40C11-1_APU_EM_49-00-00_R11

DOCUMENT 40C11-1

ENGINE MANUAL AUXILIARY POWER UNIT (APU) MODEL NUMBER T-62T-40C11 PART NUMBER 4501966 © 1993, 1995, 1997, 2001 - 2004, 2007 Hamilton Sundstrand Corporation

NOTICE THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION (HSC). RECIPIENT AGREES TO HOLD ALL SUCH INFORMATION IN CONFIDENCE AND AGREES IT SHALL BE USED ONLY FOR RECIPIENT’S INTERNAL PURPOSES TO MAINTAIN RECIPIENT’S EQUIPMENT OR AS MAY OTHERWISE BE PERMITTED IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND HSC. THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN SHALL NOT BE USED FOR ANY OTHER PURPOSE, INCLUDING THE CREATION, MANUFACTURE, DEVELOPMENT, OR DERIVATION OF ANY REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGN, OR CONFIGURATION CHANGES, OR TO OBTAIN FAA OR ANY OTHER GOVERNMENT OR REGULATORY APPROVAL FOR SAME. RECIPIENT AGREES NOT TO DISCLOSE SUCH INFORMATION TO ANY THIRD PARTY, EXCEPT AS MAY OTHERWISE BE PROVIDED FOR IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND HSC. COPYING OR DISCLOSURE OF THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN BY ANYONE WITHOUT HSC’S PRIOR WRITTEN PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY.

INFORMATION SUBJECT TO EXPORT CONTROL LAWS THE TECHNICAL DATA IN THIS DOCUMENT (OR FILE) IS CONTROLLED FOR EXPORT UNDER THE EXPORT ADMINISTRATION REGULATIONS (EAR), 15 SFR PARTS 730-774, 9A991, VIOLATIONS OF THESE LAWS MAY BE SUBJECT TO FINES AND PENALTIES UNDER THE EXPORT ADMINISTRATION ACT.

NOTICE THE DATA IN THIS DOCUMENT WERE DEVELOPED ONLY TO MAINTAIN SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. THE DATA MAY NOT BE APPLICABLE TO ANY OTHER SYSTEMS AND/OR PARTS, REGARDLESS OF THEIR APPARENT SIMILARITY TO SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. DO NOT RELY IN ANY WAY ON DATA IN THIS DOCUMENT TO MAINTAIN OR OTHERWISE SUPPORT SYSTEMS AND/OR PARTS THAT WERE NOT MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND WITHOUT EVIDENCE THAT THE FEDERAL AVIATION ADMINISTRATION OR OTHER REGULATORY AGENCY HAS DETERMINED THAT THE DATA IN THIS DOCUMENT IS VALID FOR SUCH USE.

TITLE PAGE, 1 ORIGINAL ISSUE JUN 30/99 REVISION 11 NOV 15/07

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TITLE PAGE Page 2 MAY 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES TO:

Holders of Document 40C11-1 (Engine Manual), Hamilton Sundstrand Auxiliary Power Unit (APU), Part Number 4501966, Model Number T-62T-40C11, used on Embraer ERJ 145 and 135 aircraft. Revision 11, dated November 15, 2007 HIGHLIGHTS

Shown below are highlights of the significant changes and the affected pages contained in this revision. Remove the used affected pages and put the new affected pages into the manual as shown in the List of Effective Pages. We recommend that you put this revision into your manual without delay. Mark the Record of Revisions sheet with the new revision number and date, and write your initials on the Record of Revisions sheet in the appropriate spaces after you have put the revised pages in your manual. If you have any questions about this revision, please contact Technical Publications by telephoning (858) 627-6000, FAX: (858) 627-6677, or write Hamilton Sundstrand Power Systems, Technical Publications Department 374-S-1, 4400 Ruffin Road, P.O. Box 85757, San Diego, California 921865757. Page Number

Description of Change

Title, Page 1

Revised for Revision 11.

Safety Advisory, Page 7

Updated.

Record of Temporary Revisions, Page 1

Updated.

Service Bulletin List, Pages, 1, 3, 4, 5, 6, 7, 8

Updated.

List of Effective Pages, Pages 1, 2, 3, 4, 5

Updated.

Introduction, Page 1

Revised reference to Standard Practices Manual.

Page 5

Corrected specification for dry cleaning solvent.

49-00-00 Operational Check, Page 202

Incorporated TR 49-4.

Removal/Installation, 302

Corrected specification for isopropyl alcohol.

Page 318

Added removal/installation instructions (SB-49-189).

Pages 319 to 329

Text moved (no technical changes). HIGHLIGHTS Page 1 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Page Number

Description of Change

Pages 330 and 331

Added removal/installation instructions for start fuel nozzle holder assemblies (SB-49-181 and SB-49-191).

Pages 332 to 344

Text moved (no technical changes).

