in-lb (10.5 Nm). (Post SPB 131-GTE1328) Tighten clamps (50B) to a torque value of 40 in-lb (4.5 Nm).

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 22 Page 4003 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

INSTALLATION 22 Page 4004 18 Dec 2019

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ENGINE MANUAL 131-9[B]

COMPRESSOR DISCHARGE DUCT INSTALLATION-23 TASK 49-20-00-450-823 1.

General A.

This section contains procedures for installation of the compressor discharge duct.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials None

4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4001 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience.

UP552142

Table 4001. Parts to be Replaced at Each Installation Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

150

Air Packing

1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Compressor Discharge Duct

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. CLAMP (IPC FIG. 5) -10B. CLAMP

130. WASHER

30. SEAL

140. COMPRESSOR DISCHARGE DUCT

50. CLAMP

150. AIR PACKING

-50B. CLAMP

190. ENGINE ASSY

70. SEAL 5.

120. BOLT

-. ITEM NOT ILLUSTRATED

Procedure

SUBTASK 49-20-00-450-023 A.

Install the compressor discharge duct. (Refer to Figure 4001.) (1)

Install total pressure probe assembly on compressor discharge duct. (Refer to INSTALLATION-07.)

(2)

Install air packing (150) on the compressor discharge duct (140).

(3)

Install seals (30, 70) on the compressor discharge duct (140).

(4)

Attach compressor discharge duct (140) to the engine assembly (190) with bolts (120) and washers (130). Tighten bolts to a torque value of 120 in-lb (13.6 Nm).

(5)

(Pre SPB 131-GTE1328) Attach compressor discharge duct (140) to surge control valve with clamp (50). Tighten clamp to a torque value of 93 in-lb (10.5 Nm). (Post SPB 131-GTE1328) Attach compressor discharge duct (140) to surge control valve with clamp (50B). Tighten clamp to a torque value of 40 in-lb (4.5 Nm).

(6)

(Pre SPB 131-GTE1328) Attach compressor discharge duct (140) to bleed air valve with clamp (10). Tighten clamp to a torque value of 103 in-lb (11.6 Nm).

UP552142

(Post SPB 131-GTE1328) Attach compressor discharge duct (140) to bleed air valve with clamp (10B). Tighten clamp to a torque value of 40 in-lb (4.5 Nm).

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

BLEED AIR VALVE (BAV) INSTALLATION-24 TASK 49-20-00-450-824 1.

General A.

This section contains procedures for installation of the bleed air valve.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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INSTALLATION 24 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Bleed Air Valve

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. CLAMP (IPC FIG. 5) -10B. CLAMP

190. ENGINE ASSY

30. SEAL 5.

40. BLEED AIR VALVE -. ITEM NOT ILLUSTRATED

Procedure

SUBTASK 49-20-00-450-024 A.

Install the bleed air valve. (Refer to Figure 4001.) (1)

Put seal (30) on the compressor discharge duct.

(2)

(Pre SPB 131-GTE1328) Install bleed air valve (40) with clamp (10) on the engine assembly (190). (Post SPB 131-GTE1328) Install bleed air valve (40) with clamp (10B) on the engine assembly (190).

(3)

Align the alignment mark on the bleed air valve (40) with the alignment mark on the compressor discharge duct.

(4)

(Pre SPB 131-GTE1328) Tighten clamps (10) to a torque value of 103 in-lb (11.6 Nm). (Post SPB 131-GTE1328) Tighten clamps (10B) to a torque value of 40 in-lb (4.5 Nm).

UP552142

(5)

EFFECTIVITY ALL

Install the bleed duct assembly. (Refer to INSTALLATION-25.)

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

BLEED DUCT ASSEMBLY INSTALLATION-25 TASK 49-20-00-450-825 1.

General A.

This section contains procedures for installation of the bleed duct assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Bleed Duct Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. CLAMP (IPC FIG. 5) -10B. CLAMP

30. SEAL 190. ENGINE ASSY

20. BLEED DUCT ASSEMBLY

-. ITEM NOT ILLUSTRATED

-20B. BLEED DUCT ASSEMBLY 5.

Procedure

SUBTASK 49-20-00-450-025 A.

UP552142

B.

EFFECTIVITY ALL

(Pre SB 131-49-8233 and Pre SPB 131-GTE1328) Install the bleed duct assembly. (Refer to Figure 4001.) (1)

Install seal (30) on the bleed air valve.

(2)

Install bleed duct assembly (20) with clamp (10) on the bleed air valve.

(3)

Align the alignment mark on the bleed duct assembly (20) with the alignment mark on the adjacent bleed air valve.

(4)

Tighten clamp (10) to a torque value of 103 in-lb (11.6 Nm).

(5)

Install seal (30) on the bleed duct assembly (20) discharge end.

(6)

Install clamp (10) on bleed duct assembly (20) discharge end. Tighten clamp hand tight.

(Post SB 131-49-8233 and Post SPB 131-GTE1328) Install the bleed duct assembly. (Refer to Figure 4001.) (1)

Install seal (30) on the bleed air valve.

(2)

Install bleed duct assembly (-20B) with clamp (-10B) on the bleed air valve.

(3)

Tighten clamp (-10B) to a torque value of 40 in-lb (4.5 Nm).

(4)

Install seal (30) on the bleed duct assembly (-20B) discharge end.

(5)

Install clamp (-10B) on bleed duct assembly (-20B) discharge end. Tighten clamp hand tight.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

SURGE DUCT ASSEMBLY INSTALLATION-26 TASK 49-20-00-450-826 1.

General A.

This section contains procedures for installation of the surge duct assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Surge Duct Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. CLAMP (IPC FIG. 5) -10B. CLAMP

70. SEAL 110. SURGE DUCT ASSEMBLY

30. SEAL

190. ENGINE ASSY

50. CLAMP

-. ITEM NOT ILLUSTRATED

-50B. CLAMP 5.

Procedure

SUBTASK 49-20-00-450-026 A.

Install the surge duct assembly. (Refer to Figure 4001.) (1)

Install seal (70) on the surge control valve discharge end.

(2)

Install seal (30) on the surge duct assembly (110) discharge end.

(3)

(Pre SPB 131-GTE1328) Loosely attach surge duct assembly (110) to the engine assembly (190) with clamps (10, 50). (Post SPB 131-GTE1328) Loosely attach surge duct assembly (110) to the engine assembly (190) with clamps (10B, 50B).

(4)

(Pre SPB 131-GTE1328) Tighten clamps (10) to a torque value of 103 in-lb (11.6 Nm) and clamp (50) to a torque value of 93 in-lb (10.5 Nm).

UP552142

(Post SPB 131-GTE1328) Tighten clamps (10B, 50B) to a torque value of 40 in-lb (4.5 Nm).

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

IGNITER PLUG INSTALLATION-27 TASK 49-20-00-450-827 1.

General A.

This section contains procedures for installation of the igniter plug.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4001 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience.

UP552142

Table 4001. Parts to be Replaced at Each Installation Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

30

Gasket

1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Igniter Plug

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 20. IGNITER PLUG (IPC FIG. 7)

240. ENGINE ASSY

30. GASKET 5.

Procedure

SUBTASK 49-20-00-450-027 WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENERGIZED AND GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT TERMINAL.

UP552142

A.

EFFECTIVITY ALL

Install igniter plug. (Refer to Figure 4001.) (1)

Put gasket (30) on the igniter plug (20).

(2)

Install igniter plug (20) with gasket on the engine assembly (240). Tighten igniter plug to a torque value of 225 in-lb (25.42 Nm).

(3)

Install igniter plug lead on igniter plug (20). (Refer to INSTALLATION-29.)

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

IGNITION UNIT INSTALLATION-28 TASK 49-20-00-450-828 1.

General A.

This section contains procedures for installation of the ignition unit.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. (Pre SB 131-49-7527) Installation of Ignition Unit

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 4001 40. BOLT (IPC FIG. 7)

80. BOLT

50. BOLT

90. BONDING STRAP

60. WASHER

100. IGNITION BRACKET

70. IGNITION UNIT

240. ENGINE ASSEMBLY

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4002. (Post SB 131-49-7527) Installation of Ignition Unit

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4002 40. BOLT (IPC FIG. 7)

80. BOLT

60. WASHER

90. BONDING STRAP

70. IGNITION UNIT 5.

240. ENGINE ASSEMBLY

Procedure

SUBTASK 49-20-00-450-028 WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENERGIZED AND GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT TERMINAL. A.

(Pre SB 131-49-7527) Install ignition unit. (Refer to Figure 4001) (1)

Attach ignition bracket (100) and bonding strap (90) to eductor housing with bolts (80). (a)

(2)

Install ignition unit (70) to ignition bracket (100) with bolts (40, 50) and washers (60). (a)

(3) B.

Install igniter plug lead on igniter plug and ignition unit.(Refer to INSTALLATION-29.)

Attach bonding strap (90) on the engine assembly (240). (a)

(2)

UP552142

(3)

Attach bonding strap (90) with bolt (80) at eductor housing ignition bracket. Tighten bolt to a torque value of 50 in-lb (5.6 Nm).

Install ignition unit (70) on the eductor housing ignition unit bracket. (a)

ALL

Tighten bolts to a torque value of 50 in-lb (5.6 Nm).

(Post SB 131-49-7527) Install ignition unit. (Refer to Figure 4002.) (1)

EFFECTIVITY

Tighten bolt to a torque value of 50 in-lb (5.6 Nm).

Attach ignition unit to eductor housing ignition unit bracket with bolts (40) and washers (60). Tighten bolts to a torque value of 50 in-lb (5.6 Nm).

Install igniter plug lead on igniter plug and ignition unit. (Refer to INSTALLATION-29.)

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

IGNITER PLUG LEAD INSTALLATION-29 TASK 49-20-00-450-829 1.

General A.

This section contains procedures for installation of the igniter plug lead.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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INSTALLATION 29 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Igniter Lead

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 10. IGNITER PLUG LEAD (IPC FIG. 7) 5.

240. ENGINE ASSY

Procedure

SUBTASK 49-20-00-450-029 WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENERGIZED AND GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT TERMINAL. A.

Install igniter plug lead. (Refer to Figure 4001.)

UP552142

(1)

EFFECTIVITY ALL

Install igniter plug lead (10) on the ignition unit and igniter plug. Tighten both ends to a torque value of 225 in-lb (25.42 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

COMBUSTOR CASE DRAIN PLUG INSTALLATION-30 TASK 49-20-00-450-830 1.

General A.

This section contains procedures for installation of the combustor case drain plug.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

2.

None 3.

Equipment and Materials None

4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 4001 must be replaced at each installation. However, actual replacement of parts may be done on in-service experience.

UP552142

Table 4001. Parts to be Replaced at Each Installation Figure No.

Item No.

Nomenclature

Quantity

Figure 4001

150

Gasket

1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Combustor Case Drain Plug

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 140. PLUG (IPC FIG. 7) -140A. PLUG

240. ENGINE ASSY -. ITEM NOT ILLUSTRATED

150. GASKET 5.

Procedure

SUBTASK 49-20-00-450-030 A.

Install combustor case drain plug. (Refer to Figure 4001.) (1)

(Pre SB 131-49-7667) Install gasket (150) on drain plug (140). (Post SB 131-49-7667) Install gasket (150) on drain plug (-140A).

(2)

(Pre SB 131-49-7667) Install drain plug (140) with gasket on the engine assembly (240). Tighten drain plug to a torque value of 125 in-lb (14.1 Nm). CAUTION:

MAKE SURE THE LOCKWIRE THAT SECURES THE DRAIN PLUG (-140A) AND FUEL NOZZLE BOLT IS INSTALLED ON THE FUEL NOZZLE BOLT SHOWN IN FIGURE 4001.

UP552142

(Post SB 131-49-7667) Install drain plug (-140A) with gasket on the engine assembly (240). Tighten drain plug to a torque of 125 in-lb (14.1 Nm) and lockwire drain plug to fuel nozzle bolt with lockwire MS20995C32 per NASM33540.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

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ENGINE MANUAL 131-9[B]

PLUMBING AND ELECTRICAL INSTALLATION INSTALLATION-31 TASK 49-20-00-450-831 1.

General A.

This section contains procedures for installation of the plumbing and electrical installation.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All hot section hardware shall be lubricated with liqui-moly thread compound or milk of magnesia.

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

Lubricate all other male threads and back sides of tubing nuts with MIL-PRF-7808 or MIL-PRF-23699. (1)

Apply thread lubricants to male fittings only.

(2)

Apply lubricants in such a manner as to prevent the possibility of line or sealing surface contamination with the lubricant.

E.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

F.

Installation of threaded connectors. (1)

Align the key of one part with the groove or keyway of the other part to find the correct position of the connector in relation to the receptacle.

(2)

Start the connector in the receptacle with a light forward pressure. Engage the threads of the coupling ring and receptacle.

CAUTION:

(3)

G.

Carefully push in on the connector and tighten the coupling ring until the connector is seated and tight. If necessary use connector pliers to tighten coupling rings more than finger tight.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

NEVER USE FORCE TO ENGAGE THE CONNECTORS TO THE RECEPTACLES. DO NOT HAMMER A PLUG INTO THE RECEPTACLE. DO NOT USE A TORQUE WRENCH OR PLIERS TO LOCK THE COUPLING RINGS.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment

UP552142

None

EFFECTIVITY ALL

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INSTALLATION 31 Page 4001 18 Dec 2019

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ENGINE MANUAL 131-9[B] 3.

Equipment and Materials A.

4.

Table 4001 shows the equipment and materials needed for installation.

Expendable Parts None Table 4001. Equipment and Materials Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Anti-seize compound (Milk of Magnesia)

Commercially available

Anti-seize lubricant

Lockrey Co. Inc., P.O. Box 1269,

(Liqui-Moly, Brand NV Thread Compound)

2517 Finlaw Ave., Merchantville,

(MIL-PRF-907)

NJ 08109

Oil (MIL-PRF-7808 or

Commercially available

MIL-PRF-23699) 5.

Procedure

SUBTASK 49-20-00-450-031

UP552142

A.

EFFECTIVITY ALL

Install the plumbing and electrical installation. (1)

Install the APU on the engine maintenance stand assembly. (Refer to INSTALLATION 01.)

(2)

Install the plumbing and electrical installation. (Refer to Figure 4001 through Figure 4009.)

(3)

Connect bonding strap from lower inlet duct and bonding strap from ignition unit bracket to flow divider (210) with bolt (325) and nut (205). Tighten bolt and nut to a torque value of 50 in-lb (5.6 Nm).

(4)

(Post SB 131-49-7513) Refer to Figure 4009. (a)

Remove the bolt that holds the existing ground strap to the data memory module mounting bracket.

(b)

Use the bolt to attach both the existing ground strap and the new ground strap (25) to the data memory module mounting bracket. Tighten bolt to 60 in-lbs (6.78 Nm) of torque.

(c)

Remove the uppermost bolt on the inlet guide vane rod end cover plate.

(d)

Use the bolt to attach the free end of the ground strap (25) to the cover plate. Tighten the bolt to 50 in-lbs (5.65 Nm) of torque.

(e)

Put the clamp (375) on the aft bearing supply tube assembly and locate it near the center of the ground strap.

(f)

Put the clamp (380) on the ground strap (25).

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UP552142

ENGINE MANUAL 131-9[B]

EFFECTIVITY ALL

(g)

Attach the clamps together with bolt (90) and nut (205).

(h)

Adjust the clamp and ground strap as required for the best clearances with other parts. Tighten the nut (205) to 50 in-lbs (5.65 Nm) of torque.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001

UP552142

5A. WIRING HARNESS-BRANCHED (IPC FIG. 2) 225. NUT-ATTACHED WASHER

240. TUBE-FUEL SUPPLY

230. TAPE

340. PACKING

EFFECTIVITY ALL

235A. HARNESS-GENERATOR

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4002. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 4002 30. TUBE-GEARBOX VENT (IPC FIG. 2)

215. WASHER

90. BOLT

225. NUT-ATTACHED WASHER

110. CLAMP-COOLER TUBES

230. TAPE

115. GROMMET

335. PACKING

120. GROMMET -COOLER TUBES

355. CLAMP-HINGED

130. GROMMET

360. CLAMP-HINGED

135. PACKING

365. BRACKET-GENERATOR FILTER

205. NUT

370. BRACKET-VENT-TUBE

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4003. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4003 10. TUBE-COOLER RETURN (IPC FIG. 2)

170. PACKING

15. TUBE-COOLER SUPPLY

180. PACKING

20. TUBE-AFT BRG RETURN

195. ADAPTER-ORIFICED TUBE

- 20A. TUBE-AFT BRG RETURN (POST SB 131-49-7597) 25. TUBE-AFT BRG SUPPLY

UP552142

- 25A. TUBE-AFT BRG SUPPLY (POST SB 131-49-7597)

215. WASHER 225. NUT-ATTACHED WASHER

35. TUBE-IGV SUPPLY

230. TAPE

40. TUBE-IGV RETURN

275. GASKET

45. TUBE-LRU FUEL DRAIN

300. CLAMP-QUAD-TUBE

60. TUBE-MANIFOLD SUPPLY

315. CLAMP-HARN-4TH-MNT

65. ADAPTER

360. CLAMP-HINGED

80. REDUCER-ADAPTER

375. CLAMP-LOOP

85. CLAMP-MAIN HARNESS

380. CLAMP-LOOP

90. BOLT

390. CLAMP

115. GROMMET

410. CLAMP

120. GROMMET

420. BRACKET (POST SB 131-49-7597)

130. GROMMET

425. GROMMET (POST SB 131-49-7597)

135. PACKING

430. NUT (POST SB 131-49-7597)

155. PACKING

-. ITEM NOT ILLUSTRATED

EFFECTIVITY ALL

205. NUT

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4004. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4004 55. TUBE-P STATIC (IPC FIG. 2)

185. PACKING

90. BOLT

230. TAPE

120. GROMMET

245. TUBE-MUFFLER DRAIN

170. PACKING

285. CLAMP-GRBX-TO-VENT

UP552142

180. PACKING

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4005. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 4005 90. BOLT (IPC FIG. 2)

205. NUT

95. CLAMP-BAV TO GRBX

230. TAPE

100. CLAMP-GRBX/HARNESS

295. CLAMP-GRBX-HARN/TUBE

170. PACKING

305. CLAMP-COMP-TO-HARN

175. PACKING

320. CLAMP-HARN-NR-IGV

180. PACKING

350. CLAMP-LOOP

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4006. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4006 50. TUBE-P TOTAL (IPC FIG. 2)

210. FLOW DIVIDER

65. ADAPTER

215. WASHER

70. SPACER

220. UNION-FLARED

75. ADAPTER

230. TAPE

90. BOLT

250. TUBE-EDUCTOR DRAIN

105. PACKING

255. TUBE-DUCT DRAIN

115. GROMMET

260. TUBE-SEAL-WITNESS

120. GROMMET

265. PLATE-DRAIN-MAST

125. NUT-TUBE

270. GASKET-DRAIN-MAST

140. RETAINER-PACKING

280. FITTING-ASSY-ORIFICE

145. PACKING

290. CLAMP-GRBX-TO-FUEL

150. PACKING

325. BOLT

160. PACKING

330. CLAMP-LOOP-SQUARE

165. PACKING

380. CLAMP-LOOP

190. PACKING

385. BOLT

200. VALVE-SOLENOID

400. PLATE

UP552142

205. NUT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4007. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4007

UP552142

90. BOLT (IPC FIG. 2) 205. NUT

450. NUT (POST SB 131-49-7902)

375. CLAMP-LOOP

460. CLAMP-LOOP (POST SB 131-49-7902)

380. CLAMP-LOOP

470. CLAMP-LOOP (POST SB 131-49-7902)

EFFECTIVITY ALL

440. BOLT (POST SB 131-49-7902)

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4008. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4008 45. FUEL DRAIN TUBE ASSEMBLY (PRE SB 131-49-8023) (IPC FIG. 2)

500. FUEL DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

485. FCU DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

505. DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

490. SCV DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

510. TEE (POST SB 131-49-8023)

UP552142

495. INLET GUIDE VANE DRAIN TUBE ASSEMBLY (POST SB 131-49-8023)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4009. Install the Plumbing and Electrical Installation (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4009 25. GROUND STRAP (IPC FIG. 10)

375. CLAMP

90. BOLT (IPC FIG. 2)

380. CLAMP

UP552142

205. NUT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

IDENTIFICATION PLATE INSTALLATION-32 TASK 49-20-00-450-832 1.

General A.

This section contains procedures for installation of the identification plate.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

All the nuts, bolts, and screws must be tightened to a standard torque and tolerance unless the torque is specified in the text. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01, for the standard torque.

D.

When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can be used if there is a minimum of one full thread more than the face of the threaded part or nut. NOTE:

2.

There are no alternate screw or bolt lengths permitted for blind hole applications.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 4001. Installation of Identification Plate

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 4001 200. SCREW (IPC FIG. 7)

240. ENGINE ASSY

210. IDENTIFICATION PLATE 5.

Procedure

SUBTASK 49-20-00-450-032 A.

Install the identification plate. (Refer to Figure 4001.)

UP552142

(1)

EFFECTIVITY ALL

Install screws (200) and identification plate (210) on the engine assembly (240). Tighten screws to a torque value of 4 in-lb (0.5 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

FINAL INSTALLATION-33 TASK 49-20-00-400-833 1.

General A.

2.

This section contains recommended procedures that should be done by all users of this manual after all other installation procedures have been completed.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts None

5.

Procedure

SUBTASK 49-20-00-210-001 A.

Do general final checks as follows: (1)

(2)

(3)

Examine the engine identification plate for: (a)

Serial number.

(b)

Series and changes.

Examine plumbing installation as follows: (a)

Examine plumbing for damage.

(b)

Examine tubes for routing and tightness of clamps for chaffing.

Examine electrical installation as follows: (a)

Examine the APU wire harness for routing and clamps for tightness and chaffing.

(b)

Examine electrical connectors for tightness.

SUBTASK 49-20-00-600-002 B.

Service the APU with oil. (Refer to SERVICING 01.)

SUBTASK 49-20-00-550-003 C.

Install caps and covers for storage as follows:

UP552142

(1)

EFFECTIVITY ALL

Install a cap in the opening of the upper inlet duct.

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ENGINE MANUAL 131-9[B] (2)

Install a cap in the opening of the ATS adapter duct.

SUBTASK 49-20-00-400-001

UP552142

D.

EFFECTIVITY ALL

Install warning tags as follows: (1)

Install a warning tag to show the type of engine lubricating oil that has been added.

(2)

Install a warning tag to show removal of caps and covers before the APU is operated.

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ENGINE MANUAL 131-9[B]

APU CLEANING-01 TASK 49-20-00-100-801 A.

General (1)

B.

This section contains procedures for cleaning the components of the APU.

Cleaning Methods (1)

Table 6001 and Table 6002 shows the standard cleaning methods necessary for cleaning of the components. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01 for the cleaning procedures. Table 6001. Cleaning Methods

IPC Figure No.

Cleaning Methods Item No.

Nomenclature

All standard metallic hardware

203A

203E

X

X

203J

Plumbing and fittings

203M

UP552142

X

5

APU wire harness

Refer to ATA No. 49-11-01

235

Generator harness

Refer to ATA No. 49-11-03

3

20

Starter/Generator

Refer to ATA No. 24-21-14

4

20

Fuel control unit

Refer to ATA No. 49-30-99

40

Lube module

Refer to ATA No. 49-90-57

80

Data memory module

Refer to ATA No. 49-60-65

10, 50

Clamp

X

X

X

30, 70

Seal

X

X

X

40

Bleed air valve

Refer to ATA No. 49-52-29

60

Surge control valve

Refer to ATA No. 49-52-31

140

Compressor discharge duct

X

X

X

170

Flow sensor

X

X

X

5

EFFECTIVITY ALL

203N

X

Rubber, fiber, or plastic parts 2

203Q

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ENGINE MANUAL 131-9[B] Table 6001. Cleaning Methods (Cont) IPC Figure No.

Item No.

Nomenclature

203A

6

20

Speed sensor

X

150

Inlet temperature sensor

X

10

Igniter lead

X

20

Igniter plug

X

70

Ignition unit

Refer to ATA No. 49-41-09

100

Ignition unit bracket

X

120

EGT thermocouple

180

Inlet guide vane actuator

230

Access door

10

Secondary fuel manifold

X

20

Primary fuel manifold

X

10

Oil cooler

Refer to ATA No. 49-94-32

40

Fireshield bracket

X

X

X

50

Fireshield

X

X

X

70

Temperature control valve

Refer to ATA No. 49-94-30

10

Upper inlet duct

X

20

Lower inlet duct

X

50

Quill shaft

7

8

9

10

11

Cleaning Methods 203E

X

203J

203M

203Q

203N

X X

Refer to ATA No. 49-50-07 X

X

UP552142

Table 6002. Cleaning Methods IPC Figure No.

Item No.

Nomenclature

5

20

Bleed duct

X

110

Surge duct

X

EFFECTIVITY ALL

Cleaning Methods 203K

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ENGINE MANUAL 131-9[B]

CHECK 1.

Refer to Inspection/Repair Manual, ATA No. 49-26-85, for check procedures.

UP552142

NOTE:

EFFECTIVITY ALL

Inspection/Repair Manual, ATA No. 49-26-85, is a companion manual to this Engine Manual.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

REPAIR

UP552142

1.

Refer to ATA No. 49-26-85 for repair procedures.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

APU SERVICING-01 TASK 49-20-00-610-801 1.

General CAUTION:

A.

DO NOT MIX OILS OF DIFFERENT SPECIFICATIONS/TYPES WHEN YOU ADD OR CHANGE OIL IN THE APU. INCORRECT OILS CAN CAUSE DAMAGE TO THE APU BECAUSE OF THE DIFFERENT SPECIFIED TEMPERATURES FOR EACH SPECIFICATION/TYPE OF OIL.

Lubrication system general description. The APU gearbox is a wet sump type and is used as a reservoir for the APU lubrication system which supplies pressure lubrication for all of the APU. Table 11001 is a list of oils currently approved for use in this APU. Different specifications/types of oils must not be mixed. Table 11001. Approved Oil Ambient Temperature

Approved Oil Brand Name

Minimum

Maximum

Refer to Service Bulletin 49-7933 2.

Equipment and Materials A.

Table 11002 shows the equipment and materials needed to do servicing. Table 11002. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/material can be used.

Lockwire (PN MS20995C20)

Commercially available

*Oil (MIL-PRF-23699, Type II)

Commercially available

*Oil (MIL-PRF-7808, Type I)

Commercially available

Degreasing solvent (MIL-PRF-680)

Commercially available

*Refer to Table 11001 for approved lubricant brand name. 3.

Lubrication System Service There are two approved methods for changing oil brands in Honeywell engines, depending on the severity of change.

UP552142

A.

EFFECTIVITY ALL

Drain, flush and refill: This requires an oil drain, refill with new oil brand, run the engine for 10 minutes minimum, drain the oil and refill with fresh new oil and filter. This method must be used when changing to an oil that conforms to a specification/type different than the oil currently used

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ENGINE MANUAL 131-9[B] in the engine (for example, changing from MIL-PRF-7808 to MIL-PRF-23699). This method can also be used for changing to different approved oil brands within a given oil specification/type.

UP552142

Using the drain, flush and refill method quickly removes a large percentage of the current oil brand. With the engine filled with the new oil, the benefits of this oil can begin to be realized immediately. This method is more labor intensive and consumes more oil to accomplish the change-over.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 11001. (Sheet 1 of 2) APU Servicing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 11001. (Sheet 2 of 2) APU Servicing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 11001 50. MAGNETIC DRAIN PLUG (IPC FIG. 12)

80. PLUG

60. MAGNETIC PLUG

90. PACKING

70. PACKING B.

Top off: Topping off is changing to a different approved oil by replenishing oil in the reservoir through routine oil servicing without any draining or flushing. This method should only be used for changing approved oil brands conforming to the same oil specification/type (for example, oils conforming to MIL-PRF-23699). This method should not be used for changing to approved oil brands that conform to a specification/type that is different than the oil currently used in the engine. Topping off provides the easiest way to change oil brands within a given oil specification/type and consumes the least quantity to make the change. It will however, take time for the benefits of the new oil to be detectable since the new oil is being introduced as a gradually increasing fraction of the total oil volume. The operating time needed to completely convert to the new oil will depend on the engine oil consumption rate.

4.

Procedure

SUBTASK 49-20-00-610-001 A.

Drain the oil. (Refer to Figure 11001, Sheets 1 and 2.) (1)

Pull up on the retaining clamp to loosen the cap on the oil filler housing to open the gearbox to drain oil easier.

(2)

Put an oil resistant (5 gallon) container below the magnetic drain plug (50).

(3)

Remove magnetic plug (60) with packing (70) from plug (80). NOTE:

(4)

Remove the packing (70) from the magnetic plug (60). Discard packing.

CAUTION:

(5)

Push in on the magnetic plug (60) and turn the magnetic plug counterclockwise for removal.

DO NOT USE THE LOCKWIRE AGAIN AFTER REMOVAL. USED LOCKWIRE CAN BREAK IF YOU APPLY TOO MUCH FORCE TO IT. THIS CAN CAUSE DAMAGE TO THE EQUIPMENT.

Remove lockwire from the plug (80).

UP552142

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

EFFECTIVITY ALL

(6)

Remove plug (80) with packing (90) from the gearbox.

(7)

Use the oil resistant container (5 gal) to drain the oil from the APU gearbox.

(8)

Remove packing (90) from plug (80). Discard packing.

(9)

Examine drained oil for contamination which can show internal damage to the APU. If contamination is found, examine the APU to find the level of damage.

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ENGINE MANUAL 131-9[B] (10)

Remove and examine the oil filter element and generator scavenge oil filter element. (Refer to ATA No. 49-90-57.)

(11)

Examine the internal spring load valve on plug (80) for damage or misalignment which can cause leaks.

(12)

Install new oil filter element and generator scavenge oil filter element. (Refer to ATA No. 49-90-57.)

(13)

Clean magnetic plug (60) and plug (80). (Refer to Section 49-21-00, CLEANING 02.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (14)

Lubricate new packing (90) with oil.

(15)

Install new packing (90) on plug (80).

(16)

Install plug (80) into the gearbox.

(17)

Lockwire plug (80) to the gearbox with lockwire MS20995C20 per NASM33540.

(18)

Lubricate new packing (70) with oil.

(19)

Install new packing (70) on magnetic plug (60).

(20)

Install magnetic plug (60) into plug (80). NOTE:

Push in on the magnetic plug (60) and turn the magnetic plug clockwise for the installation.

SUBTASK 49-20-00-610-002 B.

Oil servicing. WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. (1)

Clean the outer area of the cap and the neck of the oil filler housing with degreasing solvent (MIL-PRF-680).

(2)

Pull up on the retaining clamp to open the cap on the oil filler housing and wipe clean.

UP552142

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

EFFECTIVITY ALL

(3)

Slowly add oil until the oil shows full in the oil level sight glass.

(4)

Close the oil fill cap and engage the retaining clamp on the oil filler housing, then push down on the retaining clamp handle until it is against the oil fill cap.

(5)

Attach a service tag to the APU to show the specification/type of oil that was used.

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ENGINE MANUAL 131-9[B] C.

Top off method to change the brand of oil (optional). NOTE:

The top off method is only applicable to oil changes in an airline fleet that uses the same oil specification/type but a different brand (refer to Table 11001).

UP552142

Use this procedure when it is not necessary to get the immediate benefits of the brand of oil to be used.

EFFECTIVITY ALL

(1)

Check the oil level at the oil level sight glass. (Refer to Figure 11001, Sheet 2.)

(2)

Add the new approved oil of the same specification/type in accordance with the procedure in Paragraph 4.B. (a)

Make sure the oil level is at the full mark on the oil level sight glass.

(b)

Continue to add the new approved oil to the oil sump as necessary at each inspection interval.

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ENGINE MANUAL 131-9[B]

UP552142

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EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

APU STORAGE-01 TASK 49-20-00-620-801 1.

General

2.

A.

Refer to Service Bulletin 49-7997 for standard preservation and storage guidelines.

B.

The supplemental procedures in this section are specific to the APU Model 131-9[B].

Equipment and Materials A.

Table 12001 shows the equipment and materials needed for storage. Table 12001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/material can be used.

Degreasing solvent (MIL-PRF-680)

Commercially available

Mineral base oil

Commercially available

(Grade 1010) (MIL-PRF-6081) 3.

Procedure

SUBTASK 49-20-00-620-001 A.

Preserve the APU. (Refer to Figure 12001.) WARNING: USE THE CORRECT PERSONAL PROTECTION. FUEL CAN CAUSE SKIN, EYE, AND LUNG DAMAGE. (1)

Remove fuel manifold supply tube from the flow divider and let the fuel drain.

CAUTION:

(2)

DO NOT PERMIT HYDROCARBONS OR OILS TO GET INTO THE COMPRESSOR SECTION. A POSSIBLE COMBUSTION CAN RESULT THAT CAN NOT BE CONTROLLED.

Supply the mineral base oil to the fuel supply tube. Supply the mineral base oil with light pressure if necessary.

UP552142

NOTE:

EFFECTIVITY ALL

Use of a corrosion-preventive mixture in the APU lubrication system is not necessary. APU lubrication oil is a satisfactory corrosion-preventative.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 12001. APU Preservation

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] CAUTION:

DO NOT OPERATE THE STARTER/GENERATOR MORE THAN THREE STARTS OR ATTEMPTS FOLLOWED BY A 15 MINUTE WAITING PERIOD.

(3)

Motor the APU and let the mineral base oil flow overboard from the fuel manifold supply tube.

(4)

Install the fuel manifold supply tube on the flow divider.

(5)

Disconnect the supply of mineral base oil from the fuel supply tube.

CAUTION:

(6)

USE THE APPROVED CAPS, PLUGS AND BARRIER MATERIALS TO PROTECT THE PART AFTER CLEANING. DO NOT USE THE TAPE, PLASTIC OR RAGS TO PROTECT CLEAN PARTS; DAMAGE TO THE PARTS COULD OCCUR.

Install caps on all APU connections for airplane furnished and remote installed equipment.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. (7)

Remove fuel and oil from the exterior of the APU with degreasing solvent (MIL-PRF-680).

UP552142

CAUTION:

EFFECTIVITY ALL

USE THE APPROVED CAPS, PLUGS AND BARRIER MATERIALS TO PROTECT THE PART AFTER CLEANING. DO NOT USE THE TAPE, PLASTIC OR RAGS TO PROTECT CLEAN PARTS; DAMAGE TO THE PARTS COULD OCCUR.

(8)

Install plugs or caps on all external pressure taps, ports, fittings and other openings on the APU.

(9)

Attach a warning tag to the APU to show that the APU must be depreserved before operation.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

APU STORAGE-02 TASK 49-20-00-550-801 1.

2.

General A.

Refer to Service Bulletin 49-7997 for standard preservation and storage guidelines.

B.

Refer to Field Service Note 49-00-00-09 for standard packaging/handling/shipping guidelines.

Equipment and Materials A.

3.

Refer to Service Bulletin 49-7997.

Procedure

SUBTASK 49-20-00-550-001

UP552142

Refer to Service Bulletin 49-7997.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

APU - TESTING TASK 49-20-00-760-801 1.

General

2.

A.

This test procedure describes the setup, instrumentation, necessary data, limits, and outlines the procedures to test the 131-9[B] Auxiliary Power Unit (APU). These procedures are done to make sure that the APU is repaired correctly and meet operating limits.

B.

The starter-generator is included in this APU test. An electronic control unit (ECU), start power unit (SPU), and a start converter unit (SCU) are necessary to conduct this test, but they are not necessary to function with a specific APU and are not tested as a system.

C.

Table 13001 and Table 13002 supply information on special tools and equipment.

D.

Table 13003 supplies information on the parameters for the instrumentation. To make sure of the accuracy of the readings found during testing, it is recommended that all instrumentation be examined on a periodic basis. Any errors in the accuracy limits must be corrected before the equipment is used.

E.

Table 13006 gives definitions for the symbols used in the TESTING Section.

F.

Table 13007 and Table 13008 give ARINC and Transmit labels definitions and parameters.

G.

A test cell or test facility applicable for high speed rotating equipment must be used for all tests. Test setup is shown in Figure 13001, Figure 13002, Figure 13003 and Figure 13004.

H.

Instructions for data corrections are given with the use of tables and equations.

I.

The APU will be tested at prevailing ambient conditions. The collected performance data will be corrected to installed, sea level, 100°F (38°C) conditions.

J.

EGT trim and shutdown schedules and inlet guide vane (IGV) trim schedules are shown in Figure 13008 and Figure 13009.

Special Tools, Fixtures and Equipment A.

Table 13001 shows the special tools, fixtures and equipment needed for testing. Table 13001. Special Tools, Fixtures and Equipment

Nomenclature/Description

UP552142

NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Cart Assembly

Includes PN 834990-1 engine stand/cart, Interface Mount, PN 834892-2 and PN 834892-3 Aft Mount arm, PN 834898-1 Adjustable Mount.

834892-1

Mounting Arm Adapter

Adapt aft mount arm to engine build stand

834807-1/-2

Bleed Duct

Instrument with pressure and temperature

834867-1

Exhaust Duct

To simulate airplane APU exhaust pipe

834882-1

Bleed Duct Support

Component of PN 834892-1. To hold APU bleed duct in APU test stand

834894-1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table 13001. Special Tools, Fixtures and Equipment (Cont) Nomenclature/Description

Use

Part No.

Interface Bolt (2 necessary)

Component of PN 834892-1. Adapt engine assembly to aft mount arms

834895-1

Aft Mount Arm

Component of PN 834892-1. Mount engine in 834892-2 engine build stand using diffuser housing aft mount

Aft Mount Arm

Component of PN 834892-1. Mount engine in 834892-3 engine build stand using diffuser housing aft mount

Engine Build Stand

Component of PN 834892-1. Build and test stand for APU

834990-1

Exhaust Gas Temperature Rake

Instrument exhaust per Figure 13006

834944-1

Inlet Duct

Instrument inlet per Figure 13001, Figure 13002, Figure 13003 and Figure 13004

834946-1/-2

Pressure Compressor Discharge (PCD) Probe Temperature Compressor Discharge (TCD) Probe

Pressure and temperature probe

834947-1

Start Power Unit (SPU)

Start converter unit

1152426-245 1152466-250

Start Converter Unit (SCU)

Start power unit

1151984-261 1152464-265

Data Memory Module Interface Cable Interface DMM to PC (RS-232)

2024215-1/-2/-3

Turbine Post Vibration Mount

Mount accelerometer on turbine

2025265-1

Borescope Guide Tube

To include guide tube as required for inspection of turbine blades

2025465-1

221 Electronic Control Unit (ECU)

Electronic control unit

2118966-221 2118966-222

Vibration Sensor Bracket

Necessary to mount accelerometer on turbine

834134-1

3.

Equipment and Materials A.

Table 13002 shows the equipment and materials needed for testing. Table 13002. Equipment and materials

Nomenclature/Description NOTE:

Equivalent equipment/materials can be used.

UP552142

Accelerometer (PN DCS-A/02)

EFFECTIVITY ALL

Description/Manufacturer Vibration sensors necessary for gearbox and turbine vibration measurement. Endevco Corp., 30700 Rancho Viejo Rd., San Juan Capistrano, CA 92675-1789

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ENGINE MANUAL 131-9[B] Table 13002. Equipment and materials (Cont) Nomenclature/Description

Description/Manufacturer

Airflow measuring section

Necessary for bleed airflow measurement. Customer furnished.

Electrical load bank

To absorb electrical load for APU generator. Customer furnished.

Electrical power, 200 VAC line-to-line, 3-phase, 400 Hz, 30 ampere, and 29 VDC, 500 ampere (maximum) 28 VDC power

AC and DC power supplied to Start Power Unit (SPU), Start Control Unit (SCU) and Electronic Control Unit (ECU) for starting and operation. Customer furnished. Independent 28 VDC power supply must be provided for the SCU and ECU control power. Customer furnished.

Fuel flow meter

Measures the flow of fuel. Customer furnished.

Fuel MIL-DTL-5624, Grade JP-4 or JP-5

Filtered and supplied at 110°F (43°C) maximum and 10 to 60 PSIG (69 to 414 kPa). Commercially available.

ASTM D-1655-75T, Jet A, A-1, or Jet B Mineral base oil (Grade 1010) (MIL-PRF-6081)

Commercially available.

Oil (MIL-PRF-7808 Type I or MIL-PRF-23699 Type II) Commercially available. Refer to Description and Operation, Table 2 for approved oils. Slave Filter Bypass Valve (PN 4132094-test) Slave Filter Bypass Valve (Preferred tool) (PN 3700352-1) Slave Oil Filters

Used when the 3-micron filter is installed to prevent unfiltered oil from entering the lube system during cool weather testing. A 3-micron filter used for the ATP. Two required, to be replaced prior to shipment with the bill of material filters (PN 3880938-1).

(PN 3094540-1)

UP552142

Used when the 3-micron filter is installed to prevent unfiltered oil from entering the lube system during cool weather testing. (Alternate to PN 3700352-1) Commercially available.

Degreasing solvent (MIL-PRF-680)

Commercially available.

Test Cell

Test facility for APU. Commercially available.

Test Cell APU Master Control Panel

Commercially available.

ARINC Computer

386/33 mhz or better IBM compatible with ARINC 429 communication protocol, Commercially available.

Vibration amplifier and meter

Monitors, analyzes and measures vibration. Commercially available.

Wiring

Facility, ECU, SPU, SCU, and starter-generator interconnect wiring. Customer furnished.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 4.

Equipment and Instrumentation Check List A.

Table 13003 shows the parameters for the instrumentation. Table 13003. Equipment and Instrumentation Check List Data Acquisition

Parameter

Range

Console

Digital

Barometric pressure

13 to 15 PSIA (672 to 776 mm Hg) X1

X

Cell pressure

12 to 17 PSIA (620 to 880 mm Hg) X

X

Cell temperature

-65 to 130°F (-54 to 54°C)

X

X

Engine speed

0 to 100,000 RPM

X

X

Generator current

0 to 1500 amps

X

Generator voltage (at generator terminals)

0 to 300 VAC

X

Generator electrical power (at generator terminals)

0 to 100 kW

X

X

Oil pressure, lube pump outlet

0 to 100 PSIG (0 to 690 kPa)

X

X

Oil temperature, lube pump outlet

0 to 500°F (0 to 260°C)

X

X

Oil sump temperature

0 to 500°F (0 to 260°C)

X

X

Oil sump pressure

0 to 100 in (0 to 2540 mm) H2O

X

X

Fuel inlet temperature

0 to 150°F (0 to 66°C)

Fuel inlet pressure

0 to 50 PSIG (0 to 345 kPa)

X X

X 1

Fuel flow

0 to 2.5 gpm (0 to 9.5 lpm)

X

X

APU inlet air total temperature, 12 probes

-65 to 130°F (-54 to 54°C)

X

X

Orifice PT, bleed air

0 to 100 PSIA (0 to 5171 mm Hg)

X

X

Orifice DP, bleed air

0 to 5 PSID (0 to 35 kPad)

X

X

Orifice TT, bleed air

0 to 500°F (0 to 260°C)

X

X

2

1

X

1

Bleed air total pressure, 5 probes (minimum)

0 to 100 PSIA (0 to 5171 mm Hg)

X

Bleed air total temperature, 4 probes (minimum)

0 to 500°F (0 to 260°C)

X

X

Compressor discharge static pressure

0 to 150 PSIG (0 to 1034 kPa)

X

X

Compressor discharge temperature

0 to 1000°F (0 to 538°C)

X

X

EGT - lab rake, 12 probes

0 to 2000°F (0 to 1093°C)

X

X

EGT - unit 1 and 2

0 to 2000°F (0 to 1093°C)

X

Exhaust static pressure, 4 probes

±2.5 PSIG (±17 kPa)

Vibration, gearbox and turbine velocity

0 to 10 in/sec (0 to 254 mm/sec)

X

Cell valve position

0 to 100% open

X

1

1

X X X

Only if manual data is recorded.

2

UP552142

Only if cell bleed control valve is upstream of measuring orifice. If valve is downstream, range becomes 0 to 60 PSIA (0 to 3102 mm Hg). EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table 13003. Equipment and Instrumentation Check List (Cont) Data Acquisition Parameter

Range

32F reference

31.6 to 32.4°F (-0.2 to 0.2°C)

Bleed orifice diameter

Thumbwheel

X

X

Bleed duct diameter

Thumbwheel

X

X

Fuel specific gravity

Query

X

Fuel lower heating value

Query

X

Test condition

Thumbwheel

X

Surge control valve (SCV) position

0 to 100 degrees

X

IGV_POSITION (from ECU)

0 to 100 degrees

X

X

T2 (from ECU)

-100, +150°F (-73 to 66°C)

X

X

P2 (from ECU)

0 to 20 PSIA (0 to 1034 mm Hg)

X

X

PT (from ECU)

0 to 100 PSIA (0 to 5171 mm Hg)

X

X

DP (from ECU)

0 to 20 PSID (0 to 138 kPad)

X

X

WFMES (from ECU)

0 to 500 lb/hr (0 to 227 kg/hr)

X

X

1

Console

Digital X

X

Only if manual data is recorded.

2

Only if cell bleed control valve is upstream of measuring orifice. If valve is downstream, range becomes 0 to 60 PSIA (0 to 3102 mm Hg). 5.

Operating Limits A.