Cleaning, Page 601

Corrected specification for isopropyl alcohol and dry cleaning solvent.

Pages 605 and 606

Correct metric equivalent of pressure in the compressed air warnings.

Inspection/Check, Pages 803, 804, and 806

Added new inspections to Figure 801 (SOH99086R4) (RDE06011R1) (RDE07036).

Page 805

Text moved (no technical changes).

Pages 806A and 806B

Added pages.

49-20-00 Disassembly, Page 504

Added disassembly instructions related to clamps and attaching parts (SB-49-181 and SB-49-191).

Page 505

Added disassembly instructions for start fuel nozzle tube assemblies (SB-49-181 and SB-49-191).

Pages 506 to 509

Text moved (no technical changes).

Page 510

Added disassembly instructions for start fuel nozzle holder assemblies (SB-49-181 and SB-49-191).

Pages 511 and 512

Text moved (no technical changes).

Assembly, Page 1001

Corrected specification for isopropyl alcohol.

Page 1010

Text moved (no technical changes).

Pages 1011 and 1012

Added assembly instructions for start fuel nozzle holder assemblies (SB-49-181 and SB-49-191).

Pages 1013 to 1022

Text moved (no technical changes).

Page 1023

Added assembly instructions for start fuel nozzle tube assemblies, related clamps, and attaching parts (SB-49-181 and SB-49-191).

Pages 1024 to 1032

Text moved (no technical changes).

Storage, Page 1201 Page 1206

Revised paragraphs 1. and 2. to include depreservation. Added a procedure for depreservation of the APU from storage (TOH04004).

Testing, Page 1301

Added an alternate fuel (SOH06128R1).

Page 1317

Corrected equation in step 7.C.(4) (PAR SM062005) (SOH05163).

HIGHLIGHTS Page 2 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Page Number

Description of Change

49-23-00 Assembly, Page 1001

Corrected specification for isopropyl alcohol.

The following Action Items (AIs) have been incorporated into this revision: AIs

Location

RDE06011R1

49-00-00, Inspection/Check

RDE07036

49-00-00, Inspection/Check

SOH05163

49-20-00, Testing

SOH06128R1

49-20-00, Testing

SOH99086R4

49-00-00, Inspection/Check

TOH04004

49-20-00, Storage

HIGHLIGHTS Page 3 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

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HIGHLIGHTS Page 4 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES SAFETY ADVISORY 1.

Scope A.

2.

3.

This publication describes processes that may require the use of chemicals, solvents, paints, or other materials that can affect a person’s health or safety. It may also cover high energy procedures that can affect a person’s health or safety. Warnings are placed just ahead of these procedures to bring attention to the existence of a procedure or material that can be dangerous.

Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS WARNING:

BEFORE USING ANY OF THE MATERIALS SPECIFIED IN HAMILTON SUNDSTRAND MAINTENANCE PUBLICATIONS, BE AWARE OF ALL HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH MANUFACTURER'S OR SUPPLIER'S RECOMMENDATIONS MAY RESULT IN PERSONAL INJURY OR DISEASE.

WARNING:

THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL SAFETY DATA SHEETS (OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) FORM 20 OR EQUIVALENT) FROM THE MANUFACTURERS OR SUPPLIERS OF MATERIALS TO BE USED. THE USER MUST BECOME COMPLETELY FAMILIAR WITH THE MANUFACTURER OR SUPPLIER INFORMATION AND ADHERE TO THE PROCEDURES, RECOMMENDATIONS, WARNINGS, AND CAUTIONS OF THE MANUFACTURER OR SUPPLIER FOR THE SAFE USE, HANDLING, STORAGE, AND DISPOSAL OF THESE MATERIALS.

A.

Refer to the materials list at the beginning of each section of this manual for materials used to repair and maintain the covered equipment.

B.

If you do not have a copy of the manufacturer’s MSDS for the materials covered in the materials list, contact the manufacturer and request that a MSDS be supplied before you use the material.

Purpose A.

The warnings bring your attention to the existence of a procedure that can affect a person’s health or safety.

B.

Short warnings are provided in this maintenance publication to alert operating and maintenance personnel of potential hazards that could result in personal injury or health hazards. The warnings do not replace the manufacturer's recommendations. When there is a reference to the Warnings Registry 341-006, that publication will provide more information about the dangers of the material. The information contained in the Warnings Registry is a summary of the manufacturer’s MSDS. The full-length warnings provide three principle parts of safety: (1) a listing of the known dangers, (2) what is needed to do to protect you from the dangers, and (3) what to do if the dangers occur. New Safety Advisory for Sustaining Manuals Figure 1 (Sheet 1 of 2)

SAFETY ADVISORY Page 1 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

4.

5.

C.

The detailed warnings in Warnings Registry 341-006 are a summary of the manufacturer’s MSDS and are not intended to replace the material on the sheet, but are intended to supplement them.