Table 13004 shows the operating limits for the APU. Table 13004. Operating Limits Type

Limit

Tolerance

Remarks

Leakage Fuel Eductor/combustor case drain Surge Control Valve (SCV) Fuel Control Unit (FCU) Inlet Guide Vane Act. (IGVA) Oil, compressor seal drain

UP552142

Light-Off Time

EFFECTIVITY ALL

--

See Remarks Fuel leakage from the eductor/combustor case drain is permitted only after a false start or blowout

1/3 cm³ per hour per component

Maximum

At drain

0

Maximum

At drain

10 seconds after 7% speed

Maximum

Any condition

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ENGINE MANUAL 131-9[B] Table 13004. Operating Limits (Cont) Type

Limit

Tolerance

Oil Pressure (normal)

67.5 PSIG (465 kPa)

±7.5 PSIG (±52 kPa)

Oil Pressure (shutdown)

35 PSIG (240 kPa)

±5 PSIG (±35 kPa)

Oil Pressure Fluctuation

±3 PSI (±20 kPa)

Maximum

Measured at oil pump discharge port

Refer to remarks

Maximum

Three starts or attempts allowed followed by a 15-minute waiting period

5 cm³/hr

Maximum

Verified by gearbox pressure less than 20 inH2O (510 mmH2O) and visual observation

Inlet air

130°F (54°C)

Maximum

Oil (shutdown)

300°F (149°C)

Maximum EGT (on-speed operation)

Refer to Figure 13008

±25°F (±14°C)

Shutdown and T5 trim limits shown

Maximum EGT (starting and acceleration)

Refer to Figure 13009

±25°F (±14°C)

Shutdown limits shown

(under steady-state operating conditions) Starter-Generator Duty Cycle Lube Consumption

Remarks Measured at oil pump discharge port

Temperature

EGT Shutdown Limits for Starting and Acceleration

Refer to Figure 13008

EGT Shutdown and Trim Limits for On Speed Operation

Refer to Figure 13009

±10°F (±5°C) Measured at oil temperature sensor

Rotor Speed Continuous operation

48,800 RPM

±0.25%

Absolute maximum

51,728 RPM

±0.25%

Overspeed shutdown (106%) (hardware)

51,728 RPM

±0.25%

Overspeed shutdown (106%) (software)

±125 RPM

--

No instantaneous speed deviation will exceed the limit

±125 RPM

--

No amplitude modulation rate in a 1- second time will exceed the limit. Repetition rate must be lower than 2 Hz

±2,100 RPM

--

Speed variation, steady state

Speed variation load transients Vibration

Refer to Figure 13002 for locations

On-speed operation

UP552142

Gearbox

EFFECTIVITY ALL

0.65 in./sec (16.5 mm/sec)

Maximum

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ENGINE MANUAL 131-9[B] Table 13004. Operating Limits (Cont) Type

Limit

Tolerance

Remarks

Turbine Mount

0.65 in./sec (16.5 mm/sec)

Maximum

Turbine Bearing Carrier

4.0 in./sec (101.6 mm/sec)

Maximum

Gearbox

1.0 in./sec (25.4 mm/sec)

Maximum

Turbine Mount

1.0 in./sec (25.4 mm/sec)

Maximum

Turbine Bearing Carrier

5.5 in./sec (139.7 mm/sec)

Maximum

Temperature spread between No.1 and No. 2 thermocouple rakes

60°F (33°C)

Maximum

On-speed operation* (Heavy Repair limit)

80°F (44°C)

Maximum

On-speed operation* (Light/Medium Repair (Continuous-Time) Limit)

Temperature spread between unit average and lab average EGT readings

30°F (16°C)

Maximum

On-speed operation* (Heavy Repair limit)

40°F (22°C)

Maximum

On-speed operation* (Light/Medium Repair (Continuous-Time) Limit)

Ambient pressure

±20.0 inH20

Maximum response between 800 to 825 Hz on RTA is 3.25 in./sec (82.55 mm/sec)

Starting and acceleration

Unit EGT Spread

Gearbox pressure, steady state

(±508 mm H20)

Generator Voltage *NOTE:

6.

Any condition

119 VAC

±4.5 VAC

Any steady-state condition

EGT spread limits only apply to the performance tests of Paragraph 8.D., RTL, ECS and MES respectively.

Performance Load Limits A.

Table 13005 shows the performance load limits for the APU. Table 13005. Performance Load Limits

Step

UP552142

8.D.(1)(g)

EFFECTIVITY ALL

Condition No load

Mode

Gen. Output Corrected GENSL, kW

Disch. Corr. Bleed Airflow WBCDNA, l b/min (kg/min)

IGV Position, deg (Approx)

Minimum Time, minutes

Digital Data Point

RTL 1

0

0

22

5

0001

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ENGINE MANUAL 131-9[B] Table 13005. Performance Load Limits (Cont) Disch. Corr. Bleed Airflow WBCDNA, l b/min (kg/min)

IGV Position, deg (Approx)

Minimum Time, minutes

Digital Data Point

Step

Condition

Mode

Gen. Output Corrected GENSL, kW

8.D.(3)(c)

Two-pack high ECS plus generator load

ECS 2

60 -0.0, +2.0

58.2 ±1 (26.4 ±.5)

--

10

0002

8.D.(4)(g)

MES plus generator load

MES 3

65 -0.0, +2.0

50.0 ±1 (22.7 ±.5)

90

10

0003

8.E.(9)

Flow sensor check

ECS 2

0

(SCV crack point)

90

--

0004

8.E.(12)

Flow sensor check

ECS 2

0

(SCV closure point)

90

--

0005

8.G.(5)

Surge margin check

MES 3

0

(Figure 13007)

90

--

0006

8.I.(2)

No load

RTL

0

0

22

5

--

8.I.(4)

Generator load

RTL 1

96 -0, +2

0

22

5

0007

8.I.(5)

No load

RTL

0

0

22

5

--

8.I.(7)

MES, no generator load

MES 3

0

90

5

0008

8.I.(8)

No load

RTL

0

22

5

--

8.I.(10)

MES, plus generator load

MES 3

96 -0, +2

90

10

0009

8.I.(11)

No load

RTL

0

22

5

-

7.

50 ±1 (22.7 ±.5) 0 50 ±1 (22.7 ±.5) 0

Symbol Definitions A.

Table 13006 shows the definitions for the symbols used in the TESTING Section. Table 13006. Symbol Definitions

Symbol

UP552142

APU

P or PS9

Definition Differential pressure between the APU inlet and PN 834882-1 APU test cell exhaust duct.

ECU

Electronic control unit.

EGT

Exhaust gas temperature °F (°C), measured.

EGTCOR

Corrected exhaust gas temperature in °F (°C) for standard sea level condition.

ECS

Environmental control system.

IGV

Inlet guide vane.

KW

Kilowatts.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table 13006. Symbol Definitions (Cont) Symbol

Definition

MES

Main engine start.

PB (measured)

Bleed pressure PSIA (bar).

PBCOR

Corrected bleed air pressure in PSIA (bar) for standard sea level condition.

PBREQ

Minimum necessary bleed pressure.

PCELL

APU test cell pressure.

PT

Flow sensor total pressure PSIA as calculated by the ECU.

P2

Inlet air pressure. (ECU)

RTL

Ready to load.

SCU

Start converter unit.

SCV

APU surge control valve.

SHPCOR

Generator shaft load, hp, for standard sea level condition.

SPU

Start power unit.

T2

APU inlet temperature in °F (°C). (ECU)

TB (measured)

Bleed temperature °F (°C).

TBCOR

Corrected bleed temperature °F (°C) for standard sea level condition.

WC

Discharge corrected bleed flow as calculated by ECU.

WB

Bleed airflow pounds per minute (kilogram per second).

WBCDNA

Load compressor corrected discharge flow pounds per minute (kilogram per minute).

WBCOR

Corrected bleed air flow in pounds per minute (kilogram per minute) for standard sea level condition.

WF

Fuel flow pounds per hour (kilogram per hour).

WFCOR

Corrected fuel consumption in pounds per hour (kilogram per hour) for standard sea level condition.

P (DP) δ (delta)

Flow sensor differential pressure PSID (kPA), measured. English units: Pbar inches Hgabs/29.92 inches Hgabs

UP552142

Metric units: Pbar mm Hgabs)/760 mm Hgabs

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table 13007. ARINC Receive Label Definition Label (SDI)

Label Name

Code

Min

Max

Bits

Range

LSB

Test Cell Varispeed

Binary

100

200

16

0 to 128%

0.001953125

204 (01, 10)

Altitude

Binary

200

240

17

0 to 131,072 Ft

1 foot

205 (01, 10)

Mach

Binary

200

240

16

0 to 4.096

0.0000625

211 (01, 10)

Total Air Temperature

Binary

250

500

12

953.6 to -886.6°F (512 to -510°C)

0.225°F (0.125°C)

Greenwich Mean Time

BCD

1000

NA

19

NA

0.1 Min

111

125

BITS 29-27 Hours X 10, BITS 26-23 Hours, Bits 22-19 Minutes X 10 BITS 18-15 Minutes, BITS 14-11 Minutes X 0.1

222

Test Cell IGV Demand

Binary

100

200

16

0 to 128 Deg.

0.001953125

242 (01, 10)

Total Pressure

Binary

200

240

16

0 to 2048 Mb

0.03125 Mb

246 (01, 10)

Corrected Static Pressure

Binary

100

200

16

0 to 2048 Mb

0.03125 Mb

Date

BCD

200

240

19

NA

1 Day

260

BITS 29-28 Days X 10, BITS 27-24 Days, Bits 23-23 Months X 10 BITS 22-19 Months, BITS 18-15 Years X 10, BITS 14-11 Years 350

Cds DEU Discrete Word 1

Discrete

100

200

NA

NA

NA

352

Cds DEU Discrete Word 2

Discrete

100

200

NA

NA

NA

357

CDU Maintenance

ISO5

NA

200

NA

NA

NA

UP552142

Table 13008. Labels Transmitted to ARINC Monitor Computer

Software Symbol

Code

Update Min

Rate (Ms) Max.

Bits

Range

LSB Resolution

Label

Parameter

040

APU Rotor Speed

N

Binary

100

250

8

0 to 128

0.5% RPM

045

Oil Temperature

OIL_TEMP (Con. to °C)

Binary

100

250

9

± 512

1°C

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Table 13008. Labels Transmitted to ARINC Monitor Computer (Cont)

Software Symbol

Code

Update Min

Rate (Ms) Max.

Bits

Range

LSB Resolution

Label

Parameter

046

T5

T5 (Con. to °C)

Binary

100

250

11

± 2048

1°C

047

T2

T2 (Con. to °C)

Binary

100

250

9

± 512

1°C

050

P2

P2

Binary

100

250

8

0 to 16

0.06250 PSIA

051

IGV Position

IGV_ POSITION

Binary

100

250

8

± 128

0.5 Deg.

052

APU Hours

APU_ HOURS

Binary

1000

1500

18

0 to 65536

0.25 Hour

054

APU Cycles

APU_ CYCLES

Binary

1000

15000

16

0 to 65536

1 Start

055

Failed Starts

ABSTARTS

Binary

1000

1500

16

0 to 65536

1 Start

057

APU Serial Number

*APU_SN

BCD

1000

1500

19

0 to 79999

N/A

060

SCV

SCV_ POSITION

Binary

100

250

8

± 128

0.5 Deg.

061

Total Pressure

PT

Binary

100

250

10

0 to 128

0.5 Deg.

062

Delta Pressure

DP

Binary

100

250

9

± 32

0.0625 PSIA

063

Fuel Flow

WFMES

Binary

100

250

9

0 to 512

1 lb/hr

064

Corrected Flow

WC

Binary

100

250

9

0 to 2

0.00390625 lb/sec

065

ECU Serial Number

ECU_SN

Binary

1000

1500

18

±262144

1

066

Corrected EGT

CT5ATP

Binary

1000

1500

11

±2048

1°C

067

Corrected PT

CPTATP

Binary

1000

1500

10

0 to 128

0.125 PSIA

070

Corrected WF

CWFATP

Binary

1000

1500

9

0 to 512

1 lb/hr

EFFECTIVITY ALL

7

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ENGINE MANUAL 131-9[B] Table 13008. Labels Transmitted to ARINC Monitor Computer (Cont)

Software Symbol

Code

Update Min

Rate (Ms) Max.

Bits

Range

LSB Resolution

Label

Parameter

071

IGV Position

IGVATP

Binary

1000

1500

8

0 to 128

0.5 Deg.

351

Maintenance Word 1

Table 13009

Discrete

1000

1500

N/A

N/A

N/A

352

Maintenance Word 2

Table 13010

Binary

1000

1500

N/A

N/A

N/A

360 361 362 363 364

Fault #1 Last 5# in maint Binary Fault #2 Fault memo of fault see FIM #3 Fault #4 Fault #5

1000

1500

17

0 to 131072

1

(*Serial number excluding prefix and suffix converted from a string to a number.) 7

ECU_SN format is AANNNNN, where A is A-Z, N is 0-9. The BNR value is the 5 MSBs= (AA26 -1) where the value of A=1 and Z=26 and the 14 LSBs=NNNNN10. Initial unit is “_A00001”, “_” is a space, its value is 0. Serial numbers that are invalid or do not fit in the bits provided shall be reported as value 0.

UP552142

Table 13009. ARINC Label 351 Definition 1750 Word/Bit

BIT Number

1/8 1/9 1/10 1/11 1/12 1/13 1/14 1/15

1 2 3 4 5 6 7 8

1/4 1/3

9 10

EFFECTIVITY ALL

Function

Value 1 1 1 0 1 0 0 1

LABEL 351

SDI

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ENGINE MANUAL 131-9[B] Table 13009. ARINC Label 351 Definition (Cont) 1750 Word/Bit

BIT Number

Function

1/2 1/1 1/0 2/15 2/14 2/13 2/12 1/11 2/10 2/9 2/8 2/7 2/6 2/5 2/4 2/3 2/2 2/1 2/0

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

OIL TEMPERATURE SENSOR BUS POWER CONTROL CIRCUIT SPEED SENSOR1 SPEED SENSOR2 INLET GUIDE VANE ACTUATOR DELTA PRESSURE SENSOR INLET PRESSURE SENSOR TOTAL PRESSURE SENSOR EGT1 THERMOCOUPLE EGT2 THERMOCOUPLE INLET TEMPERATURE SENSOR FUEL CONTROL UNIT SURGE CONTROL VALVE OIL LEVEL SENSOR START POWER UNIT START CONVERTER UNIT IGNITION UNIT AIR INLET DOOR ACTUATOR APU GENERATOR CONTROL UNIT

1/6 1/5

30 31

SSM SSM

1/7

32

PARITY

Value

UP552142

Table 13010. ARINC Label 352 Definition 1750 Word/Bit

BIT Number

1/8 1/9 1/10 1/11 1/12 1/13 1/14 1/15

1 2 3 4 5 6 7 8

LABEL 352

1/4 1/3

9 10

SDI

EFFECTIVITY ALL

Function

Value 1 1 1 0 1 0 1 0

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ENGINE MANUAL 131-9[B]

UP552142

Table 13010. ARINC Label 352 Definition (Cont) 1750 Word/Bit

BIT Number

1/2 1/1 1/0 2/15 2/14 2/13 2/12 1/11 2/10 2/9 2/8 2/7 2/6 2/5

11 12 13 14 15 16 17 18 19 20 21 22 23 24

BLEED AIR VALVE OVERSPEED INDICATOR LOW OIL PRESSURE INDICATOR DATA MEMORY MODULE ELECTRONIC CONTROL UNIT FAULT INDICATOR LOW OIL PRESSURE SWITCH LOW OIL QUANTITY MAINTENANCE INDICATOR FUEL FLOW DIVIDER GENERATOR APU FUEL SHUTOFF VALVE SG IMPENDING BYPASS FILTER SWITCH SG IMPENDING BYPASS FILTER

2/4 2/3 2/2 2/1 2/0

25 26 27 28 29

LSB SHUTDOWN CODE (Number, of the first inhibited shutdown, PROT_SDN is false, or number of the shutdown which caused PROT_SDN to transition true) MSB SHUTDOWN CODE

1/6 1/5

30 31

SSM SSM

1/7

32

PARITY

EFFECTIVITY ALL

Function

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Value

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ENGINE MANUAL 131-9[B]

Figure 13001. Model 131-9[B] APU General Test Setup Schematic 8.

Procedure

UP552142

SUBTASK 49-20-00-480-001

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] A.

Prepare the APU for testing. (Refer to Table 13001 and Table 13002 for the special tools and equipment needed.) (1)

Preliminary Preparation. (a)

Install APU in PN 834943-1 portable engine stand/cart. Refer to REMOVAL-01.

(b)

Connect the APU to the test cell digital data acquisition system according to the 1319BPROD digital setup file. Request the production digital calculate file 131_9B_PROD.EQU at location [140,117]. Make sure digital pages have been set-up to calculate the data corrections automatically. NOTE:

UP552142

(c)

EFFECTIVITY ALL

These pages are also set up to show the operator individual parameters and probes that can help to find instrumentation problems.

The digital page names and their use are shown below:

CA1

2-PACK ECS OPERATION

CA2

MES OPERATION

CA3

PRODUCTION INSTRUMENTATION CHECK

CA4

BLEED FLOW INSTRUMENTATION AND SIMULATED SPEED TEST

(2)

Connect the test equipment as shown in the APU General Test Schematic. (Refer to Figure 13001 through Figure 13004.)

(3)

Do all tests at ambient temperature, barometric pressure and humidity.

(4)

During all tests, monitor the operating limits in Table 13004.

(5)

All necessary performance test parameters must be corrected from ambient temperature to 103°F (39°C) for both of the ECS and MES points.

(6)

Complete identification data and collected data during the tests must be put on the Test Data Sheets, Figure 1307.

(7)

Install PN 834894-1 bleed duct support arm on to engine stand/cart and bleed duct.

(8)

Connect APU to the customer furnished electronic control unit (ECU), start power unit (SPU) and start control unit (SCU) test cell interface. (Refer to Figure 13004.)

(9)

Supply an external 28 VDC, 500 ampere (maximum) start power source to the SPU.

(10)

Supply a 200 VAC line-to-line, 3 phase, 400 Hz, 30 ampere (maximum) electrical power source for the SPU.

(11)

Supply a separate 28 VDC electrical power source to the ECU and SCU.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13002. APU Vibration Pickup Locations

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] (12)

Make sure the APU is fully serviced with fuel. (Refer to Table 13002 for fuel specifications.) NOTE:

(13)

Install PN 2025265-1 bearing carrier accelerometer mount post. (Refer to Figure 13003.) (a)

(14)

The fuel supplied to the APU must be from 10 to 60 PSIG (69 to 414 kPa) at a maximum temperature of 110°F (43°C).

Install the accelerometer mount post on the bearing carrier. 1

Thread the post directly into the turbine bearing carrier through the hollow strut in the bearing support housing.

2

Tighten the post to a torque value of 50 in-lb (5.65 Nm).

3

Make sure the post does not touch any portion of the strut. If the post does touch the strut, rotate the turbine bearing carrier as necessary to eliminate this situation.

(b)

Install a standard vibration accelerometer with isolation pad onto readings for this location are for the frequency range of 0 to 2000 Hz.

(c)

The overall vibration reading for this location is for diagnostic purposes only. Accept-reject criteria is based on one per revolution. Refer to Table 13004.

Install the slave filter bypass valve and test filter. Refer to ATA 49-90-57. WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN.

(15)

(a)

Remove the oil filter.

(b)

Remove the filter bypass valve.

(c)

Install the slave filter bypass valve. (Refer to Table 13002, ATA 49-20-00.)

(d)

Install the 3-micron filter. (Refer to Table 13002.)

Do an oil level sensor check. (a)

Verify the APU oil sump is drained.

(b)

Supply power to the ECU by turning on the MASTER switch and RUN/STOP switch.

(c)

On the ECU monitor, enter F10 and F12 to view the OIL QUANTITY page.

(d)

Make sure the oil quantity reads "LOW" and the APU MAINTENANCE light on the master panel is "ON". 1

(e)

UP552142

(16)

EFFECTIVITY ALL

Follow the fault isolation procedure if the oil quantity does not read "LOW" or the APU MAINTENANCE light is not on.

Write the oil quantity status and the maintenance light status in the APU logbook.

Make sure that the APU is fully serviced with oil. (Refer to Table 13002 for oil specification.)

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ENGINE MANUAL 131-9[B] (17)

Do a final check. (a)

Verify the APU oil level is above the ADD mark in the sight glass.

(b)

Supply power to the ECU by turning on the MASTER switch and RUN/STOP switch.

(c)

On the ECU monitor, enter F10 and F12 to get the OIL QUANTITY page.

(d)

Verify the oil quantity reads "FULL" and that the APU MAINTENANCE light on the master panel is OFF. 1

(e)

Follow the fault isolation procedure if the oil quantity does not read "FULL" or the APU MAINTENANCE light is not on.

Write the oil quantity status and the maintenance light status in the APU logbook.

(18)

Examine all instrumentation and plumbing connections for correct installation.

(19)

Prior to powering up the master panel, make sure all master panel switches are set as follows: Switch MASTER POWER

OFF

RUN/STOP

STOP

SPAR VALVE/APU INLET DOOR

AUTO

AIR/GROUND

GROUND

AIRCRAFT SIGNATURE

-700

ESSENTIAL/NON-ESSENTIAL

NON-ESSENTIAL

START CONVERTER

AC

LEFT ECS

OFF

RIGHT ECS

OFF

MES

OFF

APU BLEED DEMAND

OFF

T2 POT ADJUST

NORMAL

RS 232

BACK

UP552142

NOTE:

EFFECTIVITY ALL

Position

If the AIRCRAFT SIGNATURE switch position is changed, the master panel power must be cycled OFF and ON for the new aircraft signature to be recognized by the ECU.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13003. APU Vibration Pickup Locations

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13004. APU

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] SUBTASK 49-20-00-760-001 B.

Do an APU run-in procedure as follows: NOTE:

(1)

UP552142

ALL

Motor the APU as follows: (a)

Make sure the APU test cell fuel supply valve is OFF.

(b)

Motor the APU with the starter-generator for 30 seconds at minimum of 9000 RPM. Refer to Paragraph P.

(c)

Make sure there are no unusual noises or vibration.

(d)

Make sure APU oil pressure reached 20 PSIG (138 kPa) minimum during motoring.

(e)

Permit the APU to decrease to zero speed.

(f)

Make sure there are no unusual noises or vibration during roll-down.

(2)

Start the APU. (Refer to Paragraph N.)

(3)

Do the following operating APU run-in steps. Make sure the APU operates in the limits in Table 13004.

(4)

EFFECTIVITY

During testing make sure to evaluate labels 351 and 352 are set at zero for bits 11 thru 24. If a bit is set (1) then refer to labels 360, 361, 362, 363, 364 to identify Fault Isolation Manual (FIM) procedure for repair isolation. Use Table 13009 and Table 13010 to further aid in identifying repair procedure.

(a)

Operate the APU at ready to load (RTL) for 10 minutes.

(b)

Operate the APU Bleed Demand and MES switches and do the following steps. 1

Close test cell valve until the discharge corrected airflow (WBCDNA) is approximately 50 lb/min (23 kg/min).

2

Apply 65 kW generator load and run the APU until the oil temperature reaches 170 ±10°F (77 ±6°C).

3

Make sure the APU is stable in the operating limits given in Table 13004.

4

Examine the APU for fuel, oil and air leaks. No leaks permitted.

Stop the APU. (Refer to Paragraph O.)

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13005. Magnetic Chip Collector

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] SUBTASK 49-20-00-210-002 C.

Do an examination of the oil system. (Refer to Figure 13005.) (1)

Remove the magnetic plug and examine for contamination as follows: (a)

(b)

Small chips on magnet. 1

Permitted: Thin slivers.

2

Not permitted: Flakes that have a silver color or large pieces of metal with definite shape.

Moderate accumulation of particles (other than silver). 1

Clean the magnetic plug and install in the APU.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. 2

Service the gearbox with oil. (Refer to SERVICING 01.)

CAUTION:

(c)

REFERENCE TABLE 13004 STARTER GENERATOR DUTY CYCLE THREE STARTS OR ATTEMPTS ALLOWED FOLLOWED BY A 15 MINUTE WAITING PERIOD. MAKE SURE THE OIL SYSTEM IS FILLED BEFORE THE APU IS OPERATED.

3

Start and operate the APU for 15 minutes. (Refer to Paragraph N.)

4

Stop the APU. (Refer to Paragraph O.) a

Permitted: No more accumulation of chips after 15 minutes of APU operation.

b

Not Permitted: Continued build-up of chips on the magnetic plug. Any flake accumulation that has a silver color, i.e. bearing material.

Heavy particle accumulation. 1

Not Permitted: Heavy build-up shows abnormal APU internal conditions.

(2)

Visually examine the delta-P button on the lube filter element. The delta-P button must not be extended.

(3)

Make sure there is no DP fault for the generator filter element.

UP552142

SUBTASK 49-20-00-760-002

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] D.

Do performance tests as follows: NOTE:

During the performance tests make sure that all instrumentation operates correctly. Monitor the APU operating limits. The APU operating limits must not be more than given in Table 13004. If the test cell bleed flow control valve is used to set bleed flow rates it is not necessary to shutdown the APU between each test.

(1)

(2)

Put APU in ready to load (RTL) mode as follows: (a)

Select page 1 of the digital system.

(b)

Make sure the test cell flow control valve is open.

(c)

Start the APU. (Refer to Paragraph N.)

(d)

Put the APU in RTL mode.

(e)

With the APU in ready to load (RTL) mode, apply a generator load of 65, -0, +2/δ kW for a minimum of 5 minutes.

(f)

Remove the generator load and operate the APU for 5 minutes.

(g)

Record Digital Data Point 0001 with the thumbwheel TCOND = 0001.

Do an IGV offset adjustment as follows: (a)

With the APU operating in RTL mode, apply a generator load equivalent (GENSL) to 60, -0, +2/δ kW.

(b)

Set the TENIVA value on digital Page 1 equal to (Label 047-Refer to Table 13008) APU inlet temperature lab rake T1 (average) ± 3°F (2°C).

(c)

Operate the APU BLEED DEMAND switch and select LEFT and RIGHT ECS on the master panel.

(d)

Slowly close the test cell bleed flow control valve until the discharge corrected airflow (WBCDNA) is 58.2 ±1.0 lb/min (26.40 ±0.45 kg/min), then operate the APU for a minimum of 5 minutes.

(e)

Write the initial value of IGV_POSITION (label 051 Table 13008) and PBCOR from the digital page 1 in the data sheet.

(f)

If PBCOR is more than 52.2 PSIA (3.60 bar) use the ARINC computer to find the necessary IGV ECS offset for the DMM as follows: 1

(g)

Continue to adjust the IGVs as necessary, Steps (2)(a) through (f), until PBCOR is stable and is between 51.2 and 52.2 PSIA (3.53 to 3.60 bar) with WBCDNA at 58.2 ±1.0 lb/min (26.40 ±0.45 kg/min) and GENSL at 60, -0, +2/δ kW.

UP552142

NOTE:

EFFECTIVITY ALL

Use ARINC computer label 222 (Table 13007) and decrease value two degrees less than the IGV_POSITION written in Step (e).

The ECS_OFFSET is limited to an adjustment between 0 and -8.0 degrees. The ARINC computer will not permit adjustment beyond this limit.

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ENGINE MANUAL 131-9[B] (h)

Write the final values of IGV_POSITION, PBCOR and ECS_OFFSET in the data sheet. NOTE:

(3)

The final ECS_OFFSET value is found by subtracting the initial IGV_POSITION, written in Step (e), from the final IGV_POSITION written in Step (h).

Do a combination load, environmental control system (ECS) test. (a)

Let the APU operate for a minimum of 5 minutes at the conditions of Step (2)(h).

(b)

Do a Two-Pack High flow mode ECS test using left and right ECS mode. Make sure all parameter limits in Table 13011 are met. Parameters are defined as follows:

Table 13011. ECS Performance Limits (Two-Pack High) Parameter

Heavy Repair Limit

Minimum bleed pressure, PBCOR

51.2 PSIA (3.53 bar)

Maximum bleed temperature, TBCOR

445°F (229°C)

Minimum bleed airflow WBCOR

155.0 lb/min (1.172 kg/second)

Maximum EGT, EGTCOR

1090°F (588°C) Light/Medium Repair (Continuous-Time) Limit

Parameter

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(4)

EFFECTIVITY ALL

Minimum bleed pressure, PBCOR

51.2 PSIA (3.53 bar)

Maximum bleed temperature, TBCOR

445°F (229°C)

Minimum bleed airflow WBCOR

155.0 lb/min (70.31 kg/min)

Maximum EGT, EGTCOR

1115°F (602°C)

(c)

Record Digital Data Point 0002 with the thumbwheel TCOND = 0002.

(d)

Remove ECS bleed load.

(e)

Open the test cell bleed flow control valve.

(f)

Disable transmission of label 222.

Do a MES performance test. (a)

Select page 2 of the digital system.

(b)

Apply a generator load of 65, -0, +2/δ kW.

(c)

Operate the APU BLEED DEMAND switch and select MES on the master panel.

(d)

Slowly close the test cell bleed flow control valve until discharge corrected airflow (WBCDNA) is 50.0 ±1.0 lb/min (22.68 ±0.45 kg/min).

(e)

Operate the APU for a minimum of 10 minutes at load.

(f)

Make sure all parameter limits in Table 13012 are met.

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ENGINE MANUAL 131-9[B] Table 13012. MES Performance Limits. Parameter

Heavy Repair Limit

Minimum bleed pressure, PBCOR

54.5 PSIA (3.76 bar)

Maximum bleed temperature, TBCOR

445°F (229°C)

Minimum bleed airflow WBCOR

N/A

Maximum EGT, EGTCOR

1080°F (582°C) Light/Medium Repair (Continuous-Time) Limit

Parameter Minimum bleed pressure, PBCOR

53.7 PSIA (3.70 bar)

Maximum bleed temperature, TBCOR

445°F (229°C)

Minimum bleed airflow WBCOR

N/A

Maximum EGT, EGTCOR

1105°F (596°C)

(g)

Record Digital Data Point 0003 with the thumbwheel TCOND = 0003.

(h)

Remove MES bleed load.

(i)

Open the test cell bleed flow control valve.

(j)

Remove the generator load from the generator.

SUBTASK 49-20-00-760-003

UP552142

E.

EFFECTIVITY ALL

Do a flow sensor test as follows: (1)

Select Page 3 of the digital system.

(2)

Make sure the test cell bleed flow control valve is open.

(3)

Operate the master panel APU BLEED DEMAND switch ON and select LEFT ECS and RIGHT ECS.

(4)

Make sure generator load is zero.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13006. Flow Sensor Tolerance Band

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] (5)

Set the IGV position to 90 degrees using the ARINC computer label 222 as follows: (a)

Press 90.0 and press <ENTER>.

(b)

Look at the monitor to make sure the parameter label 051 (IGV_POSITION) shows 89.5 to 90.5 degrees. Write this value.

(c)

Look at the monitor to make sure actual label 060 (SCV_POSITION) is 88 to 90 degrees when fully closed.

(6)

Readjust the T2 POT ADJ knob if necessary to make T2 (LABEL 047) in degrees equal to T1 ±3°F (±2°C) on digital Page 4.

(7)

Slowly close the test cell bleed flow control valve until the SCV begins to open, as seen on the ARINC parameter variable SCV_POSITION changes to a number less than in Step (5)(c).

(8)

Make sure that the load compressor discharge corrected flow (WBCDNA) is in the tolerance band given in Figure 13006.

(9)

Record Digital Data Point 0004 with the thumbwheel TCOND = 0004.

(10)

Slowly open test cell bleed flow control valve until SCV just closes (when SCV_POSITION returns to the value written in Step (5)(c)).

(11)

Make sure that the load compressor discharge corrected flow (WBCDNA) is in the tolerance band given in Figure 13006.

(12)

Record Digital Data Point 0005 with the thumbwheel TCOND = 0005.

(13)

Make sure the load compressor discharge corrected flow measured by the flow sensor (WC, from ARINC computer label 064) is within 5 percent of that measured by the test cell measuring section (WBCDNA) on the digital monitor as follows: (a)

Write WC and WBCDNA on the data sheet.

(b)

Calculate the resultant percentage using the following formula. (WC*60 - WBCDNA)

*100=____ percent (a value between -5 and +5)

WBCDNA Write this value in the data sheet. NOTE:

UP552142

(14)

EFFECTIVITY ALL

If calculated resultant percentage does not fall within 5 percent, look for possible leak or failed cell transducer.

Turn the MES on.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13007. Corrected Flow Limit for Surge Margin Check

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] CAUTION:

IF THERE IS LOAD COMPRESSOR SURGE, QUICKLY OPEN THE TEST CELL BLEED FLOW CONTROL VALVE.

(15)

Close the test cell bleed flow control valve as fast as possible to make sure the load compressor does not surge, simultaneously turning MES off.

(16)

Open the test cell bleed flow control valve.

SUBTASK 49-20-00-760-004 F.

Do a Surge Control Valve (SCV) stability test as follows: (1)

Keep the IGVs at 90 degrees and close the test cell bleed flow control valve until the load compressor corrected discharge flow (WBCDNA) is 55 ±2.0 lb/min (24.9 ±0.9 kg/min). (a)

(2)

Make sure the SCV is not changing more than 10 degrees per second without ever becoming stable.

Close the test cell bleed flow control valve completely to permit all the bleed air to go through the SCV. (a)

Make sure the SCV is not changing more than 10 degrees per second without ever becoming stable.

SUBTASK 49-20-00-760-005 G.

Do a minimum surge margin test as follows: (1)

Keep the IGVs at 90 degrees and open the test cell bleed flow control valve so that WBCDNA is more than 60 lb/min (27.2 kg/min).

(2)

Operate the MES switch to close the SCV.

(3)

Use T1 (average inlet rake temperature) from the digital monitor to find the necessary WBCDNA from Figure 13007.

CAUTION: (4)

IF THERE IS LOAD COMPRESSOR SURGE, QUICKLY OPEN THE TEST CELL BLEED FLOW CONTROL VALVE.

Slowly close the test cell bleed flow control valve until WBCDNA decreases and meets the necessary airflow found in Step (3) ± 1.0 lb/min (0.5 kg/min).

(5)

Record Digital Data Point 0006 with the thumbwheel TCOND = 0006.

(6)

Move the MES switch to OFF to return control of the SCV to the ECU.

(7)

Disable transmission of label 222.

(8)

Operate the master panel APU BLEED DEMAND, LEFT ECS and RIGHT ECS switches OFF to unload the APU.

(9)

Stop the APU. (Refer to Paragraph O.)

UP552142

SUBTASK 49-20-00-760-006

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] CAUTION: H.

MAKE SURE THE STARTER-GENERATOR DUTY CYCLE STAYS IN THE OPERATING LIMITS OF TABLE 13004.

Do four consecutive automatic start tests as follows: NOTE: (1)

The automatic starts tests may be run in conjunction with other tests as long as they are not interrupted by an unsuccessful start. In that case all four starts must be rerun. Do two consecutive ac fully automatic starts and accelerations to governed speed. The start times must be less than 60 seconds. (Refer to Paragraphs N and O.) (a)

Write the time to governed speed for one ac start. NOTE:

(2)

Do two consecutive dc fully automatic starts and accelerations to governed speed. The start times must be less than 60 seconds. (Refer to Paragraphs N and O.) (a)

Write the time to governed speed for one dc start. NOTE:

(3)

Time to governed speed is defined as the time from initiation of APU speed as seen on the lab Daytronic system until the RTL light comes on.

Time to governed speed is defined as the time from initiation of APU speed as seen on the lab Daytronic system until the RTL light comes on.

Stop the APU. (Refer to Paragraph O.)

SUBTASK 49-20-00-760-007

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I.

EFFECTIVITY ALL

Do load cycle tests as follows: (1)

Start the APU. (Refer to Paragraph N.)

(2)

Operate the APU in RTL for a minimum of 5 minutes.

(3)

Load the generator with 96 -0, +2/δ kw (GENSL on Page 2 of digital monitor) and operate the APU in this condition for a minimum of 5 minutes.

(4)

Record Digital Data Point 0007 with the thumbwheel TCOND = 0007.

(5)

Remove generator load and operate in RTL for a minimum of 5 minutes.

(6)

Operate the APU BLEED DEMAND and MES switches on the master control panel and operate in this condition at WBCDNA of 50 ±1 lb/min (22.7 ±0.5 kg/min) for a minimum of 5 minutes.

(7)

Record Digital Data Point 0008 with the thumbwheel TCOND = 0008.

(8)

Set the APU BLEED DEMAND and MES switches to OFF, to remove pneumatic load from the APU, and operate in RTL for a minimum of 5 minutes.

(9)

Repeat Step (6) and add 96 -0, +2/δ kw (GENSL) of generator load and operate in this condition for a minimum of 10 minutes.

(10)

(Heavy Repair) Record Digital Data Point 0009 with the thumbwheel TCOND = 0009. Record EGTCOR on data sheet. EGTCOR must be less than 1135°F (612.8°C).

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ENGINE MANUAL 131-9[B] (11)

(Light/Medium Repair) Record Digital Data Point 0009 with the thumbwheel TCOND = 0009. Record EGTCOR on data sheet. EGTCOR must be less than 1160°F (626.7°C).

(12)

Remove pneumatic load and generator load and operate in this condition for a minimum of 5 minutes in RTL.

(13)

Stop the APU. (Refer to Paragraph O.)

SUBTASK 49-20-00-820-001 J.

Data corrections. (1)

(2)

The performance data must be corrected as outlined below: (a)

Bleed pressure (PB), bleed airflow (WB), delta pressure across the APU (APU P), and fuel flow (WF) for ambient pressure (i.e., δ correction) to simulate sea level conditions.

(b)

PB, WB, bleed temperature (TB), EGT, and WF for ambient temperature (i.e., lapse rate correction) to simulate 100°F (38°C) ambient. (The lapse rate correction also accounts for IGV scheduling effects.)

(c)

EGT and WF for APU ducting.

(d)

PB, WB, TB, EGT, and WF for airplane installation effects.

(e)

If the corrected bleed pressure (PBCOR) is more than the minimum limit, correct EGT and WF to simulate power section performance with a minimum specification load compressor.

Digital acquisition system.

UP552142

(a)

EFFECTIVITY ALL

P to remove the effects of laboratory inlet and exhaust

If the digital data acquisition system is available, reduce the data. Carefully review the data to make sure that the measured parameters are in the operating limits of Table 13004 and meet the ECS performance limits of Table 13011 and MES performance limits of Table 13012 when operated at the applicable performance load limits of Table 13005 conditions. Once it is certain the data are accurate and acceptable, write the values on the data sheet.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13008. EGT Shutdown Limits for Starting and Acceleration

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13009. EGT Shutdown and Trim Limits for On Speed Operation

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] (3)

Manual Correction. (a)

If necessary, the data may be manually corrected and written in the data sheet. Parameters are defined as follows:

Pb measured

=

PB

=

bleed pressure, PSIA (bar)

Wb measured

=

WB

=

bleed flow, lb/min (kg/second)

Tb measured

=

TB

=

bleed temperature, °F (°C)

EGT measured

=

EGT

=

exhaust gas temperature, °F (°C)

WF measured

=

WF

=

fuel flow, lb/hr (kg/hr)

FLHV

=

lab fuel lower heating value, BTU/lb (kg)

(b)

Two-Pack ECS Calculations. English units: PBCOR = PB / δ + DELPB (Table 13014) - 1.6 WBCOR = WB / δ + DELWB (Table 13014) - 4.0 TBCOR = TB + DELTB (Table 13014) EGTCOR = EGT + DELEGT (Table 13014) + 33 * [(PCELL - PS9) / δ] + 30 10 * (PBCOR - PBREQ) WFCOR = (WF * FLHV / δ * 18,550) + DELWF (Table 13014) + 8 * [(PCELL PS9) / δ] + 0.6 - 4 * (PBCOR - PBREQ) WBCDNA= (WB {[(TB + 459.7) / 518.7] ^ 1/2}) / (PB / 14.696) Metric units: PBCOR = PB / δ + DELPB (Table 13014) – 0.11 WBCOR = WB / δ + DELWB (Table 13014) – 0.03 TBCOR = TB + DELTB (Table 13014) EGTCOR = EGT + DELEGT (Table 13014) + 18.3 * [(PCELL - PS9) / δ] + 16.7 – 5.5 * (PBCOR - PBREQ) WFCOR = (WF * FLHV / δ * 8414) + DELWF (Table 13014) + 3.6 * [(PCELL PS9) / δ] + 0.27 – 1.8 * (PBCOR - PBREQ)

UP552142

WBCDNA=(WB {[(TB+273.15) / 288.15] ^ 1/2}) / (PB / 1.0132)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] (c)

MES Calculations. English units: PBCOR = PB / δ + DELPB (Table 13013) - 1.6 WBCOR = WB / δ + DELWB (Table 13013) - 4.0 TBCOR = TB + DELTB (Table 13013) EGTCOR = EGT + DELEGT (Table 13013) + 33 * [(PCELL - PS9) / δ] + 30 10 * (PBCOR - PBREQ) WFCOR = (WF * FLHV / δ * 18,550) + DELWF (Table 13013) + 8 * [(PCELL PS9) / δ] + 0.6 - 4 * (PBCOR - PBREQ) WBCDNA= (WB {[(TB + 459.7) / 518.7] ^ 1/2}) / (PB / 14.696) Metric units: PBCOR = PB / δ + DELPB (Table 13013) - 0,11 WBCOR = WB / δ + DELWB (Table 13013) - 0,03 TBCOR = TB + DELTB (Table 13013) EGTCOR = EGT + DELEGT (Table 13013) + 18.3 * [(PCELL - PS9) / δ] + 16.7 - 5,5 * (PBCOR - PBREQ) WFCOR = (WF * FLHV / δ * 8414) + DELWF (Table 13013) + 3.6 * [(PCELL PS9) / δ] + 0.27 – 1.8 * (PBCOR - PBREQ) WBCDNA=(WB {[(TB+273.15) / 288.15] ^ 1/2}) / (PB / 1.0132)

SUBTASK 49-20-00-790-001 K.

Do a leak check. (1)

Remove all of the test equipment and fixtures from the APU.

(2)

Check the oil filters and filter bypass valve and replace if necessary. (Refer to ATA No. 49-90-57.)

(3)

Check the fuel filter element and replace if necessary.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. (4)

Wash the APU with degreasing solvent (MIL-PRF-680).

UP552142

(a)

EFFECTIVITY ALL

Connect the preservation oil supply, MIL-L-6081, Grade 1010, or 1005 oil to the fuel supply inlet of the APU with a manual shutoff valve. The preservation oil must be pressurized at 10 to 25 PSIG (0.7 to 1.75 bar) and be a minimum of 1 gallon (3.79 L) of fluid. The fuel supply must be capable of being shut off with the APU operating and the preservation fluid then provided to the APU fuel inlet. This must be done rapidly. Leave the valve connecting the preservation fluid closed at this time.

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ENGINE MANUAL 131-9[B] (5)

Start the APU and operate at idle for at least 5 minutes before the final leak check.

(6)

Examine the APU for fuel, oil or air leaks.

(7)

If leaks are found, repair as necessary to correct the problem. If the APU must be shut down to repair the leaks, do Paragraph K again after repairs are complete. (a)

(8)

UP552142

(9)

EFFECTIVITY ALL

Shutdown the APU by switching RUN/STOP switch to STOP. Within 15 seconds disconnect the fuel supply and open the preservation oil shutoff valve. It is acceptable for the APU to shutdown prior to the end of the normal cooldown cycle.

Deleted. (a)

Deleted.

(b)

Deleted.

(c)

Deleted.

(d)

Deleted.

(e)

Deleted.

After engine test is complete: (a)

Place wrench on F/N 77 and on F/N 103 and loosen F/N 103 while holding F/N 77 still.

(b)

Torque F/N 77 to 95 in-lb (10.73 Nm).

(c)

Place wrench on F/N 77 then torque F/N 103 to 250 in-lbs (28.25 Nm), be careful not to overtorque F/N 77. Hold F/N 77 still with wrench while retorquing F/N 103.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 13010. Combustor Case Drain

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] SUBTASK 49-20-00-210-003 L.

Do an examination of the magnetic chip collector. (Refer to Figure 13005.) (1)

Remove the magnetic plug and examine for contamination as follows: (a)

(b)

Small chips on magnet. 1

Permitted: Thin slivers.

2

Not Permitted: Flakes that have a silver color or large pieces of metal with definite shape.

Moderate accumulation of particles (other than silver). 1

Clean the magnetic plug and install in the APU.

2

Service the gearbox with oil. (Refer to SERVICING 01.)

CAUTION:

(c)

REFERENCE TABLE 13004 STARTER GENERATOR DUTY CYCLE THREE STARTS OR ATTEMPTS ALLOWED FOLLOWED BY A 15 MINUTE WAITING PERIOD. MAKE SURE THE OIL SYSTEM IS FILLED BEFORE THE APU IS OPERATED.

3

Start and operate the APU for 15 minutes. (Refer to Paragraph 8.N)

4

Stop the APU. (Refer to Paragraph 8.O) a

Permitted: No more accumulation of chips after 15 minutes of APU operation.

b

Not Permitted: Continued build-up of chips on the magnetic plug. Any flake accumulation that has a silver color, i.e. bearing material.

Heavy particle accumulation. 1

Not Permitted: Heavy build-up shows abnormal APU internal conditions.

SUBTASK 49-20-00-820-002 M.

If the APU has been returned for overhaul or repair, reset DMM values and adjust the ECS offset in the data memory module as follows: (1)

Disconnect DMM connector at the APU.

(2)

Connect PN 2024215-1 or -2 or -3 DMM interface cable to DMM and a parallel port on an IBM compatible PC.

(3)

Power the DMM/PC interface cable using a 12-VDC power supply (acdc converter is supplied with the cable).

(4)

The following commands are to be input through the keyboard of the PC.

UP552142

(a)

EFFECTIVITY ALL

Press “CONTROL Q” to exit the ARINC monitor program and to return to a listing of software.

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ENGINE MANUAL 131-9[B]

(5)

(b)

Select the number corresponding to the DMM file BATCH FILE TO RUN DMM.EXE (ALL PROGRAMS) and press <ENTER>.

(c)

Select the number for the 131B.

After the Honeywell copyright information has been displayed, the main menu will show as follows: DMM SERIAL NUMBER INITIALIZATION FOR 131B APU DMM.EXE version 3.00.00 131B.FIL version 1.00.00 Ctrl Z to exit Program

MAIN MENU 1 : INITIALIZE DMM AND ENTER APU SERIAL NUMBER 2 : DOWNLOAD DMM CONTENTS TO A FILE ON DISK 3 : CHANGE SPECIFIC DMM CONTENTS 4 : ADD NEW LABEL TO DMM 5 : EXIT PROGRAM ENTER DESIRED SELECTION ( 1,2,3,4 OR 5 ): (6)

Make sure software versions in the display are as follows: (a)

DMM.EXE version 3.00.00 or newer.

(b)

131B.FIL version 1.00.00 or newer.

(7)

Press the character 3 on the keyboard to get access to DMM variables, which may be changed.

(8)

The user will be prompted for the label change number. Press the character 2 followed by <ENTER> on the keyboard.

(9)

The user will be prompted for the new value of ECS_OFFSET. Press the correct ECS offset found in Step 8.D.(2)(h) followed by <ENTER> on the keyboard.

UP552142

NOTE:

EFFECTIVITY ALL

ECS_OFFSET is limited to a value between 0 and -8 degrees.

(10)

Make sure the ECS_OFFSET value to be recorded is correct. If correct, press the character Y on the keyboard. If not correct, press the character N on the keyboard and Step (9) will repeat automatically.

(11)

The user will be prompted whether to change an additional label. Press the character Y on the keyboard.

(12)

The user will be prompted for the label change number. Press one of the following numbers. (a)

6 <ENTER> if the Turbine section was repaired or replaced.

(b)

7 <ENTER> if the Load compressor was repaired or replaced.

(c)

8 <ENTER> If the Engine compressor was repaired or replaced.

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ENGINE MANUAL 131-9[B] (13)

The user will be prompted for the new value. Press the number 0 followed by <ENTER>.

(14)

Make sure the values to be recorded are correct. If correct, press the character Y on the keyboard. If not correct, press the character N and the previous step will repeat automatically.

(15)

The user will be prompted whether to change an additional label. Press the character Y to return to the label selection menu.

(16)

Repeat Step (12) until current shop visit workscope is input.

(17)

The user will be prompted for the label change number. Press the character 1 followed by <ENTER> on the keyboard.

(18)

The user will be prompted for the new value of SW Version. Press the characters 00 followed by <ENTER> on the keyboard.

(19)

Make sure the SW Version value to be recorded is correct. If correct, press the character Y on the keyboard. If not correct, press the character N and Step (13) will repeat automatically.

(20)

The user will be prompted whether to change an additional label. Press the character N to return to the main menu.

(21)

After being prompted for the desired function, press the character 2 on the keyboard to create a file that has the DMM contents on the PC disk drive.

(22)

After being prompted for the desired function, press the character 5 to exit the program.

(23)

If an error message shows or data was entered incorrectly, Steps (4) through (17) must be repeated.

(24)

Disconnect the DMM/PC interface cable from the DMM and reconnect the DMM.

SUBTASK 49-20-00-760-008 N.

Start the APU. (1)

Make sure APU test cell fuel valve is open.

(2)

Set the Master Power switch to ON.

(3)

Set the Master Panel Run/Stop switch to RUN.

SUBTASK 49-20-00-760-009 O.

Stop the APU. (1)

Set the Master Panel Run/Stop switch to STOP.

(2)

Set the Master Power switch to OFF.

SUBTASK 49-20-00-760-010 P.

APU Motor (electric starter motor).

UP552142

(1)

EFFECTIVITY ALL

Disconnect the APU wire harness connector from the ignition unit.

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ENGINE MANUAL 131-9[B] (2)

Disconnect the APU wire harness connector from the fuel control unit.

(3)

Set the Master Power switch to ON.

CAUTION:

DO NOT OPERATE THE STARTER-GENERATOR MORE THAN THREE TIMES FOLLOWED BY A 15 MINUTE WAITING PERIOD.

(4)

Set the Master Panel Run/Stop switch to RUN.

(5)

Set the Master Panel Run/Stop switch to STOP.

(6)

Set the Master Power switch to OFF.

(7)

Connect the APU wire harness connector to the ignition unit.

(8)

Connect the APU wire harness connector to the fuel control unit.

UP552142

Table 13013. MES Lapse Rates TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

-20 (-29)

-50.8 (-0.384)

-14.2 (-0.977)

116 (65)

146 (81)

-50.9 (-23.08)

-19 (-28)

-50.4 (-0.381)

-14.1 (-0.973)

116 (64)

146 (81)

-50.3 (-22.81)

-18 (-28)

-50.1 (-0.379)

-14.0 (-0.968)

115 (64)

145 (81)

-49.7 (-22.53)

-17 (-27)

-49.8 (-0.377)

-14.0 (-0.963)

114 (63)

145 (80)

-49.1 (-22.25)

-16 (-27)

-49.5 (-0.374)

-13.9 (-0.958)

113 (63)

144 (80)

-48.4 (-21.97)

-15 (-26)

-49.2 (-0.372)

-13.8 (-0.953)

112 (62)

144 (80)

-47.8 (-21.69)

-14 (-26)

-48.9 (-0.369)

-13.7 (-0.948)

111 (62)

144 (80)

-47.2 (-21.40)

-13 (-25)

-48.5 (-0.367)

-13.7 (-0.942)

110 (61)

143 (80)

-46.5 (-21.11)

-12 (-24)

-48.2 (-0.364)

-13.6 (-0.937)

109 (61)

143 (79)

-45.9 (-20.83)

-11 (-24)

-47.9 (-0.362)

-13.5 (-0.932)

108 (60)

143 (79)

-45.2 (-20.52)

-10 (-23)

-47.5 (-0.359)

-13.4 (-0.926)

107 (60)

142 (79)

-44.6 (-20.23)

-9 (-23)

-47.2 (-0.357)

-13.4 (-0.921)

106 (59)

142 (79)

-44.0 (-19.95)

-8 (-22)

-46.9 (-0.354)

-13.3 (-0.915)

106 (59)

142 (79)

-43.3 (19.65)

-7 (-22)

-46.5 (-0.352)

-13.2 (-0.909)

105 (58)

142 (79)

-42.7 (-19.37)

-6 (-21)

-46.2 (-0.349)

-13.1 (-0.903)

104 (58)

141 (78)

-42.1 (-19.08)

-5 (-21)

-45.8 (-0.346)

-13.0 (-0.897)

103 (57)

141 (78)

-41.4 (-18.78)

-4 (-20)

-45.5 (-0.344)

-12.9 (-0.891)

102 (57)

141 (78)

-40.7 (-18.48)

-3 (-19)

-45.1 (-0.341)

-12.8 (-0.884)

101 (56)

141 (78)

-40.1 (-18.19)

-2 (-19)

-44.7 (-0.338)

-12.7 (-0.878)

100 (56)

140 (78)

-39.4 (-17.89)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Table 13013. MES Lapse Rates (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

-1 (-18)

-44.3 (-0.335)

-12.6 (-0.871)

99 (55)

140 (78)

-38.8 (-17.59)

0 (-18)

-44.0 (-0.332)

-12.5 (-0.865)

98 (55)

140 (78)

-38.1 (-17.29)

1 (-17)

-43.6 (-0.329)

-12.4 (-0.858)

97 (54)

140 (78)

-37.4 (-16.99)

2 (-17)

-43.2(-0.327)

-12.3 (-0.851)

96 (54)

139 (77)

-36.9 (-16.72)

3 (-16)

-42.8 (-0.324)

-12.2 (-0.844)

95 (53)

139 (77)

-36.3 (-16.47)

4 (-16)

-42.4 (-0.32)

-12.1 (-0.837)

95 (53)

138 (77)

-35.7 (-16.21)

5 (-15)

-41.9 (-0.317)

-12.0 (-0.828)

94 (52)

138 (77)

-35.1 (-15.94)

6 (-14)

-41.4 (-0.313)

-11.9 (-0.818)

93 (51)

138 (76)

-34.6 (-15.67)

7 (-14)

-41.0 (-0.31)

-11.7 (-0.809)

92 (51)

137 (76)

-34.1 (-15.45)

8 (-13)

-40.5 (-0.306)

-11.6 (-0.8)

91 (50)

135 (75)

-33.6 (-15.24)

9 (-13)

-40.0 (-0.302)

-11.5 (-0.791)

90 (50)

134 (75)

-33.2 (-15.04)

10 (-12)

-39.5 (-0.299)

-11.3 (-0.781)

89 (49)

133 (74)

-32.7 (-14.84)

11 (-12)

-39.0 (-0.295)

-11.2 (-0.772)

88 (49)

132 (73)

-32.3 (-14.63)

12 (-11)

-38.5 (-0.291)

-11.1 (-0.762)

87 (48)

131 (73)

-31.8 (-14.43)

13 (-11)

-38.0 (-0.288)

-10.9 (-0.753)

86 (48)

130 (72)

-31.4 (-14.23)

14 (-10)

-37.5 (-0.284)

-10.8 (-0.743)

85 (47)

128 (71)

-30.9 (-14.02)

15 (-9)

-37.0 (-0.28)

-10.6 (-0.733)

84 (47)

127 (71)

-30.5 (-13.82)

16 (-9)

-36.6 (-0.276)

-10.5 (-0.724)

83 (46)

126 (70)

-30.0 (-13.62)

17 (-8)

-36.1 (-0.273)

-10.4 (-0.714)

82 (46)

125 (69)

-29.6 (-13.41)

18 (-8)

-35.6 (-0.269)

-10.2 (-0.704)

81 (45)

124 (69)

-29.1 (-13.21)

19 (-7)

-35.1 (-0.265)

-10.1 (-0.694)

80 (44)

123 (68)

-28.7 (-13.00)

20 (-7)

-34.5 (-0.261)

-9.9 (-0.684)

79 (44)

121 (67)

-28.2 (-12.80)

21 (-6)

-34.0 (-0.257)

-9.8 (-0.674)

78 (43)

120 (67)

-27.8 (-12.60)

22 (-6)

-33.5 (-0.254)

-9.6 (-0.664)

77 (43)

119 (66)

-27.3 (-12.39)

23 (-5)

-33.0 (-0.25)

-9.5 (-0.654)

76 (42)

118 (66)

-26.9 (-12.19)

24 (-4)

-32.6 (-0.246)

-9.3 (-0.644)

75 (42)

117 (65)

-26.4 (-11.98)

25 (-4)

-32.1 (-0.242)

-9.2 (-0.634)

74 (41)

116 (64)

-26.0 (-11.77)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Table 13013. MES Lapse Rates (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

26 (-3)

-31.5 (-0.238)

-9.0 (-0.624)

73 (41)

115 (64)

-25.5 (-11.57)

27 (-3)

-31.0 (-0.235)

-8.9 (-0.613)

72 (40)

114 (63)

-25.1 (-11.36)

28 (-2)

-30.5 (-0.231)

-8.8 (-0.603)

71 (40)

112 (62)

-24.6 (-11.16)

29 (-2)

-30.0 (-0.227)

-8.6 (-0.593)

70 (39)

111 (62)

-24.1 (-10.95)

30 (-1)

-29.5 (-0.223)

-8.5 (-0.583)

69 (38)

110 (61)

-23.7 (-10.75)

31 (-1)

-29.0 (-0.219)

-8.3 (-0.573)

68 (38)

109 (61)

-23.2 (-10.54)

32 (0)

-28.5 (-0.216)

-8.2 (-0.563)

67 (37)

108 (60)

-22.8 (-10.33)

33 (1)

-28.0 (-0.212)

-8.0 (-0.553)

66 (37)

107 (60)

-22.3 (-10.13)

34 (1)

-27.5 (-0.208)

-7.9 (-0.543)

65 (36)

106 (59)

-21.9 (-9.93)

35 (2)

-27.0 (-0.204)

-7.7 (-0.532)

64 (36)

105 (58)

-21.5 (-9.73)

36 (2)

-26.5 (-0.2)

-7.6 (-0.522)

63 (35)

104 (58)

-21.0 (-9.53)

37 (3)

-26.0 (-0.197)

-7.4 (-0.512)

62 (35)

103 (57)

-20.6 (-9.32)

38 (3)

-25.5 (-0.193)

-7.3 (-0.502)

61 (34)

102 (57)

-20.1 (-9.12)

39 (4)

-25.0 (-0.189)

-7.1 (-0.492)

60 (34)

101 (56)

-19.7 (-8.92)

40 (4)

-24.5 (-0.185)

-7.0 (-0.483)

59 (33)

100 (56)

-19.2 (-8.71)

41 (5)

-24.0 (-0.181)

-6.9 (-0.476)

59 (33)

99 (55)

-18.8 (-8.53)

42 (6)

-23.6 (-0.178)

-6.7 (-0.462)

58 (32)

99 (55)

-18.4 (-8.35)

43 (6)

-23.1 (-0.175)

-6.6 (-0.455)

57 (32)

98 (54)

-17.8 (-8.07)

44 (7)

-22.6 (-0.171)

-6.4 (-0.441)

56 (31)

97 (54)

-17.5 (-7.94)

45 (7)

-22.1 (-0.167)

-6.3 (-0.434)

55 (31)

96 (53)

-17.0 (-7.71)

46 (8)

-21.6 (-0.163)

-6.2 (-0.427)

54 (30)

95 (53)

-16.7 (-7.57)

47 (8)

-21.2 (-0.160)

-6.0 (-0.414)

53 (29)

94 (52)

-16.2 (-7.35)

48 (9)

-20.7 (-0.156)

-5.9 (-0.407)

52 (29)

93 (52)

-15.8 (-7.17)

49 (9)

-20.2 (-0.153)

-5.8 (-0.400)

51 (28)

92 (51)

-15.4 (-6.99)

50 (10)

-19.8 (-0.150)

-5.6 (-0.386)

50 (28)

91 (51)

-15.0 (-6.80)

51 (11)

-19.3 (-0.146)

-5.5 (-0.379)

49 (27)

90 (50)

-14.6 (-6.62)

52 (11)

-18.9 (-0.143)

-5.4 (-0.372)

48 (27)

89 (49)

-14.2 (-6.44)

EFFECTIVITY ALL

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TESTING Page 13045 18 Dec 2019

RELEASED FOR THE EXCLUSIVE USE BY: SPICEJET LTD

ENGINE MANUAL 131-9[B]

UP552142

Table 13013. MES Lapse Rates (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

53 (12)

-18.4 (-0.139)

-5.3 (-0.365)

47 (26)

88 (49)

-13.9 (-6.30)

54 (12)

-18.0 (-0.136)

-5.1 (-0.352)

46 (26)

87 (48)

-13.6 (-6.17)

55 (13)

-17.6 (-0.133)

-5.0 (-0.345)

45 (25)

85 (47)

-13.2 (-5.99)

56 (13)

-17.1 (-0.129)

-4.9 (-0.338)

44 (24)

85 (47)

-12.7 (-5.76)

57 (14)

-16.7 (-0.126)

-4.8 (-0.331)

43 (24)

83 (46)

-12.5 (-5.67)

58 (14)

-16.3 (-0.123)

-4.6 (-0.317)

42 (23)

81 (45)

-12.1 (-5.49)

59 (15)

-15.9 (-0.120)

-4.5(-0.310)

41 (23)

80 (44)

-11.8 (-5.35)

60 (16)

-15.5 (-0.117)

-4.4 (-0.303)

40 (22)

78 (43)

-11.4 (-5.17)

61 (16)

-15.0 (-0.113)

-4.3 (-0.296)

39 (22)

77 (43)

-11.1 (-5.03)

62 (17)

-14.6 (-0.110)

-4.2 (-0.290)

38 (21)

76 (42)

-10.7 (-4.85)

63 (17)

-14.2 (-0.107)

-4.1 (-0.283)

37 (21)

74 (41)

-10.4 (-4.72)

64 (18)

-13.8 (-0.104)

-3.9 (-0.269)

36 (20)

73 (41)

-10.0 (-4.54)

65 (18)

-13.4 (-0.101)

-3.8 (-0.262)

35 (19)

71 (39)

-9.7 (-4.40)

66 (19)

-13.0 (-0.098)

-3.7 (-0.255)

34 (19)

70 (39)

-9.3 (-4.22)

67 (20)

-12.5 (-0.094)

-3.6 (-0.248)

33 (18)

68 (38)

-9.0 (-4.08)

68 (20)

-12.1 (-0.091)

-3.5 (-0.241)

32 (18)

66 (37)

-8.7 (-3.95)

69 (21)

-11.7 (-0.088)

-3.4 (-0.234)

31 (17)

64 (36)

-8.4 (-3.81)

70 (22)

-11.3 (-0.085)

-3.2 (-0.221)

30 (17)

63 (35)

-8.0 (-3.63)

71 (22)

-10.9 (-0.082)

-3.1 (-0.214)

29 (16)

61 (34)

-7.7 (-3.49)

72 (22)

-10.5 (-0.079)

-3.0 (-0.207)

28 (16)

60 (33)

-7.4 (-3.36)

73 (23)

-10.1 (-0.076)

-2.9 (-0.200)

27 (15)

58 (32)

-7.1 (-3.22)

74 (23)

-9.7 (-0.073)

-2.8 (-0.193)

26 (14)

56 (31)

-6.7 (-3.04)

75 (24)

-9.3 (-0.070)

-2.7 (-0.186)

25 (14)

54 (30)

-6.4 (-2.90)

76 (24)

-9.0 (-0.068)

-2.6 (-0.179)

24 (13)

53 (29)

-6.2 (-2.81)

77 (25)

-8.5 (-0.064)

-2.4 (-0.165)

23 (13)

51 (28)

-5.8 (-2.63)

78 (26)

-8.2 (-0.062)

-2.3 (-0.159)

22 (12)

49 (27)

-5.5 (-2.49)

79 (26)

-7.8 (-0.059)

-2.2 (-0.152)

21 (12)

47 (26)

-5.1 (-2.31)

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

TESTING Page 13046 18 Dec 2019

RELEASED FOR THE EXCLUSIVE USE BY: SPICEJET LTD

ENGINE MANUAL 131-9[B]

UP552142

Table 13013. MES Lapse Rates (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

80 (26)

-7.4 (-0.056)

-2.1 (-0.145)

20 (11)

46 (26)

-4.8 (-2.18)

81 (27)

-7.0 (-0.053)

-2.0 (-0.138)

19 (11)

44 (24)

-4.5 (-2.04)

82 (28)

-6.6 (-0.050)

-1.9 (-0.131)

18 (10)

42 (23)

-4.3 (-1.95)

83 (28)

-6.2 (-0.047)

-1.8 (-0.131) x

17 (9)

39 (22)

-4.0 (-1.81)

84 (29)

-5.9 (-0.045)

-1.7 (-0.117)

16 (9)

37 (21)

-3.7 (-1.68)

85 (29)

-5.5 (-0.042)

-1.6 (-0.110)

15 (8)

35 (19)

-3.5 (-1.59)

86 (30)

-5.1 (-0.039)

-1.5 (-0.103)

14 (8)

33 (18)

-3.2 (-1.45)

87 (31)

-4.7 (-0.036)

-1.4 (-0.097)

13 (7)

31 (17)

-3.0 (-1.36)

88 (31)

-4.4 (-0.033)

-1.2 (-0.083)

12 (7)

28 (16)

-2.8 (-1.27)

89 (32)

-4.0 (-0.030)

-1.1 (-0.076)

11 (6)

26 (14)

-2.5 (-1.13)

90 (32)

-3.6 (-0.027)

-1.0 (-0.069)

10 (6)

24 (13)

-2.3 (-1.04)

91 (33)

-3.2 (-0.024)

-0.9 (-0.062)

9 (5)

22 (12)

-2.1 (-0.95)

92 (33)

-2.9 (-0.022)

-0.8 (-0.055)

8 (4)

19 (11)

-1.8 (-0.82)

93 (34)

-2.5 (-0.019)

-0.7 (-0.048)

7 (4)

17 (9)

-1.6 (-0.73)

94 (34)

-2.1 (-0.016)

-0.6 (-0.041)

6 (3)

14 (8)

-1.4 (-0.64)

95 (35)

-1.8 (-0.014)

-0.5 (-0.034)

5 (3)

12 (7)

-1.1 (-0.50)

96 (35)

-1.4 (-0.011)

-0.4 (-0.028)

4 (2)

10 (6)

-0.9 (-0.41)

97 (36)

-1.1 (-0.008)

-0.3 (-0.021)

3 (2)

7 (4)

-0.7 (-0.32)

98 (37)

-0.7 (-0.005)

-0.2 (-0.014)

2 (1)

5 (3)

-0.4 (-0.18)

99 (37)

-0.4 (-0.003)

-0.1 (-0.007)

1 (0)

3 (2)

-0.2 (-0.09)

100 (38)

0.0 (0.000)

0.0 (0.000)

0 (0)

0 (0)

0.0 (0.00)

101 (38)

0.4 (0.003)

0.1 (0.007)

-1 (0)

-2 (-1)

0.2 (0.09)

102 (39)

0.7 (0.005)

0.2 (0.014)

-2 (-1)

-5 (-3)

0.5 (0.23)

103 (39)

1.1 (0.008)

0.3 (0.021)

-3 (-2)

-7 (-4)

0.7 (0.32)

104 (40)

1.4 (0.011)

0.4 (0.028)

-4 (-2)

-10 (-6)

0.9 (0.41)

105 (41)

1.8 (0.014)

0.5 (0.034)

-5 (-3)

-12 (-7)

1.2 (0.54)

106 (41)

2.1 (0.016)

0.6 (0.041)

-6 (-3)

-14 (-8)

1.4 (0.64)

EFFECTIVITY ALL

49-20-00 © Honeywell International Inc. Do not copy without express permission of Honeywell.

TESTING Page 13047 18 Dec 2019

RELEASED FOR THE EXCLUSIVE USE BY: SPICEJET LTD

ENGINE MANUAL 131-9[B] Table 13013. MES Lapse Rates (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

107 (42)

2.4 (0.018)

0.7 (0.048)

-7 (-4)

-16 (-9)

1.7 (0.77)

108 (42)

2.8 (0.021)

0.8 (0.055)

-8 (-4)

-19 (-11)

1.9 (0.86)

109 (43)

3.2 (0.024)

0.9 (0.062)

-9 (-5)

-21 (-12)

2.1 (0.95)

110 (43)

3.5 (0.026)

1.0 (0.069)

-10 (-6)

-24 (-13)

2.4 (1.09)

UP552142

Table 13014. Two Pack Lapse Rate TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

-20 (-29)

27.6 (0.209)

13.7 (0.943)

174 (97)

299 (166)

22.4 (10.18)

-19 (-28)

28.2 (0.213)

13.8 (0.953)

173 (96)

299 (166)

23.1 (10.49)

-18 (-28)

28.7 (0.217)

14.0 (0.964)

172 (96)

299 (166)

23.8 (10.79)

-17 (-27)

29.3 (0.222)

14.1 (0.974)

172 (95)

299 (166)

24.5 (11.1)

-16 (-27)

29.9 (0.226)

14.3 (0.985)

171 (95)

299 (166)

25.2 (11.41)

-15 (-26)

30.5 (0.23)

14.4 (0.995)

170 (94)

298 (166)

25.8 (11.72)

-14 (-26)

31.1 (0.235)

14.6 (1.006)

169 (94)

298 (166)

26.5 (12.02)

-13 (-25)

31.6 (0.239)

14.7 (1.017)

168 (94)

298 (166)

27.2 (12.33)

-12 (-24)

32.2 (0.244)

14.9 (1.027)

168 (93)

298 (165)

27.9 (12.63)

-11 (-24)

32.8 (0.248)

15.0 (1.037)

167 (93)

298 (165)

28.5 (12.94)

-10 (-23)

33.4 (0.252)

15.2 (1.048)

166 (92)

298 (165)

29.2 (13.24)

-9 (-23)

34.0 (0.257)

15.3 (1.058)

165 (92)

297 (165)

29.9 (13.55)

-8 (-22)

34.5 (0.261)

15.5 (1.069)

164 (91)

297(165)

30.5 (13.85)

-7 (-22)

35.1 (0.265)

15.6 (1.079)

164 (91)

297 (165)

31.2 (14.15)

-6 (-21)

35.7 (0.27)

15.8 (1.089)

163 (90)

297 (165)

31.9 (14.45)

-5 (-21)

36.3 (0.274)

16.0 (1.1)

162 (90)

297 (165)

32.5 (14.75)

-4 (-20)

36.8 (0.279)

16.1 (1.11)

161 (90)

297 (165)

33.2 (15.05)

-3 (-19)

37.4 (0.283)

16.3 (1.121)

160 (89)

296 (165)

33.8 (15.35)

-2 (-19)

38.0 (0.287)

16.4 (1.131)

160 (89)

296 (165)

34.5 (15.64)

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Table 13014. Two Pack Lapse Rate (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

-1 (-18)

38.6 (0.292)

16.6 (1.141)

159 (88)

296 (164)

35.1 (15.94)

0 (-18)

39.2 (0.296)

16.7 (1.152)

158 (88)

296 (164)

35.8 (16.23)

1 (-17)

39.3 (0.297)

16.7 (1.154)

157 (87)

295 (164)

36.2 (16.4)

2 (-17)

39.5 (0.299)

16.8 (1.156)

156 (87)

294 (164)

36.5 (16.57)

3 (-16)

39.7 (0.3)

16.8 (1.158)

155 (86)

294 (163)

36.9 (16.74)

4 (-16)

39.9 (0.302)

16.8 (1.16)

154 (86)

293 (163)

37.3 (16.91)

5 (-15)

40.1 (0.303)

16.9 (1.162)

153 (85)

292 (162)

37.6 (17.07)

6 (-14)

40.3 (0.304)

16.9 (1.164)

152 (85)

291 (162)

38.0 (17.24)

7 (-14)

40.5 (0.306)

16.9 (1.166)

151 (84)

290 (161)

38,3 (17.37)

8 (-13)

40.6 (0.307)

16.9 (1.168)

150 (83)

289 (160)

38.5 (17.48)

9 (-13)

40.8 (0.309)

17.0 (1.17)

149 (83)

287 (160)

38.8 (17.59)

10 (-12)

41.0 (0.31)

17.0 (1.172)

148 (82)

286 (159)

39.0 (17.7)

11 (-12)

41.2 (0.311)

17.0 (1.174)

147 (82)

284 (158)

39.3 (17.81)

12 (-11)

41.4 (0.313)

17.1 (1.177)

146 (81)

283 (157)

39.5 (17.92)

13 (-11)

41.6 (0.314)

17.1 (1.179)

145 (81)

281 (156)

39.7 (18.03)

14 (-10)

41.7 (0.316)

17.1 (1.181)

144 (80)

280 (156)

40.0 (18.14)

15 (-9)

41.9 (0.317)

17.2 (1.183)

143 (80)

279 (155)

40.2 (18.25)

16 (-9)

42.1 (0.318)

17.2 (1.185)

142 (79)

277 (154)

40.5 (18.36)

17 (-8)

42.3 (0.32)

17.2 (1.186)

141 (78)

276 (153)

40.7 (18.46)

18 (-8)

42.5 (0.321)

17.2 (1.188)

140 (78)

274 (152)

40.9 (18.57)

19 (-7)

42.7 (0.323)

17.3 (1.19)

139 (77)

273 (152)

41.2 (18.68)

20 (-7)

42.9 (0.324)

17.3 (1.193)

138 (77)

272 (151)

41.4 (18.79)

21 (-6)

43.0 (0.325)

17.3 (1.195)

137 (76)

270 (150)

41.7 (18.9)

22 (-6)

43.2 (0.327)

17.4 (1.197)

136 (76)

269 (149)

41.9 (19)

23 (-5)

43.4 (0.328)

17.4 (1.199)

135 (75)

267 (149)

42.1 (19.11)

24 (-4)

43.6 (0.33)

17.4 (1.201)

134 (75)

266 (148)

42.3 (19.18)

25 (-4)

43.8 (0.331)

17.4 (1.203)

133 (74)

264 (147)

42.5 (19.26)

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Table 13014. Two Pack Lapse Rate (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

26 (-3)

44.0 (0.332)

17.5 (1.205)

132 (73)

262 (146)

42.6 (19.33)

27 (-3)

44.1 (0.334)

17.5 (1.207)

131 (73)

261 (145)

42.8 (19.41)

28 (-2)

44.3 (0.335)

17.5 (1.209)

130 (72)

259 (144)

43.0 (19.48)

29 (-2)

44.5 (0.337)

17.6 (1.211)

129 (72)

258 (143)

43.1 (19.56)

30 (-1)

44.7 (0.338)

17.6 (1.215)

128 (71)

256 (142)

43.3 (19.63)

31 (-1)

44.6 (0.337)

17.6 (1.211)

127 (70)

254 (141)

43.2 (19.60)

32 (0)

44.5 (0.337)

17.5 (1.207)

125 (70)

252 (140)

43.2 (19.59)

33 (1)

44.5 (0.336)

17.5 (1.203)

124 (69)

250 (139)

43.1 (19.55)

34 (1)

44.4 (0.335)

17.4 (1.200)

123 (68)

248 (138)

43.1 (19.55)

35 (2)

44.3 (0.335)

17.3 (1.196)

122 (68)

247 (137)

43.1 (19.55)

36 (2)

44.2 (0.334)

17.3 (1.192)

121 (67)

245 (136)

43.1 (19.53)

37 (38)

44.1 (0.333)

17.2 (1.188)

119 (66)

243 (135)

43.0 (19.49)

38 (3)

44.0 (0.333)

17.2 (1.184)

118 (66)

241 (134)

42.9 (19.48)

39 (4)

43.9 (0.332)

17.1 (1.180)

117 (65)

239 (133)

42.9 (19.47)

40 (4)

43.8 (0.331)

17.1 (1.177)

116 (64)

237 (132)

42.9 (19.46)

41 (5)

43.8 (0.331)

17.0 (1.173)

114 (64)

235 (131)

42.8 (19.43)

42 (6)

43.7 (0.330)

17.0 (1.169)

113 (63)

233 (129)

42.8 (19.41)

43 (6)

43.6 (0.330)

16.9 (1.165)

112 (62)

231 (128)

42.7 (19.37)

44 (7)

43.5 (0.329)

16.9 (1.162)

111 (62)

229 (127)

42.7 (19.35)

45 (7)

43.4 (0.328)

16.8 (1.158)

110 (61)

227 (126)

42.6 (19.34)

46 (8)

43.4 (0.328)

16.7 (1.155)

108 (60)

225 (125)

42.6 (19.31)

47 (8)

43.3 (0.327)

16.7 (1.151)

107 (60)

223 (124)

42.5 (19.30)

48 (9)

43.2 (0.327)

16.6 (1.147)

106 (59)

221 (123)

42.5 (19.27)

49 (9)

43.1 (0.326)

16.6 (1.144)

105 (58)

219 (122)

42.5 (19.26)

50 (10)

43.1 (0.326)

16.5 (1.141)

103 (57)

218 (121)

42.4 (19.24)

51 (11)

43.0 (0.325)

16.5(1.137)

102 (57)

216 (120)

42.4 (19.22)

52 (11)

43.0 (0.325)

16.4 (1.134)

101 (56)

214 (119)

42.4 (19.21)

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ENGINE MANUAL 131-9[B]

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Table 13014. Two Pack Lapse Rate (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

53 (12)

42.9 (0.324)

16.4 (1.131)

100 (55)

212 (118)

42.3 (19.19)

54 (12)

42.8 (0.324)

16.4 (1.128)

99 (55)

209 (116)

42.2 (19.14)

55 (13)

42.8 (0.323)

16.3 (1.124)

97 (54)

207 (115)

42.1 (19.11)

56 (13)

42.7 (0.323)

16.3 (1.121)

96 (53)

204 (113)

42.1 (19.08)

57 (14)

42.7 (0.323)

16.2 (1.118)

95 (53)

202 (112)

42.0 (19.04)

58 (144)

42.6 (0.322)

16.2 (1.115)

94 (52)

199 (111)

41.9 (18.99)

59 (15)

42.6 (0.322)

16.1 (1.112)

93 (51)

197 (109)

41.8 (18.98)

60 (16)

40.0 (0.303)

15.3 (1.052)

89 (50)

190 (106)

39.9(18.08)

61 (16)

37.6 (0.284)

14.4 (0.993)

86 (48)

183 (102)

37.9 (17.18)

62 (17)

35.2 (0.266)

13.6 (0.937)

83 (46)

177 (98)

36.0 (16.31)

63 (17)

32.9 (0.249)

12.8 (0.882)

80 (44)

170 (95)

34.2 (15.50)

64 (18)

30.7 (0.232)

12.0 (0.828)

77 (43)

164 (91)

32.3 (14.64)

65 (18)

28.5 (0.215)

11.3 (0.776)

74 (41)

157 (87)

30.5 (13.83)

66 (19)

26.4 (0.200)

10.5 (0.726)

71 (39)

151 (84)

28.8 (13.05)

67 (19)

24.4 (0.185)

9.8 (0.678)

68 (38)

145 (80)

27.1 (12.29)

68 (20)

22.6 (0.171)

9.2 (0.633)

65 (36)

139 (77)

25.4 (11.52)

69 (21)

20.8 (0.158)

8.5 (0.588)

62 (35)

132 (74)

23.7 (10.76)

70 (21)

19.1 (0.144)

7.9 (0.544)

59 (33)

126 (70)

22.1 (10.01)

71 (22)

17.3 (0.131)

7.2 (0.500)

57 (31)

120 (67)

20.4 (9.25)

72 (22)

15.6 (0.118)

6.6 (0.456)

54 (30)

114 (63)

18.8 (8.50)

73 (23)

13.8 (0.104)

6.0 (0.413)

51 (28)

107 (60)

17.1 (7.75)

74 (24)

12.1 (0.091)

5.3 (0.368)

49 (27)

101 (56)

15.4 (7.00)

75 (24)

10.3 (0.078)

4.7 (0.324)

46 (26)

95 (53)

13.8 (6.26)

76 (24)

8.7 (0.065)

4.1 (0.283)

43 (24)

89 (49)

12.2 (5.54)

77 (25)

7.1 (0.054)

3.6 (0.245)

41(23)

83 (46)

10.8 (4.89)

78 (26)

5.8 (0.044)

3.0 (0.209)

39 (21)

77 (43)

9.4 (4.26)

79 (27)

4.5 (0.034)

2.6 (0.176)

36 (20)

72 (40)

8.1 (3.67)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Table 13014. Two Pack Lapse Rate (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

80 (27)

3.3 (0.025)

2.1 (0.144)

34 (19)

66 (37)

6.8 (3.08)

81 (27)

3.1 (0.023)

2.0 (0.136)

32 (18)

63 (35)

6.5(2.93)

82 (28)

2.9 (0.022)

1.9 (0.128)

30 (17)

60 (33)

6.1 (2.78)

83 (28)

2.7 (0.020)

1.7 (0.120)

29 (16)

56 (31)

5.7 (2.60)

84 (29)

2.5 (0.019)

1.6 (0.112)

27(15)

53 (30)

5.4 (2.45)

85 (29)

2.3 (0.017)

1.5 (0.104)

25 (14)

50 (28)

5.1 (2.30)

86 (30)

2.1 (0.016)

1.4 (0.097)

24 (13)

47 (26)

4.8 (2.15)

87 (31)

1.9 (0.015)

1.3 (0.089)

22 (12)

44 (24)

4.4 (2.00)

88 (31)

1.8 (0.013)

1.2 (0.082)

20 (11)

40 (22)

4.1 (1.85)

89 (32)

1.6 (0.012)

1.1 (0.075)

19 (10)

37 (21)

3.7 (1.70)

90 (32)

1.4 (0.011)

1.0 (0.068)

17 (9)

34 (19)

3.4 (1.55)

91 (33)

1.3 (0.010)

0.9 (0.061)

15 (9)

30 (17)

3.1 (1.40)

92 (33)

1.2 (0.009)

0.8 (0.055)

14 (8)

27 (15)

2.7 (1.24)

93 (34)

1.0 (0.008)

0.7 (0.048)

12 (7)

24 (13)

2.4 (1.09)

94 (34)

0.9 (0.007)

0.6 (0.041)

10 (6)

21 (11)

2.1 (0.95)

95 (35)

0.8 (0.006)

0.5 (0.035)

9 (5)

17 (10)

1.8 (0.80)

96 (36)

0.6 (0.005)

0.4 (0.029)

7 (4)

14 (8)

1.4 (0.65)

97 (36)

0.5 (0.004)

0.3 (0.022)

5 (3)

11 (6)

1.1 (0.50)

98 (37)

0.3 (0.002)

0.2 (0.015)

3 (2)

7 (4)

0.7 (0.33)

99 (37)

0.2 (0.001)

0.1 (0.007)

2 (0)

4 (2)

0.4 (0.16)

100 (38)

0.0 (0.000)

0.0 (0.000)

0 (0)

0 (0)

0.0 (0.00)

101 (38)

0.5 (0.003)

0.1 (0.008)

0 (0)

-2 (0)

0.4 (0.16)

102 (39)

0.9 (0.007)

0.2 (0.017)

-2 (0)

-3 (-2)

0.7 (0.33)

103 (39)

1.3 (0.010)

0.4 (0.025)

-3 (-1)

-5 (-3)

1.1 (0.50)

104 (40)

1.8 (0.013)

0.5 (0.033)

-4 (-2)

-7 (-4)

1.5 (0.67)

105 (41)

2.2 (0.017)

0.6 (0.042)

-4 (-2)

-8 (-5)

1.9 (0.84)

106 (41)

2.7 (0.020)

0.7 (0.050)

-5 (-3)

-10 (-6)

2.2 (0.99)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

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Table 13014. Two Pack Lapse Rate (Cont) TAMB DEG °F (°C)

DELWB PPM (KPS)

DELPB PSIA (BAR)

DELTB DEG °F (°C)

DELEGT DEG °F (°C)

DELWF PPH (KPH)

107 (42)

3.1 (0.024)

0.8 (0.058)

-6 (-3)

-12 (-7)

2.5 (1.14)

108 (42)

3.6 (0.027)

1.0 (0.066)

-7 (-4)

-14 (-8)

2.8 (1.29)

109 (43)

4.0 (0.030)

1.1 (0.074)

-8 (-4)

-16 (-9)

3.2 (1.43)

110 (43)

4.4 (0.033)

1.2 (0.083)

-9 (-5)

-18 (-10)

3.5 (1.58)

EFFECTIVITY ALL

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Figure 13011. (Sheet 1 of 4) Test Data Sheet

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Figure 13011. (Sheet 2 of 4) Test Data Sheet

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Figure 13011. (Sheet 3 of 4) Test Data Sheet

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Figure 13011. (Sheet 4 of 4) Test Data Sheet

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Blank Page

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ENGINE MANUAL 131-9[B]

LIST OF EFFECTIVE PAGES Subheading and Page

Date

List of Effective Pages LEP-1 18 Dec 2019 LEP-2 18 Dec 2019 Table of Contents TC-1 18 Dec 2019 TC-2 18 Dec 2019 49-21-00 GEARBOX ASSEMBLY SYSTEMS DESCRIPTION SECTION 1 18 Dec 2019 2 18 Dec 2019 49-21-00 GEARBOX ASSEMBLY DISASSEMBLY-01 5001 18 Dec 2019 5002 18 Dec 2019 5003 18 Dec 2019 5004 18 Dec 2019 5005 18 Dec 2019 5006 18 Dec 2019 5007 18 Dec 2019 5008 18 Dec 2019 5009 * 18 Dec 2019 5010 18 Dec 2019 5011 * 18 Dec 2019 5012 18 Dec 2019 49-21-00 GEARBOX ASSEMBLY CLEANING-01 6001 18 Dec 2019 6002 18 Dec 2019 49-21-00 CLEAN MAGNETIC DRAIN PLUG CLEANING-02 6001 18 Dec 2019 6002 18 Dec 2019 49-21-00 GEARBOX HOUSING CLEANING-03 6001 18 Dec 2019 6002 18 Dec 2019

Subheading and Page

Date

49-21-00 CHECK 8001 18 Dec 2019 8002 18 Dec 2019 49-21-00 REPAIR 9001 18 Dec 2019 9002 18 Dec 2019 49-21-00 GEARBOX GEARSHAFTS ASSEMBLY-01 10001 18 Dec 2019 10002 * 18 Dec 2019 10003 18 Dec 2019 10004 18 Dec 2019 10005 * 18 Dec 2019 10006 18 Dec 2019 49-21-00 GEARBOX ASSEMBLY ASSEMBLY-02 10001 18 Dec 2019 10002 18 Dec 2019 10003 18 Dec 2019 10004 18 Dec 2019 10005 18 Dec 2019 10006 18 Dec 2019 10007 18 Dec 2019 10008 18 Dec 2019 10009 18 Dec 2019 10010 18 Dec 2019 10011 18 Dec 2019 10012 18 Dec 2019 10013 18 Dec 2019 10014 18 Dec 2019 10015 18 Dec 2019 10016 18 Dec 2019 10017 18 Dec 2019 10018 18 Dec 2019 10019 18 Dec 2019 10020 18 Dec 2019 10021 18 Dec 2019 10022 18 Dec 2019

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* Indicates a changed or added page. F Indicates a foldout page. EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TABLE OF CONTENTS CHAPTER - 49

UP552142

Title

Page

49-21-00 - GEARBOX ASSEMBLY .................................................................................................

1

49-21-00 - GEARBOX ASSEMBLY SYSTEMS DESCRIPTION SECTION ............................

1

49-21-00 - GEARBOX ASSEMBLY DISASSEMBLY-01 .........................................................

5001

49-21-00 - GEARBOX ASSEMBLY CLEANING-01 ................................................................

6001

49-21-00 - CLEAN MAGNETIC DRAIN PLUG CLEANING-02 ...............................................

6001

49-21-00 - GEARBOX HOUSING CLEANING-03 ...................................................................

6001

49-21-00 - CHECK ..................................................................................................................

8001

49-21-00 - REPAIR .................................................................................................................

9001

49-21-00 - GEARBOX GEARSHAFTS ASSEMBLY-01 ..........................................................

10001

49-21-00 - GEARBOX ASSEMBLY ASSEMBLY-02 ...............................................................

10001

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ENGINE MANUAL 131-9[B]

GEARBOX ASSEMBLY SYSTEMS DESCRIPTION SECTION 1.

Introduction The purpose of the gearbox assembly is to interface between the APU power section and the gearbox mounted lube module, fuel control and starter/generator. The gearbox assembly also serves as the lubrication distribution system for the APU and starter/generator.

2.

General Description The gearbox assembly supplies drive pads for the following APU accessories: -

Oil cooled starter/generator assembly

-

Lube module/fuel control unit

The gearbox assembly has:

3.

-

An oil filler housing with strainer and oil fill cap

-

An oil level sight glass

-

A magnetic chip collector

-

An air-oil separator adapter with access to the cluster gearshaft for manual rotation of the APU

-

Oil jets for the generator splines and bearings

-

Four spur gears

-

An oil pickup tube with a filter screen

-

An oil quantity sensor port

Operation During APU operation, oil is drawn from the gearbox assembly oil sump through the oil sump pickup filter screen. From that point oil enters the lube module where it goes through a temperature control system and lube filter. The conditioned oil is distributed internally to the gearbox oil jets for lubrication of the components, and externally to the starter/generator and APU power section bearings. The gearbox assembly receives power directly from the turbine through the driven compressor shaft. The generator gear is meshed with the high speed pinion gear to receive/supply power from/to the starter/generator. The cluster gearshaft, with integral air-oil separator, meshes with the high speed pinion gear and the lube pump gear drives the lube module and fuel control unit.

UP552142

Unwanted air that collects in the gearbox assembly is sent through the air-oil separator. Once air is separated from the oil, the air is sent through the gearbox vent to the APU exhaust.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 1. Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

GEARBOX ASSEMBLY DISASSEMBLY-01 TASK 49-21-00-030-801 1.

General

2.

A.

This section contains procedures for disassembly of the gearbox assembly.

B.

Do the disassembly procedures in a dry, bright, clean room.

C.

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

D.

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

E.

Do not disassemble any staked, welded, riveted, soldered, swaged, or press fit assemblies.

F.

Do not remove plates, passage hole plugs, or threaded inserts unless replacement is necessary.

G.

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

H.

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

I.

Make a list of the quantities and thickness of the shims and washers. This will help when the part is assembled.

J.

Refer to Section 49-20-00 for removal of the gearbox assembly.

Special Tools, Fixtures and Equipment A.

Table 5001 shows the special tools, fixtures and equipment needed for disassembly. Table 5001. Special Tools, Fixtures and Equipment

Nomenclature

UP552142

NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Step Plate Adapter

Used to remove bearings from the high speed pinion gear, generator gear, cluster gear and lube module gear

834822

Seal Puller

Used to remove the seal from the air-oil separator

834829-1

Split Plate Adapter

Used to remove bearings from the high speed pinion gear, cluster gear and lube module gear

834928-1

Split Plate Adapter

Used to remove bearings from the generator gear

834929-1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 3.

Equipment and Materials A.