D.

Cautions are provided in the maintenance publication or service bulletin to alert operating and maintenance personnel to conditions that could result in equipment damage.

Definitions Applying to Warnings A.

Flammable: a material that can catch fire easily and can be explosive. These materials are labeled according to the flash point of the material.

B.

Flash Point: the lowest temperature at which a flammable liquid gives off fumes that can burn.

C.

Ignition Source: includes flames, sparks, or heat. (1)

Flames: materials that are burning such as lit matches, propane torches, or pilot lights.

(2)

Sparks: materials such as lighted cigarettes, electrical motors, or static electricity.

(3)

Heat: any source of energy that will raise the temperature of a flammable material to its flash point and could include hot parts, heated tools, or direct sunlight.

D.

Corrosive: acidic or alkaline material that will remove human tissue or create chemical reactions with other materials.

E.

Toxic: material that is poisonous.

F.

Reactive: material that will make fumes, burn, or can be explosive when mixed with certain other materials.

G.

Shock (Electrical): the result of any source of electricity more than 50 volts that causes current to flow through a person and can result in dangerous burns to human tissues or death.

H.

Exposure: contact with the material or physical process without protection. Contact may be by the eyes, breathing, touch, skin absorption, or swallowing.

I.

Irritation: any sense of pain, soreness, rash, or general discomfort.

Reporting Materials or Processes Not Covered A.

Please call (858) 627-6000, FAX (858) 627-6677, or write to Hamilton Sundstrand, Technical Publications, Department 374, 4400 Ruffin Road, P.O. Box 85757, San Diego, CA 92186-5757, if you find a material in a Hamilton Sundstrand maintenance document that is known to be covered by a material data safety sheet (MSDS) but is not covered by a warning in the procedure. New Safety Advisory for Sustaining Manuals Figure 1 (Sheet 2 of 2)

SAFETY ADVISORY Page 2 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES This Safety Advisory has all the WARNINGS included in this manual. WARNING: MAKE SURE YOU FOLLOW ALL OF THE MANUFACTURER'S OR SUPPLIER'S INSTRUCTIONS WHEN YOU USE THE MATERIALS SPECIFIED IN THIS MANUAL. FAILURE TO OBEY MANUFACTURE'S OR SUPPLIER'S INSTRUCTIONS CAN CAUSE INJURY OR DISEASE. WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. TO AVOID INJURY, BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED. WARNING: MAKE SURE ELECTRICAL POWER SUPPLY IS REMOVED FROM THE APU. ENERGIZED CIRCUITS CAN CAUSE INJURY TO PERSONS. WARNING:

DO NOT TOUCH THE COMPONENTS OF THE OIL SYSTEM IF THE APU IS HOT. THESE COMPONENTS STAY HOTTER THAN OTHER COMPONENTS. HOT COMPONENTS CAN BURN YOU.

WARNING: HOT OIL MAY CAUSE BURNS TO EYES AND SKIN. PUT ON SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION. WARNING: DO NOT LET THE OIL STAY ON YOUR SKIN. YOU CAN ABSORB POISONOUS MATERIALS FROM THE OIL THROUGH YOUR SKIN. WARNING: OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN USING CONSUMABLES. TO AVOID INJURY, WEAR NECESSARY PROTECTIVE GEAR DURING HANDLING AND USE. MAKE CERTAIN CONSUMABLES AND THEIR VAPORS ARE KEPT AWAY FROM HEAT, SPARK, AND FLAME. WARNING: USE LOCQUIC PRIMER GRADE N OR T, CORRECTLY. THE PRIMER IS FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE PRIMER, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0135SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE PRIMER, PUT ON CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES (BUTYL RUBBER). MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE PRIMER FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE) CORRECTLY. THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE DRY ICE, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0088SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE DRY ICE, PUT ON INSULATED GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. SAFETY ADVISORY Page 3 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS. WARNING: LIQUID NITROGEN WILL FREEZE SKIN INSTANTLY. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT. PUT ON SPLASH GOGGLES AND INSULATED GLOVES. IN CASE OF SKIN CONTACT SEEK MEDICAL ATTENTION. IN CASE OF EYE CONTACT, SEEK MEDICAL ATTENTION. WARNING: TO AVOID INJURY, STAY CLEAR OF ENERPAC RAM DURING STRETCHING PROCEDURE. DO NOT USE STRETCH ROD (ST78693-02) IF THE 400 CYCLE LIMIT IS ACHIEVED. WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICALSPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING EXHAUST DEPOSITS INTO OPEN WOUNDS. WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. WARNING: NYCOTE 7-11, NYLON VARNISH IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL VENTILATED AREA FREE FROM SPARKS, FLAME OR HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

SAFETY ADVISORY Page 4 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE CLEANING SOLVENT (ALSO KNOWN AS DRY CLEANING SOLVENT, STODDARD SOLVENT, MINERAL SPIRITS, NAPHTHA, PETROLEUM SPIRITS, MIL-PRF-680 TYPE II, ASTM D235 TYPE II, OR AMS3160) CORRECTLY. THE SOLVENT IS FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE SOLVENT, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0158SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE SOLVENT, PUT ON CHEMICALSPLASH GOGGLES, AND SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SOLVENT FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: LOCTITE 404 OR 480 ADHESIVE CAUSES INSTANT BONDING OF SKIN OR OTHER HUMAN TISSUE. USE CARE WHEN HANDLING THE ADHESIVE. USE THE ADHESIVE CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ADHESIVE, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0013SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ADHESIVE, REMOVE YOUR CONTACT LENSES. PUT ON NITRILE OR POLYETHYLENE GLOVES AND SAFETY GLASSES OR CHEMICAL SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ADHESIVE FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE LOCTITE RC640 PRIMER, CORRECTLY. THE COMPOUND IS FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0067SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

SAFETY ADVISORY Page 5 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE ANAEROBIC RETAINING COMPOUND, MIL-R-46082 CORRECTLY. THE COMPOUND IS COMBUSTIBLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0069SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND NEOPRENE, RUBBER, OR BUTYL RUBBER GLOVES. WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDESHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. WARNING: USE SILICONE ADHESIVE/SEALANT, DOW CORNING 3145, CORRECTLY. KEEP THE SEALANT AWAY FROM WATER OR MOIST AIR. THE SEALANT CAN REACT WITH WATER OR MOIST AIR TO MAKE METHYL ALCOHOL GAS. METHYL ALCOHOL GAS IS VERY FLAMMABLE AND CAN BE EXPLOSIVE. DO NOT SWALLOW THE SEALANT, IT CAN MAKE METHYL ALCOHOL THAT CAN CAUSE DEATH OR BLINDNESS. BEFORE YOU USE THE SEALANT, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0202SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE ANAEROBIC SEALANT AND LOCKING COMPOUND, MIL-S22473, CORRECTLY. THE COMPOUND IS FLAMMABLE. IT CAN HAVE A BAD EFFECT ONYOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING W0068SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND PUT ON SAFETY GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

SAFETY ADVISORY Page 6 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE MANGANESE DIOXIDE-CURED POLYSULFIDE RUBBER SEALANT PR1440 B-2, CORRECTLY. THE SEALANT CONTAINS POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE SEALANT, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0189SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES OR CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE PIPE SEALANT COMPOUND CORRECTLY. THE COMPOUND IS COMBUSTIBLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0069SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND NEOPRENE, RUBBER, OR BUTYL RUBBER GLOVES. WARNING: LUBRICANT, DRY FILM, IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES. WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

SAFETY ADVISORY Page 7 Nov 15/07

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SAFETY ADVISORY Page 8 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES RECORD OF REVISIONS REV NO.

ISSUE DATE

DATE REV ISSUE INSERTED BY NO. DATE

1

Jan 15/97

Jun 30/99

HS

2

Oct 15/97

Jun 30/99

HS

3

Jul 15/98

Jun 30/99

HS

4

Mar 1/99

Jun 30/99

HS

5

Jun30/99

Jun 30/99

HS

6

Jul 1/00

Jul 1/00

HS

7

Aug 1/01

Aug 1/01

HS

8

May 1/02

May 1/02

HS

9

Jan 15/03

Jan 15/03

HS

10

Mar 15/04

Mar 15/04

HS

11

Nov 15/07

Nov 15/07

HS

DATE REV INSERTED BY NO.

ISSUE DATE

DATE INSERTED BY

RECORD OF REVISIONS Page 1 Mar 15/04

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RECORD OF REVISIONS Page 2 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES RECORD OF TEMPORARY REVISIONS TEMPORARY REV. NO. 49-1

PAGE NUMBER Servicing 603

ISSUE DATE Apr 9/99

BY HS

DATE REMOVED Jun 30/99

BY HS

49-2

Assembly 1023

Sep 2/99

HS

Jul 1/00

HS

49-3

See below

Sep 15/03

HS

Mar 15/04

HS

Removal/ Installation Disassembly

302-305, 309, 311, 312, 318-320, 322-324 503, 505

Assembly

1001, 1016, 1019

49-4

Operational Check 202

Jul 14/04

HS

Nov 15/07

HS

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES SERVICE BULLETIN LIST SB NO.