Table 5002 shows the equipment and materials needed for disassembly. Table 5002. Equipment and Materials

Equipment/Materials NOTE:

Equivalent equipment/material can be used.

UP552142

Standard arbor press

EFFECTIVITY ALL

Description/Manufacturer Commercially available

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5001. Disassembly of Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5001 10. PLUG (IPC FIG. 12)

100. RETAINING RING

20. PACKING

110. FILTER ELEMENT

30. PLUG

120. NUT

40. PACKING

130. WASHER

50. MAGNETIC DRAIN PLUG

140. BOLT

60. MAGNETIC PLUG

150. OIL FILL CAP

70. PACKING

160. OIL FILL CAP ROLLER

80. PLUG

170. GEARBOX ASSY

90. PACKING 4.

Procedure

SUBTASK 49-21-00-030-001

UP552142

A.

EFFECTIVITY ALL

Disassemble the gearbox assembly. (Refer to Figure 5001.) (1)

Rotate the gearbox assembly until the drive pads point up.

(2)

Remove nuts (120), washers (130), bolts (140), oil fill cap (150) and oil fill cap roller (160) from the gearbox assembly (170).

(3)

Remove the plugs (10, 30) with packings (20, 40) from the gearbox assembly (170). Discard packing.

(4)

Remove assembled magnetic plug (60, 80) with packing (70, 90) from the gearbox assembly (170). Discard packing.

(5)

Remove retaining ring (100) and filter element (110) from the gearbox assembly (170).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5002. Disassembly of Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5002 10. BOLT (IPC FIG. 13)

60. STATIONARY AIR-OIL SEAL

20. WASHER

70. SHIM

30. AIR-OIL SEPARATOR ADAPTER

80. PACKING

35. INSERT

90. PACKING

40. PLUG

100. GEARBOX ASSY

50. PACKING

UP552142

B.

EFFECTIVITY ALL

Disassemble the gearbox assembly components. (Refer to Figure 5002.) (1)

Remove bolts (10), washers (20), and air-oil separator adapter (30) with plug (40), stationary air-oil seal (60), packings (50, 80, 90), and installed quantity of shims (70) from the gearbox assembly (100).

(2)

Disassemble the air-oil separator adapter (30) as follows: (a)

Use a PN 834829-1 seal puller to remove stationary air-oil seal (60), from air-oil separator adapter (30). Remove the installed quantity of shims (70) and packings (80, 90) from air-oil separator adapter (30). Discard packings.

(b)

Remove plug (40) with packing (50) from the air-oil separator adapter (30). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5003. Disassembly of Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5003 10. BOLT (IPC FIG. 14)

110. SHIM

20. BEARING RETAINER

120. PACKING

30. BOLT

130. BOLT

40. BEARING RETAINER

140. BOLT

50. BOLT

150. WASHER

60. BEARING RETAINER

160. BEARING CARRIER

70. SHIM

170. PACKING

80. BOLT

180. LUBRICATING NOZZLE ASSY

90. WASHER

210. PACKING

100. LUBE MANIFOLD

UP552142

C.

EFFECTIVITY ALL

220. GEARBOX ASSY

Disassemble the gearbox assembly. (Refer to Figure 5003.) (1)

Rotate the gearbox assembly until the drive pads point down.

(2)

Remove bolts (10) and bearing retainer (20) from the gearbox assembly (220).

(3)

Remove bolts (30) and bearing retainer (40) from the gearbox assembly (220).

(4)

Remove bolts (50), bearing retainer (60), and installed quantity of shims (70) from the gearbox assembly (220).

(5)

Remove bolts (80, 130), washers (90, 150), lube manifold (100), installed quantity of shims (110), and packing (120) from the gearbox assembly (220). Discard packing.

(6)

Remove bolts (140), washers (150), bearing carrier (160), packing (170), and lubricating nozzle assembly (180) with packing (210) from the gearbox assembly (220). Discard packing.

(7)

Remove lubricating nozzle assembly (180) with packing (210) from the bearing carrier (160).

(8)

Remove packing (210) from the lubricating nozzle assembly (180). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5004. Disassembly of Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5004 10. HIGH SPEED PINION GEAR (IPC FIG. 15)

50. BEARING

20. BEARING

60. GENERATOR GEARSHAFT

30. RETAINING RING

70. BEARING

40. LUBE PUMP GEARSHAFT ASSY

80. GEARBOX ASSY

UP552142

D.

EFFECTIVITY ALL

Disassemble the gearbox assembly. (Refer to Figure 5004.) (1)

Remove high speed pinion gear (10) with bearings (20) and retaining ring (30) from the gearbox assembly (80).

(2)

Use a PN 834928-1 split plate adapter and a PN 834822 step plate adapter to remove bearings (20) from high speed pinion gear (10).

(3)

Remove retaining ring (30).

(4)

Remove lube pump gearshaft assembly (40) with bearings (50) from the gearbox assembly (80).

(5)

Use a PN 834928-1 split plate adapter and a PN 834822 step plate adapter to remove bearings (50) from lube pump gear (40).

(6)

Remove generator gearshaft (60) with bearings (70) from the gearbox assembly (80).

(7)

Use a PN 834929-1 split plate adapter and a PN 834822 step plate adapter to remove bearings (70) from generator gearshaft (60).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5005. Disassembly of Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5005 10. CLUSTER GEARSHAFT (IPC FIG. 16)

85. JET BEARING

20. AIR-OIL SEPARATOR

90. PACKING

30. SEAL DISK

100. BOLT

40. SEAL RING

110. WASHER

50. BEARING

120. SIGHT GLASS

60. BOLT

130. PACKING

70. WASHER

140. GEARBOX HOUSING

80. OIL PICKUP TUBE

UP552142

E.

EFFECTIVITY ALL

Disassemble the gearbox assembly. (Refer to Figure 5005.) (1)

Remove assembled cluster gearshaft (10) from the gearbox housing (140).

(2)

Disassemble the cluster gearshaft (10) as follows: (a)

Remove seal disk (30) and seal ring (40) from cluster gearshaft (10). Discard seal ring.

(b)

Use a PN 834928-1 split plate adapter and a PN 834822 step plate adapter to remove bearings (50) from cluster gearshaft (10).

(c)

Remove air-oil separator adapter (20) from the cluster gearshaft (10).

(3)

Remove bolts (60), washers (70), and oil pickup tube (80) with packing (90) from the gearbox housing (140).

(4)

Remove packing (90) from oil pickup tube (80). Discard packing.

(5)

Remove bolts (100), washers (110), sight glass (120), and packing (130) from the gearbox housing (140). Discard packing.

(6)

Remove jet bearing (85) from the gearbox housing (140).

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ENGINE MANUAL 131-9[B]

GEARBOX ASSEMBLY CLEANING-01 TASK 49-21-00-100-801 1.

General A.

2.

This section contains procedures for cleaning the components of the gearbox assembly.

Cleaning Methods A.

Table 6001 shows the standard cleaning methods necessary for cleaning of the components. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01 for the cleaning procedures. Table 6001. Cleaning Methods

IPC Figure No.

Cleaning Methods Item No.

Nomenclature

All standard metallic hardware

X

203B

203E

203F

110

Filter Element

13

30

Air/Oil Separator Adapter

X

X

60

Stationary Air/Oil Seal

X

X

X

20, 40, 60

Retainer

X

X

X

70, 110

Shim

X

X

X

100

Lube Manifold

X

X

X

X

160

Bearing Carrier

X

X

X

X

180

Lubricating Nozzle Assembly

X

X

X

X

10

High Speed Pinion Gear

X

X

20

Bearing Set

30

Retaining Ring

X

X

X

40

Gearshaft Assembly

X

X

X

50

Bearing Set

60

Generator Gearshaft

70

Bearing Set

15

EFFECTIVITY ALL

203Q

203P

203R

X

12

14

UP552142

203A

X X

X X

X X

X

X X

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ENGINE MANUAL 131-9[B] Table 6001. Cleaning Methods (Cont) IPC Figure No.

Item No.

16

10

Cluster Gearshaft

X

X

X

20

Air-oil separator

X

X

X

30

Seal Disk

X

X

X

50

Bearing Set

80

Oil Pickup Tube

120

Sight Glass

20

Bearing

X

50

Bearing

X

70

Bearing

X

15

3.

Cleaning Methods Nomenclature

203A

203B

203E

203F

203Q

203P

203R

X X

X

X X

Special Procedures A.

Table 6002 shows the special cleaning methods necessary for cleaning of the components. Refer to cleaning 02 this section for the cleaning procedures.

UP552142

Table 6002. Cleaning Methods IPL Figure No.

Item No.

Nomenclature

12

50

Magnetic Drain Plug

16

140

Gearbox Housing Set

EFFECTIVITY ALL

Cleaning Methods 203B

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203E

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ENGINE MANUAL 131-9[B]

CLEAN MAGNETIC DRAIN PLUG CLEANING-02 TASK 49-21-00-110-801 1.

Clean magnetic drain plug (IPC Figure 12, item 50)

2.

Equipment and Materials A.

Table 6001 shows the equipment and materials needed for cleaning. Table 6001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Degreasing solvent (MIL-PRF-680) 3.

Commercially available

Procedure

SUBTASK 49-21-00-110-001 A.

Clean the magnetic drain plug. WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. ALWAYS WEAR SOLVENT-RESISTANT GLOVES, SUCH AS NEOPRENE, WHEN USING SOLVENT. (1)

Put the components of the magnetic drain plug fully into the degreasing solvent (MIL-PRF-680) to clean.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

UP552142

(2)

EFFECTIVITY ALL

Dry with clean compressed air.

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UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

GEARBOX HOUSING CLEANING-03 TASK 49-21-00-110-802 1.

Clean gearbox housing (IPC Figure 16, item 140)

2.

Equipment and Materials A.

Table 6001 shows the equipment and materials needed for cleaning. Table 6001. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Alkaline cleaner (Ridoline 909) (MIL-S-5002)

Henkel Surface Technologies, 32100 Stephenson Hwy., Madison Heights, MI 48071

Distilled water

Commercially available

Degreasing solvent (MIL-PRF-680)

Commercially available

3.

Procedure

SUBTASK 49-21-00-160-001 A.

Prepare alkaline cleaner solution. WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. (1)

Add 4 to 6 ounces (113 to 170 g) of alkaline cleaner with sufficient water to make 1 gallon (3.8 L) of solution and mix fully.

(2)

Keep the solution at 130 to 180°F (54 to 82°C) in an air-agitated tank.

SUBTASK 49-21-00-110-002 B.

Clean the gearbox housing. (1)

Remove the grease from the gearbox housing. (Refer to APPENDIX 1.).

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. ALWAYS WEAR SOLVENT-RESISTANT GLOVES, SUCH AS NEOPRENE, WHEN USING SOLVENT.

UP552142

(2)

EFFECTIVITY ALL

If necessary, put the gearbox housing in an alkaline cleaner solution and clean with a soft, fiber bristled brush.

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ENGINE MANUAL 131-9[B] (3)

Flush the gearbox housing with water at 140 to 200°F (60 to 93°C).

(4)

Immediately after flushing with water, flush the gearbox housing with distilled water.

(5)

Dry the gearbox housing with one of the methods as follows: WARNING: USE THE CORRECT PERSONAL PROTECTION. THE HEATED PARTS WILL CAUSE BURNS. (a)

Put the gearbox housing in an oven at 150 to 200°F (66 to 93°C) until dry.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

UP552142

(b)

EFFECTIVITY ALL

Dry with clean compressed air.

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ENGINE MANUAL 131-9[B]

CHECK 1.

Refer to Inspection/Repair Manual, ATA No. 49-26-85, for check procedures.

UP552142

NOTE:

EFFECTIVITY ALL

Inspection/Repair Manual, ATA No. 49-26-85, is a companion manual to this Engine Manual.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

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ENGINE MANUAL 131-9[B]

REPAIR

UP552142

1.

Refer to ATA No. 49-26-85 for repair procedures.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

GEARBOX GEARSHAFTS ASSEMBLY-01 TASK 49-21-00-440-801 1.

General A.

2.

This section contains procedures for assembly of the gearshafts.

Special Tools, Fixtures and Equipment A.

Table 10001 shows the special tools, fixtures and equipment needed for installation. Table 10001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Bearing Driver

Used to install bearing on the generator gearshaft assembly.

834702-1

Bearing Driver

Used to install bearing on the high speed pinion gear.

834703-1

Bearing Driver

Used to install bearings on the lube pump gear and 834819-1 cluster gearshaft assembly.

3.

Equipment and Materials A.

Table 10002 shows the equipment and materials needed for installation. Table 10002. Equipment and Materials

Equipment/Materials

UP552142

NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Corrosion-preventive compound (Braycote 248) (MIL-C-11796, Class 3)

Air BP Lubricants Div., Maple Plaza II, 1N, 6 Campus Dr., Parsippany, NJ 07054-4406

Standard arbor press

Commercially available

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10001. Assemble the High Speed Pinion Gear, Lube Pump Gear and Generator Gearshaft

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10001 10. HIGH SPEED PINION GEAR (IPC FIG. 15)

50. BEARING

20. BEARING

60. GENERATOR GEARSHAFT

30. RETAINING RING

70. BEARING

40. LUBE PUMP GEAR 4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 10003 be replaced at each assembly. However, actual replacement of parts can be done on in-service experience. Table 10003. Parts to be Replaced at Each Assembly

Figure No.

Item No.

Nomenclature

Quantity

Figure 10001

30

Seal Disk

1

40

Seal Ring

1

5.

Procedure

SUBTASK 40-21-00-440-001 A.

Assemble the bearings and retaining ring on the high speed pinion gear. (Refer to Figure 10001.) NOTE:

When installing bearings onto gear assemblies, make sure that the THRUST marking on the outer race of the bearing is facing out. If the bearing has no THRUST marking, make sure that the part number is facing out.

(1)

Put bearing (20) on one side of the high speed pinion gear (10).

(2)

Push bearing (20) on high speed pinion gear (10) with PN 834703-1 bearing driver and a standard arbor press.

(3)

Do Steps (1) and (2) again for the other bearing (20).

(4)

Install the retaining ring (30) in the high speed pinion gear (10).

(5)

Hold assembled components (10, 20, 30) for installation into the gearbox assembly.

SUBTASK 40-21-00-440-002 B.

Assemble the bearings on the lube pump gear. (Refer to Figure 10001.) NOTE:

UP552142

(1)

EFFECTIVITY ALL

When installing bearings on gear assemblies, make sure that the THRUST marking on the outer race of the bearing is pointing out. If the bearing has no THRUST marking, make sure that the part number is pointing out. Put bearing (50) on one side of the lube pump gear (40).

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ENGINE MANUAL 131-9[B] (2)

Push bearing (50) on lube pump gear (40) with PN 834819-1 bearing driver and a standard arbor press.

(3)

Do Steps (1) and (2) again for the other bearing (50).

(4)

Hold assembled components (40, 50) for installation into the gearbox assembly.

SUBTASK 40-21-00-440-003 C.

Assemble the bearings on the generator gearshaft. (Refer to Figure 10001.) NOTE:

When installing bearings on gear assemblies, make sure that the THRUST marking on the outer race of the bearing is pointing out. If the bearing has no THRUST marking, make sure that the part number is pointing out.

(1)

Put bearing (70) on one side of the generator gearshaft (60).

(2)

Push bearing (70) on generator gearshaft (60) with PN 834702-1 bearing driver and a standard arbor press.

(3)

Do Steps (1) and (2) again for the other bearing (70).

(4)

Hold assembled components (60, 70) for installation into the gearbox assembly.

SUBTASK 40-21-00-440-004 D.

Assemble the bearings and seal disk on the cluster gearshaft. (Refer to Figure 10002.)

UP552142

NOTE:

EFFECTIVITY ALL

When installing bearings on gear assemblies, make sure that the THRUST marking on the outer race of the bearing is pointing out. If the bearing has no THRUST marking, make sure that the part number is pointing out.

(1)

Install air-oil separator (20) on the cluster gearshaft (10).

(2)

Put bearing (50) on one side of the cluster gearshaft (10).

(3)

Push bearing (50) on cluster gearshaft (10) with PN 834819-1 bearing driver and a standard arbor press.

(4)

Do Steps (2) and (3) again for the other bearing (50).

(5)

Coat seal ring (40) with Braycote 248.

(6)

Install seal ring (40) in the seal disk (30).

(7)

Layer the seal ring (40) with Braycote 248 and push the seal disk (30), with installed seal ring, on the cluster gearshaft (10).

(8)

Hold assembled components (10, 20, 30, 40, 50) for installation into the gearbox assembly.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10002. Assemble the Cluster Gearshaft

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10002 10. CLUSTER GEARSHAFT (IPC FIG. 16)

40. SEAL RING

20. AIR OIL SEPARATOR

50. BEARING

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30. SEAL DISK

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

GEARBOX ASSEMBLY ASSEMBLY-02 TASK 49-21-00-430-801 1.

General A.

2.

This section contains procedures for assembly of the gearbox assembly.

Special Tools, Fixtures and Equipment Table 10001. Special Tools, Fixtures and Equipment Nomenclature NOTE:

Use

Equivalent tools, fixtures and equipment can be used.

Shaft Driver

3.

Part No.

Used to install stationary air-oil seal in the air-oil separator adapter.

834824-1

Equipment and Materials A.

Table 10002 shows the equipment and materials needed for installation. Table 10002. Equipment and Materials

Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Lockwire (PN MS20995C20)

Commercially available

Oil (MIL-PRF-7808 or

Commercially available

UP552142

MIL-PRF-23699)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10001. Install Oil Pickup Tube and Sight Glass on Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10001 60. BOLT (IPC FIG. 16)

100. BOLT

70. WASHER

110. WASHER

80. OIL PICKUP TUBE

120. SIGHT GLASS

85. OIL JET BEARING

130. PACKING

90. PACKING

140. GEARBOX ASSY Table 10003. Check Point Summary

Check Point

Operation

Page

10

Make sure shim pack calculated in Step 5.A.(5)(c)2 is correct and placed on the correct bearing.

10011

20

Make sure shim pack calculated in Step 5.A.(6)(c)2 is correct and placed on the correct bearing.

10013

30

Make sure calculations used to find thickness of shims (70) are correct.

10017

40

Examine gearbox for complete assembly, obvious damage and freedom of rotation.

10021

4.

Expendable Parts A.

Honeywell recommends that the parts shown in Table 10004 be replaced at each assembly. However, actual replacement of parts can be done on in-service experience.

UP552142

Table 10004. Parts to be Replaced at Each Assembly Figure No.

Item No.

Nomenclature

Quantity

Figure 10001

90, 130

Packing

1

Figure 10004

70, 170, 210

Packing

1

Figure 10007

120

Packing

1

Figure 10008

80, 90

Packing

1

Figure 10009

20, 40, 70, 90, 180

Packing

1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10002. Install Oil Jet Bearing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10002

UP552142

85. OIL JET BEARING

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10003. Install Gear Assemblies in the Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10003 80. GEARBOX ASSY (IPC FIG. 15) 5.

Procedure

SUBTASK 40-21-00-430-001 A.

Assemble the gearbox assembly. WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (1)

(2)

(3)

Install oil pickup tube and sight glass on gearbox. (Refer to Figure 10001.) (a)

Lubricate new packing (90) with oil.

(b)

Install packing (90) on oil pickup tube (80).

(c)

Install oil pickup tube (80), with installed packing (90), in gearbox assembly (140) with bolts (60) and washers (70).

(d)

Tighten bolts (60) to a torque value of 50 in-lb (5.6 Nm).

(e)

Lubricate packing (130) with oil.

(f)

Install packing (130) on sight glass (120) and attach sight glass to the gearbox assembly (140) with bolts (100) and washers (110).

(g)

Alternately tighten bolts (100) to a torque value of 50 in-lb (5.6 Nm).

Install oil jet as follows: (Refer to Figure 10002.) (a)

Apply loctite 620 at oil jet thread and install oil jet (85) on gearbox assembly (140). Maintain position as shown in Figure 10002.

(b)

Punch mark in three positions to secure position of oil jet.

Install gear assemblies in gearbox assembly as follows. (Refer to Figure 10003.)

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NOTE:

EFFECTIVITY ALL

Place gearbox assembly (80) flat with front down when installing gear assemblies into the gearbox.

(a)

Install cluster gearshaft, air oil separator and bearing assembly into the gearbox assembly (80).

(b)

Install generator gearshaft and bearing assembly into the gearbox assembly (80).

(c)

Install lube pump gearshaft and bearing assembly into the gearbox assembly (80).

(d)

Install high speed pinion gear and bearing assembly into the gearbox assembly (80).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10004. Install Lubricating Nozzle Assembly and Bearing Carrier in Gearbox Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10004 20. BEARING (IPC FIG. 15)

170. PACKING

70. PACKING (IPC FIG. 11)

180. LUBRICATING NOZZLE ASSY

140. BOLT (IPC FIG. 14)

210. PACKING

150. WASHER

220. GEARBOX ASSY

160. BEARING CARRIER (4)

Install lubricating nozzle assembly and bearing carrier in gearbox. (Refer to Figure 10004.) WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. (a)

Lubricate packings (70, 210) with oil.

(b)

Install packings (70, 210) on the lubricating nozzle assembly (180). Put oil through lubricating nozzle assembly to make sure oil passage is not closed.

(c)

Put lubricating nozzle assembly (180) with installed packings (70, 210) in the gearbox assembly (220) oil port, located near the high speed pinion bearing (20), until it makes bottom.

(d)

Turn the lubricating nozzle assembly (180), approximately 90 degrees in the clockwise direction, until lubricating nozzle assembly oil jet arm is in line with the center of the high speed pinion bearing (20).

(e)

Install packing (170) on the oil supply port in the gearbox assembly (220).

(f)

Put bearing carrier (160) on the gearbox assembly (220) and over the bearing/gear assemblies.

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NOTE:

EFFECTIVITY ALL

Make sure index pin on the lubricating nozzle assembly (180) goes into the index hole in the bearing carrier (160) when the bearing carrier is installed on the gearbox assembly (220).

(g)

Install bolts (140) and washers (150).

(h)

Tighten bolts (140) to a torque value of 50 in-lb (5.6 Nm).

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ENGINE MANUAL 131-9[B]

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Figure 10005. Calculate and Install Generator Gearshaft Bearing Shims

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10005 60. GENERATOR GEARSHAFT (IPC FIG. 15)

160. BEARING CARRIER

70. BEARING

220. GEARBOX ASSY

110. SHIM (IPC FIG. 14) (5)

Calculate and install generator gearshaft bearing shims. (Refer to Figure 10005.) (a)

Make sure generator gearshaft (60) and assembled bearings (70) are fully engaged in gearbox assembly (220).

(b)

Measure between top of bearing carrier (160) and top of bearing (70) outer race. Write the measurement as Dimension A.

(c)

Use the following equation to calculate the correct amount of shims (110) for the generator gearshaft (60).

(d)

1

Dimension A = ______ inch (mm).

2

Correct shim pack (110) = Dimension A - 0.010 inch (0.25 mm) ± 0.005 inch (0.13 mm).

Install calculated shim (110) pack on top of bearing (70) outer race.

UP552142

Check Point 10:

EFFECTIVITY ALL

Make sure shim pack calculated in Step 5.A.(5)(c)2 is correct and placed on the correct bearing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10006. Calculate and Install Cluster Gearshaft Bearing Shims

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10006 10. CLUSTER GEARSHAFT (IPC FIG. 16)

160. BEARING CARRIER

50. BEARING

220. GEARBOX ASSEMBLY

70. SHIM (IPC FIG. 14) (6)

Calculate and install cluster gearshaft bearing shims. (Refer to Figure 10006.) (a)

Make sure cluster gearshaft (10) and assembled bearings (50) are fully seated in the gearbox assembly (220).

(b)

Measure between the top of the bearing carrier (160) and the top of the bearing (50) outer race. Write the measurement as Dimension B.

(c)

Use the following equation to calculate the correct amount of shims (70) for the cluster gearshaft (10).

(d)

1

Dimension B = ________inch (mm).

2

Correct shim pack (70) = Dimension B - 0.010 inch (0.25 mm) ± 0.005 inch (0.13 mm).

Install calculated shim (70) pack on top of bearing (50) outer race.

UP552142

Check Point 20:

EFFECTIVITY ALL

Make sure shim pack calculated in Step 5.A.(6)(c)2 is correct and placed on the correct bearing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10007. Install Lube Manifold and Bearing Retainers on Bearing Carrier

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10007 10. BOLT (IPC FIG. 14) 20. RETAINER

100. LUBE MANIFOLD

30. BOLT

120. PACKING

40. RETAINER

130. BOLT

50. BOLT

150. WASHER

60. RETAINER

160. BEARING CARRIER

80. BOLT

220. GEARBOX ASSEMBLY

(7)

Install lube manifold on bearing carrier. (Refer to Figure 10007.) NOTE:

(8)

(9)

UP552142

EFFECTIVITY

Make sure all gear assembly shim packs are in their correct positions on top of their related bearings.

(a)

Install packing (120) on oil supply port in bearing carrier (160).

(b)

Put lube manifold (100) on bearing carrier (160).

(c)

Attach lube manifold (100) to bearing carrier (160) with bolts (80, 130) and washers (90, 150).

(d)

Tighten bolts (80, 130) to a torque value of 50 in-lb (5.6 Nm).

Install bearing retainers on bearing carrier. (a)

Install retainer (60) on bearing carrier (160) and attach with bolts (50).

(b)

Tighten bolts (50) to a torque value of 50 in-lb (5.6 Nm).

(c)

Install retainer (20) on bearing carrier (160) and attach with bolts (10).

(d)

Tighten bolts (10) to a torque value of 50 in-lb (5.6 Nm).

(e)

Install retainer (40) on bearing carrier (160) and attach with bolts (30).

(f)

Tighten bolts (30) to a torque value of 50 in-lb (5.6 Nm).

Install air-oil separator adapter. (Refer to Figure 10008.) (a)

ALL

90. WASHER

Determine the shims (70) necessary for the stationary air-oil seal (60) as follows:

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10008. Install Air-Oil Separator Adapter on Gearbox Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10008 10. BOLT (IPC FIG. 13)

80. PACKING

20. WASHER

90. PACKING

30. AIR-OIL SEPARATOR ADAPTER

100. SEAL DISK (30, IPC FIG. 16)

60. STATIONARY AIR-OIL SEAL

110. GEARBOX ASSY (140, IPC FIG. 16)

70. SHIM 1

Measure from the face of the gearbox assembly (110) to the face of the seal disk (100). Write as Dimension A. (Refer to Dimension A, Detail A.)

2

Measure from the top of the air-oil separator adapter (30) to the face of the air-oil separator adapter flange. Write as Dimension B. (Refer to Dimension B, Detail B.)

3

Measure from the top of the air-oil separator adapter (30) to the air-oil separator adapter seal land. Write as Dimension C. (Refer to Dimension C, Detail B.)

4

Calculate the necessary shims as follows: a

Dimension A = ____________inch (mm).

b

Dimension B = ____________inch (mm).

c

Dimension C = ____________inch (mm).

d

Necessary shim (70) pack inch (mm) = A-B+C-0.450 inch (11.43 mm) ±0.002 inch (0.05 mm).

Check Point 30:

(b)

Make sure calculations used to find thickness of shims (70) are correct.

Install shim (70) pack calculated in Step 5.A.(9)(a)4 d.

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

Lubricate packing (90) with oil.

(d)

Install packing (90) in the air-oil separator adapter (30).

(e)

Use PN 834824-1 shaft driver to install stationary air-oil seal (60) up against the installed shim (70) pack in the air-oil separator adapter (30).

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. UP552142

(f) EFFECTIVITY ALL

Lubricate packing (80) with oil.

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ENGINE MANUAL 131-9[B]

EFFECTIVITY ALL

(g)

Install packing (80) on the air-oil separator adapter (30).

(h)

Put air-oil separator adapter (30) with installed packing (80, 90), shim (70) pack and stationary air-oil seal (60) on the gearbox assembly (110) and attach the air-oil separator adapter to the gearbox assembly with bolts (10) and washers (20).

(i)

Tighten bolts (10) to a torque value of 50 in-lb (5.6 Nm).

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ENGINE MANUAL 131-9[B]

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Figure 10009. Install Plugs, Filter Element and Oil Cap on Gearbox Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10009 10. PLUG (IPC FIG. 12)

110. FILTER ELEMENT

20. PACKING

120. NUT

30. PLUG

130. WASHER

40. PACKING

140. BOLT

50. MAGNETIC DRAIN PLUG

150. OIL FILL CAP

60. MAGNETIC PLUG

160. OIL FILL CAP ROLLER

70. PACKING

170. PLUG (40, IPC FIG. 13)

80. PLUG

180. PACKING (50, IPC FIG. 13)

90. PACKING

190. GEARBOX ASSY (170, IPC FIG. 12)

100. RETAINING RING (10)

Install plugs, filter element and oil fill cap on gearbox assembly. (Refer to Figure 10009.) (a)

Install filter element (110) and retaining ring (100) in the gearbox assembly (190).

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

Lubricate packing (20) with oil.

(c)

Install plug (10) with packing (20) on gearbox assembly (190).

(d)

Lockwire plug (10) per NASM33540 using lockwire MS20995C20.

(e)

Lubricate packing (40) with oil.

(f)

Install plug (30) with packing (40) on gearbox assembly (190).

(g)

Lockwire plug (30) per NASM33540 using lockwire MS20995C20.

(h)

Lubricate packing (90) with oil.

(i)

Install plug (80) with packing (90) on gearbox assembly (190). Tighten plug to a torque of 80 to 90 in-lb (9.04 to 10.2 Nm).

(j)

Lockwire plug (80) per NASM33540 using lockwire MS20995C20.

UP552142

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

EFFECTIVITY ALL

(k)

Lubricate packing (70) with oil.

(l)

Install magnetic plug (60) with packing (70) on installed plug (80).

(m)

Lubricate packing (180) with oil.

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ENGINE MANUAL 131-9[B] (n)

Install plug (170) with packing (180) on gearbox assembly (190).

(o)

Install oil fill cap roller (160), oil fill cap (150) and attach to gearbox assembly (190) with bolts (140), washers (130) and nuts (120).

(p)

Tighten nuts (120) on bolts (140) to a torque value of 40 in-lb (4.5 Nm).

UP552142

Check Point 40:

EFFECTIVITY ALL

Examine gearbox for complete assembly, obvious damage and freedom of rotation.

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ENGINE MANUAL 131-9[B]

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Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

LIST OF EFFECTIVE PAGES Subheading and Page

Date

List of Effective Pages LEP-1 18 Dec 2019 LEP-2 18 Dec 2019 LEP-3 18 Dec 2019 LEP-4 18 Dec 2019 Table of Contents TC-1 18 Dec 2019 TC-2 18 Dec 2019 49-22-00 POWER SECTION ASSEMBLY SYSTEMS DESCRIPTION SECTION 1 18 Dec 2019 2 18 Dec 2019 49-22-00 POWER SECTION ASSEMBLY DISASSEMBLY-01 5001 18 Dec 2019 5002 18 Dec 2019 49-22-00 POWER SECTION ASSEMBLY DISASSEMBLY-02 5001 18 Dec 2019 5002 18 Dec 2019 5003 18 Dec 2019 5004 18 Dec 2019 5005 18 Dec 2019 5006 18 Dec 2019 5007 18 Dec 2019 5008 * 18 Dec 2019 5009 * 18 Dec 2019 5010 18 Dec 2019 5011 18 Dec 2019 5012 18 Dec 2019 5013 18 Dec 2019 5014 18 Dec 2019 5015 * 18 Dec 2019 5016 18 Dec 2019 5017 * 18 Dec 2019 5018 18 Dec 2019 5019 * 18 Dec 2019 5020 18 Dec 2019

Subheading and Page

Date

5021 18 Dec 2019 5022 18 Dec 2019 5023 18 Dec 2019 5024 18 Dec 2019 5025 18 Dec 2019 5026 18 Dec 2019 5027 18 Dec 2019 5028 18 Dec 2019 5029 18 Dec 2019 5030 18 Dec 2019 5031 18 Dec 2019 5032 18 Dec 2019 5033 18 Dec 2019 5034 18 Dec 2019 49-22-00 INLET GUIDE VANE ASSEMBLY DISASSEMBLY-03 5001 18 Dec 2019 5002 18 Dec 2019 5003 18 Dec 2019 5004 18 Dec 2019 49-22-00 FIRST STAGE STATOR ASSEMBLY DISASSEMBLY-04 5001 18 Dec 2019 5002 18 Dec 2019 5003 18 Dec 2019 5004 18 Dec 2019 49-22-00 TURBINE AND COMPRESSOR ASSEMBLY CLEANING-01 6001 18 Dec 2019 6002 18 Dec 2019 6003 18 Dec 2019 6004 18 Dec 2019 6005 18 Dec 2019 6006 18 Dec 2019 49-22-00 CHECK 8001 18 Dec 2019 8002 18 Dec 2019

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ENGINE MANUAL 131-9[B]

LIST OF EFFECTIVE PAGES (Cont) Subheading and Page

Date

49-22-00 REPAIR 9001 18 Dec 9002 18 Dec 49-22-00 INLET GUIDE VANE ASSEMBLY ASSEMBLY-01 10001 18 Dec 10002 18 Dec 10003 18 Dec 10004 18 Dec 10005 * 18 Dec 10006 * 18 Dec 10007 18 Dec 10008 18 Dec 49-22-00 ROTATING GROUP ASSEMBLY ASSEMBLY-02 10001 18 Dec 10002 18 Dec 10003 18 Dec 10004 18 Dec 10005 18 Dec 10006 18 Dec 10007 18 Dec 10008 18 Dec 10009 18 Dec 10010 18 Dec 49-22-00 DIFFUSER HOUSING ASSEMBLY ASSEMBLY-03 10001 18 Dec 10002 * 18 Dec 10003 18 Dec 10004 * 18 Dec 10005 18 Dec 10006 18 Dec 10007 18 Dec 10008 18 Dec

2019 2019

2019 2019 2019 2019 2019 2019 2019 2019

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

2019 2019 2019 2019 2019 2019 2019 2019

Subheading and Page

Date

49-22-00 FIRST STAGE STATOR ASSEMBLY ASSEMBLY-04 10001 18 Dec 2019 10002 18 Dec 2019 10003 18 Dec 2019 10004 18 Dec 2019 10005 18 Dec 2019 10006 18 Dec 2019 49-22-00 SECOND STAGE STATOR ASSEMBLY ASSEMBLY-05 10001 18 Dec 2019 10002 18 Dec 2019 10003 18 Dec 2019 10004 18 Dec 2019 49-22-00 POWER SECTION ASSEMBLY ASSEMBLY-06 10001 18 Dec 2019 10002 18 Dec 2019 10003 18 Dec 2019 10004 18 Dec 2019 10005 * 18 Dec 2019 10006 18 Dec 2019 10007 18 Dec 2019 10008 18 Dec 2019 10009 18 Dec 2019 10010 18 Dec 2019 10011 18 Dec 2019 10012 18 Dec 2019 10013 18 Dec 2019 10014 18 Dec 2019 10015 18 Dec 2019 10016 18 Dec 2019 10017 * 18 Dec 2019 10018 18 Dec 2019 10019 18 Dec 2019 10020 18 Dec 2019 10021 18 Dec 2019 10022 18 Dec 2019 10023 18 Dec 2019

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ENGINE MANUAL 131-9[B]

LIST OF EFFECTIVE PAGES (Cont) Subheading and Page

10024 10025 10026 10027 10028 10029 10030 10031 10032 10033 10034 10035 10036 10037 10038 10039 10040 10041 10042 10043 10044 10045 10046 10047 10048 10049 10050 10051 10052 10053 10054 10055 10056 10057 10058 10059 10060 10061 10062 10063 10064 10065 10066 10067

Date

*

*

*

*

*

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

Subheading and Page

10068 10069 10070 10071 10072 10073 10074 10075 10076 10077 10078 10079 10080 10081 10082 10083 10084 10085 10086 10087 10088 10089 10090 10091 10092 10093 10094 10095 10096 10097 10098 10099 10100 10101 10102 10103 10104 10105 10106 10107 10108 10109 10110 10111

Date

* * * *

*

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

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ENGINE MANUAL 131-9[B]

LIST OF EFFECTIVE PAGES (Cont) Subheading and Page

10112 * 10113 * 10114 10115 10116 10117 10118 10119 10120 10121 10122 49-26-95 TASK AND SUBTASK INDEX 10001 10002 10003 10004 10005 10006 10007 10008

Date

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019 2019 2019 2019

18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec 18 Dec

2019 2019 2019 2019 2019 2019 2019 2019

Subheading and Page

Date

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ENGINE MANUAL 131-9[B]

TABLE OF CONTENTS CHAPTER - 49

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Title

Page

49-22-00 - POWER SECTION ASSEMBLY ....................................................................................

1

49-22-00 - POWER SECTION ASSEMBLY SYSTEMS DESCRIPTION SECTION ...............

1

49-22-00 - POWER SECTION ASSEMBLY DISASSEMBLY-01 ............................................

5001

49-22-00 - POWER SECTION ASSEMBLY DISASSEMBLY-02 ............................................

5001

49-22-00 - INLET GUIDE VANE ASSEMBLY DISASSEMBLY-03 .........................................

5001

49-22-00 - FIRST STAGE STATOR ASSEMBLY DISASSEMBLY-04 ....................................

5001

49-22-00 - TURBINE AND COMPRESSOR ASSEMBLY CLEANING-01 ..............................

6001

49-22-00 - CHECK ..................................................................................................................

8001

49-22-00 - REPAIR .................................................................................................................

9001

49-22-00 - INLET GUIDE VANE ASSEMBLY ASSEMBLY-01 ...............................................

10001

49-22-00 - ROTATING GROUP ASSEMBLY ASSEMBLY-02 ................................................

10001

49-22-00 - DIFFUSER HOUSING ASSEMBLY ASSEMBLY-03 .............................................

10001

49-22-00 - FIRST STAGE STATOR ASSEMBLY ASSEMBLY-04 ..........................................

10001

49-22-00 - SECOND STAGE STATOR ASSEMBLY ASSEMBLY-05 .....................................

10001

49-22-00 - POWER SECTION ASSEMBLY ASSEMBLY-06 ..................................................

10001

49-26-95 - TASK AND SUBTASK INDEX ..............................................................................

10001

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

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ENGINE MANUAL 131-9[B]

POWER SECTION ASSEMBLY SYSTEMS DESCRIPTION SECTION 1.

Introduction The purpose of the power section assembly is to supply the necessary power during the operation of the APU.

2.

General Description The power section is a single-shaft design that includes a single-stage centrifugal compressor and a two-stage axial flow turbine. The single main shaft also ties the engine compressor and turbine to the load compressor and is supported by two bearings, a duplex ball bearing located forward of the load compressor and a roller bearing located aft of the second stage turbine. Carbon seals are used in the front and rear bearing cavities. The load compressor bearing has a bellows carbon face seal, and the turbine bearing has a segmented carbon ring seal. The carbon seals are buffered with air pressure to minimize oil consumption and give additional operational redundancy. The engine compressor has a single-stage, high-pressure-ratio impeller, followed by single-stage, radial-flow diffuser vanes and axial deswirl vanes. The axial flow turbine design has two stages, each has a stator and turbine wheel. The first stage stator is air cooled. The first stage turbine wheel has inserted blades, and the second stage turbine wheel has a diffusion-bonded blade ring. High-energy containment is provided for the engine compressor and turbine wheels if needed. The load compressor section has a single-stage centrifugal compressor mounted on a common shaft with the power section rotating group. The load compressor shares a common inlet with the power section, and provides compressed air to the airplane pneumatic system. The forward end of the power section assembly has provision to attach a gearbox, and supplies torque to meet the gearbox power requirements.

3.

Operation During operation the engine compressor supplies compressed air to the annular combustion chamber where ten dual-orifice fuel nozzles continuously inject fuel into the incoming air to sustain combustion that gives the necessary energy to power the two-stage turbine. The turbine section provides the necessary power to drive the engine compressor, load compressor and gearbox for all airplane design load applications.

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The load compressor output is regulated by variable inlet guide vanes located upstream of the load compressor impeller. Output is based on airplane environmental control system, main engine start, and electrical load demands as indicated by airplane signals to the APU electronic control unit (ECU). The inlet guide vanes are scheduled by the ECU and are moved to the necessary position by the hydraulic actuator. The inlet guide vane assembly has 16 vanes located radially at the load compressor inlet. The vanes are supported at one end and are driven by gear segments attached to each vane. The gear segments mesh with a cylindrical rack to synchronize vane position.

EFFECTIVITY ALL

SYSTEMS DESCRIPTION SECTION Page 1 18 Dec 2019

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ENGINE MANUAL 131-9[B]

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Figure 1. Power Section Assembly

EFFECTIVITY ALL

SYSTEMS DESCRIPTION SECTION Page 2 18 Dec 2019

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ENGINE MANUAL 131-9[B]

POWER SECTION ASSEMBLY DISASSEMBLY-01 TASK 49-22-00-420-801 1.

General

2.

A.

This section contains procedures to install the power section assembly in the portable engine stand/cart.

B.

Do the disassembly procedures in a dry, bright, clean room.

C.

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

Special Tools, Fixtures and Equipment A.

Table 5001 shows the special tools, fixtures and equipment needed for preparation of the power section assembly for disassembly. Table 5001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Part No.

Equivalent tools, fixtures and equipment can be used.

Cart Assembly

Includes PN 834990-1 engine stand/cart, PN 834895-1 Interface Mount, PN 834892-2 and PN 834892-3 Aft Mount arm, PN 834898-1 Support Arm.

834892-1

Lifting Adapter

Used with hoist to lift the power section assembly out of shipping carton and place into portable engine stand/cart.

834888-1

Interface Bolts

Component of PN 834892-1. Adapt APU mounts to aft mount arms and support arm (3 necessary).

834895-1

Aft Mount Arm

Component of PN 834892-1. Adapt engine assembly 834892-2 into portable engine stand/cart (right aft engine mount).

Aft Mount Arm

Component of PN 834892-1. Adapt engine assembly 834892-3 into portable engine stand/cart (left aft engine mount).

Support Arm

Component of PN 834892-1. Support engine assembly 834898-1 on forward right side in portable engine stand/cart.

Portable Engine

Component of PN 834892-1. Build stand and test cart 834990-1 for APU.

Stand/Cart

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Use

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] SUBTASK 49-22-00-420-001 3.

Procedure A.

Install the power section assembly in the portable engine stand/cart. (1)

Install PN 834895-1 interface bolts on the power section aft mounts and forward right mount.

(2)

Attach PN 834892-2 aft mount arm to the PN 834895-1 interface bolt on the power section assembly right aft mount.

(3)

Attach PN 834892-3 aft mount arm to the PN 834895-1 interface bolt on the power section assembly left aft mount.

(4)

Install PN 834898-1 support arm on the PN 834990-1 portable engine stand/cart with the support arm attaching hole inboard in relation to the portable engine stand/cart.

(5)

Install power section assembly in PN 834990-1 portable engine stand/cart as follows.

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(6)

EFFECTIVITY ALL

(a)

Position the power section assembly in the PN 834990-1 portable engine stand/cart with the power section assembly forward right side next to the portable engine stand/cart support arm.

(b)

Attach the PN 834892-2 and PN 834892-3 aft mount arms to the PN 834895-1 interface bolts on the power section assembly aft mounts.

(c)

Attach the PN 834898-1 forward support arm to the PN 834895-1 interface bolt on the forward right power section assembly mount.

Remove PN 834888-1 lifting adapter from the power section assembly.

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ENGINE MANUAL 131-9[B]

POWER SECTION ASSEMBLY DISASSEMBLY-02 TASK 49-22-00-030-801 1.

General A.

This section contains procedures for disassembly of the power section assembly.

B.

Do the disassembly procedures in a dry, bright, clean room.

C.

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

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

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

E.

Do not disassemble any staked, welded, riveted, soldered, swaged, or press fit assemblies.

F.

Do not remove plates, passage hole plugs, or threaded inserts unless replacement is necessary.

G.

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

H.

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

I.

Make a list of the quantities and thickness of the shims and washers. This will help when the part is assembled.

Special Tools, Fixtures and Equipment

2.

A.

Table 5001 shows the special tools, fixtures and equipment needed for disassembly. Table 5001. Special Tools, Fixtures and Equipment

Nomenclature

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NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Shaft Stretch Kit

Used with stretch shaft tool.

834740-2

Torque Adapter

Adapt torque wrench to tieshaft nut.

834801-1

Turbine Shaft Simulator

Simulate turbine rotating section when the compressor 834886-1 section is shimmed.

Maintenance Adapter Set

Attach L/C scroll to mounting arm adapter.

834805-1

Cart Assembly

Includes PN 834990-1 engine stand/cart, PN 834895-1 Interface Mount, PN 834892-2 and PN 834892-3 Aft Mount arm.

834892-1

Bearing Remover

Remove duplex ball bearing.

834808-1

Seal Remover

Remove oil stationary seal.

834810-1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Table 5001. Special Tools, Fixtures and Equipment (Cont) Nomenclature

Use

Part No.

Wheel Remover Adapter

Remove turbine wheels (two required).

834812-1

Lifting Adapter

Lift power section assembly by turbine shaft.

834816-1

Diffuser Puller

Remove load compressor diffuser.

834836-1

Exhaust Cap Remover

Remove exhaust cap.

834863-1

Driven Compressor Coupling Shaft Holding Fixture

Hold driven compressor coupling shaft while turbine shaft is removed.

834864-1

Bearing Puller

Remove turbine roller bearing.

834883-1

Stretch Tool

Shaft stretch tool used with shaft stretch kit.

834889-1

Interface Bolts

Component of PN 834892-1. Adapt power section to aft mount arms.