Description

Parts Added or Changed

MOD Symbol

Serial No. Effectivity

SB-T-62T-49-58 Rev 1

Magnetic Chip Detector Inspection Procedure

All fielded Units

SB-T-62T-49-124 Rev 3

Improved Combustor Housing and Start Fuel System

924-10, 4502885B, 4502433C, 4503257, 4503258, 4503259, MS21045C3, MS51853-1SS or MS51853-2SS, 115352-1, MS21919WCJ4, MS21919WCJ2 MS21279-06

SB-T-62T-49-126

Replacement of Electronic Sequence Unit

4501973D

None

All fielded units

SB-T-62T-49-133

Introduction of Electrical Wire Harness

4502160B

Mod Dot 3

All fielded units up to S/N SPE974051

SB-T-62T-49-139

Introduction of Electrical Wire Harness Improvements

4951334-1

Mod Dot 4

All fielded units up to S/N SPE974060

SB-T-62T-49-147 Rev 1

Replacement of V-Band Clamp (Superseded by SB-T-62T-49-199)

4951327

Mod Dot 5

SP-E954001 through SP-E984134

SB-T-62T-49-149 Rev 2

Introduction of Resized Turbine Nozzle and Revised Rotor Clearances

4503900, 4502089-152

Mod Dot 6

SP-E954001 through SP-E974116

Mod Dot 1

SP-E954001 through SP-E954033

SERVICE BULLETIN LIST Page 1 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES SB NO.

Description

Parts Added or Changed

MOD Symbol

Serial No. Effectivity

SB-T-62T-49-150

Performance Upgrade

115352-4, 4503958, 4950745, 4504051, 4503552, 4503551, 4504270, 4504050, 4501984B

Mod Dot 7

SP-E954001 through SP-E984116

SB-T-62T-49-151

Introduction of New Reduction Drive Assembly

4501979, 4501979B, 4503225, 4950254, 4951153, 4503363-1, 4951154, 4503293, 4503226

Mod Dot 8

SP-E954001 through SP-E984129

SB-T-62T-49-152 Rev 1

Improves High Altitude Starting

4503259, 4504160, 4504270, 4504401, 4951439, 924-019, MS21279-06, MS21279-08, MS21919WCJ2, MS51853-2SS

Mod Dot 9

SP-E954001 through SP-E994215

SB-T-62T-49-155

Introduction of Improved Acceleration Control Assembly

4504015

Mod Dot 14

SP-E954001 through SP-E994234

SB-T-62T-49-156 Rev 1

Introduction of New Fuel Pump

4951545

Mod Dot 15

SP-E954001 through SP-E994231

SB-T-62T-49-157

Reinforced Combustor Liner with Improved Airflow and Lower Operating Temperatures

4503552A

Mod Dot 12

SP-E954001 through SPE994215

SERVICE BULLETIN LIST Page 2 Jan 15/03

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES SB NO.

Description

Parts Added or Changed

MOD Symbol

Serial No. Effectivity

SB-T-62T-49-158

Introduction of Improved Turbine Wheel Tie-Bolt Nut

4504439

Mod Dot 13

SP-E954001 through SP-E994215

SB-T-62T-49-159

Turbine Wheel Assembly with Rolled Tie-Bolt Threads

4503776, 4501993, 4501989B, 4501989C

Mod Dot 11

SP-E954001 through SP-E984129

SB-T-62T-49-160

Introduction of Turbine Assembly to Combustor Housing Flex Seal

4951556

Mod Dot 10

SP-E954001 through SP-E994271

SB-T-62T-49-161

Turbine Wheel with Improved Tie Bolt Material and Increased Tie Bolt Stretch

4504574, M4501993, M4503776, M4501989B, 4501989E, 4504439

Mod Dot 16

SP-E954001 through SP-E994289

SB-T-62T-49-162 Rev 1

Air Inlet Screen Assembly Replacement

4504583

Mod Dot 17

SP-E954001 through SP-E994241

SB-T-62T-49-166

Wrapping Control Harness Assembly Exciter and Bleed Valve with SelfBonding Silcone Tape

SB-T-62T-49-167 Rev 4

Improved Turbine Assembly

4504497, 4504692, 4951644, 4504838, 4505325, M172268-100, 172268-100A, 4501987,

Mod Dot 19

SP-E954001 through SP-E004320

SERVICE BULLETIN LIST Page 3 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

SB NO.

Description

SB-T-62T-49-168

Turbine Roller Bearing and Labyrinth Seal AntiRotation Features, Increased-Clearance Thrust-Bearing, Thrust-Bearing Retainer Plate with Sealing Feature, and Increased ThrustBearing Retainer Nut Torque

SB-T-62T-49-169 Rev 1

Effusion Cooled Combustor Liner and Recalibrated Acceleration Control

SB-T-62T-49-170 Rev 2

Altitude Start Improvement Modified Start Fuel Injection (Superseded by SB-49-181)