834895-1

Aft Mount Arm

Component of PN 834892-1. Mount engine in engine 834892-2 build stand using diffuser housing assembly engine aft mount.

Aft Mount Arm

Component of PN 834892-1. Mount engine in engine build stand using diffuser housing engine aft mount.

834892-3

Engine Build Stand

Component of PN 834892-1. Build stand for engine.

834990-1

3.

Equipment and Materials A.

Table 5002 shows the equipment and materials needed for installation. Table 5002. Equipment and Materials

Equipment/Materials NOTE:

Equivalent equipment/materials can be used.

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Oil (MIL-PRF-7808 or MIL-PRF-23699)

EFFECTIVITY ALL

Description/Manufacturer Commercially available

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ENGINE MANUAL 131-9[B]

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Figure 5001. Disassemble the Thermal Insulation Blanket Set from the Power Section Assembly (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5001

4.

20. SIDE BLANKET (IPC FIG. 17)

40. SIDE BLANKET

30. SIDE BLANKET

50. POWER SECTION ASSY

Procedure

SUBTASK 49-22-00-030-001 A.

Disassemble the Power Section Assembly. (1)

Disassemble thermal insulation blanket set from the power section assembly. (Refer to Figure 5001.)

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WARNING: USE EYE PROTECTION WHEN YOU CUT THE LOCKWIRE. WHEN YOU CUT THE LOCKWIRE, PIECES THAT BREAK OFF CAN HIT YOUR EYES AND CAUSE INJURY.

EFFECTIVITY ALL

(a)

Remove lockwire that holds the side blankets (20, 30, 40) together.

(b)

Remove side blankets (20, 30, 40) from the power section assembly (50).

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ENGINE MANUAL 131-9[B]

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Figure 5002. Disassemble the Eductor Housing Assembly from the Power Section Assembly (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5002 10. NUT (IPC FIG. 18)

30. EDUCTOR HOUSING ASSY

20. BOLT

40. POWER SECTION ASSY

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(2)

EFFECTIVITY ALL

Disassemble eductor housing assembly from the power section assembly. (Refer to Figure 5002.) (a)

Remove nuts (10) and bolts (20) from the power section assembly (40).

(b)

Remove eductor housing assembly (30) from the power section assembly (40).

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ENGINE MANUAL 131-9[B]

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Figure 5003. Disassemble the Turbine Bearing Housing Section (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5003 10. BOLT (IPC FIG. 19)

150. TIESHAFT WASHER

20. EXHAUST CAP

160. BOLT

30. BOLT

170. TURBINE BEARING HOUSING ASSY

40. SEAL WASHER

-170D. TURBINE BEARING HOUSING ASSY

50. NUT

-170E. TURBINE BEARING HOUSING ASSY

60. OIL TUBE RETAINER

-170F. TURBINE BEARING HOUSING ASSY

-60A. OIL TUBE RETAINER 70. OUT TUBE ASSY

180. NUT 190. FWD TURBINE BEARING INSULATION BLANKET

-70A. OUT TUBE ASSY

200. NUT

-70B. OUT TUBE ASSY

210. STATIONARY AIR SEAL

-70C. OUT TUBE ASSY

220. AFT BEARING SHAFT

75. GASKET

230. REAR BEARING SEAL

80. IN TUBE ASSY

240. REAR BEARING SEAL GASKET

90. SEAL WASHER

250. SPRING WASHER

100. FLARELESS FITTING

260. SEAL RETAINER

110. NUT

270. BEARING SET

120. BEARING RETAINER ASSY

280. POWER SECTION ASSY

130. AFT BEARING COVER GASKET 140. TIESHAFT NUT (3)

-290. TURBINE SHAFT (120, IPC FIG. 25) -. ITEM NOT ILLUSTRATED

Disassemble the turbine bearing housing section. (Refer to Figure 5003.) (a)

Remove bolts (10) and use a PN 834863-1 exhaust cap remover to remove exhaust cap (20) from the turbine bearing housing assembly (170).

(b)

(Pre SB 131-49-7597) Remove bolts (30) and seal washers (40) from the out tube assembly (70) and the in tube assembly (80). (Post SB 131-49-7597) Remove bolts (30) and out tube (-70A) and the in tube assembly (Refer to 49-20-00, Removal 02, Figure 3001, Sheet 3, item 25A). (Post SB 131-49-7953) Remove bolts (30) and out tube (-70B ) and the in tube assembly (Refer to 49-20-00, Removal 02, Figure 3001, Sheet 3, item 25A). (Post SPB D20181000017) Remove bolts (30) and out tube (-70C) and the in tube assembly (Refer to 49-20-00, Removal 02, Figure 3001, Sheet 3, item 25A).

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(c)

EFFECTIVITY ALL

(Pre SB 131-49-7597) Remove nuts (50) and oil tube retainers (60) from the turbine bearing housing assembly (170).

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ENGINE MANUAL 131-9[B] (Post SB 131-49-7597) Remove nuts (50) and oil tube retainers (-60A) from the turbine bearing housing assembly (-170D, -170E, -170F). (d)

(Pre SB 131-49-7597) Remove out tube assembly (70), in tube assembly (80) and seal washers (90) from the turbine bearing housing (170). (Post SB 131-49-7597) Remove out tube assembly (-70A), in tube assembly (80) from the turbine bearing housing (-170D, -170E, -170F). (Post SB 49-7953) Remove out tube assembly (-70B), in tube assembly (80) from the turbine bearing housing (-170D, -170E, -170F), Remove gasket (75) from out tube (-70B). Discard the gasket. (Post SPB D20181000017) Remove out tube assembly (-70C), in tube assembly (80) from the turbine bearing housing (-170D, -170E, -170F), Remove gasket (75) from out tube (-70C). Discard the gasket.

(e)

Remove bearing retainer assembly from the power section assembly as follows: 1

Remove nuts (110) from the turbine bearing housing assembly (170).

2

(Pre SB 131-49-7597) Remove bearing retainer assembly (120) from the turbine bearing housing assembly (170). (Post SB 131-49-7597) Remove bearing retainer assembly (-120A) from the turbine bearing housing assembly (-170D, -170E, -170F).

3

Remove aft bearing cover gasket (130) from the turbine bearing housing assembly (170). Discard the gasket.

(f)

Remove bearing outer race from the bearing set (270) and turbine bearing housing (170).

(g)

Remove tieshaft nut and tieshaft washer as follows: 1

Install PN 834889-1 stretch shaft tool with PN 834740-2 shaft stretch kit on the turbine shaft (290). NOTE:

Back PN 834889-1 stretch shaft off four turns from full seat.

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT.

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(h)

EFFECTIVITY ALL

2

Apply 5100 to 5400 PSIG (35163 to 37232 kPa) to the PN 834889-1 stretch shaft tool and hand loosen the tieshaft nut (140) three turns.

3

Remove PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit from the turbine shaft (290).

4

Remove tieshaft nut (140) and tieshaft washer (150) from the turbine shaft (290).

Remove bolts (160) from the turbine bearing housing assembly (170).

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ENGINE MANUAL 131-9[B]

EFFECTIVITY ALL

(i)

Remove assembled turbine bearing housing assembly (170) from the power section assembly (280).

(j)

Remove nuts (180, 200), forward turbine bearing insulation blanket (190) and stationary air seal (210) from the turbine bearing housing assembly (170).

(k)

Remove assembled aft bearing shaft (220) from the turbine bearing housing (170).

(l)

Use PN 834883-1 bearing puller to remove bearing set (270) from the aft bearing shaft (220).

(m)

Remove seal retainer (260), spring washer (250), rear bearing seal gasket (240) and rear bearing seal (230) from the turbine bearing shaft (220).

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ENGINE MANUAL 131-9[B]

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Figure 5004. Disassemble the First Stage Stator Section (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5004 10. RING SEAL (IPC FIG. 20)

170. SHROUD SEGMENT SEAL

20. SECOND STAGE TURBINE ROTOR ASSY

180. FIRST STAGE TURBINE SHROUD SEGMENT

30. CURVIC RING SEAL

180A. FIRST STAGE TURBINE SHROUD SEGMENT

40. COUPLING SHAFT

190. FEATHER SEAL

50. NUT

200. FIRST STAGE STATOR ASSY SHROUD SEGMENT

60. BOLT

210. BOLT

70. SECOND STAGE TURBINE STATOR BAFFLE

220. AIR SEAL

80. SLEEVE SPACER

230. TURBINE SEAL

90. SECOND STAGE STATOR SEAL WELDMENT

240. POWER SECTION ASSY

100. SECOND STAGE STATOR ASSY

-250. COMPRESSOR ROTOR (10, IPC FIG. 23)

110. FIRST STAGE TURBINE ROTOR ASSY

-260. TURBINE SHAFT (120, IPC FIG. 25)

120. CURVIC RING SEAL

-270. TIESHAFT NUT (140, IPC FIG. 19)

130. COUPLING SHAFT

-280. DRIVEN COMPRESSOR BEARING HOUSING (230, IPC FIG. 26)

140. TURBINE PLENUM SHIM

-290. DIFFUSER HOUSING ASSY (50, IPC FIG. 23)

150. RETAINING RING

-. ITEM NOT ILLUSTRATED

160. SHROUD SUPPORT RING (4)

Disassemble the turbine section. (Refer to Figure 5004.) (a)

Remove ring seal (10) from the second stage turbine rotor assembly (20).

(b)

Use two PN 834812-1 wheel removal adapters to remove the second stage turbine rotor assembly (20) from the coupling shaft (40).

(c)

Remove curvic ring seal (30) and the coupling shaft (40) from the first stage turbine rotor assembly (110).

(d)

Remove second stage stator assembly (100) from the power section assembly (240).

(e)

Disassemble the second stage stator as follows: 1

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(f)

EFFECTIVITY ALL

Remove nuts (50), bolts (60), second stage turbine stator baffle (70), spacers (80) and second stage stator seal weldment (90) from the second stage stator assembly (100).

Use two PN 834812-1 wheel removal adapters to remove the first stage turbine rotor assembly (110) from the coupling shaft (130).

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ENGINE MANUAL 131-9[B] (g)

Remove curvic ring seal (120) from the coupling shaft (130).

(h)

Remove coupling shaft (130) from the power section assembly (240).

(i)

Use jacking screws to remove first stage stator assembly (200) with the assembled retaining ring (150), shroud support ring (160), shroud segment seal (170), first stage turbine shroud segments (180) and feather seals (190) from the power section assembly (240).

(j)

Remove installed quantity of turbine plenum shims (140) from the power section assembly (240).

(k)

Remove retaining ring (150), shroud support ring (160), shroud segment seal (170), first stage turbine shroud segments (180), and feather seals (190) from the first stage stator assembly (200). Refer to DISASSEMBLY 04 for further disassembly of first stage stator assembly (200) if necessary.

(l)

Remove bolts (210), air seal (220) and turbine seal (230) from the power section assembly (240).

(m)

Change power section mount position in engine build stand to driven compressor bearing housing as follows: 1

Install PN 834886-1 turbine shaft simulator on the compressor rotor (250). Make sure the curvics are not stacked.

2

Install tieshaft nut (270) on the turbine shaft (260). Tighten tieshaft nut hand tight.

3

Install PN 834740-2 and PN 834889 stretch shaft tooling on the turbine shaft (260).

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WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT.

EFFECTIVITY ALL

4

Stretch turbine shaft (260) to a load of 5100 to 5400 PSIG (35163 to 37232 kPa) and hand tighten tieshaft nut (270).

5

Release pressure on PN 834740-2 ram and remove PN 834740-2 and PN 834889 stretch shaft tooling from the turbine shaft (260).

6

Install PN 834816-1 lifting adapter on the turbine shaft (260).

7

Install PN 834805-1 maintenance adapter set on the driven compressor bearing housing (280) mount pads.

8

Use hoist attached to PN 834816-1 lifting adapter to move power section assembly (240) in PN 834990-1 engine build stand using PN 834805-1 maintenance adapter set. Keep power section assembly aft end up.

9

Remove PN 834892-2 and PN 834892-3 aft mount arms from the diffuser housing (290).

10

Remove PN 834816-1 lifting adapter from the turbine shaft (260).

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UP552142

ENGINE MANUAL 131-9[B]

EFFECTIVITY ALL

11

Install PN 834740-2 and PN 834889 stretch shaft tooling on the turbine shaft (260), apply a load of 5100 to 5400 PSIG (35163 to 37232 kPa) and remove tieshaft nut (270).

12

Release pressure on PN 834740-2 ram and remove PN 834740-2 and PN 834889 stretch shaft tooling from the turbine shaft (260).

13

Remove PN 834886-1 turbine shaft simulator from the turbine shaft (260).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5005. Disassemble the Engine Mounts and Brackets (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5005 10. NUT (IPC FIG. 21) 20. BOLT

70. LEFT AFT MOUNT -80. RIGHT AFT MOUNT

30. NUT

90. NUT

40. BOLT

100. BOLT

50. SPACER

110. AFT LIFTING BRACKET

60. WASHER (5)

-. ITEM NOT ILLUSTRATED Disassemble the engine mounts and brackets as follows. (Refer to Figure 5005, Figure 5006, Figure 5007 and Figure 5008.) (a)

(Pre SB 131-49-8182) Remove nuts (10, 30), bolts (20, 40), spacers (50), washers (60), left aft mount (70) and right aft mount (80) from the power section assembly (250). (Post SB 131-49-8182) Remove nuts (10A, 30A), bolts (20A, 40A), spacers (50A), washers (60A), left aft mount (70B) and right aft mount (80B) from the power section assembly (250).

(b)

Remove nuts (90), bolts (100) and aft lifting brackets (110, 120) from the power section assembly (250).

(c)

Remove nuts (130), bolts (140), combustor to harness clamp (150) and surge duct bracket (160) from the power section assembly (250).

(d)

(Pre SB 131-49-8182) Remove nuts (170), bolts (180) and washers (190) from the power section assembly (250). (Post SB 131-49-8182) Remove nuts (170A), bolts (180A, 185) and washers (190A) from the power section assembly (250).

UP552142

(e)

EFFECTIVITY ALL

Remove nuts (200), bolts (210), washers (220), flow divider harness bracket (230) and inlet duct supports (240) from the power section assembly (250).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5006. Disassemble the Engine Mounts and Brackets (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5006 10. NUT (IPC FIG. 21)

150. COMBUSTOR TO HARNESS CLAMP

20. BOLT

160. SURGE DUCT BRACKET

30. NUT

170. NUT

40. BOLT

180. BOLT

50. SPACER

190. WASHER

60. WASHER

200. NUT

80. RIGHT AFT MOUNT

210. BOLT

90. NUT

220. WASHER

100. BOLT

230. FLOW DIVIDER HARNESS BRACKET

120. AFT LIFTING BRACKET

240. INLET DUCT SUPPORT

130. NUT

250. POWER SECTION ASSY

UP552142

140. BOLT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5007. Disassemble the Engine Mounts and Brackets (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5007 10A. NUT (IPC FIG. 21) 20A. BOLT

100. BOLT

30A. NUT

110. AFT LIFTING BRACKET

40A. BOLT

170A. NUT

50A. SPACER

180A. BOLT

60A. WASHER

185. BOLT

70B. LEFT AFT MOUNT

UP552142

-80B. RIGHT AFT MOUNT

EFFECTIVITY ALL

90. NUT

190A. WASHER -. ITEM NOT ILLUSTRATED

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5008. Disassemble the Engine Mounts and Brackets (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5008 10A. NUT (IPC FIG. 21)

150. COMBUSTOR TO HARNESS CLAMP

20A. BOLT

160. SURGE DUCT BRACKET

30A. NUT

170A. NUT

40A. BOLT

180A. BOLT

50A. SPACER

185. BOLT

60A. WASHER 80B. RIGHT AFT MOUNT

UP552142

90. NUT

200. NUT 210. BOLT

100. BOLT

220. WASHER

120. AFT LIFTING BRACKET

230. FLOW DIVIDER HARNESS BRACKET

130. NUT

240. INLET DUCT SUPPORT

140. BOLT

250. POWER SECTION ASSY

EFFECTIVITY ALL

190A. WASHER

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5009. Disassemble the Combustor Case and Attached Hardware (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5009 10. PIN (IPC FIG. 22)

100. ANNULAR COMBUSTION CHAMBER

20. LOCKING PLATE

110. NUT

30. BOLT

120. WASHER

40. FUEL INJECTION NOZZLE

130. PACKING WITH RETAINER

50. GASKET

140. DIFFUSER SPACER

60. FUEL NOZZLE AIR SHROUD

150. ENGINE COMPRESSOR DIFFUSER BOLT

70. NUT

160. AIR STATIONARY SEAL SUPPORT

-70A. NUT (170A, IPC FIG. 21)

165. INSERT

80. BOLT (IPC FIG. 22)

170. ENGINE COMPRESSOR DESWIRL

-85. BOLT (185, IPC FIG. 21)

180. POWER SECTION ASSY

90. COMBUSTOR CASE (IPC FIG. 22)

-. ITEM NOT ILLUSTRATED

95. NUT (6)

Disassemble the combustor case and attached hardware. (Refer to Figure 5009.) (a)

(b)

Remove fuel injection nozzles as follows: 1

Remove pins (10) and locking plates (20) from the combustor case (90).

2

Remove bolts (30), fuel injection nozzles (40), gaskets (50) and fuel nozzle air shrouds (60) from the combustor case (90). Discard the gaskets.

(Pre SB 131-49-8182) Remove nuts (70), bolts (80) and combustor case (90) from the power section assembly (180).

UP552142

(Post SB 131-49-8182) Remove nuts (70, 70A), bolts (80,-85) and combustor case (90) from the power section assembly (180).

EFFECTIVITY ALL

(c)

Remove the annular combustion chamber (100) from the power section assembly (180).

(d)

Remove the nuts (110), washers (120), packing with retainers (130), diffuser spacers (140), bolts (150), air stationary seal support (160) and engine compressor deswirl (170) from the power section assembly (180).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5010. Disassemble the Engine Compressor Section (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5010 10. COMPRESSOR ROTOR (IPC FIG. 23)

80. SPACER

20. CURVIC RING SEAL

90. BOLT

30. ENGINE COMPRESSOR DIFFUSER

100. WASHER

40. ENGINE COMPRESSOR SHROUD ASSY

110. INLET GUIDE VANES COVER

50. DIFFUSER HOUSING ASSY

120. SHAFT ASSY

60. INLET HOUSING SHIM

130. CURVIC RING SEAL

70. BOLT

140. POWER SECTION ASSY

UP552142

(7)

EFFECTIVITY ALL

Disassemble the engine compressor section and remove the inlet guide vanes cover. (Refer to Figure 5010.) (a)

Remove compressor rotor (10) from the power section assembly (140).

(b)

Remove curvic ring seal (20) from the power section assembly (140).

(c)

Remove engine compressor diffuser (30) from the power section assembly (140).

(d)

Remove engine compressor shroud assembly (40) from the power section assembly (140).

(e)

Remove diffuser housing assembly (50) and installed quantity of inlet housing shims (60) from the power section assembly (140).

(f)

Remove bolts (70, 90), spacer (80), washers (100) and inlet guide vanes cover (110) from the power section assembly (140).

(g)

Remove shaft assembly (120) and curvic ring seal (130) from the power section assembly (140).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5011. Disassemble Inlet Guide Vanes Linkage and Inlet Housing from the Power Section (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5011 10. BOLT (IPC FIG. 24)

60. ACTUATOR ROD

20. WASHER

70. NUT

30. COVER

80. ROD END BEARING

35. BOLT

90. NUT

36. WASHER

100. WASHER

37. BOLT

110. PACKING WITH RETAINER

38. WASHER

120. L/C REDUCED SHANK BOLT

40. NUT

130. INLET HOUSING ASSY

-50. CLEVIS ASSY

140. POWER SECTION ASSY

50A. CLEVIS ASSY (8)

-. ITEM NOT ILLUSTRATED

Disassemble inlet guide vanes linkage and inlet housing from the power section. (Refer to Figure 5011.) (a)

Remove bolts (10), washers (20) and covers (30) from the inlet housing assembly (130).

(b)

Remove bolt (37) and washer (38) securing rod end bearing (80) to inlet guide vane assembly. Remove the inlet guide vane linkage from the power section assembly (140).

(c)

Disassemble the inlet guide vane linkage as follows:

UP552142

WARNING: USE EYE PROTECTION WHEN YOU CUT THE LOCKWIRE. WHEN YOU CUT THE LOCKWIRE, PIECES THAT BREAK OFF CAN HIT YOUR EYES AND CAUSE INJURY.

EFFECTIVITY ALL

1

Remove lockwire from nut (70).

2

Remove rod end bearing (80) and nut (70) from actuator rod (60).

3

Remove bolt (35) and washer (36) from clevis assembly (50A).

4

Remove nut (40) and clevis assembly (50A) from the actuator rod (60).

(d)

Remove nuts (90), washers (100), packing with retainers (110) and load compressor reduced shank bolts (120) from the power section assembly (140). Discard packings with retainers.

(e)

Remove inlet housing assembly (130) from the power section assembly (140).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5012. Disassemble the Inlet Guide Vane Assembly and Load Compressor Section from the Power Section assembly (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5012 10. BOLT (IPC FIG. 25)

90. PACKING

20. WASHER

100. PACKING

30A. INLET GUIDE VANE ASSY

110. HEAT SHIELD

40. CENTRIFUGAL CASE

120. TURBINE SHAFT

50. PACKING

130. POWER SECTION ASSY

60. COMPRESSOR ROTOR 70. CENTRIFUGAL DIFFUSER

-140. DRIVEN COMPRESSOR COUPLING SHAFT (IPC FIG. 26) -. ITEM NOT ILLUSTRATED

80. PACKING

UP552142

(9)

EFFECTIVITY ALL

Disassemble the inlet guide vane assembly and load compressor section from the power section as follows. (Refer to Figure 5012.) (a)

Remove bolts (10), washers (20) and inlet guide vane assembly (30A) from the power section assembly (130).

(b)

Remove centrifugal case (40) from the power section assembly (130).

(c)

Remove packing (50) from the centrifugal diffuser (70). Discard packing.

(d)

Remove compressor rotor (60) from the power section assembly (130).

(e)

Double nut turbine shaft (120) threaded end and use PN 834864-1 driven compressor coupling shaft holding fixture on driven compressor coupling shaft (140) to remove turbine shaft from the power section assembly (130).

(f)

Use a PN 834836-1 diffuser puller to remove centrifugal diffuser (70) with packing (80) from the power section assembly (130). Discard packing.

(g)

Remove packing (90, 100) from the power section assembly (130). Discard packing.

(h)

Remove heat shield (110) from the power section assembly (130).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5013. Disassemble the Driven Compressor Bearing Housing Section (Partial Breakdown)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5013 10. COMPRESSOR BEARING NUT (IPC FIG. 26)

130. OIL STATIONARY SEAL

20. NUT LOCKING KEY

140. DRIVEN COMPRESSOR COUPLING SHAFT

30. BOLT

150. PACKING

40. COMPRESSOR BEARING RETAINING PLATE

160. PACKING

50. BEARING DAMPER RING

170. BOLT

60. SPRING RETAINER

180. WASHER

70. COMPRESSION SPRING WASHER

190. FWD LEFT MOUNT

80. MATCHED DUPLEX BALL BEARING ASSY SET

200. FWD RIGHT MOUNT

90. SEAL ROTOR

210. PLUG

100. COMPRESSOR BEARING HOUSING

220. PACKING

110. LC BEARING SHIM

230. DRIVEN COMPRESSOR BEARING HOUSING

120. RETAINING RING (10)

Disassemble the driven compressor bearing housing section. (Refer to Figure 5013.) (a)

Bend up nut locking key (20) and use PN 834801-1 torque adapter to remove compressor bearing nut (10) and nut locking key from the driven compressor coupling shaft (140).

(b)

Remove bolts (30) and retaining plate (40) from the driven compressor bearing housing (230).

(c)

(Pre SB 131-49-8065) Remove bearing damper ring (50) and spring retainer (60) from the driven compressor bearing housing (230).

(d)

Remove spring washer from the driven compressor bearing housing (230).

(e)

Use PN 834808-1 bearing puller to remove matched duplex ball bearing assembly set (80) from the driven compressor coupling shaft (140).

UP552142

NOTE:

EFFECTIVITY ALL

Driven compressor coupling shaft (140) will release when matched duplex ball bearing assembly set (80) is removed.

(f)

Remove seal rotor (90) from the driven compressor coupling shaft (140).

(g)

Remove compressor bearing housing (100) with packing (150, 160) and installed quantity of LC bearing shims (110) from the driven compressor bearing housing (230). Discard packing.

(h)

Remove retaining ring (120) and use PN 834810-1 seal removal and driver tool to remove oil stationary seal (130) from the compressor bearing housing (100).

(i)

Remove bolts (170), washers (180), forward left mount (190) and forward right mount (200) from the driven compressor bearing housing (230).

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ENGINE MANUAL 131-9[B]

UP552142

(j)

EFFECTIVITY ALL

Remove plug (210) with installed packing (220) from the driven compressor bearing housing (230). Discard packing.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

INLET GUIDE VANE ASSEMBLY DISASSEMBLY-03 TASK 49-22-00-040-801 1.

General A.

This section contains procedures for disassembly of the inlet guide vane assembly.

B.

Do the disassembly procedures in a dry, bright, clean room.

C.

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

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

2.

D.

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

E.

Do not disassemble any glued assemblies.

F.

Do not remove bushings unless replacement is necessary.

G.

Examine all bearing surfaces for roughness and wear. These conditions can be an indication of possible damage.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5001. Disassemble the Inlet Guide Vane Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5001 10. COTTER PIN (IPC FIG. 30) 20. SPRING PIN

4.

50A. INLET GUIDE VANE 85. IGV BUSHING

30. SEGMENT GEAR

70D. FACE GEAR

40. SPRING WASHER

80B. HOUSING

Procedure

SUBTASK 49-22-00-040-001 A.

Disassemble the Inlet Guide Vane Assembly. (Refer to Figure 5001.) (1)

Remove cotter pins (10) from spring pins (20).

(2)

Remove spring pins (20).

(3)

Remove segment gears (30) from spring washers (40).

(4)

Remove spring washers (40).

(5)

Remove inlet guide vanes (50A) from the IGV bushings (85). NOTE:

UP552142

(6)

EFFECTIVITY ALL

IGV bushings (85) are glued into housing (80B) and should not be removed from the housing except by special machining process when replacement of the IGV bushings is necessary.

Remove face gear (70D) from the housing (80B).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

FIRST STAGE STATOR ASSEMBLY DISASSEMBLY-04 TASK 49-22-00-040-802 1.

General A.

This section contains procedures for disassembly of the first stage stator assembly.

B.

Do the disassembly procedures in a dry, bright, clean room.

C.

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

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

2.

D.

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

E.

Do not remove pins unless replacement is necessary.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 5001. Disassemble the First Stage Stator Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 5001

4.

10. PIN (IPC FIG. 29)

80. FIRST STAGE STATOR SUPPORT BOLT

20. INNER TRANSITION LINER

90. SLEEVE SPACER

30. STATOR SUPPORT RING

100. CONTAINMENT RING

40. FIRST STAGE TURBINE NOZZLE SEGMENT

110. FIRST STAGE NOZZLE SUPPORT

50. FEATHER SEAL

120. PIN

60. STATOR SEAL RING

130. PIN

70. SELF-LOCKING NUT

140. PIN

Procedure

SUBTASK 49-22-00-040-002 A.

Disassemble the First Stage Stator Assembly. (Refer to Figure 5001.)

UP552142

CAUTION:

EFFECTIVITY ALL

CAREFULLY REMOVE ANY PARTICLES CREATED BY DRILLING AND/OR CUTTING.

(1)

Drill out pins (10) and remove inner transition liner (20), stator support ring (30), first stage nozzle segments (40), feather seals (50) and stator seal ring (60) from the first stage nozzle support (110).

(2)

Remove self-locking nuts (70), first stage stator support bolts (80), sleeve spacers (90) and containment ring (100) from the first stage nozzle support (110).

(3)

If pins (120) are worn, drill them out from first stage nozzle support (110).

(4)

If pins (130) are worn, remove them from first stage nozzle support (110).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TURBINE AND COMPRESSOR ASSEMBLY CLEANING-01 TASK 49-22-00-100-801 1.

General A.

2.

This section contains procedures for cleaning the components of the turbine and compressor assembly.

Cleaning Methods A.

Table 6001 shows the standard cleaning methods necessary for cleaning of the components. Refer to Standard Practices Manual (SPM) 20-00-02/70-00-01 for the cleaning procedures. Table 6001. Cleaning Methods

UP552142

IPL Figure No.

Cleaning Methods Item No.

203A

203B

All standard metallic hardware

X

X

17

20, 30, 40

Side blanket

X

X

18

30

Eductor housing assembly

19

20

Exhaust center body cap

X

X

X

70, 80

Tube assembly

X

X

X

120

Bearing retainer assembly

X

X

X

170

Turbine bearing housing

X

X

X

190

Forward turbine X bearing insulation blanket

X

X

210

Stationary air seal X

X

X

220

Aft bearing shaft

X

X

X

230

Rear bearing seal X

X

X

250

Spring washer

X

X

X

260

Seal retainer

X

X

X

EFFECTIVITY ALL

Nomenclature

203E

203F

203J

203Q

203P

203K

203V

X

X

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ENGINE MANUAL 131-9[B] Table 6001. Cleaning Methods (Cont) IPL Figure No.

20

21

UP552142

22

Cleaning Methods Item No.

Nomenclature

270

Bearing set

10, 30, 120

Seal ring

X

X

X

20

Second stage turbine rotor assembly

X

X

X

40, 130

Coupling shaft

X

X

X

70

Second stage turbine stator baffle

X

X

X

90

Second stage stator seal weldment

X

X

X

100

Second stage stator assembly

X

X

X

140

Shim

X

X

X

150

Retaining ring

X

X

X

160

Shroud support ring

X

X

X

170

Shroud segment

X

X

X

180

First stage turbine X segment shroud

X

X

190

Feather seal

X

X

X

220

Air seal

X

X

X

230

Turbine seal

X

X

X

70

Aft left mount

X

X

X

80

Aft right mount

X

X

X

110, 120

Aft lifting bracket

X

X

X

60

Fuel nozzle air shroud

X

X

X

EFFECTIVITY ALL

203A

203B

203E

203F

203J

203Q

203P

203K

203V

X

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ENGINE MANUAL 131-9[B] Table 6001. Cleaning Methods (Cont) IPL Figure No.

23

24

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25

Cleaning Methods Item No.

Nomenclature

203A

203B

90

Combustor case

X

X

X

100

Annular combustion chamber

X

X

X

160

Air stationary seal X support

X

X

170

Engine compressor deswirl

X

X

10

Compressor rotor

30

Engine compressor diffuser

40

Engine X compressor shroud assembly

50

Diffuser housing assembly

X

X

X

60

Shim

X

X

X

110

Inlet guide vanes cover

120

Shaft assembly

X

X

X

50

Clevis assembly

X

X

X

60

Actuator rod

X

X

X

80

Rod end bearing

X

130

Inlet housing assembly

40

Centrifugal case

60

Compressor rotor

70

Centrifugal diffuser

X

X

X

110

Heat shield

X

X

X

120A

Turbine shaft

X

X

X

EFFECTIVITY ALL

X

203E

203F

203J

203Q

203P

203K

203V

X X

X

X

X

X

X X

X

X

X

X

X X

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ENGINE MANUAL 131-9[B] Table 6001. Cleaning Methods (Cont)

Item No.

26

27

29

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Cleaning Methods

IPL Figure No.

Nomenclature

203A

203B

10

Compressor bearing nut

X

X

X

40

Compressor bearing retaining plate

X

X

X

50

Bearing damper ring

X

X

X

60

Spring retainer

X

X

X

70

Compression spring washer

X

X

X

80

Matched duplex ball bearing assy

90

Seal rotor

X

X

X

100

Compressor bearing housing

X

X

X

110

Shim

X

X

X

120

Retaining ring

X

X

X

140

Driven compressor coupling shaft

X

X

X

190, 200

Forward mount

X

X

230

Driven compressor bearing housing

X

X

100

Bearing carrier

X

X

110

Gearbox housing

X

X

20

Inner transition liner

X

X

X

30

Stator support ring

X

X

X

40

First stage turbine X nozzle segment

X

X

50

Feather seal

X

X

EFFECTIVITY ALL

203E

203F

203J

203Q

203P

203K

203V

X

X

X

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ENGINE MANUAL 131-9[B] Table 6001. Cleaning Methods (Cont) IPL Figure No.

30

UP552142

32

Cleaning Methods Item No.

Nomenclature

203A

203B

60

Stator seal ring

X

X

X

100

Containment ring X

X

X

110

First stage nozzle X support

X

X

30

Segment gear

40

Spring washer

50A

Inlet guide vane

X

X

70D

Face gear

X

X

80B

Housing

X

X

10

Axial turbine disk X

X

X

20

Turbine rotor blade

X

X

X

30

Blade retainer

X

X

X

40

Turbine blade seal

X

X

X

EFFECTIVITY ALL

203E

203F

203J

203Q

203P

203K

203V

X X

X

X

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EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

CHECK 1.

Refer to Inspection/Repair Manual, ATA No. 49-26-85, for check procedures.

UP552142

NOTE:

EFFECTIVITY ALL

Inspection/Repair Manual, ATA No. 49-26-85, is a companion manual to this Engine Manual.

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ENGINE MANUAL 131-9[B]

REPAIR

UP552142

1.

Refer to ATA No. 49-26-85 for repair procedures.

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

INLET GUIDE VANE ASSEMBLY ASSEMBLY-01 TASK 49-22-00-440-801 1.

General

2.

A.

This section contains procedures for assembly of the inlet guide vane assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

Special Tools, Fixtures and Equipment A.

Table 10001 shows the special tools, fixtures and equipment needed for installation. Table 10001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Spring Pin Installer

Install spring pins

834861-1

IGV Assembly Mount

Hold inlet guide vanes in position during assembly

834935-1

Force Meter

Gives required force to move IGV vanes

Chatillion Model DPP25 or Equivalent

3.

Equipment and Materials A.

Table 10002 shows the equipment and materials needed for installation. Table 10002. Equipment and Materials

Description NOTE:

Manufacturer

Equivalent equipment/material can be used.

Plastic squirt bottle with siphon

Commercially available

tube (used for cleaning parts) QD Contact Cleaner,

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PN 03131 or 03132

EFFECTIVITY ALL

CRC Industries Inc., 885 Louis Dr., Warminster, PA 18974-2869

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10001. Assemble the Inlet Guide Vane Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10001 10. COTTER PIN (IPC FIG. 30)

50A. INLET GUIDE VANE

20. SPRING PIN

4.

85. IGV BUSHING

30. SEGMENT GEAR

70D. FACE GEAR

40. SPRING WASHER

80B. HOUSING

Expendable Parts None

5.

Procedure A.

Inlet Guide Vane (IGV) Assembly. Table 10003. Parts to Clean Prior to Power Section Assembly

Nomenclature

Section

Figure

Item Number

Driven Compressor Bearing Housing

ASSEMBLY-06

Figure 10006

230

Compressor Bearing Nut

ASSEMBLY-06

Figure 10018

10

Seal Rotor

ASSEMBLY-06

Figure 10018

90

Driven Compressor Coupling Shaft

ASSEMBLY-06

Figure 10018

140

Compressor Bearing Retaining Plate

ASSEMBLY-06

Figure 10019

40

Damper Bearing Ring

ASSEMBLY-06

Figure 10019

50

Spring Retainer

ASSEMBLY-06

Figure 10019

60

Compression Spring Washer

ASSEMBLY-06

Figure 10019

70

Duplex Ball Bearing Assembly

ASSEMBLY-06

Figure 10019

80

Compressor Bearing Housing

ASSEMBLY-06

Figure 10019

100

B.

Special cleaning procedures before assembly. (Refer to Table 10003.) NOTE:

This special cleaning procedure is done to help prevent lube system contamination in the load compressor bearing zone.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL.

UP552142

(1)

EFFECTIVITY ALL

Prepare 1.0 qt (1.0 L) plastic squirt bottle, with siphon tube, for cleaning parts as follows. (a)

Put 0.5 qt (0.5 L) contact cleaner (QD Contact Cleaner, PN 03131 or 03132) in squirt bottle.

(b)

Shake the squirt bottle and squirt contact cleaner through the siphon tube to completely clean the siphon tube and rinse the bottle internally.

(c)

Remove the cap with siphon tube from the plastic bottle and rinse and pour out remainder of contact cleaner into a collection tray.

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ENGINE MANUAL 131-9[B] (d)

Fill squirt bottle with fresh contact cleaner and install cap with siphon tube.

WARNING: CLEAN THE PARTS IN AN AREA OPEN TO THE AIR, THAT HAS GOOD LIGHT AND SUFFICIENT SAFETY AND FIRE PREVENTION EQUIPMENT. (2)

Clean the parts listed in Table 10003 as follows: NOTE:

Clean the driven compressor coupling shaft, (140, Figure 10018), after all rotating group balance and run-out procedures are completed. Make sure the alignment marks made during Step 5.D.(1) are not removed. It is not necessary to clean the impeller air side of the compressor bearing housing, (230, Figure 10006) if the part is installed on the APU immediately after cleaning. Both sides of the housing must be cleaned if the part will not be installed immediately after cleaning.

(a)

Use the squirt bottle to flush and clean the parts with contact cleaner. 1

Collect the used contact cleaner in a collection tray.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN. (b)

Use filtered compressed air to dry the parts.

(c)

The lube module must be cleaned as follows: 1

Remove the inboard filter housing with packing and filter from the lube module.

2

Remove the protective plastic cap from the opening of the oil passage downstream of the oil filter.

3

Use the squirt bottle to flush and clean the oil passage from the filter end with contact cleaner.

4

Use filtered compressed air to dry the oil passage.

5

Clean the plastic cap with contact cleaner.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

UP552142

(3)

EFFECTIVITY ALL

6

Use filtered compressed air to dry the plastic cap.

7

Install the plastic cap on the lube module.

8

Install the filter and filter housing with packing on the lube module. Torque the filter housing to a torque value of 20 lb-in (2.26 Nm).

If the part(s) are not installed on the APU immediately after being cleaned, do the following: (a)

Put the cleaned part(s) in a new clean plastic bag.

(b)

Fold over the open end of the plastic bag and staple closed.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10002. Assemble the Inlet Guide Vane Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10002 10. COTTER PIN (IPC FIG. 30)

50A. INLET GUIDE VANE

20. SPRING PIN

85. IGV BUSHING

30. SEGMENT GEAR

70D. FACE GEAR

40. SPRING WASHER

80B. HOUSING

Table 10004. Dimensional Limits Limits Inches (mm)

Reference DIM.A

Reference

Limits Inches (mm)

0.000 to 0.150 (0.00 to 3.81)

SUBTASK 49-22-00-440-001 C.

Assemble the Inlet Guide Vane (IGV) Assembly. (1)

Install face gear (70D) on housing (80B) with face gear actuator tab between housing stops. (Refer to Figure 10001.)

(2)

Install inlet guide vanes (50A) and segment gears (30) as follows. (Refer to Figure 10002.) (a)

Put assembled face gear (70D) and housing (80B) on IGV assembly mount PN 834935-1.

(b)

Install inlet guide vanes (50A) into housing (80B).

(c)

Position face gear (70D) against stop in direction shown in View A-A.

(d)

With inlet guide vanes (50A) fully closed, install spring washers (40) and segment gears (30) on inlet guide vanes as shown in Section C-C. Make sure segment gears are aligned with V mark on inlet guide vanes and engaged with face gear (70D) as shown in View A-A.

(e)

Use spring pin installer PN 834861-1 to install spring pins (20) into assembled segment gears (30) and inlet guide vanes (50A). (Refer to Section B-B.)

(f)

Make sure inlet guide vanes (50A) are fully closed, then measure Dimension A as shown in View A-A. Dimension A must be 0.000 to 0.150 inch (0.00 to 3.81 mm).

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1

EFFECTIVITY ALL

If Dimension A is not in limits repeat Steps (d) through (f).

(g)

Install cotter pins (10) into spring pins (20). Bend and trim cotter pin ends as show in Section B-B.

(h)

(Alternate Method) Install cotter pins (10) into spring pins (20). Cut cotter pin unevenly and bend perpendicularly over gear segment as show in Section B-B (Alternate Method).

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ENGINE MANUAL 131-9[B]

UP552142

(3)

EFFECTIVITY ALL

Move face gear (70D) on housing (80B) to make sure inlet guide vane assembly works smoothly. The force necessary to move the face gear on the housing must not be more than 5 pounds-force (22 newtons). Measure force using Chatillion Model DPP25 or equivalent Force Meter.

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

ROTATING GROUP ASSEMBLY ASSEMBLY-02 TASK 49-22-00-820-801 1.

General

2.

A.

This section contains procedures for balance and runout alignment of the rotating group assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

Special Tools, Fixtures and Equipment A.

Table 10001 shows the special tools, fixtures and equipment needed for installation. Table 10001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Balance Machine

Balance rotating group

Commercially available

Runout Checking Fixture

Check rotating group runout

285868-2-1

Bearing Driver

Press on bearing simulator

834701-1

Ram 20 Ton

Stretch turbine shaft

834740-2

Nut

Stretch turbine shaft

834740-6

Safety Cover

Personal protection

834740-10

Button Press

Support and press bearing simulator

834759-8

Rotating Group Support

Measure rotating group length

834857-1

Coupling Holder

Hold driven compressor coupling shaft when tie shaft is torqued

834864-1

Removal Tool

Remove bearing simulator

834883-1

Shaft Stretch Tooling

Stretch turbine shaft assembly

834889-1

Assembly

Coupling

834889-2

Nut

834889-3

Shaft

834889-4

Torque Adapter

Adapt torque wrench to tieshaft nut

834890-1

Roller Bearing Simulator

Simulate roller bearing

834926-1

Roller Bearing Simulator

Simulate roller bearing

834926-1

3.

Equipment and Materials

UP552142

A.

EFFECTIVITY ALL

Table 10002 shows the equipment and materials needed for installation.

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ENGINE MANUAL 131-9[B] Table 10002. Equipment and Materials Equipment/Materials NOTE:

Description/Manufacturer

Equivalent equipment/materials can be used.

Anti-seize lubricant (Liqui-Moly, Brand NV Thread Compound) (MIL-PRF-907)

Lockrey Co. Inc., P.O. Box 1269, 2517 Finlaw Ave. Merchantville, NJ 08109

Marking compound (Dykem Hi-Spot Blue or Steel Blue/Red)

ITW Dykem, P.O. Box 340, 805 E. Highway 56 Olathe, KS 66051-0340

Marking compound (Ink, Violet 127 1/2)

Pannier Corp., 207 Sandusky St. Pittsburgh, PA 15212-5823, Telephone: 412-323-4900

4.

Expendable Parts None

5.

Procedure Table 10003. Check Point Summary Check Point

Operation

Page

10

Verify and write down Dimension U and BU.

10005

20

Verify and write ram pressure Actual Load.

10007

30

Verify and write Dimension BS and S.

10007

40

Verify balance is correct and within limits.

10009

50

Verify runout is correct and within limits.

10010

60

Verify assembly components have been grouped together 10010 as matched parts for the next assembly.

70

Verify lot and serial numbers of noted hardware are correctly written on traceability card.

10010

SUBTASK 49-22-00-440-002 A.

Assemble the Rotating Group Assembly. (1)

Install turbine shaft on driven compressor coupling shaft as follows:

UP552142

(a)

EFFECTIVITY ALL

Put PN 834864-1 driven compressor coupling shaft holding fixture in a vice and install driven compressor coupling shaft (140) on fixture spline.

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ENGINE MANUAL 131-9[B] WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL.

(2)

(b)

Lubricate threads on forward end of turbine shaft (90) with liqui-moly and install forward end of turbine shaft into driven compressor coupling shaft (140).

(c)

Tighten turbine shaft (90) in driven compressor coupling shaft (140) to 150 in-lb (16.9 Nm) with two nuts jammed together on free end of turbine shaft.

Assemble rotating elements on turbine shaft as follows. (Refer to Figure 10001.) (a)

Position assembled driven compressor coupling shaft (140) and turbine shaft (90) on PN 834857-1 rotating group stand.

(b)

Install the compressor rotor (30), the shaft assembly (120), large diameter up, and the compressor rotor (10) on the driven compressor coupling shaft (140). NOTE:

(c)

Make sure the curvic high-point mark on each curvic coupling is positioned 180 degrees from the high-point mark on the mating curvic coupling.

Install the coupling shaft (130) on the compressor rotor (10). NOTE:

Make sure the curvic high-point mark on each curvic coupling is positioned 180 degrees from the high-point mark on the mating curvic coupling. Make sure curvic is clean using SPM 20-00-20/70-00-01.

(d)

Install the first stage turbine rotor assembly (110), with the word "AFT" pointing up, on the coupling shaft (130). NOTE:

Make sure the curvic high-point mark on each curvic coupling is positioned 180 degrees from the high-point mark on the mating curvic coupling. Make sure the first stage turbine rotor assembly (110) is positioned with the word "AFT" pointing up.

(e)

Install the coupling shaft (40) and the second stage turbine rotor assembly (20) on the first stage turbine rotor assembly (110).