SB-T-62T-49-173

Grounding Stud

SB-T-62T-49-177

SB-T-62T-49-179

Parts Added or Changed

MOD Symbol

Serial No. Effectivity

1809-4-3, 4504497A, M4501987A, 4504794, 4951647, 4951648, 4951649, 4951645, 4951646, 4505445

Mod Dot 20

SP-E954001 through SP-E004329

4504015, 4504015A, 4500874, 4503552A, 4504694A, 4504694B, M4504694, M4504694A

Mod Dot 21

SP-E954001 through SP-E004343 and SP-E004343 through SP-E014499

Mod Dot 22

Serial number SP-E954003

4503930, NAS1149D0316J

Mod Dot 23

All APUs through SP-E004271

Replacement of Engine Control Harness Assembly part number 45041051 with part number 4504051A

4504051, 4504051A, 4502160, 4502160A, 4502160B

Mod Dot 24

SP-E954001 through SP-E004363

Introduction of Support Clamps for Maximum Fuel Solenoid Valve

0335702760, MS21919WCJ18, MS21919WCJ6, MS21279-06, MS21045C3

Mod Dot 30

SP-E954001 through SP-E014506

SERVICE BULLETIN LIST Page 4 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES SB NO.

Description

SB-T-62T-49-180

Introduction of Hour Meter/Event Counter part number 4951559

4950077, 4950135, 4504051B, M4504051

SB-T-62T-49-181

Altitude Start Improvement Modified Start Fuel Injector

4503259B, 4504270, MS51852-2SS, MS21919WCJ2, MS21279-08 AN960C10

Mod Dot 33

All APUs with three start fuel nozzles 4504401 series

SB-T-62T-49-183 Rev 2

Effusion-Cooled Combustor Liner with Enlarged Dilution Holes

4505344, 4504694, 4504694A 4504694B MS51852-2SS, 4503259, 4504270, M4504694 M4504694A, M4504694B

Mod Dot 26

SP-E004344 through SP-E004431

4950745, 4503958, 4505587, 4951861, NAS1160-3-6H, AN960C416L

Mod Dot 25

SB-T-62T-49-185

Introduction of Exciter Mounting Bracket Assembly with Isolation Pads

Parts Added or Changed

SB-T-62T-49-186

Incorporation of Modification Plate

0335702760

SB-T-62T-49-187

Containment Ring Inspection/ Replacement and Modification of Containment Ring Notches

M168404-200

MOD Symbol

Serial No. Effectivity SP-E954001 through SP-E014513

SP-E954001 through SP-E004343

SP-E954001 through SPE984116 (Post SB-T62T-49-150) SP-E954117 through SP-E004470

None

Mod Dot 22

SP-E954001 through SP-E04470 All fielded units

SERVICE BULLETIN LIST Page 5 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

SB NO.

Description

SB-T-62T-49-189

Modification of Engine Control Harness Assembly for Oxley Hour Meter/Event Counter to Curtis Meters

SB-T-62T-49-190

Parts Added or Changed

MOD Symbol

Serial No. Effectivity

4504051, 4504051A, 4950077, 4950135, 4951334-1, 4501991, MS16995-10, AN960C4, MS21045C04, M39029-4-110

Mod Dot 34

SP-E014514 and subsequent. SP-E954001 through SP-E14513 with SB-T-62T-49180 incorporated.

Introduction of Start Fuel Nozzle Holder Assembly with Tabbed Lock Washer

4504401, 4503259, 4504401A, 4503259A

Mod Dot 27

SP-E954001 through SP-E014483

SB-T-62T-49-191

Modification from Two High-Flow to Three Low-Flow Start Fuel Nozzles

4504401A, 4504050, MS51853-2SS, MS21919WCJ4, MS21919WCJ2, MS21279-06, MS21045C3

Mod Dot 32

SP-E014515 SP-E014516 SP-E014521

SB-T-62T-49-192

Engine Harness Assembly Relocation to Eliminate Bleed Valve Contact

Mod Dot 28

SP-E954001 through SP-E014474

SB-T-62T-49-193

Introduction of Acceleration Control Assembly part number 4505716

4504015, 4504015A, 4505716

Mod Dot 29

SP-E014500 through Subsequent

SB-T-62T-49-194

De-Icing Fluid Resistant Fuel Solenoid Valve

4952316-1, 4952316-2

Mod Dot 35

All fielded units through SP-E014521

SERVICE BULLETIN LIST Page 6 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

SB NO.

Description

Parts Added or Changed

MOD Symbol

Serial No. Effectivity

SB-T-62T-49-197

Introduction of High Oil Temperature Switch with Improved OverTemperature Protection

4952459-2

Mod Dot 37

All fielded units through serial number SP-E044522

SB-T-62T-49-198

Introduction of Air Inlet Housing with Features to Improve Roller Bearing Longevity

M4504497A 4507007A

Mod Dot 38

All fielded units through serial number SP-E04522

SB-T-62T-49-199 (Supercedes SB-T-62T-49-147)

Introduction of V-Band Clamp with an Improved Clamp

4952538 4951556

Mod Dot 39

All fielded units through serial number SP-E014522

SB-T-62T-49-200

Introduction of Air Inlet Housing Assembly with Improved Moisture and Corrosion Resistance

4507007B or M4504497B

Mod Dot 40

All fielded units through serial number SP-E054523

SERVICE BULLETIN LIST Page 7 Nov 15/07

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SERVICE BULLETIN LIST Page 8 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES LIST OF EFFECTIVE PAGES Subject

Page

Date

Subject

Title Page Blank

1 2

Nov 15/07 May 1/02

Airworthiness

Highlights

1 2 3 4

Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07

49-00-00 APU System

Blank

1 2 3 4 5 6 7 8

Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Nov 15/07 Mar 15/04

Record of Revisions Blank

1 2

Mar 15/04 May 1/02

Record of Temporary Revisions

1 2

Nov 15/07 May 1/02

Service Bulletin List

1 2 3 4 5 6 7 8

Nov 15/07 Jan 15/03 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07

Blank

1 2 3 4 5 6

Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Mar 15/04

Table of Contents Blank

1 2

Mar 15/04 May 1/02

Introduction

1 2 3 4 5 6

Nov 15/07 Jan 15/03 May 1/02 May 1/02 Nov 15/07 May 1/02

Blank Safety Advisory

Blank List of Effective Pages

Page

Date

1 2

Jan 15/03 May 1/02

Title Page Blank

1 2

Jul 1/00 Aug 1/01

Description and Operation

1 2

Jul 1/00 Jan 15/03

Fault Isolation

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135

Aug 1/01 Jul 1/00 Jul 1/00 Jul 1/00 May 1/02 Jul 1/00 Jul 1/00 May 1/02 Jul 1/00 Jul 1/00 May 1/02 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 May 1/02 Jul 1/00 Jul 1/00 Mar 15/04 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jan 15/03 Jan 15/03 Aug 1/01 Aug 1/01 Jul 1/00 Jul 1/00 Jul 1/00

LIST OF EFFECTIVE PAGES Page 1 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Subject Fault Isolation (Cont.)

Blank

Operational Check

Blank Removal/Installation

Page

Date

136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152

Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02

201 202 203 204 205 206 207 208

Jul 1/00 Nov 15/07 May 1/02 Jan 15/03 May 1/02 Jul 1/00 Jul 1/00 Jul 1/00

301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322

Mar 15/04 Nov 15/07 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07

Page

Subject

Date

Removal/Installation (Cont.)

323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344

Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07

Cleaning

601 602 603 604 605 606

Nov 15/07 Jan 15/03 Jan 15/03 Jan 15/03 Nov 15/07 Nov 15/07

801 802 803 804 805 806 806A 806B 807 808 809 810 811 812 813 814 815 816

Mar 15/04 Mar 15/04 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04

Inspection/Check

Blank

LIST OF EFFECTIVE PAGES Page 2 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Subject

Page

Subject

Date

Inspection/Check (Cont.) Blank

817

Mar 15/04

818

Mar 15/04

Repair Blank

901 902

Mar 15/04 Mar 15/04

Servicing

1101 1102 1103 1104 1105 1106

Mar 15/04 Mar 15/04 Jul 1/00 Mar 15/04 Mar 15/04 Mar 15/04

Title Page Blank

1 2

Jul 1/00 Aug 1/01

Description and Operation

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Jul 1/00 Aug 1/01 Jul 1/00 Jul 1/00 May 1/02 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02

501 502 503 504 505

Mar 15/04 Aug 1/01 Mar 15/04 Nov 15/07 Nov 15/07

Disassembly (Cont.)

Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07

Assembly

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

Nov 15/07 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07 Nov 15/07

Storage

1201 1202 1203 1204 1205 1206

Nov 15/07 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Nov 15/07

49-20-00 Engine

Blank Disassembly

Date

506 507 508 509 510 511 512

Blank

Blank

Page

LIST OF EFFECTIVE PAGES Page 3 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Subject Testing

Page 1301 1302 1303 1304 1305 1306 1307 1308 1309 1310 1311 1312 1313 1314 1315 1316 1317 1318 1319 1320

Nov 15/07 Jul 1/00 Jul 1/00 Jul 1/00 Jan 15/03 Jan 15/03 Jan 15/03 Jan 15/03 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 May 1/02 Nov 15/07 Jan 15/03 Jan 15/03 Jan 15/03

1501 1502 1503 1504 1505 1506

Jul 1/00 Jul 1/00 Jul 1/00 May 1/02 May 1/02 May 1/02

Title Page Blank

1 2

Jul 1/00 Aug 1/01

Description and Operation

1 2

Jul 1/00 Jul 1/00

Special Tools, Fixtures, and Equipment

Blank

Subject

Date

501 502 503 504 505 506 507 508 509 510 511

Mar 15/04 May 1/02 Jul 1/00 Jul 1/00 Jul 1/00 Mar 15/04 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Mar 15/04