UP552142

NOTE:

EFFECTIVITY ALL

Make sure the curvic high-point mark on each curvic coupling is positioned 180 degrees from the high-point mark on the mating curvic coupling.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10001. Assemble the Rotating Group

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10001 10. COMPRESSOR ROTOR (IPC FIG. 23)

120. SHAFT ASSY (IPC FIG. 23)

20. SECOND STAGE TURBINE ROTOR ASSY (IPC FIG. 20)

130. COUPLING SHAFT (IPC FIG. 20)

30. COMPRESSOR ROTOR (IPC FIG. 25)

140. COMPRESSOR COUPLING SHAFT (IPC FIG. 26)

40. COUPLING SHAFT (IPC FIG. 20)

150. TIESHAFT WASHER (IPC FIG. 19)

90. TURBINE SHAFT (120, IPC FIG. 25)

160. TIESHAFT NUT (140, IPC FIG. 19)

110. FIRST STAGE TURBINE ROTOR ASSY (IPC FIG. 20)

220. AFT BEARING SHAFT

WARNING: USE THE CORRECT PERSONAL PROTECTION. THE HEATED PARTS WILL CAUSE BURNS. (f)

Heat the PN 834926-1 roller bearing simulator to 350°F (177°C) and install on the aft bearing shaft (220). NOTE:

(g)

Install the aft bearing shaft (220) with installed roller bearing simulator, on the second stage turbine rotor assembly (20).

(h)

Install the tieshaft washer (150).

(i)

Install the tieshaft nut (160) on the turbine shaft (90). NOTE:

(j) (3)

Use arbor press PN 834759-8 press button and PN 834701-1 bearing press tube to push on the PN 834926-1 roller bearing simulator on curvic end of the aft bearing (220).

Make sure no curvices are stacked.

Use PN 834890-1 torque adapter to tighten the tieshaft nut (160) to a torque value of 120 in-lb (13.6 Nm).

Measure the rotating group. (Refer to Figure 10002.) (a)

Measure and write unstretched Dimension U and Dimension BU as follows.

(b)

Install assembled rotating group on PN 834857-1 rotating group support assembly. 1

Measure Dimension U and write below (to be used when engine is in various build stages to make sure rotating group is not stacked). Dimension U _______________________inch (mm)

2

Use mic stand to measure Dimension BU and record below: Dimension BU _____________________inch (mm)

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Check Point 10:

EFFECTIVITY ALL

Verify and write down Dimension U and BU.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10002. Measure the Rotating Group

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10002 120. TURBINE SHAFT (IPC FIG. 25) (c)

140. TIESHAFT NUT (IPC FIG. 19)

Measure and write down the results of the stretched Dimension BS and S as follows: 1

Stretch the turbine shaft (120) as follows: a

Install the PN 834740-X and PN 834889-X stretch shaft tooling.

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT. b

Stretch the turbine shaft (120) to a load of 5400 to 5600 PSIG (37232 to 38611 kPa) and hand tighten tieshaft nut (140). Write the actual load below: Ram pressure Actual Load = ______________PSIG (kPa).

Check Point 20:

2

Verify and write ram pressure Actual Load.

c

Release pressure on PN 834740-2 ram.

d

Remove the PN 834740-X and PN 834889-X stretch shaft tooling.

Use PN 834857-1 rotating group support assembly to measure Dimension BS and record below. Dimension BS __________________inch (mm)

3

Use the following equation to get actual tieshaft stretch and compare to necessary actual stretch. Actual Stretch BS = Dimension BU - Dimension BS = ______________________inch (mm). Necessary Actual Stretch BS = 0.104 to 0.106 inch (2.64 to 2.69 mm). NOTE:

4

If Actual Stretch BS does not equal Necessary Stretch BS repeat Step 5.A.(3)(c)1, adjust Actual Load to get Actual Stretch BS equal to Necessary Actual Stretch BS in limits shown.

Use PN 834857-1 rotating group support assembly to measure Dimension S and record below. Dimension S _________________inch (mm)

UP552142

Check Point 30:

EFFECTIVITY ALL

Verify and write Dimension BS and S.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10003. Rotating Group Balance and Runout Check

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10003 40. COUPLING SHAFT (IPC FIG. 20)

140. DRIVEN COMPRESSOR COUPLING SHAFT (IPC FIG. 26)

120. TURBINE SHAFT (IPC FIG. 25) DIM.

A

220. AFT BEARING SHAFT (IPC FIG. 19)

0.900 IN. (22.86 MM)

DIM.

B

0.707 IN. (17.96 MM)

SUBTASK 49-22-00-820-001 B.

Balance the rotating group. (Refer to Figure 10003.) (1)

Balance the rotating group on Datum A and B and write down the results. BALANCE

NOTE:

Check Point 40:

PLANE

LIMIT: OZ-INCH (mNm)

ACTUAL OZ-INCH (mNm)

C

0.070 (0.49)

___________(______)

D

0.100 (0.71)

___________(______)

Reduce group imbalance by unstretching and restacking to index curvic high marks 90 degrees clockwise from starting position if required. Verify balance is correct and within limits.

SUBTASK 49-22-00-820-002 C.

Measure rotating group runout. (Refer to Figure 10003.) (1)

Put the rotating group in the PN 285868-2-1 runout checking fixture on Datum A and B and measure the rotating group runout at Planes E, F, G and H.

(2)

Write down the results of the runouts.

UP552142

RUNOUT

EFFECTIVITY ALL

PLANE

LIMIT: INCHES (MM)

ACTUAL INCHES (MM)

F

0.002 (0.05)

___________(______)

G

0.002 (0.05)

___________(______)

E

0.002 (0.05)

___________(______)

H

0.002 (0.05)

___________(______)

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ENGINE MANUAL 131-9[B] (3)

If runout is not in limits do the following: (a)

Turn each component, one at a time, in increments of 90 degrees or less until the runouts are in limits.

(b)

Repeat Steps 5.B.(1)Steps 5.B.(1) through 5.C.(3)5.C.(3).

Check Point 50:

Verify runout is correct and within limits.

SUBTASK 49-22-00-040-001 D.

Disassemble the rotating group. (Refer to Figure 10003.) CAUTION: (1)

DO NOT USE LEAD PENCIL OR OTHER MARKER THAT CAN LEAVE CARBON RESIDUE ON THE TURBINE PART.

Mark the final assembly with marking compound to show necessary alignment during actual engine assembly.

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT. (2)

Use PN 834740 and PN 834889 stretch shaft tooling to unstretch rotating group.

(3)

Disassemble the rotating group as follows: (a)

At each stage of disassembly mark the turbine shaft (120) with marking compound in line with the marks made on the stack group. NOTE:

(b)

Leave driven compressor coupling shaft (140) attached to turbine shaft (120).

Check Point 60:

(4)

UP552142

ALL

Verify assembly components have been grouped together as matched parts for the next assembly.

Use PN 834883-1 removal tool to remove coupling and dummy bearing simulator from the aft bearing shaft (220). Check Point 70:

EFFECTIVITY

Mark coupling shaft (40) with marking compound on the aft side, as it is removed from the rotating group, with three dots to make sure the coupling is installed the same way at final assembly.

Verify lot and serial numbers of noted hardware are correctly written on traceability card.

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ENGINE MANUAL 131-9[B]

DIFFUSER HOUSING ASSEMBLY ASSEMBLY-03 TASK 49-22-00-440-802 1.

2.

General A.

This section contains procedures for assembly of the diffuser housing assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

Special Tools, Fixtures and Equipment None

3.

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10001. Assembly of Diffuser Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Key to Figure 10001 10. DIFFUSER HOUSING ASSY (50, IPC FIG. 23)

170. NUT

30. NUT (IPC FIG. 21)

180. BOLT

40. BOLT

190. WASHER

50. SPACER

200. NUT

60. WASHER

210. BOLT

70. LEFT AFT MOUNT

220. WASHER

80. RIGHT AFT MOUNT

240. INLET DUCT SUPPORT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10002. Assembly of Diffuser Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10002 10. DIFFUSER HOUSING ASSY (50, IPC FIG. 23)

5.

170A. NUT

30A. NUT (IPC FIG. 21)

180A. BOLT

40A. BOLT

190A. WASHER

50A. SPACER

200. NUT

60A. WASHER

210. BOLT

70B. LEFT AFT MOUNT

220. WASHER

80B. RIGHT AFT MOUNT

240. INLET DUCT SUPPORT

Procedure

SUBTASK 49-22-00-440-003 A.

Install inlet duct supports and aft engine mounts on diffuser housing. (Refer to Figure 10001 and Figure 10002) (1)

Lay diffuser housing (10) aft side down flat on table.

(2)

(Pre SB 131-49-8182) Install inlet duct support (240) on upper half of diffuser housing assembly (10) and attach with bolts (180, 210), washers (190, 220) and nuts (170, 200). Tighten bolts to a torque value of 40 in-lb (4.5 Nm). (Post SB 131-49-8182) Install inlet duct support (240) on upper half of diffuser housing assembly (10) and attach with bolts (180A, 210), washers (190A, 220) and nuts (170A, 200). Tighten bolts to a torque value of 40 in-lb (4.5 Nm).

(3)

(Pre SB 131-49-8182) Install inlet duct support (240) and flow divider harness bracket (230) on lower half of diffuser housing (10) and attach with bolts (180, 210) washers (190, 220) and nuts (170, 200). Tighten bolts to a torque value of 40 in-lb (4.5 Nm). (Refer to Figure 10003, View A.) (Post SB 131-49-8182) Install inlet duct support (240) and flow divider harness bracket (230) on lower half of diffuser housing (10) and attach with bolts (180A, 210), washers (190A, 220) and nuts (170A, 200). Tighten bolts to a torque value of 40 in-lb (4.5 Nm). (Refer to Figure 10003, View A.)

(4)

(Pre SB 131-49-8182) Install left aft mount (70) and right aft mount (80) on diffuser housing assembly (10) and attach with bolts (40), washers (60), spacers (50) and nuts (30). Tighten bolts to a torque value of 60 in-lb (6.8 Nm). (Post SB 131-49-8182) Install left aft mount (70B) and right aft mount (80B) on diffuser housing assembly (10) and attach with bolts (40A), washers (60A), spacers (50A) and nuts (30A). Tighten bolts to a torque value of 80 in-lb (9.03 Nm).

UP552142

NOTE:

EFFECTIVITY ALL

Make sure mounts are located properly. Incorrect location could affect installation in aircraft.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10003. Assembly of Diffuser Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10003 10. DIFFUSER HOUSING ASSY (50, IPC FIG. 23) 200. NUT

220. WASHER 230. FLOW DIVIDER HARNESS BRACKET

UP552142

210. BOLT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

FIRST STAGE STATOR ASSEMBLY ASSEMBLY-04 TASK 49-22-00-440-803 1.

General

2.

A.

This section contains procedures for assembly of the first stage stator assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

Special Tools, Fixtures and Equipment A.

Table 10001 shows the special tools, fixtures and equipment needed for installation. Table 10001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Use

Equivalent tools, fixtures and equipment can be used.

Installer

3.

Part No.

Used to aid in aligning compressor liner and first stage nozzle.

834956-1

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10001. Assemble the First Stage Stator Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10001 10. PIN (IPC FIG. 29)

90. SLEEVE SPACER

20. INNER TRANSITION LINER 30. STATOR SUPPORT RING

100. CONTAINMENT RING -100B. CONTAINMENT RING

40. FIRST STAGE TURBINE NOZZLE SEGMENT

110. FIRST STAGE NOZZLE SUPPORT

50. FEATHER SEAL

-110A. FIRST STAGE NOZZLE SUPPORT

60. STATOR SEAL RING

-110B. FIRST STAGE NOZZLE SUPPORT

70. SELF LOCKING NUT

-. ITEM NOT ILLUSTRATED

80. BOLT

5.

DIM.

D

0.001 ±0.001 IN. (0.03 ±0.03 MM)

DIM.

G

0.01 IN. (0.3 MM) MAX.

DIA.

E

0.1240 ±0.0002 IN. (3.150 ±0.005 MM) DIM.

H

4.00 ±0.02 IN. (101.6 ±0.5 MM)

DIM.

F

6.228 IN. (158.191 MM)

J

0.01 ±0.01 IN. (0.3 ±0.3 MM)

DIM.

Procedure

SUBTASK 49-22-00-440-004 A.

Assemble First Stage Nozzle Segments in the First Stage Stator Assembly. (Refer to Figure 10001 and Figure 10002.) (1)

(Pre SB 131-49-7577) Install containment ring (100) on first stage nozzle support (110) and attach with bolts (80), sleeve spacers (90) and self locking nuts (70). Tighten nuts to a torque value of 50 in-lb (5.6 Nm).

UP552142

(Post SB 131-49-7577) Install containment ring (-100B) on first stage nozzle support (-110A, -110B) and attach with bolts (80), sleeve spacers (90) and self locking nuts (70). Tighten nuts to a torque value of 50 in-lb (5.6 Nm).

EFFECTIVITY ALL

(2)

Set the first stage nozzle support (110) aft end down.

(3)

Install stator seal ring (60) into first stage nozzle support (110).

(4)

Install the first stage nozzle segments (40) in the first stage nozzle support (110) as follows: (a)

Assemble the first stage nozzle segments (40) around the stator support ring (30) and use a rubber band to hold them in place.

(b)

Install the assembled first stage nozzle segments (40) and stator support ring (30) into the first stage nozzle support (110) and over the installed stator seal ring (60). Make sure the slots in the first stage nozzle segments (40) engage with the anti-rotation pins in first stage nozzle support (110).

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ENGINE MANUAL 131-9[B] (5)

Install the inner transition liner (20) on the first stage nozzle support (110) as follows. (a)

Install the inner transition liner (20) to Dimension D on the first stage nozzle support (110).

WARNING: USE THE CORRECT PERSONAL PROTECTION. PROCEDURES THAT NEED GRIND/MACHINE WORK WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. (b)

Use PN 834956-1 pin installer to compress transition liner (20) and first stage nozzle support (110) to align holes.

CAUTION:

UP552142

(6)

EFFECTIVITY ALL

CAREFULLY REMOVE ANY PARTICLES CREATED BY DRILLING AND/OR CUTTING.

(c)

Drill one hole at each Location A, B and C through the inner transition liner (20) and the first stage nozzle support (110) to the dimensions shown. Make sure the drill point does not go more than Dimension G from Dimension H.

(d)

Install pins (10) to a depth of Dimension J.

Install from the back, the feather seals (50) into the slots in between the first stage nozzle segments (40).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10002. Assemble the First Stage Stator Assembly

EFFECTIVITY ALL

ANG

A

12, 36, 60, 84 OR 108 DEGREES

ANG

B

120 DEGREES

ANG

C

120 DEGREES

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

SECOND STAGE STATOR ASSEMBLY ASSEMBLY-05 TASK 49-22-00-440-804 1.

General

2.

A.

This section contains procedures for assembly of the second stage stator assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

Special Tools, Fixtures and Equipment A.

Table 10001 shows the special tools, fixtures and equipment needed for installation. Table 10001. Special Tools, Fixtures and Equipment

Nomenclature NOTE:

Use

Equivalent tools, fixtures and equipment can be used.

Second Stage Stator Support 3.

Part No.

Used to support stator during assembly

834949-1

Equipment and Materials None

4.

Expendable Parts

UP552142

None

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10001. Assemble the Second Stage Stator Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10001 50. NUT (IPC FIG. 20)

80. SLEEVE SPACE

60. BOLT

90. SECOND STAGE STATOR SEAL WELDMENT

70. SECOND STAGE TURBINE STATOR BAFFLE 5.

100. SECOND STAGE STATOR ASSY

Procedure

SUBTASK 49-22-00-440-005 A.

Assemble the Second Stage Stator Assembly. (1)

Install the second stage stator seal weldment (90), sleeve spacers (80) and second stage turbine stator baffle (70) in the second stage stator assembly (100). Attach with bolts (60) and nuts (50). Do not tighten nuts at this time. (Refer to Figure 10001.) NOTE:

(2)

Use four feeler gauges positioned equal distances apart to place second stage stator seal weldment (90) in the center of the second stage stator assembly (100). (Refer to Figure 10002.)

UP552142

NOTE:

EFFECTIVITY ALL

Use PN 834949-1 second stage stator fixture to support stator assembly (100).

The feeler gauges are approximately 0.01 to 0.02 inch (0.25 to 0.51 mm).

(a)

Adjust the feeler gauges until the measurements are equal circumferentially between the second stage stator seal weldment (90) and the second stage stator assembly (100).

(b)

Tighten nuts (50) to a torque value of 40 in-lb (4.5 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10002. Assemble the Second Stage Stator Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

POWER SECTION ASSEMBLY ASSEMBLY-06 TASK 49-22-00-430-801 1.

General

2.

A.

This section contains procedures for assembly of the power section assembly.

B.

Remove all corrosion preventive compound and any contamination from the parts before assembly.

C.

Refer to ASSEMBLY 01 for assembly of inlet guide vane assembly, ASSEMBLY 02 for assembly of rotating group, ASSEMBLY 03 for assembly of diffuser housing, ASSEMBLY 04 for assembly of first stage stator assembly, and ASSEMBLY 05 for assembly of second stage stator assembly.

Special Tools, Fixtures and Equipment Table 10001 shows the special tools, fixtures and equipment needed for installation.

A.

Table 10001. Special Tools, Fixtures and Equipment Nomenclature

UP552142

NOTE:

Use

Part No.

Equivalent tools, fixtures and equipment can be used.

Knurled Screw

Attach PN 834850-1 stand off to PN 834711 micing bar. CL-4-KHS Component of PN 834744-1.

Bearing Driver

Install roller bearing on aft bearing shaft.

834701-1

Micing Bar

Used with two PN 834850-1 stand off for measurements. Component of PN 834774-1.

834711-2 834711-6

Shaft Stretch Kit

Used with stretch shaft tooling.

834740-2

Press Button

Use with arbor press to remove roller bearing simulator. 834759-8

Micing Bridge Set

Includes PN 834711-2 and PN 834711-6 micing bar, two PN 834850-1 stand off and two CL-4-KHS knurled screws.

834774-1

Torque Adapter

Adapt torque wrench to tieshaft nut.

834801-1

Maintenance Adapter Set

Attach load compressor scroll to mounting arm adapter. 834805-1/2/3

Mounting Arm Adapter

Attach maintenance adapter set to portable stand assembly.

834807-1/-2

Bearing Remover

Remove duplex ball bearing.

834808-1

Cart Assembly

Includes PN 834990-1 engine stand/cart, PN 834895-1 Interface Mount, PN 834892-2 and PN 834892-3 Aft Mount arm.

834892-1

Alignment Pin

Align combustor to combustor case (3 necessary).

834809-1

Installation Seal Driver

Install stationary seal in compressor bearing housing.

834810-2

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Table 10001. Special Tools, Fixtures and Equipment (Cont) Nomenclature

Use

Part No.

Wheel Removal Adapter

Remove turbine wheels from power section (2 necessary).

834812-1

Duplex Bearing Nut Simulator

Simulate compressor bearing nut when compressor is measured for shims.

834814-1

Load Compressor Centering Tool

Support and move turbine shaft axially as required during 834815-1 build.

Lifting Adapter

Lift power section by turbine shaft.

834816-1

Housing Simulator

Simulate compressor bearing housing.

834818-1

Stand Off

Used with PN 834711-2 or PN 834711-6 micing bar for measurements. Component of PN 834774-1.

834850-1

Coupling Holder

Hold driven compressor coupling shaft when tie shaft is 834864-1 torqued.

Aft Bearing Puller

Remove bearings from gearshafts.

834883-1

Turbine Shaft Simulator

Simulate turbine rotating section when turbine shaft is stretched.

834886-1

IGV Gauge Set

Used as slave IGV actuator during IGV linkage build dimension adjustment.

834887-1

Stretch Shaft Tooling

Stretch turbine shaft.

834889-1

Torque Adapter

Adapt torque wrench to tieshaft nut.

834890-1

Centering Bridge Adapter

Support the aft rotating section when the compressor section is shimmed.

834891-1

Aft Mount Arm

Component of PN 834892-1. Adapt power section assembly to engine build stand.

834892-2

Aft Mount Arm

Component of PN 834892-1. Adapt power section assembly to engine build stand.

834892-3

Interface Bolts

Component of PN 834892-1. Adapt power section to aft 834895-1 mount arms (2 necessary).

Roller Bearing Simulator

Simulate roller bearing during power section build.

834926-1

Alignment Pin Remover

Removes alignment pin out of combustor case.

834931-1

IGV Vane Alignment Tool

Used to align IGV vanes.

834948-1

Bearing Support

Used to measure compressor bearing.

834950-1

Seal Spacer

Used to aid in assembly turbine seal.

834951-1

Portable Engine Stand/Cart

Component of PN 834892-1. Build stand for engine.

834990-1

Alignment Pin

Used to align bearing retainer assembly.

2025264-1

Adapter

Install duplex ball bearing assembly.

3700537-1 or -2

Installation Tool

Handling duplex ball bearing assembly.

3700539-1

Nut Tool

Seat duplex ball bearing.

3700508-1

Bearing Installation Tool

Seat ceramic duplex ball bearing.

70641924-1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 3.

Equipment and Materials A.

Table 10002 shows the equipment and materials needed for installation. Table 10002. Equipment and Materials

Equipment/Materials NOTE:

Equivalent equipment/materials can be used.

Adhesive sealant (RTV 106)

General Electric Co., GE Silicones, 260 Hudson River Rd., Waterford, NY 12188

Anti-seize compound (C5-A Copper Based)

Henkel Loctite Corp., 1001 Trout Brook Crossing, Rocky Hill, CT 06067

Anti-seize lubricant (Liqui-Moly, Brand NV

Lockrey Co. Inc., P.O. Box 1269, 2517 Finlaw Ave., Merchantville, NJ 08109

Thread Compound) (MIL-PRF-907) Degreasing solvent (MIL-PRF-680)

Commercially available

Corrosion-preventive compound

Air BP Lubricants Div., Maple Plaza II, 1 N., 6 Campus Dr., Parsippany, NJ 07054-4406

(Braycote 248) Dry-film lubricant (MS-122DF or MS-122V or MS-122XD)

Miller-Stephenson Chemical Co. Inc., George Washington Hwy., Danbury, CT 06810

Electrocleaner (FS)

Henkel Surface Technologies, 32100 Stephenson Hwy., Madison Heights, MI 48071

Jointing compound (Heavy)

Marston Bentley Ltd, 9 Naylor St, Liverpool, L3 6DS United Kingdom

(Hylomar PL32H) Jointing compound (Light) (Hylomar PL32L) Jointing compound (Medium) (Hylomar PL32M)

Marston Bentley Ltd, 9 Naylor St, Liverpool, L3 6DS United Kingdom Marston Bentley Ltd, 9 Naylor St, Liverpool, L3 6DS United Kingdom

Lockwire (PN MS20995C20)

Commercially available

Lockwire (PN MS20995C32)

Commercially available

Lubricant (Molykote Z) (AMS-M-7866)

Dow Corning Corp., P.O. Box 995, 3901 S. Saginaw Rd., Midland, MI 48640

Oil (MIL-PRF-7808 or MIL-PRF-23699)

Commercially available

Seal (PN S8187A)

Honeywell Consumables Solutions, P.O. Box 100473, Pasadena, CA 91198-0473, Telephone: 800-601-3099

Silver aluminum paint

Intrepid Coatings, 1910 E. Riverview Dr., Phoenix, AZ 85034

(TT-P-28) 4.

Expendable Parts A.

UP552142

Description/Manufacturer

EFFECTIVITY ALL

Honeywell recommends that the parts shown in Table 10003 be replaced at each assembly. However, actual replacement of parts may be done on in-service experience.

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ENGINE MANUAL 131-9[B]

UP552142

Table 10003. Parts to be Replaced at Each Assembly Figure No.

Item No.

Nomenclature

Quantity

Figure 10006

50 80 90 100

Packing Packing Packing Packing

1 1 1 1

Figure 10009

110

Packing with retainer

50

Figure 10018

150 160

Packing Packing

1 1

Figure 10019

20

Nut locking key

1

Figure 10028

130

Packing with retainer

21

Figure 10041 and Figure 10042 240

Rear bearing seal gasket

1

Figure 10045

Seal washer Seal washer Aft bearing cover gasket

2 2 1

EFFECTIVITY ALL

40 90 130

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ENGINE MANUAL 131-9[B] 5.

Procedure

UP552142

Table 10004. Check Point Summary Check Point

Operation

10

Make sure Dimensions A1, B, C, D, E, F, G, H and L are written down and 10009 calculated Dimension X is correctly calculated.

20

Make sure Dimension C is 0.007 ± 0.001 inch (0.18 ± 0.03 mm).

10009

30

Make sure Dimension T is written.

10013

40

With PN 834887-1 IGV gauge set installed make sure Dimension A is zero 10030 with inlet guide vanes fully closed.

50

Make sure Dimensions R and S are written.

10039

60

Make sure calculation to find L/C bearing shim (110) pack thickness is correct.

10041

70

Make sure installed L/C bearing shim (110) pack thickness is same as calculated L/C bearing shim (110) pack thickness.

10041

80

Make sure Calculated Dimension X is within +0.002/-0.001 inch (+0.05/-0.03 10046 mm) of Measured Dimension X.

90

Make sure compressor bearing nut (10) is tightened and seated.

10047

100

Make sure locking tab of the nut locking key (20) is bent down flat into the locking slot of the compressor bearing nut (10).

10048

110

Make sure Dimensions F, D, B, A1, and X are properly measured, calculated 10054 and recorded within the limits provided.

120

Make sure calculation to find L/C bearing shim (110) pack thickness is correct.

10060

130

Make sure installed L/C bearing shim (110) pack thickness is same as calculated L/C bearing shim pack thickness.

10061

140

Make sure Calculated Dimension X is within +0.002/-0.001 inch (+0.05/-0.03 10066 mm) of Measured Dimension X.

150

Make sure compressor bearing nut (10) is tightened and seated.

155

Calculation in Step 4 must equal 0.045 ±0.001 inch (1.14 ±0.03 mm). If it is 10068 not 0.045 ±0.001 inch (1.14 ±0.03 mm), adjust shim stack accordingly and record.

160

Make sure locking tab of the nut locking key (20) is bent down flat into the locking slot of the compressor bearing nut (10).

170

Make sure calculation to find Necessary Shim (60) Pack Thickness is correct. 10070

EFFECTIVITY ALL

Page

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10067

10068

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10001. (Pre SB 131-49-8065) Bearing Carrier Measurements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10001 1. HOUSING SIMULATOR (PN 834818-1)

100. COMPRESSOR BEARING HOUSING (IPC FIG. 25)

Table 1004 Check Point Summary (Cont) Check Point

Operation

Page

180

Make sure engine compressor tip clearance is the same measurement as in Step (15)(b).

10071

190

Make sure Dimension Y is written.

10079

200

Make sure Dimension Z1 is written.

10082

210

Make sure Dimension S is same as written down during assembly of rotating 10091 group.

220

Make sure Dimension Y minus the thickness of the micing bar and buttons 10091 is 1.812 ± 0.001 inch (46.02 ± 0.03 mm).

230

Make sure and write down Dimension Z2.

10097

240

Verify calculation to make sure first stage stator assembly (200) is seated is 0.000 ± 0.001 inch (0.00 ± 0.03 mm).

10097

250

Make sure Dimension U is same as written down during assembly of rotating 10110 group.

260

Make sure Dimension S is same as written down during assembly of rotating 10110 group.

270

Make sure completeness of assembly and freedom of rotation of the rotating 10116 group.

SUBTASK 49-22-00-430-001 A.

Assemble the Power Section. (1)

(Pre SB 131-49-8065) Measure compressor bearing components as follows: (a)

Measure and write the results of the bearing carrier measurements. (Refer to Figure 10001.) FLANGE DEPTH

DIMENSION E =______________inch (mm) (Compressor Bearing Housing (100)) DIMENSION F = ______________inch (mm) (Compressor Bearing Housing (100)) DIMENSION G = ______________inch (mm) (Housing Simulator (1))

UP552142

DIMENSION H = ______________inch (mm) (Housing Simulator (1))

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10002. (Pre SB 131-49-8065) Compressor Bearing Seat Measurements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10002 80. BEARING ASSEMBLY SET (IPC FIG. 25) (b)

Measure and write down the results of the compressor bearing seat measurements. Use PN 834950-1 bearing support for measurement of dimension C. (Refer to Figure 10002 and Figure 10003.)

CAUTION:

DIMENSION C MUST BE 0.007 ± 0.001 INCH (0.18 ± 0.03 MM).

DIMENSION MEASUREMENTS A1 = _____________inch (mm) B = ______________inch (mm) *C = _____________inch (mm) D = ______________inch (mm) L = ______________inch (mm)

CALCULATIONS Dimension M = E - L = ______________inch (mm) Calculated Dimension X = D - B - A1 = _____________inch (mm) NOTE:

Calculated Dimension X must equal Measured Dimension X, Step 5.A.(11)(m), within + 0.002 to -0.001 inch (+0.05 to -0.03 mm) to make sure bearing assembly set is not stacked. These measurements represent the verification method for seating the duplex bearing. Also for adjusting the load compressor shim pack to account for dimensional differences between the actual bearing carrier and the bearing carrier simulator.

Check Point 10:

UP552142

Check Point 20:

EFFECTIVITY ALL

Make sure Dimensions A1, B, C, D, E, F, G, H and L are written down and Calculated Dimension X is correctly calculated.

Make sure Dimension C is 0.007 ± 0.001 inch (0.18 ± 0.03 mm).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10003. (Pre SB 131-49-8065) Compressor Bearing Seat Measurements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10003

UP552142

90. SEAL ROTOR (IPC FIG. 26)

EFFECTIVITY ALL

140. COUPLING SHAFT

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10004. Load Compressor Rotor to Shroud Initial Tip Clearance

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10004 60. COMPRESSOR ROTOR (IPC FIG. 25) (2)

70. CENTRIFUGAL CASE

Measure the compressor rotor to centrifugal case initial tip clearance as follows. (Refer to Figure 10004.) (a)

Put the compressor rotor (60) into the centrifugal case (70). Measure the tip clearance in 120 degree increments to center the wheel and get equal tip measurements all the way around the wheel. NOTE:

Do not insert feeler gauge more than 0.120 in (3.05 mm) from tip of compressor rotor (30). LOAD COMPRESSOR (L/C) TIP CLEARANCE

Dimension T = ___________inch (mm) (Initial Tip Clearance)

UP552142

Check Point 30:

EFFECTIVITY ALL

Make sure Dimension T is written above.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10005. Build Stand Installation

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10005 30. BOLT (IPC FIG. 26)

230. DRIVEN COMPRESSOR BEARING HOUSING NOTE:

UP552142

(3)

EFFECTIVITY ALL

Housing simulator is used for Pre SB 131-49-8065 only.

Install driven compressor bearing housing in build stand installation as follows. (Refer to Figure 10005.) (a)

Install PN 834807-1 or -2 mounting arm adapter, PN 834805-1 maintenance adapter set (PN 834805-2 fixed assembly and the PN 834805-3 floating assembly) on the PN 834990-1 portable engine stand/cart.

(b)

Install driven compressor bearing housing (230) on the PN 834805-1 maintenance adapter set (PN 834805-2 fixed assembly and the PN 834805-3 floating assembly).

(c)

Use PN 834990-1 portable engine stand/cart to rotate the PN 834805-1 maintenance adapter set so driven compressor bearing housing (230) is positioned forward side up.

(d)

Line up mount holes and install PN 834818-1 housing simulator in bearing driven compressor bearing housing (230).

(e)

Install PN 834815-1 load compressor centering tool on the driven compressor bearing housing (230) and attach with two bolts (30).

(f)

Tighten bolts (30) to a torque value of 100 in-lb (11.30 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10006. Install Centrifugal Diffuser into Driven Compressor Bearing Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10006 50. PACKING (IPC FIG. 25)

100. PACKING

70. CENTRIFUGAL DIFFUSER

110. HEAT SHIELD

80. PACKING

230. DRIVEN COMPRESSOR BEARING HOUSING (IPC FIG. 26)

90. PACKING

UP552142

(4)

EFFECTIVITY ALL

Install centrifugal diffuser into driven compressor bearing housing as follows. (Refer to Figure 10006.) (a)

Use PN 834990-1 portable engine stand/cart to rotate the PN 834805-1 maintenance adapter set so driven compressor bearing housing (230) is positioned aft side up.

(b)

Lubricate packing (90, 100) with Braycote 248.

(c)

Install packings (90, 100) into corresponding grooves in the driven compressor bearing housing (230).

(d)

Install heat shield (110), with inner lip facing upward, into the driven compressor bearing housing (230).

(e)

Lubricate packings (50, 80) with Braycote 248.

(f)

Install packings (50, 80) on the centrifugal diffuser (70).

(g)

Layer driven compressor bearing housing (230) and centrifugal diffuser (70) mating surfaces with silver aluminum paint. (Refer to Figure 10007.)

(h)

Install centrifugal diffuser (70) into the driven compressor bearing housing (230) while the silver aluminum paint, from the previous step, is wet.

(i)

Align centrifugal diffuser (70) alignment pin with the corresponding hole in the driven compressor bearing housing (230).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10007. Install Centrifugal Diffuser into Driven Compressor Bearing Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10007

UP552142

70. CENTRIFUGAL DIFFUSER (IPC FIG. 25)

EFFECTIVITY ALL

230. DRIVEN COMPRESSOR BEARING HOUSING (IPC FIG. 26)

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10008. Install Turbine Shaft into Driven Compressor Bearing Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10008 120. TURBINE SHAFT (IPC FIG. 25)

230. DRIVEN COMPRESSOR BEARING HOUSING

140. DRIVEN COMPRESSOR COUPLING SHAFT (IPC FIG. 26)

UP552142

(5)

EFFECTIVITY ALL

Install turbine shaft into driven compressor bearing housing as follows. (Refer to Figure 10008.) (a)

Install PN 834814-1 duplex bearing nut simulator on the driven compressor coupling shaft (140) with assembled turbine shaft (120).

(b)

Put driven compressor coupling shaft (140), with assembled PN 834814-1 duplex bearing nut simulator and turbine shaft (120) in the driven compressor bearing housing (230).

(c)

Turn PN 834815-1 load compressor centering tool jacking screw to move driven compressor coupling shaft (140) up to a position where the knife edge is in relation to driven compressor bearing housing (230) as shown in Figure 10008, Detail A.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10009. Install Compressor Rotor and Inlet Housing Assembly on Driven Compressor Bearing Housing

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10009 40. CENTRIFUGAL CASE (IPC FIG. 25)

120. BOLT

60. COMPRESSOR ROTOR

130. INLET HOUSING ASSY

-70. CENTRIFUGAL DIFFUSER 90. NUT (IPC FIG. 24)

150. TURBINE SHAFT (120, IPC FIG. 25)

100. WASHER

230. BEARING HOUSING (IPC FIG. 26)

110. PACKING WITH RETAINER (6)

(a)

Clean curvics on the driven compressor coupling shaft (140) and the compressor rotor (60).

(b)

Align balance marks and install the compressor rotor (60) on the driven compressor coupling shaft (140) curvics so that the compressor rotor backface is pointed downward.

(c)

Make sure the curvics are engaged correctly and not stacked.

(d)

Make sure packing (80, Figure 10006) is in place on the centrifugal diffuser (70).

(e)

Install centrifugal case (40, Figure 10009) on the centrifugal diffuser (70).

(f)

CAUTION:

If necessary, lower the PN 834815-1 load compressor centering tool jacking screw slightly until the compressor rotor (60) is free from the centrifugal case (40). Make sure the curvics do not get disengaged.

MAKE SURE THE CURVICS DO NOT DISENGAGE ON COMPRESSOR COUPLING SHAFT.

(g)

If the PN 834815-1 load compressor centering tool is lowered, make sure that the curvics on the compressor rotor (60) are still engaged with those on the driven compressor coupling shaft (140).

(h)

Install the inlet housing assembly (130) and align the pin hole with hole in the centrifugal case (40). (Refer to Figure 10009.) 1

UP552142

Make sure the alignment pin is engaged in the centrifugal diffuser (70) alignment hole.

Rotate the turbine shaft (150) and coupled compressor rotor (60) to make sure the compressor rotor is free from centrifugal case (40) contact. NOTE:

ALL

-. ITEM NOT ILLUSTRATED

Install compressor rotor and inlet housing assembly on turbine shaft and driven compressor bearing housing as follows. (Refer to Figure 10009.)

NOTE:

EFFECTIVITY

-140. DRIVEN COMPRESSOR COUPLING SHAFT (IPC FIG. 26)

Lubricate and install bolts (120), washers (100) and packings with retainers (110) through the inlet housing assembly (130), centrifugal case (40), centrifugal diffuser (70) and driven compressor bearing housing (230).

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ENGINE MANUAL 131-9[B] 2

Assemble packings with retainer (110), washers (100) and nuts (90) on bolts (120).

3

Alternately tighten nuts (90) evenly until inlet housing assembly (130), centrifugal case (40) and centrifugal diffuser (70) are seated against bearing housing (230) to a torque value of 70 in-lb (7.9 Nm) and at the same time make sure compressor rotor (60) and turbine shaft (150) rotate freely.

UP552142

NOTE:

EFFECTIVITY ALL

If necessary, lower jacking screw on load compressor centering tool so jam between compressor rotor (60) and centrifugal case (40) does not occur while nuts (90) are tightened.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10010. Inlet Guide Vane Installation

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10010 10. BOLT (IPC FIG. 25)

60. ACTUATOR ROD

20. WASHER

70. NUT

30. INLET GUIDE VANE ASSY

80. ROD END BEARING

35. BOLT (IPC FIG. 24)

90. BOLT

36. WASHER

100. WASHER

37. BOLT

110. COVER (30, IPC FIG. 24)

38. WASHER

-120. CENTRIFUGAL CASE (40, IPC FIG. 25)

40. NUT

130. POWER SECTION ASSEMBLY (IPC FIG. 25)

50. CLEVIS ASSEMBLY (7)

-. ITEM NOT ILLUSTRATED

Install inlet guide vane assembly into the power section as follows: (a)

Install clevis assembly (50) on actuator rod (60) and attach with nut (40). Tighten nut (40) to a torque value of 30 in-lb (3.4 Nm). (Refer to Figure 10010)

UP552142

NOTE:

EFFECTIVITY ALL

Put clevis assembly (50) on actuator rod (60) end that has two wrench flats machined in the outside diameter.

(b)

Put nut (70) and rod end bearing (80) on actuator rod (60). Leave nut (70) loose at this time.

(c)

Install the assembled IGV linkage on the inlet guide vane assembly (30) and attach the rod end bearing (80) to the inlet guide vane clevis with bolt (37) and washer (38). Tighten bolt (37) to a torque value of 35 in-lb (4.0 Nm).

(d)

Put the inlet guide vane assembly (30), with attached IGV linkage, on the centrifugal case (120).

(e)

Attach the inlet guide vane assembly (30) to the centrifugal case (120) with bolts (10), and washers (20). Tighten bolts to a torque value of 50 in-lb (5.6 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10011. Adjust Inlet Guide Vanes

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10011 35. BOLT (IPC FIG. 24)

50. CLEVIS ASSEMBLY

36. WASHER

60. ACTUATOR ROD

37. BOLT

70. NUT

38. WASHER

80. ROD END BEARING

40. NUT (f)

UP552142

(g)

EFFECTIVITY ALL

Adjust the inlet guide vane linkage as follows. (Refer to Figure 10011.) 1

Install PN 834948-1 IGV vane alignment tool to IGV vane ribs.

2

Attach PN 834887-1 IGV gauge set to the clevis assembly (50) with clevis assembly captive bolt.

3

Turn and push PN 834887-1 IGV gauge set as necessary until the inlet guide vanes are fully closed and Dimension A is zero.

4

Tighten nut (70) against rod end bearing (80) to a torque value of 30 in-lb (3.4 Nm).

5

Loosen bolt (37) on inlet guide vane clevis and remove IGV linkage with attached PN 834887-1 IGV gauge set.

6

Loosen bolt (35) on clevis assembly and remove PN 834887-1 IGV gauge set from clevis assembly (50).

7

Remove PN 834948-1 IGV vane alignment tool from IGV vanes.

8

Lockwire nut (70) to rod end bearing (80) with lockwire MS20995C20 per NASM33540, and install seal (PN S8187A).

9

If bolt (35) on the clevis assembly (50) is not aligned with the bolt hole in the rod end bearing (80) do the following: a

Loosen nut (40) and rotate clevis assembly (50) on actuator rod (60) until bolt (35) on clevis assembly is aligned with bolt hole in the rod end bearing (80).

b

Tighten nut (40) to a torque value of 30 in-lb (3.4 Nm).

Install assembled IGV linkage into the load compressor, with bolt (35) head positioned toward actuator cover opening, and tighten bolt to a torque value of 35 in-lb (4.0 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10012. Install Inlet Guide Vanes Cover

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10012 70. BOLT (IPC FIG. 23)

110. INLET GUIDE VANES COVER

80. SPACER

130. INLET HOUSING ASSY

90. BOLT

140. POWER SECTION ASSY

100. WASHER (h)

Install PN 834887-1 IGV gauge set and attach to clevis assembly. Check Point 40:

With PN 834887-1 IGV gauge set installed make sure Dimension A is zero with inlet guide vanes fully closed.

(i)

Remove PN 834887-1 IGV gauge set.

(j)

Install cover (110) on the inlet housing and attach with bolts (90) and washers (100). Tighten bolts to a torque value of 30 in-lb (3.4 Nm). (Refer to Figure 10010.)

(k)

Install inlet guide vanes cover as follows. (Refer to Figure 10012.) 1

Install inlet guide vanes cover (110) in the power section assembly (140) and make sure the inlet guide vanes cover is engaged with inlet guide vane housing.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. 2

Attach inlet guide vanes cover (110) to the power section assembly (140) with spacer (80), washer (100) and bolts (70, 90). Tighten bolts (70, 90) to a torque value of 40 in-lb (4.5 Nm). NOTE:

UP552142

3

EFFECTIVITY ALL

Optional to add dry-film lubricant before application of RTV 106 to aid in removal of inlet guide vane cover (110) at next access.

Apply a thick layer of adhesive sealant (RTV 106) to cylindrical outside diameter of inlet guide vanes cover (110).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10013. Engine Compressor Section Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10013 10. COMPRESSOR ROTOR (IPC FIG. 23)

180. WASHER

20. CURVIC RING SEAL

190. FORWARD MOUNT, LEFT

40. ENGINE COMPRESSOR SHROUD ASSY

200. FORWARD MOUNT, RIGHT

50. DIFFUSER HOUSING ASSY

210. PLUG

-60. COMPRESSOR ROTOR (IPC FIG. 25)

220. PACKING

120. SHAFT ASSEMBLY (IPC FIG. 23)

230. DRIVEN COMPRESSOR BEARING HOUSING

130. CURVIC RING SEAL 170. BOLT (IPC FIG. 26) (8)

-315. CLAMP (IPC FIG. 2) -. ITEM NOT ILLUSTRATED

Install engine compressor components as follows. (Refer to Figure 10013.) (a)

Install initial trial shim pack of approximately 0.040 inch (1.02 mm).

(b)

Install the diffuser housing assembly (50) and align its pin hole with the pin hole on the inlet housing assembly.

(c)

Clean the curvics on the compressor rotor (60) and the shaft assembly (120).

(d)

Install the curvic ring seal (130) into the compressor rotor (60).

(e)

Install the shaft assembly (120) on the compressor rotor (60) and align the balance marks. Make sure the curvics are not stacked.

(f)

Clean the curvics on the shaft assembly (120) and the compressor rotor (10).

(g)

Put the curvic ring seal (20) into the shaft assembly (120).

(h)

Put the engine compressor shroud assembly (40) on the diffuser housing assembly (50) and align pin hole in the engine compressor shroud assembly with pin hole in the diffuser housing assembly and inlet housing assembly and attach with eight slave bolts and nuts in equally spaced places. Tighten nuts to a torque value of 180 in-lb (20.3 Nm).

(i)

Install the compressor rotor (10) on the shaft assembly (120) and align the balance marks. Make sure the curvics are not stacked.

UP552142

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

EFFECTIVITY ALL

(j)

Lubricate packing (220) with oil and install on plug (210).

(k)

Install plug (210) with packing (220) on the driven compressor bearing housing. Tighten plug to a torque value of 80 in-lb (9.04 Nm). Lockwire plug to driven compressor bearing housing per NASM33540 using lockwire MS20995C32.

(l)

Install left forward mount (190) and clamp (315, IPC 2) using washers (180, IPC Figure 26) and bolts (170). Tighten bolts to 350 in-lb (39.5 Nm) of torque.

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ENGINE MANUAL 131-9[B]

UP552142

(m)

EFFECTIVITY ALL

Install right forward mount (200) using washers (180) and bolts (170). Tighten bolts to 350 in-lb (39.5 Nm) of torque.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10014. Engine Compressor Section Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10014 10. COMPRESSOR ROTOR (IPC FIG. 23)

140. TIESHAFT NUT (IPC FIG. 19)

120. TURBINE SHAFT (IPC FIG. 25) (9)

Install turbine shaft simulator and stretch turbine shaft as follows. (Refer to Figure 10014.) (a)

Clean curvics on compressor rotor (10) and PN 834886-1 turbine shaft simulator.

(b)

Install PN 834886-1 turbine shaft simulator on compressor rotor (10). Make sure the curvics are not stacked.

(c)

Install tieshaft nut (140) on turbine shaft (120). Tighten tieshaft nut hand tight.

(d)

Install PN 834740-2 shaft stretch kit and PN 834889-1 stretch shaft tooling on turbine shaft (120). (Refer to ASSEMBLY-02.)

(e)

Stretch turbine shaft (120) to the Actual Load as written in ASSEMBLY 02, Step 5.A.(3)(c)1 bASSEMBLY 02, Step 5.A.(3)(c)1 b.

UP552142

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT.

EFFECTIVITY ALL

(f)

Tighten tieshaft nut (140) hand tight.

(g)

Remove PN 834740-2 shaft stretch kit and PN 834889-1 stretch shaft tooling from the turbine shaft (120).

(h)

Install PN 834891-1 centering bridge adapter and PN 834891-1 button tool on the diffuser housing assembly and attach with six slave bolts and nuts in equally spaced places. Tighten nuts to a torque value of 40 in-lb (4.5 Nm).

(i)

Hand tighten PN 834891-1 button tool on turbine shaft (120).

(j)

Rotate power section assembly to the fwd end up position.

(k)

Loosen PN 834891-1 button tool until it is one turn away from the turbine shaft (120).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10015. (Pre SB 131-49-8065) Shim the Load Compressor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10015 30. BOLT (IPC FIG. 26)

140. DRIVEN COMPRESSOR COUPLING SHAFT

90. SEAL ROTOR

230. DRIVEN COMPRESSOR BEARING HOUSING

UP552142

(10)

EFFECTIVITY ALL

(Pre SB 131-49-8065) Shim the load compressor as follows. (Refer to Figure 10015.) (a)

Remove bolts (30) and PN 834815-1 load compressor centering tool from the driven compressor bearing housing (230). (Refer to View A.)

(b)

Remove PN 834814-1 duplex bearing nut spacer from the coupling shaft (140).

(c)

Attach PN 834818-1 compressor bearing housing simulator to driven compressor bearing housing (230) with two bolts (30). Tighten bolts to a torque value of 100 in-lb (11.3 Nm). (Refer to View B.)

(d)

Install seal rotor (90) on the driven compressor coupling shaft (140). Make sure seal rotor is installed with inner step up as shown in View B and is fully seated.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10016. (Pre SB 131-49-8065) Shim the Load Compressor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10016 30. BOLT (IPC FIG. 26)

140. COUPLING SHAFT

90. SEAL ROTOR

230. DRIVEN COMPRESSOR BEARING HOUSING

(e)

Measure for compressor bearing shims as follows. (Refer to Figure 10016.) 1

Attach two PN 834850-1 stand off to PN 834711-6 micing bar with two CL-4-KHS knurled screws.

2

Put assembled PN 834711-6 micing bar on driven compressor bearing housing (230).

3

Measure from bottom of PN 834818-1 housing simulator to top of PN 834711-6 micing bar. Write as Dimension S. Dimension S ________________________inch (mm)

4

Measure from top of seal rotor (90) inner step to top of PN 834711-6 micing fixture. Write as Dimension R. Dimension R ________________________inch (mm)

Check Point 50: 5

Verify Dimensions R and S are written down.

Measure from end of coupling shaft (140) to top of PN 834711-6 micing fixture. Write as Stub Shaft Ref. 1.

UP552142

Stub Shaft Ref. 1 ________________inch (mm)

EFFECTIVITY ALL

6

Remove seal rotor (90) from driven compressor coupling shaft (140).

7

Remove bolts (30) and PN 834818-1 housing simulator from driven compressor bearing housing (230).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10017. (Pre SB 131-49-8065) Shim the Load Compressor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10017 110. L/C BEARING SHIM (IPC FIG. 26)

(f)

230. DRIVEN COMPRESSOR BEARING HOUSING

Calculate and install necessary shims for load compressor as follows. (Refer to Figure 10017.) 1

Write the following dimensions. Dimension C ___________________inch (mm), from Step 5.A.(1)(b) Dimension E ___________________inch (mm), from Step 5.A.(1)(a) Dimension F ___________________inch (mm), from Step 5.A.(1)(a) Dimension G ___________________inch (mm), from Step 5.A.(1)(a) Dimension H ___________________inch (mm), from Step 5.A.(1)(a) Dimension M ___________________inch (mm), from Step 5.A.(1)(b) Dimension R ___________________inch (mm), from Step 5.A.(10)(e)4 Dimension S ___________________inch (mm), from Step 5.A.(10)(e)3 Dimension T ___________________inch (mm), from Step 5.A.(2)(a)

2

Use dimensions in 1 for the following formula to calculate necessary L/C bearing shim (110) pack thickness. Dimensions S + (E - F) - (G - H) - R - T - C - M + 0.045 inch (1.14 mm) = L/C bearing shim (110) pack thickness _________inch (mm) required ± 0.001 inch (0.03 mm)

Check Point 60:

3

Select two L/C bearing shims (110) maximum of each thickness to get required shim pack thickness calculated in Step (2). Use guide pins to install L/C bearing shim (110) pack on driven compressor bearing housing (230). Write thickness of L/C bearing shim (110) pack installed inch (mm).

UP552142

Check Point 70:

EFFECTIVITY ALL

Make sure calculation to find L/C bearing shim (110) pack thickness is correct.

Make sure installed L/C bearing shim (110) pack thickness is same as calculated L/C bearing shim pack thickness.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10018. (Pre SB 131-49-8065) Shim the Load Compressor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10018 10. COMPRESSOR BEARING NUT (IPC FIG. 21)

130. STATIONARY OIL SEAL

80. MATCHED DUPLEX BALL BEARING ASSY SET (IPC FIG. 26)

140. DRIVEN COMPRESSOR COUPLING SHAFT

90. SEAL ROTOR

150. PACKING

100. COMPRESSOR BEARING HOUSING

160. PACKING

110. L/C BEARING SHIM

230. DRIVEN COMPRESSOR BEARING HOUSING

120. RETAINING RING (11)

(Pre SB 131-49-8065) Install compressor bearing components as follows. (Refer to Figure 10018.) (a)

Lubricate packings (150, 160) with Braycote 248.

(b)

Install packings (150, 160) in the compressor bearing housing (100).

(c)

Install and seat stationary oil seal (130) in the compressor bearing housing (100) from the aft end using PN 834810-2 installation seal drive tool.

(d)

Install retaining ring (120) in the compressor bearing housing (100).

CAUTION:

(e)

WHEN HEATING THE COMPRESSOR BEARING HOUSING (100) BE CAREFUL NOT TO OVERHEAT AND DAMAGE THE PACKINGS (150, 160).

Heat the compressor bearing housing (100) outer flange only. Use guide pins and install compressor bearing housing (100) on the driven compressor bearing housing (230) over the L/C bearing shims (110). NOTE:

(f)

Install seal rotor (90) on the driven compressor coupling shaft (140). NOTE:

(g)

Make sure value of L/C shim bearing (110) pack on driven compressor bearing housing (230) agrees with Step 5.A.(10)(f)2.

Make sure that the large outside diameter side of the seal rotor is installed facing aft on the driven compressor coupling shaft (140).

Clean matched duplex ball bearing assembly set (80) with degreasing solvent (MIL-PRF-680).

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN. CAUTION:

UP552142

(h)

EFFECTIVITY ALL

MAKE SURE MATCHED DUPLEX BALL BEARING ASSEMBLY SET (80) IS COMPLETELY FREE OF SOLVENT AND DRY. DO NOT SPIN BEARING WHILE DRY.

Dry matched duplex ball bearing assembly set (80) with dry compressed air.

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ENGINE MANUAL 131-9[B] WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. USE THE CORRECT PERSONAL PROTECTION. THE HEATED PARTS WILL CAUSE BURNS. (i)

Heat matched duplex ball bearing assembly set (80) to 450 to 500°F (232 to 260°C) for 20 to 30 minutes.

(j)

(Preferred method) Install matched duplex ball bearing assembly set (80). 1

Install PN 3700537 adapter on driven compressor coupling shaft (140).

CAUTION: 2

WHEN HANDLING MATCHED DUPLEX BALL BEARING ASSEMBLY SET (80) USE PN 3700539-1 INSTALLATION TOOL.

Install heated matched duplex ball bearing assembly set (80) on driven compressor coupling shaft (140) with the inner race puller groove facing up. NOTE:

(k)

3

Coat threads and face of PN 3700508-1 nut tool with lubricant (Molykote Z).

4

Tighten PN 3700508-1 nut tool to a torque value of 800 in-lb (90.4 Nm) to seat bearing.

5

Remove nut tool and adapter.

6

Coat threads and face of compressor bearing nut (10) with lubricant (Molykote Z).

7

Install compressor bearing nut (10) and use PN 834801-1 torque adapter with a torque wrench to tighten to a torque value of 600 to 680 in-lb (67.8 to 76.8 Nm). Loosen the compressor bearing nut (10) and retighten to 600 in-lb (67.8 Nm), continue to tighten to the first alignment of the key and then mark alignment.

(Alternate Method) Install matched duplex ball bearing assembly set (80). 1

Install heated matched duplex ball bearing assembly set (80).

UP552142

NOTE:

EFFECTIVITY ALL

Make sure that the inner race puller groove is facing up.

Make sure that inner race puller groove is facing up.

2

Coat threads and face of compressor bearing nut (10) with lubricant (Molykote Z).

3

Install compressor bearing nut (10) and use PN 834801-1 torque adapter with a torque wrench to tighten to a torque value of 600 to 680 in-lb (67.8 to 76.8 Nm). Loosen the compressor bearing nut (10) and retighten to 600 in-lb (67.8 Nm), continue to tighten to the first alignment of the key and then mark alignment.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10019. (Pre SB 131-49-8065) Shim the Load Compressor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10019 10. COMPRESSOR BEARING NUT (IPC FIG. 26)

70. COMPRESSION SPRING WASHER

20. NUT LOCKING KEY

80. MATCHED DUPLEX BALL BEARING ASSY SET

30. BOLT

100. COMPRESSOR BEARING HOUSING

40. COMPRESSOR BEARING RETAINING PLATE

140. DRIVEN COMPRESSOR COUPLING SHAFT

50. DAMPER BEARING RING

230. DRIVEN COMPRESSOR BEARING HOUSING

60. SPRING RETAINER (l)

Remove compressor bearing nut (10) from the driven compressor coupling shaft (140). 1

(m)

Apply a generous amount of oil (MIL-PRF-7808 or MIL-PRF-23699) to the duplex ball bearing and make sure of a thorough lubrication. Repeat this step if the bearing requires removal.

Measure and write results of Measured Dimension X. (Refer to View B.) Dimension X _____________inch (mm)

(n)

Write Calculated Dimension X from Step 5.A.(1)(b). Calculated Dimension X ___________inch (mm)

(o)

Compare Calculated Dimension X with Measured Dimension X. Calculated Dimension X must be within +0.002/-0.001 inch (+0.05/-0.03 mm) of Measured Dimension X to make sure the bearing assembly set (80) is not stacked.

(p)

If Calculated Dimension X is not within +0.002/ -0.001 inch (+0.05/-0.03 mm) of Measured Dimension X, repeat Steps 5.A.(11)(i) through (p). If necessary, use PN 834808-1 bearing puller to remove matched duplex ball bearing assembly set (80).

NOTE:

Duplex ball bearing may be reassembled as necessary if separation occurs.

UP552142

Check Point 80:

EFFECTIVITY ALL

Make sure Calculated Dimension X is within +0.002/-0.001 inch (+0.05/-0.03 mm) of Measured Dimension X.

(q)

Install compression spring washer (70) in the compressor bearing housing (100). (Refer to Figure 10019.)

(r)

Install spring retainer (60) in the compressor bearing housing (100) with small inside diameter side against compression spring washer (70).

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ENGINE MANUAL 131-9[B] (s)

Install damper bearing ring (50). WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. 1

Apply electrocleaner to a lint free soft cloth. Clean the damper bearing ring with cloth and let damper bearing ring dry.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. 2

Apply a thin layer of approved oil to the inner surface of the damper bearing ring.

3

Install damper bearing ring in the compressor bearing housing (100) with small outside diameter side against spring retainer (60).

4

Align the slot on the matched duplex ball bearing assembly set (80) outer race with the anti-rotation pin on the compressor bearing retaining plate (40).

5

Install the compressor bearing retaining plate (40) on the compressor bearing housing (100) with bolts (30). Tighten bolts to a torque value of 120 in-lb (13.6 Nm).

(t)

Place nut locking key (20) into the marked slot, made in Step (i), of the driven compressor coupling shaft (140).

(u)

Install the compressor bearing nut (10).

(v)

Tighten the compressor bearing nut (10), using PN 834801-1 torque adapter tool, to a torque value of 600 to 680 in-lb (67.8 to 75.9 Nm) to seat matched duplex ball bearing assembly set (80). Back off compressor bearing nut, then retorque to a minimum of 600 in-lb (67.8 Nm) and continue to torque in a clockwise direction until the marked alignment of the driven compressor coupling shaft (140) key slot with the compressor bearing nut (10) key slot is reached. Check Point 90:

(w)

Make sure compressor bearing nut (10) is tightened and seated.

Do a load compressor reference calculation check as follows: 1

Write Stub Shaft Ref. 1 from Step 5.A.(10)(e)5. Stub Shaft Ref. 1 __________________________inch (mm) a

2

Tighten positioning button on centering bridge adapter to 10 in-lb (1.13 Nm).

Repeat Step 5.A.(10)(e)5 except write as Stub Shaft Ref. 2.

UP552142

Stub Shaft Ref. 2 ___________________________inch (mm)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 3

Write Dimension T from Step 5.A.(2)(a)). Dimension T ____________________inch (mm)

4

With the measurements written in Steps (a), (b) and (c) do the following calculation. Stub Shaft 1 - Stub Shaft 2 + Dimension T = ______________inch (mm).

5 (x)

Calculation in Step 4 must equal 0.045 ± 0.001 inch (1.14 ± 0.03 mm).

Bend the locking tab of the nut locking key (20) down flat into the locking slot of the compressor bearing nut (10). Check Point 100:

UP552142

(y)

EFFECTIVITY ALL

Make sure locking tab of the nut locking key (20) is bent down flat into the locking slot of the compressor bearing nut (10).

Use PN 834990-1 portable engine stand/cart to rotate power section assembly aft side up.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10020. (Post SB 131-49-8065) Bearing Housing Measurements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10020

UP552142

100A. COMPRESSOR BEARING HOUSING (PN 3827265-8)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10021. (Post SB 131-49-8065) Bearing Housing Measurements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10021

UP552142

90. SEAL ROTOR (IPC FIG. 26)

EFFECTIVITY ALL

140. COUPLING SHAFT

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10022. (Post SB 131-49-8065) Bearing Housing Measurements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10022 80A. BEARING ASSEMBLY SET (PN 3822666-2) (12)

(Post SB 131-49-8065) Measure the components to shim the load compressor as follows: NOTE:

(a)

Take care in maintaining preservation (oil) of the bearing (80A) and only wipe external surfaces requiring dimensional checks. Keep the bearing (80A) in a protected state until needed for assembly. Measure and write the results of the bearing flange thickness (DIM. F), coupling shaft (DIM. D), seal rotor (DIM. B) and bearing inner race (DIM. A1). DIMENSION F = ____________________inch (mm) DIMENSION D= _____________________inch (mm) DIMENSION B =_____________________inch (mm) DIMENSION A1 =____________________inch (mm)

(b)

NOTE:

Dimension A must be 1.233 inch (31.32 mm) or copied from the package for the duplex bearing.

Indicate on the build sheet if Dimension A is 1.233 inch (31.32 mm) or recorded from the bearing packaging. (c)

Calculate Dimension X. Refer to Step 5.A.(12)(a). _______________ inch (mm) DIM. D (Coupling Shaft) - _______________ inch (mm) DIM. B (Seal Rotor) = _______________ inch (mm) Subtotal - _______________ inch (mm) DIM. A1 (Bearing Inner Race) = _______________ inch (mm) DIM. X (Calculated)

UP552142

Check Point 110:

EFFECTIVITY ALL

Make sure Dimensions F, D, B, A1, and X are properly measured, calculated and recorded within the limits provided.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10023. (Post SB 131-49-8065) Bearing Housing Measurements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10023 30. BOLT (IPC FIG. 26)

190. SCROLL HOUSING

UP552142

140. DRIVEN COMPRESSOR COUPLING SHAFT

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10024. (Post SB 131-49-8065) Bearing Housing Measurements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10024 90. SEAL ROTOR

(13)

230. DRIVEN COMPRESSOR BEARING HOUSING

(Post SB 131-49-8065) Shim the load compressor as follows: (Refer to Figure 10023 and Figure 10024.) (a)

Remove bolts (30) and PN 834815-1 load compressor centering tool from the driven compressor bearing housing (230).

(b)

Remove PN 834814-1 duplex bearing nut spacer from the coupling shaft (140).

(c)

Install seal rotor (90) on the driven compressor coupling shaft (140). Make sure seal rotor is installed with inner step up as shown in View B and is fully seated.

(d)

Measure for compressor bearing shims as follows. (Refer to Figure 10024.) 1

Attach two PN 834850-1 stand off to PN 834711-6 micing bar with two CL-4-KHS knurled screws.

2

Put assembled PN 834711-6 micing bar on driven compressor bearing housing (230).

3

Measure from top of bearing housing bore face to top of PN 834711-6 micing bar. Write as Dimension N. Dimension N _____________________inch (mm)

4

Measure from top of seal rotor (90) inner step to top of PN 834711-6 micing fixture. Write as Dimension R. Dimension R _____________________inch (mm)

5

Measure from end of coupling shaft (140) to top of PN 834711-6 micing fixture. Write as Stub Shaft Ref. 1.

UP552142

Stub Shaft Ref. 1 __________________inch (mm)

EFFECTIVITY ALL

6

Remove seal rotor (90) from driven compressor coupling shaft (140).

7

Remove assembled PN 834711-6 micing bar from driven compressor bearing housing (230).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10025. (Post SB 131-49-8065) Shim the Load Compressor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10025 110. L/C BEARING SHIM (IPC FIG. 26)

(e)

230. DRIVEN COMPRESSOR BEARING HOUSING

Calculate and install necessary shims for load compressor as follows. (Refer to Figure 10025.) 1

Write the following dimensions. Dimension A _______________inch (mm), from Step 5.A.(12)(b) Dimension F _______________inch (mm), from Step 5.A.(12)(a) Dimension R _______________inch (mm), from Step 5.A.(13)(d)4 Dimension N _______________inch (mm), from Step 5.A.(13)(d)3 Dimension T _______________inch (mm), from Step 5.A.(2)(a)

2

Use dimensions in 1 for the following formula to calculate necessary L/C bearing shim (110) pack thickness. ____________ DIM. A + ____________ DIM. N = ____________ Subtotal - ____________ DIM. R = ____________ Subtotal - ____________ DIM. F = ____________ Subtotal - ____________ DIM. T - ___0.001____ Compression Factor = ____________ Subtotal + ___0.045____ B/P = ____________ Calculated Shims Installed shims must be within ± 0.001 inch (0.03 mm) of the calculated shim value. Check Point 120:

UP552142

3

EFFECTIVITY ALL

Make sure calculation to find L/C bearing shim (110) pack thickness is correct.

Select two L/C bearing shims (110) maximum of each thickness to get required shim pack thickness calculated in 2. Use guide pins to install L/C bearing shim (110) pack on driven compressor bearing housing (230). Write thickness of L/C bearing shim (110) pack installed _______________inch (mm).

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ENGINE MANUAL 131-9[B]

UP552142

Check Point 130:

EFFECTIVITY ALL

Make sure installed L/C bearing shim (110) pack thickness is same as calculated L/C bearing shim pack thickness.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10026. (Post SB 131-49-8065) Duplex Bearing Set Installation

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10026 10. COMPRESSOR BEARING NUT (IPC FIG. 26) 20. NUT LOCKING KEY

110. L/C BEARING SHIM

30. BOLT

120. RETAINING RING

40A. COMPRESSOR BEARING RETAINING PLATE PN 3827385-2

130. STATIONARY OIL SEAL

70A. COMPRESSION SPRING WASHER PN 791-548-9301

140. DRIVEN COMPRESSOR COUPLING SHAFT

80A. MATCHED DUPLEX BALL BEARING ASSY SET PN 3822666-2

150. PACKING

90. SEAL ROTOR (14)

160. PACKING

(Post SB 131-49-8065) Install compressor bearing components as follows. (Refer to Figure 10026.) (a)

Lubricate packings (150, 160) with Braycote 248.

(b)

Install packings (150, 160) in the compressor bearing housing (100A, PN 3827265-8).

(c)

Install and seat stationary oil seal (130) in the compressor bearing housing (100A) from the aft end by hand or using PN 834810-2 installation seal drive tool.

(d)

Install retaining ring (120) in the compressor bearing housing (100A).

CAUTION:

(e)

WHEN HEATING THE COMPRESSOR BEARING HOUSING (100A) BE CAREFUL NOT TO OVERHEAT AND DAMAGE THE PACKINGS (150, 160).

Heat the compressor bearing housing (100A) outer flange only. Use guide pins and install compressor bearing housing (100A) on the driven compressor bearing housing (230) over the L/C bearing shims (110). NOTE:

(f)

(g)

UP552142

EFFECTIVITY

Make sure that the large outside diameter side of the seal rotor (90) is installed facing aft on the driven compressor coupling shaft (140).

Install the compression spring washer (70A) in the bearing housing (100A). NOTE:

(h)

Temporarily secure compressor bearing housing (100A) with three bolts (MS9557-08) while still hot and torque to 120 in-lb (13.6 Nm).

Install seal rotor (90) on the driven compressor coupling shaft (140). NOTE:

ALL

100A. COMPRESSOR BEARING HOUSING PN 3827265-8

Thrust the rotating group forward (up) by hand tightening the button on the PN 834891-1 turbine centering bridge adapter.

Clean matched duplex ball bearing assembly set (80A) with degreasing solvent (MIL-PRF-680).

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ENGINE MANUAL 131-9[B] WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN. CAUTION:

(i)

MAKE SURE MATCHED DUPLEX BALL BEARING ASSEMBLY SET (80A) IS COMPLETELY FREE OF SOLVENT AND DRY. DO NOT SPIN BEARING WHILE DRY.

Dry matched duplex ball bearing assembly set (80A) with dry compressed air.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. USE THE CORRECT PERSONAL PROTECTION. THE HEATED PARTS WILL CAUSE BURNS. (j)

Heat matched duplex ball bearing assembly set (80A) to 450 to 500°F (232 to 260°C) for 20 to 30 minutes.

(k)

(Preferred method) Install matched duplex ball bearing assembly set (80A). 1

Install PN 3700537-2 adapter on driven compressor coupling shaft (140).

CAUTION:

WHEN HANDLING MATCHED DUPLEX BALL BEARING ASSEMBLY SET (80A), USE PN 3700539-1 INSTALLATION TOOL AND/OR PROTECTIVE EQUIPMENT.

2

Install heated matched duplex ball bearing assembly set (80A) on driven compressor coupling shaft (140) with the inner race puller groove facing up.

3

Seat ball bearing assembly set (80A) using bearing driver PN 70641924-1. NOTE:

(l)

4

Cool bearing with compressed air then remove tool.

5

Oil bearing using oil (MIL-PRF-7808 or MIL-PRF-23699).

6

Coat threads and face of compressor bearing nut (10) with lubricant (Liqui-Moly).

7

Install compressor bearing nut (10) and use PN 834801-1 torque adapter with a torque wrench to tighten to a torque value of 600 to 680 in-lb (67.8 to 76.8 Nm). Loosen the compressor bearing nut (10) and retighten to 600 in-lb (67.8 Nm), continue to tighten in a clockwise direction to the first alignment of the key and then mark alignment with marking compound.

(Alternate method) Install matched duplex ball bearing assembly set (80A).

UP552142

1

EFFECTIVITY ALL

To prevent damage to stub shaft, oil the bearing driver (PN 70641924-1) threads that screw onto the stub shaft.

Install PN 3700537-1 or -2 adapter on driven compressor coupling shaft (140).

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ENGINE MANUAL 131-9[B] CAUTION: 2

WHEN HANDLING MATCHED DUPLEX BALL BEARING ASSEMBLY SET (80A), USE 3700539-1 INSTALLATION TOOL.

Install heated matched duplex ball bearing assembly set (80A) on driven compressor coupling shaft (140) with the inner race puller groove facing up. NOTE:

(m)

3

Coat threads and face of PN 3700508-1 nut tool with lubricant (Molykote Z).

4

Tighten PN 3700508-1 nut tool to a torque value of 800 in-lb (90.4 Nm) to seat bearing.

5

Remove nut tool and adapter.

6

Coat threads and face of compressor bearing nut (10) with lubricant (Molykote Z).

7

Install compressor bearing nut (10) and use PN 834801-1 torque adapter with a torque wrench to tighten to a torque value of 600 to 680 in-lb (67.8 to 76.8 Nm). Loosen the compressor bearing nut (10) and retighten to 600 in-lb (67.8 Nm), continue to tighten to the first alignment of the key and then mark alignment.

(Alternate Method) Install matched duplex ball bearing assembly set (80A). 1

Install heated matched duplex ball bearing assembly set (80A). NOTE:

UP552142

ALL

Make sure that inner race puller groove is facing up.

2

Coat threads and face of compressor bearing nut (10) with lubricant (Molykote Z).

3

Install compressor bearing nut (10) and use PN 834801-1 torque adapter with a torque wrench to tighten to a torque value of 600 to 680 in-lb (67.8 to 76.8 Nm). Loosen the compressor bearing nut (10) and retighten to 600 in-lb (67.8 Nm), continue to tighten to the first alignment of the key and then mark alignment. NOTE:

EFFECTIVITY

Make sure that the inner race puller groove is facing up.

Loosen the button on the PN 834891-1 turbine centering bridge adapter.

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ENGINE MANUAL 131-9[B]

Figure 10027. (Post SB 131-49-8065) Final Dimension X Measurement (n)

Remove compressor bearing nut (10) from the driven compressor coupling shaft (140). 1

(o)

Apply a generous amount of oil (MIL-PRF-7808 or MIL-PRF-23699) to the duplex ball bearing and make sure of a thorough lubrication. Repeat this step if the bearing requires removal.

Measure and write results of Measured Dimension X. (Refer to Figure 10027, Sheet 8.) Dimension X _______________inch (mm)

(p)

Write Calculated Dimension X from Step 5.A.(12)(c).

UP552142

Calculated Dimension X _______________inch (mm)

EFFECTIVITY ALL

(q)

Compare Calculated Dimension X with Measured Dimension X. Calculated Dimension X must be within +0.002/-0.001 inch (+0.05/-0.03 mm) of Measured Dimension X to make sure the bearing assembly set (80A) is not stacked.

(r)

If Calculated Dimension X is not within +0.002/-0.001 inch (+0.05/-0.03 mm) of Measured Dimension X, repeat Steps 5.A.(14)(i) through (p). If necessary, use

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ENGINE MANUAL 131-9[B] PN 834808-1 bearing puller to remove matched duplex ball bearing assembly set (80A). Check Point 140: Make sure Calculated Dimension X is within +0.002/ -0.001 inch (+0.05/-0.03 mm) of Measured Dimension X. WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. 1

Align the slot on the matched duplex ball bearing assembly set (80A, Figure 10026) outer race with the anti-rotation pin on the compressor bearing retaining plate (40A).

2

Install the compressor bearing retaining plate (40A) on the compressor bearing housing (100A) with bolts (30). Tighten bolts to a torque value of 120 in-lb (13.6 Nm).

(s)

Place nut locking key (20) into the marked slot, made in Step (i), of the driven compressor coupling shaft (140).

(t)

Install the compressor bearing nut (10).

(u)

Tighten the compressor bearing nut (10), using PN 834801-1 torque adapter tool, to a torque value of 600 to 680 in-lb (67.8 to 76.8 Nm) to seat matched duplex ball bearing assembly set (80A). Back off compressor bearing nut, then retorque to a minimum of 600 in-lb (67.8 Nm) and continue to torque in a clockwise direction until the marked alignment of the driven compressor coupling shaft (140) key slot with the compressor bearing nut (10) key slot is reached. Check Point 150:

(v)

Make sure compressor bearing nut (10) is tightened and seated.

Perform load compressor reference calculation check as follows: 1

Write Stub Shaft Ref. 1 from Step 5.A.(13)(d)5. Stub Shaft Ref. 1 _______________inch (mm) a

2

Tighten positioning button on centering bridge adapter to 10 in-lb (1.1 Nm).

Repeat Step 5.A.(13)(d)5 except write as Stub Shaft Ref. 2. Stub Shaft Ref. 2 _______________inch (mm)

3

Write Dimension T from Step 5.A.(2)(a). Dimension T _______________inch (mm)

4

With the measurements written in Steps 1, 2 and 3 do the following calculation.

UP552142

Stub Shaft 1 - Stub Shaft 2 + Dimension T =_______________inch (mm). EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Check Point 155:

5 (w)

Deleted.

Bend the locking tab of the nut locking key (20) down flat into the locking slot of the compressor bearing nut (10). Check Point 160:

UP552142

(x)

EFFECTIVITY ALL

Calculation in 4 must equal 0.045 ±0.001 inch (1.14 ±0.03 mm). If it is not 0.045 ±0.001 inch (1.14 ±0.03 mm), adjust shim stack accordingly and record.

Make sure locking tab of the nut locking key (20) is bent down flat into the locking slot of the compressor bearing nut (10).

Use PN 834990-1 portable engine stand/cart to rotate power section assembly aft side up.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10028. Calculate and Install Engine Compressor Shims

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10028 10. COMPRESSOR ROTOR (IPC FIG. 23)

70. TURBINE SHAFT (120, IPC FIG. 25)

40. ENGINE COMPRESSOR SHROUD ASSY

90. TIESHAFT NUT (140, IPC FIG. 19)

50. DIFFUSER HOUSING ASSY (15)

Using initial shim pack of approximately 0.040 inch (1.02 mm) previously installed in step 5.A.(8).(a), install engine compressor components as follows. (Refer to Figure 10028 and Figure 10029). (a)

Use feeler gauge or gauge pins to measure engine compressor rotor (10) to engine compressor shroud assembly (40) tip clearance. Measure each impeller blade to locate the highest blade (minimum) clearance. Write Engine Compressor Tip Clearance ___inch (mm).

(b)

Perform Shroud, PN 3827504-3 calculation as follows: Engine compressor tip clearance inch (mm) from Step 5.A.(15)(a) - (minus) 0.081 inch (2.06 mm) + initial shim pack thickness _______________inch (mm) = necessary shim (60) pack thickness ____________inch (mm). If necessary shim pack thickness is within ± 0.001 (0.03 mm) of initial shim pack thickness, no further adjustment is required. Do Shroud, PN 3827322-3 calculation as follows: Engine compressor tip clearance _____________inch (mm) from Step 5.A.(15)(a) - (minus) 0.079 inch (2.01 mm) + initial shim pack thickness _______________inch (mm) = necessary shim pack (60) thickness __________inch (mm). If necessary shim pack thickness is within ± 0.001 (0.03 mm) of initial shim pack thickness, no further adjustment is required. Check Point 170:

(c)

Make sure calculation to find Necessary Shim (60) Pack Thickness is correct.

Remove the six slave bolts and PN 834891-1 centering bridge adapter from the power section assembly.

UP552142

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT. SAFETY COVER PN 834740-10 MUST BE IN PLACE BEFORE PRESSURE IS APPLIED TO THE STRETCH SHAFT TOOL.

EFFECTIVITY ALL

(d)

Install PN 834889-1 stretch shaft tool with PN 834740-2 shaft stretch kit and apply force found in ASSEMBLY 02, Step 5.A.(3)(c)1 bASSEMBLY 02, Step 5.A.(3)(c)1 b and hand loosen the tieshaft nut (90) and then release pressure.

(e)

Remove PN 834889-1 stretch shaft tool, PN 834740-2 shaft stretch kit, tieshaft nut (90) and PN 834886-1 turbine shaft simulator tool from the power section assembly.

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ENGINE MANUAL 131-9[B] CAUTION:

DO NOT REMOVE CURVIC RING SEAL (20) FROM THE SHAFT ASSEMBLY (110).

(f)

Remove the eight slave bolts and nuts from the power section assembly.

(g)

Remove compressor rotor (10), engine compressor shroud assembly (40) and diffuser housing assembly (50) from the power section assembly.

(h)

Install/adjust shims (60, Figure 10029) calculated in (c) on inlet housing. Make sure all holes in the shims are lined up with holes in the inlet housing.

(i)

Install diffuser housing assembly (50) on installed shims (60) and align its pin with the pin on the inlet housing assembly.

(j)

Install engine compressor shroud assembly (40) in the diffuser housing (50). Align pin hole in engine compressor shroud assembly with pin in the diffuser housing.

(k)

Install eight slave nuts and bolts equally spaced through the engine compressor shroud assembly (40), diffuser housing assembly (50) and inlet housing. Tighten slave nuts to a torque value of 180 in-lb (20.3 Nm).

(l)

Install compressor rotor (10) on the turbine shaft (70) and align the balance marks. Make sure the curvics are not stacked.

(m)

Clean curvics on compressor rotor (10) and PN 834886-1 turbine shaft simulator.

(n)

Install PN 834886-1 turbine shaft simulator on compressor rotor (10). Make sure the curvics are not stacked.

(o)

Install tieshaft nut (90) on turbine shaft (70). Tighten tieshaft nut hand tight.

(p)

Install PN 834889-1 shaft stretch tool and PN 834740-2 stretch shaft kit on turbine shaft (70).

(q)

Stretch turbine shaft (70) to the same pressure as written in ASSEMBLY 02, Step 5.A.(3)(c)1 bASSEMBLY 02, Step 5.A.(3)(c)1 b.

(r)

Tighten tieshaft nut (90) hand tight.

(s)

Remove PN 834889-1 shaft stretch tool and PN 834740-2 stretch shaft kit from the turbine shaft (70).

(t)

Use feeler gauge or gauge pins to measure engine compressor tip clearance. Measure each impeller blade to locate highest blade (minimum clearance).

(u)

If tip clearance does not equal the measurement in Step (15)(b), do Steps (b) through (t) again. Check Point 180:

UP552142

(v)

EFFECTIVITY ALL

Make sure engine compressor tip clearance is the same measurement as in Step (15)(b).

Remove the eight slave bolts and nuts from the power section assembly.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10029. Assemble the Engine Compressor

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10029 10. COMPRESSOR ROTOR (IPC FIG. 23)

110. NUT (IPC FIG. 22)

30. ENGINE COMPRESSOR DIFFUSER

120. WASHER

40. ENGINE COMPRESSOR SHROUD ASSY

130. PACKING WITH RETAINER

50. DIFFUSER HOUSING ASSY

140. DIFFUSER SPACER

60. INLET HOUSING SHIM

150. BOLT

70. TURBINE SHAFT (120, IPC FIG. 25)

160. AIR STATIONARY SEAL SUPPORT

80. SHAFT ASSY (120, IPC FIG. 23)

170. ENGINE COMPRESSOR DESWIRL

UP552142

90. TIESHAFT NUT (140, IPC FIG. 19)

EFFECTIVITY ALL

(w)

Install engine compressor diffuser (30) on the power section assembly. Align the pin in the engine compressor diffuser with the hole in the engine compressor shroud assembly (40). (Refer to Figure 10029.)

(x)

Paint engine compressor diffuser (30) and engine compressor deswirl (170) mating surfaces with silver aluminum paint. (Refer to Figure 10029, Detail B.)

(y)

While paint from previous step is still wet install the engine compressor deswirl (170) on the power section assembly. Align the pin in the engine compressor diffuser (30) with the hole in the engine compressor deswirl.

(z)

Paint engine compressor deswirl (170) and air stationary seal support (160) mating surfaces with silver aluminum paint. (Refer to Figure 10029, Detail B.)

(aa)

While paint from previous step is still wet install the air stationary seal support (160) on the power section assembly. Align the pin in the engine compressor deswirl (170) with the hole in the air stationary seal support.

(ab)

Install bolts (150), diffuser spacers (140), packings with retainer (130), washers (120) and nuts (110) on the power section assembly. Tighten nuts to a torque value of 180 in-lb (20.3 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10030. Install Combustor Elements

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10030 10. NUT (IPC FIG. 21)

90. NUT (IPC FIG. 21)

-10A. NUT

100. BOLT

20. BOLT

110. AFT LIFTING BRACKET

-20A. BOLT

120. AFT LIFTING BRACKET

30. ANNULAR COMBUSTION CHAMBER (100, IPC FIG. 22)

130. NUT

40. COMBUSTOR CASE (90, IPC FIG. 22)

140. BOLT

70. NUT

150. COMBUSTOR TO HARNESS CLAMP

-75. NUT (170A, IPC FIG. 21) 80. BOLT (IPC FIG. 22)

-170. AIR STATIONARY SEAL SUPPORT (160, IPC FIG. 22)

-85. BOLT (185, IPC FIG. 21) (16)

160. SURGE DUCT BRACKET

-. ITEM NOT ILLUSTRATED

Install combustor elements as follows. (Refer to Figure 10030.) (a)

(b)

Install the annular combustion chamber (30) on the air stationary seal support (170) on the power section assembly as follows: 1

Put the combustor case (40) on the diffuser housing assembly and engage the pin on the diffuser housing assembly with the corresponding hole in the combustor case.

2

Use Dykem to mark the circumferential location of the igniter plug hole on the diffuser housing.

3

Remove the combustor case (40) from the diffuser housing.

4

Put the annular combustion chamber (30) on the air stationary seal support (170) and align the igniter plug hole location Dykem mark on the diffuser housing, made in Step 2, with the igniter hole in the annular combustion chamber.

Install the combustor case (40) on the diffuser housing assembly as follows: 1

Align the hole on the combustor case (40) flange with the corresponding pin on the diffuser housing assembly flange.

2

Use three PN 834809-1 alignment pins to align the annular combustion chamber (30) and combustor case (40) fuel nozzle holes. Make sure the igniter hole in the annular combustion chamber is aligned with the igniter hole in the combustor case.

3

(Pre SB 131-49-8182) Attach combustor case (40) to diffuser housing assembly with bolts (20, 80) and nuts (10, 70). Tighten bolts (20, 80) to a torque value of 50 in-lb (5.6 Nm) to 60 in-lb (6.8 Nm).

UP552142

(Post SB 131-49-8182) Attach combustor case (40) to diffuser housing assembly with bolts (20A, 80, 85) and nuts (10A, 70, 75). Tighten bolts

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] (80, 85) to a torque value of 50 in-lb (5.6 Nm) to 60 in-lb (6.8 Nm). Tighten bolts (20A) to a torque value of 80 in-lb (9.03 Nm).

UP552142

(17)

EFFECTIVITY ALL

4

Install aft lifting bracket (110), with bent tab facing aft, and attach with bolts (100) and nuts (90). Tighten bolts to a torque value of 50 in-lb (5.6 Nm) to 60 in-lb (6.8 Nm).

5

Install aft lifting bracket (120), with bent tab facing forward, and attach with bolts (100) and nuts (90). Tighten bolts to a torque value of 50 in-lb (5.6 Nm) to 60 in-lb (6.8 Nm).

6

Install surge duct bracket (160), with the word “FORWARD” facing forward, and attach with bolts (140) and nuts (130). Tighten bolts to a torque value of 50 in-lb (5.6 Nm) to 60 in-lb (6.8 Nm).

7

Install combustor to harness clamp (150) and attach with bolts (140) and nuts (130). Tighten bolts to a torque value of 50 in-lb (5.6 Nm) to 60 in-lb (6.8 Nm).

Install aft build stands arms and install power section in build cart as follows: (a)

Install PN 834895-1 interface bolts on diffuser housing assembly aft mounts.

(b)

Install the PN 834892-2 and PN 834892-3 aft mount arms on the diffuser housing assembly so the power section right side, aft looking forward, will face the PN 834990-1 portable engine stand/cart gearbox when the power section is installed in the portable engine stand/cart.

(c)

Install PN 834816-1 lifting adapter on the turbine shaft.

(d)

Use hoist attached to PN 834816-1 lifting adapter to move power section in PN 834990-1 portable engine stand/cart using PN 834892-2 and PN 834892-3 aft mount arms.

(e)

Remove the PN 834805-1 maintenance adapter set (PN 834805-2 fixed assembly and the PN 834805-3 floating assembly) from the bearing housing.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10031. Third Rotating Group Stretch

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10031 20. SECOND STAGE TURBINE ROTOR ASSY (IPC FIG. 20)

130. COUPLING SHAFT (IPC FIG. 20)

40. COUPLING SHAFT

140. TIESHAFT NUT (IPC FIG. 19)

110. FIRST STAGE TURBINE ROTOR ASSY

150. TIESHAFT WASHER

120. TURBINE SHAFT (IPC FIG. 25)

220. AFT BEARING SHAFT

(18)

Do a third rotating group stretch as follows. (Refer to Figure 10031.) (a)

Remove PN 834886-1 turbine shaft simulator from the turbine shaft as follows: 1

Install PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit on the turbine shaft (120).

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT.

(b)

2

Stretch the turbine shaft to force found in ASSEMBLY 02, Step 5.A.(3)(c)1 and 3 remove tieshaft nut (140) and release pressure on shaft stretch tool.

3

Remove PN 834889-1 stretch shaft tool, PN 834740-2 shaft stretch kit and PN 834886-1 turbine shaft simulator tool from the turbine shaft (120).

Install turbine rotors and coupling shafts on turbine shaft as follows: 1

Clean the curvics on coupling shaft (130) and install, with seal knife edges facing aft, on engine compressor rotor (10). Align balance marks and make sure curvics are not stacked.

2

Clean the curvics on first stage turbine rotor assembly (110) and use two PN 834812-1 wheel removal adapters to install first stage rotor on the coupling shaft (130) with the word “AFT” on the disk facing up. Align balance marks and make sure curvics are not stacked.

3

Clean the curvics on coupling shaft (40) and install, with the three marked dots facing aft, on the first stage turbine rotor assembly (110). Align balance marks and make sure curvics are not stacked.

4

Clean the curvics on second stage turbine rotor assembly (20) and use two PN 834812-1 wheel removal adapters to install second stage rotor on the coupling shaft (40). Align balance marks and make sure curvics are not stacked.

UP552142

NOTE:

EFFECTIVITY ALL

The second stage turbine rotor assembly (20) can be installed only in one direction due to the difference in its forward and aft curvics.

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ENGINE MANUAL 131-9[B] 5

Install PN 834926-1 roller bearing simulator on aft bearing shaft (220). NOTE:

(c)

The PN 834926-1 roller bearing simulator can be pushed on the aft bearing shaft (220) with a arbor press, but make sure the curvic end is placed on a clean phenolic block for protection.

6

Clean the curvics on turbine shaft (120).

7

Install turbine shaft (120) on second stage rotor assembly (20). Align balance marks and make sure curvics are not stacked.

8

Install tieshaft washer (150) and tieshaft nut (140) on the turbine shaft (120).

9

Use PN 834890-1 torque adapter to tighten tieshaft nut (140) to a torque value of 120 in-lb (13.6 Nm).

Measure Dimension U, Dimension S and Dimension Y as follows: 1

Measure and make sure Dimension U is same, ± 0.009 inch (0.23 mm), as Dimension U from ASSEMBLY-02, Step 5.A.(3)(b)1. (Refer to Figure 10033, Detail A.)

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT. 2

Install PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit. Stretch the turbine shaft (120) to actual load as written in ASSEMBLY-02, Step 5.A.(3)(c)1 bASSEMBLY-02, Step 5.A.(3)(c)1 b.

3

Measure and make sure Dimension S is same, ± 0.002 inch (0.05 mm), as Dimension S from ASSEMBLY-02, Step 5.A.(3)(c)5. (Refer to Figure 10033, Detail A.)

4

Attach two PN 834850-1 stand-offs to PN 834711-2 micing bar with two CL-4-KHS knurled screws.

5

Put assembled PN 834711-2 micing bar on the combustor case aft flange as shown in Figure 10031.

6

Use PN 834711-2 micing bar and depth mic to measure Dimension Y. a

Write Dimension Y ____________inch (mm).

Check Point 190: (d)

Remove turbine rotors and coupling shafts from the turbine shaft as follows:

UP552142

1

EFFECTIVITY ALL

Make sure Dimension Y is written.

Install PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit on the turbine shaft (120).

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ENGINE MANUAL 131-9[B]

UP552142

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT.

EFFECTIVITY ALL

2

Stretch the turbine shaft force found in ASSEMBLY 02, Steps 5.A.(3)(c)1 and 3 loosen tieshaft nut (140) and release pressure on shaft stretch tool.

3

Remove PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit from the turbine shaft (120).

4

Remove tieshaft nut (140), tieshaft washer (150) and aft bearing shaft (220) with roller bearing simulator from the turbine shaft (120).

5

Use two PN 834812-1 wheel removal adapters to remove second stage turbine rotor assembly (20) from the turbine shaft (120).

6

Remove coupling shaft (40) from the turbine shaft (120).

7

Use two PN 834812-1 wheel removal adapters to remove first stage turbine rotor assembly (110) from the turbine shaft (120).

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ENGINE MANUAL 131-9[B]

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Figure 10032. Measure Dimension W

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10032 200. FIRST STAGE STATOR ASSY (IPC FIG. 20) (19)

Measure Dimension W and Dimension Z1 as follows: (a)

Measure and write first stage stator assembly (200) flange thickness as Dimension W. (Refer to Figure 10032.) Dimension W ______________________________inch (mm)

(b)

Measure and write combustor case (90) aft flange depth as Dimension Z1. (Refer to Figure 10033.) Dimension Z1 ______________________________inch (mm)

UP552142

Check Point 200:

EFFECTIVITY ALL

Make sure Dimension Z1 is written.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10033. Measure Dimension Z1

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10033

UP552142

90. COMBUSTOR CASE (IPC FIG. 22)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10034. Install First Stage Stator Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10034 140. TURBINE PLENUM SHIM (IPC FIG. 20) (20)

Install first stage stator assembly as follows. (Refer to Figure 10034 and Figure 10035.) (a)

Calculate required first stage stator shims as follows: 1

Write the following dimensions. Build Dimension 1.812 (46.02) inch (mm) Mic Bar and Button thickness 2.000 (50.80) inch (mm) Dimension W (from Step 5.A.(19)(a)) ___________________inch (mm) Dimension Y (from Step 5.A.(18)(c)6 a) __________________inch (mm)

2

Use dimensions in Step 1 to do the following equation to calculate required turbine plenum shims (140). 1.812 (46.02) inch (mm) + 2.000 (50.80) inch (mm) Dimension W ___________________________inch (mm)Dimension Y ___________________________inch (mm) = Required Shims _________________________________inch (mm)

(b)

Install two guide studs in combustor case flange.

(c)

Install turbine plenum shims (140) as calculated in Step 5.A.(20)(a)2±0.001 (0.03) inch (mm) on the combustor case. Make sure pin hole in shim pack is aligned with pin hole in the combustor case. 1

Write installed turbine plenum shims (140) as Installed Turbine Plenum Shims _________________________________inch (mm)

(d)

Align pin in first stage stator assembly (200) flange with installed shims (140) and combustor case pin holes, then insert the first stage stator assembly (200) into the combustor case. NOTE:

UP552142

(e)

EFFECTIVITY ALL

Make sure that uniform contact is made between the first stage stator inner transition liner and combustion chamber.

Use eight slave bolts to pull the first stage stator assembly (200) down on the combustor case. While the slave bolts are tightened, make sure that uniform contact is kept between the first stage stator inner transition liner and combustion chamber. Tighten slave bolts to a torque value of 60 in-lb (6.8 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10035. Install First Stage Stator Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10035

UP552142

200. FIRST STAGE STATOR ASSEMBLY (IPC FIG. 20)

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10036. Fourth Rotating Group Stretch

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10036 20. SECOND STAGE TURBINE ROTOR ASSY (IPC FIG. 20)

140. TURBINE PLENUM SHIM

40. COUPLING SHAFT

150. TIESHAFT NUT (140, IPC FIG. 19)

110. FIRST STAGE TURBINE ROTOR ASSY

160. TIESHAFT WASHER (150, IPC FIG. 19)

120. TURBINE SHAFT (IPC FIG. 25)

220. AFT BEARING SHAFT (220, IPC FIG. 19)

-130. COUPLING SHAFT (IPC FIG. 20) (21)

Do a fourth rotating group stretch as follows. (Refer to Figure 10036.) (a)

Install turbine rotors and coupling shafts on turbine shaft as follows: 1

Clean the curvics on coupling shaft (130) and install, with seal knife edges facing aft, on engine compressor rotor (10, Figure 10028). Align balance marks and make sure curvics are not stacked.

2

Clean the curvics on first stage turbine rotor assembly (110, Figure 10036) and use two PN 834812-1 wheel removal adapters to install first stage rotor on the coupling shaft (130) with the word “AFT” on the disk facing up. Align balance marks and make sure curvics are not stacked.

3

Clean the curvics on coupling shaft (40) and install, with the three marked dots facing aft, on the first stage turbine rotor assembly (110). Align balance marks and make sure curvics are not stacked.

4

Clean the curvics on second stage turbine rotor assembly (20) and use two PN 834812-1 wheel removal adapters to install second stage rotor on the coupling shaft (40). Align balance marks and make sure curvics are not stacked. NOTE:

(b)

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ALL

The second stage turbine rotor assembly (20) can be installed only in one direction due to the difference in its forward and aft curvics.

5

Clean the curvics on aft bearing shaft (120) install aft bearing shaft, with installed PN 834926-1 roller bearing simulator, on second stage turbine rotor assembly (20). Align balance marks and make sure curvics are not stacked.

6

Install tieshaft washer (160) and tieshaft nut (150) on the turbine shaft (120).

7

Use PN 834890-1 torque adapter to tighten tieshaft nut (150) to a torque value of 120 in-lb (13.6 Nm).

Measure Dimension U, Dimension S and Dimension Y as follows. (Refer to Figure 10036, Detail A.) 1

EFFECTIVITY

-. ITEM NOT ILLUSTRATED

Measure and make sure Dimension U is same as Dimension U from ASSEMBLY-02, Step 5.A.(3)(b)1 (± 0.009 inch (0.23 mm).

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ENGINE MANUAL 131-9[B] WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT. 2

Install PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit. Stretch the turbine shaft (120) to actual load as written in ASSEMBLY 02, Step 5.A.(3)(c)1 bASSEMBLY 02, Step 5.A.(3)(c)1 b.

3

Measure and make sure Dimension S is same as Dimension S from ASSEMBLY-02, Step 5.A.(3)(c)5 (± 0.002 inch (0.05 mm). Check Point 210:

4

Use assembled PN 834711-2 micing bar and PN 834850-1 mic buttons with a depth mic to measure Dimension Y. (Refer to Figure 10036.) a

Write Dimension Y _________________inch (mm)

b

Measured Dimension Y minus the thickness of the micing bar and buttons must be 1.812 ± 0.001 inch (46.02 ± 0.03 mm).

Check Point 220:

(c)

Make sure Dimension S is same as written down during assembly of rotating group.

Make sure Dimension Y minus the thickness of the micing bar and buttons is 1.812 ± 0.001 inch (46.02 ± 0.03 mm).

Remove turbine rotors and coupling shafts from the turbine shaft as follows: 1

Install PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit on the turbine shaft (120).

UP552142

WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT.

EFFECTIVITY ALL

2

Stretch the turbine shaft to force used in ASSEMBLY 02, Step 5.A.(3)(c)1 bASSEMBLY 02, Step 5.A.(3)(c)1 b loosen tieshaft nut (150) and release pressure on shaft stretch tool.

3

Remove PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit from the turbine shaft (120).

4

Remove tieshaft nut (150), tieshaft washer (160) and aft bearing shaft (220) with roller bearing simulator from the turbine shaft (120).

5

Use two PN 834812-1 wheel removal adapters to remove second stage turbine rotor assembly (20) from the turbine shaft (120).

6

Remove coupling shaft (40) from the turbine shaft (120).

7

Use two PN 834812-1 wheel removal adapters to remove first stage turbine rotor assembly (110) from the turbine shaft (120).

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ENGINE MANUAL 131-9[B]

UP552142

(d)

EFFECTIVITY ALL

Remove eight slave bolts and first stage stator assembly (110) from the power section assembly. Leave turbine plenum shim (140) pack in place on combustor case.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10037. Install Shroud Segments in the First Stage Stator Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10037 150. RETAINING RING (IPC FIG. 20)

200. FIRST STAGE STATOR ASSY

160. SHROUD SUPPORT RING

-200D. FIRST STAGE STATOR ASSY

170. SHROUD SEGMENT SEAL

-200E. FIRST STAGE STATOR ASSY

180. FIRST STAGE TURBINE SHROUD SEGMENT

-200F. FIRST STAGE STATOR ASSY

180A. FIRST STAGE TURBINE SHROUD SEGMENT

-200G. FIRST STAGE STATOR ASSY

190. FEATHER SEAL (22)

-. ITEM NOT ILLUSTRATED

Assemble the shroud segments in the first stage stator assembly as follows. (Refer to Figure 10037.) (a)

(Pre SB 131-49-7577) Assemble the first stage turbine shroud segments (180) and feather seals (190) in the shroud support seal (170). (Post SB 131-49-7577) Assemble the first stage turbine shroud segments (180, 180A) and feather seals (190) in the shroud support seal (170).

(b)

(Pre SB 131-49-7577) Install the assembled first stage turbine shroud segments (180), feather seals (190) and shroud support seal (170) into the first stage stator assembly (200). Make sure the slot on a first stage turbine shroud segment is engaged with the pin on the first stage stator assembly. (Post SB 131-49-7577) Install the assembled first stage turbine shroud segments (180, 180A), feather seals (190) and shroud support seal (170) into the first stage stator assembly (-200D, -200E, -200F, -200G). Make sure the slot on the first stage turbine shroud segment is engaged with the pin on the first stage stator assembly.

(c)

Lower and seat the shroud support ring (160) on the assembled first stage turbine shroud segments (180), feather seals (190) and shroud support seal (170).

(d)

Install the retaining ring (150) into the groove on the first stage stator assembly (200).

UP552142

NOTE:

EFFECTIVITY ALL

The retaining ring (150) can only be installed when the assembled first stage turbine shroud segments (180), feather seals (190) and shroud support seal (170) are seated.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10038. Install Air Seal and First Stage Stator Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10038 160. AIR STATIONARY SEAL SUPPORT (IPC FIG. 22) 200. FIRST STAGE STATOR ASSY (IPC FIG. 20)

210. BOLT

-200D. FIRST STAGE STATOR ASSY

220. AIR SEAL

-200E. FIRST STAGE STATOR ASSY

230. TURBINE SEAL

-200F. FIRST STAGE STATOR ASSY DIM. (23)

GG

1

(b)

(c)

ALL

0.125 IN. (3.18 MM)

Install turbine seal (230) on the air seal (220) as follows: CAUTION:

EFFECTIVITY

-. ITEM NOT ILLUSTRATED

Install the air seal and first stage stator assembly as follows. (Refer to Figure 10038.) (a)

UP552142

-200G. FIRST STAGE STATOR ASSY

MAKE SURE TURBINE SEAL IS PROPERLY ORIENTATED (LARGE LIP FACING AFT) ON AIR SEAL.

Install the turbine seal (230) (large end of seal facing aft) on the air seal (220). Leave a 0.125 inch (3.20 mm) gap between the large lip on the turbine seal and the air seal as shown in Detail B, Dimension GG. Use PN 834951-1 turbine seal space to make sure correct gap.

Install assembled air seal (220) on the air stationary seal support (160) as follows: 1

Install the air seal (220) with the installed turbine seal (230) on to the air stationary seal support (160) and align the bolt holes.

2

Attach the air seal (220) to the air stationary seal support (160) with bolts (210). Torque bolts to a torque value of 60 in-lb (6.8 Nm).

(Pre SB 131-49-7577) Install the first stage stator assembly (200) into the combustor case as follows: 1

Align the locating pin hole in the combustor case and assembled shim pack with the pin in the first stage stator assembly (200).

2

Put the first stage stator assembly (200) on the combustor case and make sure that uniform contact is made between the first stage stator inner transition liner and combustion chamber.

3

Use eight slave bolts to pull the first stage stator assembly (200) down on the combustor case. While the slave bolts are tightened make sure that uniform contact is kept between the first stage stator inner transition liner and combustion chamber. Tighten slave bolts to a torque value of 60 in-lb (6.8 Nm).

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ENGINE MANUAL 131-9[B] (d)

(e)

(Post SB 131-49-7577) Install the first stage stator assembly (-200D, -200E,-200F, -200G) into the combustor case as follows: 1

Align the locating pin hole in the combustor case and assembled shim pack with the pin in the first stage stator assembly (-200D,-200E, -200F, -200G).

2

Put the first stage stator assembly (-200D, -200E, -200F, -200G) on the combustor case and make sure that uniform contact is made between the first stage stator inner transition liner and combustion chamber.

3

Use eight slave bolts to pull the first stage stator assembly (-200D,-200E, -200F, -200G) down on the combustor case. While the slave bolts are tightened, make sure that uniform contact is kept between the first stage stator inner transition liner and combustion chamber. Tighten slave bolts to a torque value of 60 in-lb (6.8 Nm).

Make sure the first stage stator assembly (200) is seated as follows: 1

Write the following dimensions. Installed Turbine Plenum Shims (140) installed (Step 5.A.(20)(c)1). ___________________________________________inch (mm) Dimension W (from Step 5.A.(16)(a))_____________inch (mm) Dimension Z1 (from Step 5.A.(16)(b)) _____________inch (mm)

2

Measure and write the results of Dimension Z2. Dimension Z2 = _____________________________inch (mm) Check Point 230:

3

Make sure and write Dimension Z2.

Use the following equation to make sure first stage stator assembly (200) is seated. Dimension Z1 _________________________________inch (mm) Dimension Z2 _________________________________inch (mm) Dimension W __________________________________inch (mm) Installed Turbine Plenum Shims (140) used __________inch (mm) = __________inch (mm) (must equal 0.000 ± 0.001 inch (0.00 ± 0.03 mm)) Check Point 240:

UP552142

NOTE:

EFFECTIVITY ALL

Verify calculation to make sure first stage stator assembly (200) is seated is 0.000 ± 0.001 inch (0.00 ± 0.03 mm).

Calculation in this step must equal 0.000 ± 0.001 inch (0.00 ± 0.03 mm) to make sure the first stage stator assembly (200) is seated.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10039. Install First Stage Turbine Rotor Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10039 110. FIRST STAGE TURBINE ROTOR ASSY (IPC FIG. 20)

130. COUPLING SHAFT

120. CURVIC RING SEAL (24)

Install turbine rotor assemblies, coupling shafts and second stage stator assembly as follows. (Refer to Figure 10039.) (a)

Install first stage turbine rotor as follows: 1

Install curvic ring seal (120) on the coupling shaft (130).

2

Clean the curvics on coupling shaft (130) and first stage turbine rotor assembly (110).

3

Use two PN 834812-1 wheel removal adapters to install the first stage turbine rotor assembly (110) on the coupling shaft (130). Align the balance marks and make sure curvics are not stacked.

UP552142

NOTE:

EFFECTIVITY ALL

Make sure that the word "AFT" is visible on the first stage turbine rotor assembly (110) after it has been installed.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10040. Install Second Stage Turbine Stator and Second Stage Turbine Rotor Assemblies

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10040 10. RING SEAL (IPC FIG. 20)

40. COUPLING SHAFT

20. SECOND STAGE TURBINE ROTOR ASSY

110. FIRST STAGE TURBINE ROTOR ASSY

30. CURVIC RING SEAL

UP552142

(b)

EFFECTIVITY ALL

Install second stage turbine stator assembly and second stage turbine rotor assembly as follows. (Refer to Figure 10040.) 1

Remove eight slave bolts that attach first stage stator to combustor case. Leave guide pins in place.

2

Install second stage stator assembly in the combustor case and align locating pin.

3

Clean curvics on the coupling shaft (40).

4

Install coupling shaft (40), with the three marked dots facing aft, on the first stage turbine rotor assembly (110). Align balance marks and make sure curvics are not stacked.

5

Put the curvic ring seal (30) into the coupling shaft (40).

6

Clean the curvics on the second stage turbine rotor assembly (20).

7

Use two PN 834812-1 wheel removal adapters to install the second stage turbine rotor assembly (20) on the coupling shaft (40). Align the balance marks and make sure curvics are not stacked.

8

Place the ring seal (10) into the curvics of the second stage rotor assembly (20).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10041. Install Roller Bearing on Aft Bearing Shaft

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10041 220. AFT BEARING SHAFT (IPC FIG. 19)

260. SEAL RETAINER

230. REAR BEARING SEAL

270. BEARING SET

250. SPRING WASHER (25)

Install roller bearing in the power section assembly as follows: (a)

Assemble roller bearing on aft bearing shaft. 1

Use the PN 834883-1 aft bearing puller to remove PN 834926-1 roller bearing simulator from aft bearing shaft (220). (Refer to Figure 10041.)

2

Install the rear bearing seal (230) with short shoulder facing aft on the aft bearing shaft (220).

3

Install the spring washer (250) and seal retainer (260) with inner lip on spring wave washer (250) on the aft bearing shaft (220).

4

Use arbor press PN 834759-8 press button and PN 834701-1 bearing press tube to push the bearing set (without outer race in place) (270) with the chamfer facing up (aft), on the aft bearing shaft (220). (Refer to Figure 10042.)

UP552142

NOTE:

EFFECTIVITY ALL

Make sure the bearing set (270) is seated on the aft bearing shaft (220).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10042. Install Roller Bearing on Aft Bearing Shaft

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10043. Install Assembled Roller Bearing and Aft Bearing Shaft in Turbine Bearing Housing Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10043 170. TURBINE BEARING HOUSING ASSY (IPC FIG. 19)

210. AIR SEAL

180. NUT

240. REAR BEARING SEAL GASKET

190. FWD TURBINE BEARING INSULATION BLANKET 200. NUT

-240A. REAR BEARING SEAL GASKET -. ITEM NOT ILLUSTRATED

(b)

Install assembled aft bearing shaft in the turbine bearing housing assembly. (Refer to Figure 10043.) WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. 1

(Pre SB 131-49-7561) Spray rear bearing seal gasket (240) with dry film lubricant then install on the turbine bearing housing assembly (170).

UP552142

(Post SB 131-49-7561) Spray rear bearing seal gasket (-240A) with dry film lubricant then install on the turbine bearing housing assembly (170).

EFFECTIVITY ALL

2

Install the assembled aft bearing shaft into the turbine bearing housing assembly (170).

3

Install the air seal (210) on the rear bearing housing assembly (170) and attach with nuts (200). Tighten nuts to a torque value of 50 in-lb (5.6 Nm).

4

Install the forward turbine bearing insulation blanket (190) on the turbine bearing housing assembly (170) and attach with nuts (180). Tighten nuts to a torque value of 27 in-lb (3.1 Nm).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10044. Install Assembled Turbine Bearing Housing Assembly on the Power Section Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10044 -20. SECOND STAGE ROTOR ASSY (IPC FIG. 20)

-170D. TURBINE BEARING HOUSING ASSY

-50. POWER SECTION ASSY (IPC FIG. 17)

-170E. TURBINE BEARING HOUSING ASSY

-100. SECOND STAGE STATOR ASSY (IPC FIG. 20) 160. BOLT (IPC FIG. 19)

220. AFT BEARING SHAFT -. ITEM NOT ILLUSTRATED

170. TURBINE BEARING HOUSING ASSY (c)

Install assembled turbine bearing housing assembly on the power section assembly as follows. (Refer to Figure 10044.) 1

Clean the curvics on the second stage turbine rotor assembly (20) and the aft bearing shaft (220).

2

Align the pin hole in the turbine bearing housing assembly (170, IPC Fig. 19) mount flange with the pin in the combustor case and lower the assembled turbine bearing housing assembly on the second stage stator assembly (100, IPL Fig. 20).

3

Align the balance mark on the aft bearing shaft (220, IPC Fig. 19) with the balance mark on the second stage turbine rotor assembly (20, IPC Fig. 20) and engage the curvics. Make sure the curvics are not stacked.

4

(Pre SB 131-49-7577/7597) Attach the assembled turbine bearing housing assembly (170, IPC Fig. 19) to the power section assembly (50, IPC Fig. 17) with bolts (160). Tighten bolts to a torque value of 60 in-lb (6.8 Nm).

UP552142

(Post SB 131-49-7577/7597) Attach the assembled turbine bearing housing assembly (-170D or -170E, IPC Fig. 19) to the power section assembly (50, IPC Fig. 17) with bolts (160, IPC Fig. 19). Tighten bolts to a torque value of 60 in-lb (6.8 Nm).

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10045. Stretch Turbine Shaft

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10045 120. TURBINE SHAFT (IPC FIG. 25)

150. TIESHAFT WASHER

140. TIESHAFT NUT (IPC FIG. 19) (d)

Stretch the turbine shaft as follows. (Refer to Figure 10045.) 1

2

Install the tieshaft nut and tieshaft washer as follows: a

Put liqui-moly on the turbine shaft (120) threads and install tieshaft washer (150) and tieshaft nut (140) on the turbine shaft.

b

Tighten the tieshaft nut (140) to a torque value of 120 in-lb (13.6 Nm) using PN 834890-1 adapter.

Use depth micrometer to measure Dimension U and make sure the unstretched value of Dimension U is within ±0.009 inch (0.23 mm) of Dimension U written in ASSEMBLY-02, Step 5.A.(3)(b)1. Check Point 250:

3

Make sure Dimension U is same as written during assembly of rotating group.

Stretch the turbine shaft as follows: WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY PRESSURE SLOWLY, TIGHTEN THE NUT OFTEN, DECREASE THE PRESSURE AND THREAD THE TOOL CENTER FURTHER ON THE SHAFT.

4

a

Install PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit. Stretch the turbine shaft (120) to actual load as written in ASSEMBLY 02, Step 5.A.(3)(c)1 bASSEMBLY 02, Step 5.A.(3)(c)1 b.

b

Tighten tieshaft nut (140) hand tight.

c

Remove PN 834889-1 stretch shaft tool and PN 834740-2 shaft stretch kit.

Use a depth micrometer to measure Dimension S and make sure the stretched value of Dimension S is within ±0.002 inch (0.05 mm) of Dimension S written in ASSEMBLY-02, Step 5.A.(3)(c)5.

UP552142

Check Point 260:

EFFECTIVITY ALL

Make sure Dimension S is same as written during assembly of rotating group.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10046. Install Bearing Retainer Assembly and Oil Tubes

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10046 10. BOLT (IPC FIG. 19)

100. FLARELESS FITTING

20. EXHAUST CAP

110. NUT

25. AFT BRG SUPPLY TUBE (IPC FIG. 2)

120. BEARING RETAINER ASSY

30. BOLT (IPC FIG. 19)

-120A. BEARING RETAINER ASSY

40. SEAL WASHER

130. AFT BEARING COVER GASKET

50. NUT

-150. TIESHAFT WASHER

60. OIL TUBE RETAINER

170. TURBINE BEARING HOUSING ASSY

-60A. OIL TUBE RETAINER

-170D. TURBINE BEARING HOUSING ASSY

70. OUT TUBE ASSY

-170E. TURBINE BEARING HOUSING ASSY

-70A. OUT TUBE ASSY

-170F. TURBINE BEARING HOUSING ASSY

-70B. OUT TUBE ASSY

-250. SPRING WASHER

-70C. OUT TUBE ASSY

-270. BEARING SET

-75. GASKET

-300. TURBINE SHAFT (120, IPC FIG. 25)

80. IN TUBE ASSY

-. ITEM NOT ILLUSTRATED

90. SEAL WASHER (e)

Install bearing retainer assembly and oil tubes on the turbine bearing housing assembly as follows. (Refer to Figure 10046.) 1

Install the roller bearing outer race of bearing set (270) over the installed bearing set rollers. Make sure inside chamfer of outer race goes in first.

2

Align the hole pattern and spray aft bearing cover gasket (130) with dry -film lubricant, then install the aft bearing cover gasket (130) on the turbine bearing housing assembly (170).

3

Install PN 2025264-1 alignment pin and the bearing retainer assembly on the turbine bearing housing assembly as follows. a

(Pre SB 131-49-7597) Align the oil scavenge and pressure ports on the bearing retainer assembly (120) with the corresponding holes on the turbine bearing housing assembly (170). (Post SB 131-49-7597) Align the oil scavenge and pressure ports on the bearing retainer assembly (-120A) with the corresponding holes on the turbine bearing housing assembly (-170D, -170E, -170F).

b

(Pre SB 131-49-7597) Install the bearing retainer assembly (120) on the turbine bearing housing assembly (170).

UP552142

(Post SB 131-49-7597) Install the bearing retainer assembly (-120A) on the turbine bearing housing assembly (-170D, -170E, -170F).

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] c

(Pre SB 131-49-7597) Install PN 2025264-1 alignment pin on the bearing retainer assembly (120). Make sure the alignment pin does not touch the turbine bearing housing assembly (170). (Post SB 131-49-7597) Install PN 2025264-1 alignment pin on the bearing retainer assembly (-120A). Make sure the alignment pin does not touch the turbine bearing housing assembly (-170D, -170E, -170F).

d

(Pre SB 131-49-7597) Attach the bearing retainer assembly (120) to the turbine bearing housing assembly (170) with nuts (110). (Post SB 131-49-7597) Attach the bearing retainer assembly (-120A) to the turbine housing assembly (-170D, -170E, -170F) with nuts (110).

e

4

Tighten nuts alternately and evenly to a torque value of 50 in-lbs (5.65 Nm) so turbine bearing housing assembly provides even compression of the spring washer (250).

Install the oil tubes on the turbine bearing housing assembly as follows: a

(Pre SB 131-49-7597) Install the seal washers (90) on the bearing retainer assembly (120) oil tube bosses.

b

(Pre SB 131-49-7597) Install the out tube assembly (70) and in tube assembly (80) on the installed seal washers (90). (Post SB 131-49-7597/49-7953) Apply jointing compound Hylomar PL32L or PL32M or PL32H to threads on the out tube assembly (-70A or -70B). (Post SPB D20181000017) Apply jointing compound Hylomar PL32L or PL32M or PL32H to threads on the out tube assembly (-70C). (Post SB 131-49-7597) Install the out tube assembly (-70A) on turbine bearing retainer (-120A). Install all the tube assembly (refer to 49-20-00, Installation 31, Figure 4001, Sheet 3, item 25A). Tighten out tube assembly to a torque value of 120 in-lbs (13.56 Nm). (Post SPB D20181000017) Apply a light film of Braycote 248 to gasket (-75) and install gasket (-75) on out tube ( -70C). Install the out tube assembly (-70C) and in tube assembly (refer to 49-20-00, Installation 31, Figure 4001, Sheet 3, item 25A). Tighten out tube assembly to a torque value of 320 in-lbs (36.16 Nm).

UP552142

(Post SB 131-49-7953) Apply a light film of Braycote 248 to gasket (-75) and install gasket (-75) on out tube (-70B). Install the out tube assembly (-70B) and in tube assembly (refer to 49-20-00, Installation 31, Figure 4001, Sheet 3, item 25A).

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Tighten out tube assembly to a torque value of 320 in-lbs (36.16 Nm). c

(Pre SB 131-49-7597) Install oil tube retainer (60) and nut (50). (Post SB 131-49-7597) Install oil tube retainer (-60A) and nut (50).

5

6

d

Tighten nut (50) to a torque value of 60 in-lb (6.78 Nm).

e

(Pre SB 131-49-7597) Attach the out tube assembly (70) and in tube assembly (80) with seal washers (40) and bolts (30).

f

Tighten bolts (30) to a torque value of 60 in-lb (6.78 Nm).

Install the exhaust cap on the turbine bearing housing assembly as follows: a

Align the hole pattern and install the exhaust cap (20) on the turbine bearing housing assembly (170).

b

Attach the exhaust cap (20) with bolts (10). Tighten bolts to a torque value of 60 in-lb (6.78 Nm).

Install flareless fitting (100) on the turbine housing assembly (170). a

UP552142

7

EFFECTIVITY ALL

Tighten flareless fitting to a torque value of 40 in-lb (4.52 Nm).

Connect aft bearing supply tube (25) to in tube assembly (80).

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10047. Install Eductor Housing Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10047 10. NUT (IPC FIG. 18)

30. EDUCTOR HOUSING ASSY

20. BOLT

40. POWER SECTION ASSY

(26)

Install eductor housing assembly (30) on the power section assembly (40) as follows. (Refer to Figure 10047.) (a)

Install the eductor housing assembly (30) on the power section assembly (40).

NOTE:

Align educator housing drain boss with the aft bearing oil return tube port located on the power section assembly (40). 1

Attach with bolts (20) and nuts (10). Tighten bolts to a torque value of 60 in-lb (6.8 Nm). Check Point 270:

UP552142

(b)

EFFECTIVITY ALL

Make sure completeness of assembly and freedom of rotation of the rotating group.

Rotate power section assembly (40) 180 degrees on portable stand assembly in preparation for gearbox installation.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10048. Install the Side Blankets on the Power Section Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10048 20. SIDE BLANKET (IPC FIG. 17)

40. SIDE BLANKET

30. SIDE BLANKET

50. POWER SECTION ASSY

(27)

Install the side blankets on the power section as follows. (Refer to Figure 10048.)

UP552142

CAUTION:

EFFECTIVITY ALL

LOCKWIRE MUST NOT BE INSTALLED ON THE SECTION SHOWN ON FIGURE 10049, LOCKWIRE IN THIS SECTION CAN CAUSE DAMAGE TO THE FUEL MANIFOLD.

(a)

Lockwire side blanket (40) to side blanket (30) per NASM33540 using lockwire MS20995C20.

(b)

Lockwire the assembled side blankets (30, 40) to side blanket (20) per NASM33540 using lockwire MS20995C20.

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10049. Lockwire Location Damaging Fuel Manifold

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

Figure 10050. Install the Fuel Nozzles on the Power Section Assembly

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] Key to Figure 10050 10. PIN (IPC FIG. 22)

50. GASKET

20. LOCKING PLATE

60. FUEL NOZZLE AIR SHROUD

30. BOLT

180. POWER SECTION ASSY

40. FUEL NOZZLE (28)

Install the fuel nozzles on the power section assembly (180) as follows. (Refer to Figure 10050.) WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CHEMICAL. (a)

Apply anti-seize compound (C5-A Copper Based) to the threads of bolts (30).

(b)

Install new gasket (50), fuel nozzle air shroud (60) and fuel nozzle (40) into the power section assembly (180).

CAUTION:

(c)

MAKE SURE THAT THE ALIGNMENT HOLE IN THE NOZZLE SHROUD IS CORRECTLY CENTERED OVER THE ALIGNMENT PIN ON THE FUEL NOZZLE. IF THE NOZZLE SHROUD IS INCORRECTLY INSTALLED ON THE FUEL NOZZLE, IT WILL CAUSE POSSIBLE APU SMOKING AND ENGINE DAMAGE.

Attach fuel nozzle assembly to the combustor case with bolts (30). Gradually tighten each of the two bolts (30) on the fuel nozzle assembly to apply even crush pressure on the gasket (50). Tighten the bolts to 50 in-lb (5.6 Nm). NOTE:

UP552142

(d)

EFFECTIVITY ALL

If necessary, bolts (30) can be tightened up to 70 in-lb (7.9 Nm) to align with pin (10) and locking plate (20).

Install locking plate (20), on bolts (30) and attach with pins (10).

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ENGINE MANUAL 131-9[B]

UP552142

Blank Page

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

TASK AND SUBTASK INDEX 49-20-00 FAULT ISOLATION TASK

49-20-00-810-801

Fault Isolation - General

SUBTASK

49-20-00-810-001

Fault Isolation - Procedure

SUBTASK

49-20-00-810-002

Electronic Control Unit (ECU) power-up

SUBTASK

49-20-00-810-003

APU starting

SUBTASK

49-20-00-810-004

APU shutdown

SUBTASK

49-20-00-810-005

Electronic Control Unit (ECU) BITE check

SUBTASK

49-20-00-810-006

APU loading

TASK

49-20-00-000-801

Removal - General

SUBTASK

49-20-00-540-001

Remove APU from shipping container

SUBTASK

49-20-00-410-001

Install APU on portable engine stand/cart

SUBTASK

49-20-00-600-001

Drain oil

TASK

49-20-00-050-801

Remove plumbing and electrical installation - General

SUBTASK

49-20-00-050-002

Remove plumbing and electrical installation - Procedure

TASK

49-20-00-050-802

Remove Starter/Generator - General

SUBTASK

49-20-00-050-003

Remove Starter/Generator - Procedure

TASK

49-20-00-050-803

Remove low oil pressure switch - General

SUBTASK

49-20-00-050-004

Remove low oil pressure switch - Procedure

TASK

49-20-00-050-804

Remove oil level sensor - General

SUBTASK

49-20-00-050-005

Remove oil level sensor - Procedure

TASK

49-20-00-050-805

Remove fuel control unit - General

SUBTASK

49-20-00-050-006

Remove fuel control unit - Procedure

TASK

49-20-00-050-806

Remove lube module - General

SUBTASK

49-20-00-050-007

Remove lube module - Procedure

TASK

49-20-00-050-807

Remove data memory module - General

SUBTASK

49-20-00-050-008

Remove data memory module - Procedure

TASK

49-20-00-050-808

Remove bleed duct assembly - General

SUBTASK

49-20-00-050-009

Remove bleed duct assembly - Procedure

TASK

49-20-00-050-809

Remove bleed air valve - General

SUBTASK

49-20-00-050-010

Remove bleed air valve - Procedure

TASK

49-20-00-050-810

Remove compressor discharge duct - General

SUBTASK

49-20-00-050-011

Remove compressor discharge duct - Procedure

UP552142

REMOVAL

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

49-20-00 TASK

49-20-00-050-811

Remove total pressure probe assembly - General

SUBTASK

49-20-00-050-012

Remove total pressure probe assembly - Procedure

TASK

49-20-00-050-812

Remove surge control valve- General

SUBTASK

49-20-00-050-013

Remove surge control valve - Procedure

TASK

49-20-00-050-813

Remove surge duct assembly - General

SUBTASK

49-20-00-050-014

Remove surge duct assembly - Procedure

TASK

49-20-00-050-814

Remove speed sensor - General

SUBTASK

49-20-00-050-015

Remove speed sensor - Procedure

TASK

49-20-00-050-815

Remove inlet pressure sensor - General

SUBTASK

49-20-00-050-016

Remove inlet pressure sensor - Procedure

TASK

49-20-00-050-816

Remove total pressure sensor - General

SUBTASK

49-20-00-050-017

Remove total pressure sensor - Procedure

TASK

49-20-00-050-817

Remove differential pressure sensor - General

SUBTASK

49-20-00-050-018

Remove differential pressure sensor - Procedure

TASK

49-20-00-050-818

Remove inlet temperature sensor - General

SUBTASK

49-20-00-050-019

Remove inlet temperature sensor - Procedure

TASK

49-20-00-050-819

Remove igniter plug - General

SUBTASK

49-20-00-050-020

Remove igniter plug - Procedure

TASK

49-20-00-050-820

Remove igniter plug lead - General

SUBTASK

49-20-00-050-021

Remove igniter plug lead - Procedure

TASK

49-20-00-050-821

Remove ignition unit - General

SUBTASK

49-20-00-050-022

Remove ignition unit - Procedure

TASK

49-20-00-050-822

Remove exhaust gas temperature thermocouple - General

SUBTASK

49-20-00-050-023

Remove exhaust gas temperature thermocouple - Procedure

TASK

49-20-00-050-823

Remove combustor case drain plug - General

SUBTASK

49-20-00-050-024

Remove combustor case drain plug - Procedure

TASK

49-20-00-050-824

Remove inlet guide vane actuator - General

SUBTASK

49-20-00-050-025

Remove inlet guide vane actuator - Procedure

TASK

49-20-00-050-825

Remove access door - General

SUBTASK

49-20-00-050-026

Remove access door - Procedure

TASK

49-20-00-050-826

Remove identification plate - General

SUBTASK

49-20-00-050-027

Remove identification plate - Procedure

TASK

49-20-00-050-827

Remove fuel manifold assembly- General

SUBTASK

49-20-00-050-028

Remove fuel manifold assembly - Procedure

TASK

49-20-00-050-828

Remove oil cooler - General

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B] 49-20-00 SUBTASK

49-20-00-050-029

Remove oil cooler - Procedure

TASK

49-20-00-050-829

Remove temperature control valve - General

SUBTASK

49-20-00-050-030

Remove temperature control valve - Procedure

TASK

49-20-00-050-830

Remove upper and lower inlet duct - General

SUBTASK

49-20-00-050-031

Remove upper and lower inlet duct - Procedure

TASK

49-20-00-020-801

Remove gearbox assembly - General

SUBTASK

49-20-00-020-001

Remove gearbox assembly - Procedure

TASK

49-20-00-400-801

Installation - General

SUBTASK

49-20-00-410-001

Install APU on run and transport cart - Procedure

TASK

49-20-00-450-802

Install fuel manifold assembly - General

SUBTASK

49-20-00-450-002

Install fuel manifold assembly - Procedure

TASK

49-20-00-450-803

Install access door - General

SUBTASK

49-20-00-450-003

Install access door - Procedure

TASK

49-20-00-450-804

Install inlet guide vane actuator (IGVA) - General

SUBTASK

49-20-00-450-004

Install inlet guide vane actuator (IGVA) - Procedure

TASK

49-20-00-450-805

Install upper and lower inlet duct - General

SUBTASK

49-20-00-450-005

Install upper and lower inlet duct - Procedure

TASK

49-20-00-450-806

Install differential pressure sensor (DP) - General

SUBTASK

49-20-00-450-006

Install differential pressure sensor (DP) - Procedure

TASK

49-20-00-450-807

Install total pressure sensor (PT) - General

SUBTASK

49-20-00-450-007

Install total pressure sensor (PT) - Procedure

TASK

49-20-00-450-808

Install inlet pressure sensor (P2) - General

SUBTASK

49-20-00-450-008

Install inlet pressure sensor (P2) - Procedure

TASK

49-20-00-450-809

Install inlet temperature sensor (T2) - General

SUBTASK

49-20-00-450-009

Install inlet temperature sensor (T2) - Procedure

TASK

49-20-00-450-810

Install speed sensor - General

SUBTASK

49-20-00-450-010

Install speed sensor - Procedure

TASK

49-20-00-450-811

Install oil cooler - General

SUBTASK

49-20-00-450-011

Install oil cooler - Procedure

TASK

49-20-00-450-812

Install exhaust gas temperature (EGT) thermocouple - General

SUBTASK

49-20-00-450-012

Install exhaust gas temperature (EGT) thermocouple - Procedure

TASK

49-20-00-420-813

Install gearbox assembly - General

SUBTASK

49-20-00-420-013

Install gearbox assembly - Procedure

TASK

49-20-00-450-814

Install lube module - General

UP552142

INSTALLATION

EFFECTIVITY ALL

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ENGINE MANUAL 131-9[B]

UP552142

49-20-00 SUBTASK

49-20-00-450-014

Install lube module - Procedure

TASK

49-20-00-450-815

Install temperature control valve - General

SUBTASK

49-20-00-450-015

Install temperature control valve - Procedure

TASK

49-20-00-450-816

Install oil level sensor - General

SUBTASK

49-20-00-450-016

Install oil level sensor - Procedure

TASK

49-20-00-450-817

Install low oil pressure (LOP) switch - General

SUBTASK

49-20-00-450-017

Install low oil pressure (LOP) switch - Procedure

TASK

49-20-00-450-818

Install fuel control unit (FCU) - General

SUBTASK

49-20-00-450-018

Install fuel control unit (FCU) - Procedure

TASK

49-20-00-450-819

Install starter/generator - General

SUBTASK

49-20-00-450-019

Install starter/generator - Procedure

TASK

49-20-00-450-820

Install data memory module (DMM) - General

SUBTASK

49-20-00-450-020

Install data memory module (DMM) - Procedure

TASK

49-20-00-450-821

Install total pressure probe assembly - General

SUBTASK

49-20-00-450-021

Install total pressure probe assembly - Procedure

TASK

49-20-00-450-822

Install surge control valve (SCV) - General

SUBTASK

49-20-00-450-022

Install surge control valve (SCV) - Procedure

TASK

49-20-00-450-823

Install compressor discharge duct - General

SUBTASK

49-20-00-450-023

Install compressor discharge duct - Procedure

TASK

49-20-00-450-824

Install bleed air valve (BAV) - General

SUBTASK

49-20-00-450-024

Install bleed air valve (BAV) - Procedure

TASK

49-20-00-450-825

Install bleed duct assembly - General

SUBTASK

49-20-00-450-025

Install bleed duct assembly - Procedure

TASK

49-20-00-450-826

Install surge duct assembly - General

SUBTASK

49-20-00-450-026

Install surge duct assembly - Procedure

TASK

49-20-00-450-827

Install igniter plug - General

SUBTASK

49-20-00-450-027

Install igniter plug - Procedure

TASK

49-20-00-450-828

Install ignition unit - General

SUBTASK

49-20-00-450-028

Install ignition unit - Procedure

TASK

49-20-00-450-829

Install igniter plug lead - General

SUBTASK

49-20-00-450-029

Install igniter plug lead - Procedure

TASK

49-20-00-450-830

Install combustor case drain plug - General

SUBTASK

49-20-00-450-030

Install combustor case drain plug - Procedure

TASK

49-20-00-450-831

Install plumbing and electrical installation - General

SUBTASK

49-20-00-450-031

Install plumbing and electrical installation - Procedure

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

ASSEMBLY 06 Page 10004 18 Dec 2019

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ENGINE MANUAL 131-9[B] 49-20-00 TASK

49-20-00-450-832

Install identification plate - General

SUBTASK

49-20-00-450-032

Install identification plate - Procedure

TASK

49-20-00-400-833

Final installation - General

SUBTASK

49-20-00-210-001

Perform general final checks

SUBTASK

49-20-00-600-002

Service the APU with oil

SUBTASK

49-20-00-550-003

Install caps and covers for storage

SUBTASK

49-20-00-400-001

Install warning tags

49-20-00-100-801

Cleaning - General

TASK

49-20-00-610-801

Servicing- General

SUBTASK

49-20-00-610-001

Drain oil

SUBTASK

49-20-00-610-002

Oil servicing

TASK

49-20-00-620-801

Preservation - General

SUBTASK

49-20-00-620-001

Preserve APU - Procedure

TASK

49-20-00-550-801

Storage - General

SUBTASK

49-20-00-550-001

Refer to Service Bulletin 49-7997

TASK

49-20-00-760-801

Testing- General

SUBTASK

49-20-00-480-001

Prepare APU for testing

SUBTASK

49-20-00-760-001

Perform an APU run-in procedure

SUBTASK

49-20-00-210-002

Perform a check of the oil system

SUBTASK

49-20-00-760-002

Performance tests

SUBTASK

49-20-00-760-003

Perform a flow sensor test

SUBTASK

49-20-00-760-004

Perform a surge control valve (SCV) stability test

SUBTASK

49-20-00-760-005

Perform a minimum surge margin test

SUBTASK

49-20-00-760-006

Perform four consecutive automatic start tests

SUBTASK

49-20-00-760-007

Perform load cycle tests

SUBTASK

49-20-00-820-001

Data corrections

SUBTASK

49-20-00-790-001

Perform a leak check

SUBTASK

49-20-00-210-003

Perform a check of the magnetic chip collector

SUBTASK

49-20-00-820-002

Adjust the ECS offset in the data memory module

SUBTASK

49-20-00-760-008

Start the APU

CLEANING TASK SERVICING

STORAGE

UP552142

TESTING

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

ASSEMBLY 06 Page 10005 18 Dec 2019

RELEASED FOR THE EXCLUSIVE USE BY: SPICEJET LTD

ENGINE MANUAL 131-9[B]

UP552142

49-20-00 SUBTASK

49-20-00-760-009

Stop the APU

SUBTASK

49-20-00-760-010

APU motor (electric starter motor)

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

ASSEMBLY 06 Page 10006 18 Dec 2019

RELEASED FOR THE EXCLUSIVE USE BY: SPICEJET LTD

ENGINE MANUAL 131-9[B] 49-21-00 DISASSEMBLY TASK

49-21-00-030-801

Disassemble gearbox assembly - General

SUBTASK

49-21-00-030-001

Disassemble gearbox assembly - Procedure

TASK

49-21-00-100-801

Cleaning - General

TASK

49-21-00-110-801

Clean magnetic drain plug - General

SUBTASK

49-21-00-110-001

Clean magnetic drain plug - Procedure

TASK

49-21-00-110-802

Clean gearbox housing - General

SUBTASK

49-21-00-160-001

Prepare alkaline cleaner solution - Procedure

SUBTASK

49-21-00-110-002

Clean gearbox housing - Procedure

TASK

49-21-00-440-801

Assemble gearshafts - General

SUBTASK

49-21-00-440-001

Assemble high speed pinion gear - Procedure

SUBTASK

49-21-00-440-002

Assemble lube pump gear - Procedure

SUBTASK

49-21-00-440-003

Assemble generator gearshaft - Procedure

SUBTASK

49-21-00-440-004

Assemble cluster gearshaft - Procedure

TASK

49-21-00-430-801

Assemble gearbox assembly - General

SUBTASK

49-21-00-430-001

Assemble gearbox assembly - Procedure

CLEANING

UP552142

ASSEMBLY

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

ASSEMBLY 06 Page 10007 18 Dec 2019

RELEASED FOR THE EXCLUSIVE USE BY: SPICEJET LTD

ENGINE MANUAL 131-9[B] 49-22-00 DISASSEMBLY TASK

49-22-00-420-801

Install power section assembly in portable engine stand/cart - General

SUBTASK

49-22-00-420-001

Install power section assembly in portable engine stand/cart Procedure

TASK

49-22-00-030-801

Disassemble power section assembly - General

SUBTASK

49-22-00-030-001

Disassemble power section assembly - Procedure

TASK

49-22-00-040-801

Disassemble inlet guide vane assembly - General

SUBTASK

49-22-00-040-001

Disassemble inlet guide vane assembly - Procedure

TASK

49-22-00-040-802

Disassemble first stage stator assembly - General

SUBTASK

49-22-00-040-002

Disassemble first stage stator assembly - Procedure

49-22-00-100-801

Cleaning - General

TASK

49-22-00-440-801

Assemble inlet guide vane assembly - General

SUBTASK

49-22-00-440-001

Assemble inlet guide vane assembly - Procedure

TASK

49-22-00-820-801

Assemble, balance and align rotating group assembly -General

SUBTASK

49-22-00-440-002

Assemble rotating group assembly - Procedure

SUBTASK

49-22-00-820-001

Balance rotating group assembly - Procedure

SUBTASK

49-22-00-820-002

Align runout of rotating group assembly - Procedure

SUBTASK

49-22-00-040-001

Disassemble rotating group assembly - Procedure

TASK

49-22-00-440-802

Assemble diffuser housing assembly - General

SUBTASK

49-22-00-440-003

Assemble diffuser housing assembly - Procedure

TASK

49-22-00-440-803

Assemble first stage stator assembly - General

SUBTASK

49-22-00-440-004

Assemble first stage stator assembly - Procedure

TASK

49-22-00-440-804

Assemble second stage stator assembly - General

SUBTASK

49-22-00-440-005

Assemble second stage stator assembly - Procedure

TASK

49-22-00-430-801

Assemble power section assembly - General

SUBTASK

49-22-00-430-001

Assemble power section assembly - Procedure

CLEANING TASK

UP552142

ASSEMBLY

EFFECTIVITY ALL

49-26-95 © Honeywell International Inc. Do not copy without express permission of Honeywell.

ASSEMBLY 06 Page 10008 18 Dec 2019