Date

Blank

512

Jul 1/00

Assembly

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

Mar 15/04 May 1/02 Jan 15/03 Mar 15/04 Mar 15/04 Jul 1/00 Mar 15/04 Jul 1/00 Jul 1/00 Mar 15/04 Mar 15/04 May 1/02 May 1/02 Jul 1/00 Jul 1/00 Mar 15/04 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jan 15/03 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Jan 15/03 Jan 15/03 Mar 15/04 Jan 15/03 Jan 15/03 Jan 15/03 Jan 15/03 Mar 15/04 Mar 15/04

1 2

Jul 1/00 Aug 1/01

49-22-00 Turbine Assembly

Disassembly

Page

49-23-00 Reduction Drive Assembly Title Page Blank

LIST OF EFFECTIVE PAGES Page 4 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Subject Description and Operation

Blank

Page 1 2 3 4 5 6

Date Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00 Jul 1/00

Disassembly

501 502 503 504 505 506 507 508 509 510

Mar 15/04 Jul 1/00 Jul 1/00 Jul 1/00 Mar 15/04 Jul 1/00 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04

Assembly

1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018

Nov 15/07 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04 Mar 15/04

LIST OF EFFECTIVE PAGES Page 5 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

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LIST OF EFFECTIVE PAGES Page 6 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES TABLE OF CONTENTS

Subject

Chapter Section Subject

Page

ENGINE MANUAL - AUXILIARY POWER UNIT (APU) SYSTEM Title Page Safety Advisory Record of Revisions Record of Temporary Revisions Service Bulletin List List of Effective Pages Table of Contents Introduction Airworthiness Limitations APU SYSTEM

1 1 1 1 1 1 1 1 1 49-00-00

Title Page Description and Operation Fault Isolation Operational Check Removal/Installation Cleaning Inspection/Check Repair Servicing ENGINE

1 1 101 201 301 601 801 901 1101 49-20-00

Title Page Description and Operation Disassembly Assembly Storage Testing Special Tools, Fixtures, and Equipment TURBINE ASSEMBLY

1 1 501 1001 1201 1301 1501 49-22-00

Title Page Description and Operation Disassembly Assembly REDUCTION DRIVE ASSEMBLY Title Page Description and Operation Disassembly Assembly

1 1 501 1001 49-23-00 1 1 501 1001

TABLE OF CONTENTS Page 1 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

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TABLE OF CONTENTS Page 2 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES INTRODUCTION 1.

2.

General A.

This document provides instructions for maintenance and repair for the Auxiliary Power Unit (APU) System, part number 4501966 series, Model T-62T-40C11.

B.

The APU system is manufactured by Hamilton Sundstrand Power Systems, a United Technologies Company, 4400 Ruffin Road, P.O. Box 85757, San Diego, CA 92186-5757.

C.

Maintenance, servicing or disassembly of parts which are not covered in this manual should not be attempted. Such actions will not be supported by Hamilton Sundstrand and will be sole responsibility of the aircraft operator.

Standard Practices A.

3.

Standard Practices Manual (SPM) HSPS 490001 contains information on the types and use of technical publications and provides practices and philosophies related to maintenance.

Statement of Verification Method

Date

Testing and Fault Isolation

Analysis

Jan 1/96

Disassembly

Analysis

Jan 1/96

Assembly

Analysis

Jan 1/96

Section

4.

Associated Manuals (Manual Effectivity) A.

All facilities that perform maintenance and repair of the APU system will require the following publications: Engine Manual, Document 40C11-1 Illustrated Parts Catalog, Document 40C11-3 Cleaning, Inspection, and Repair Manual, Document APS500 C/I/R Harness, CMM 49-10-15 Acceleration Control Assembly, CMM 49-31-05 Acceleration Control, CMM 49-31-14 Fuel Control (In Work), CMM 49-31-23 Fuel Pump, CMM 49-32-05 Ignition Exciter, CMM 49-42-08 Ignition Exciter, CMM 49-42-10 Exhaust Inlet Silencer Components, CMM 49-50-01 Anti-surge Valve, CMM 49-52-07 Bleed Valve (In Work), CMM 49-53-14 Electronic Sequence Unit, CMM 49-61-08 Silencer Components, CMM 49-80-01 INTRODUCTION Page 1 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 5.

Application A.

6.

Model Number

Application

T-62T-40C11

Embraer 145 Embraer 135

Materials, Equipment, Compounds, and Special Tools A.

7.

Equipment covered in this manual applies to the following applications:

Materials, equipment, compounds, and special tools are listed in appropriate sections as required. Consult these lists so that the materials, compounds, and special tools may be gathered prior to starting maintenance or repair.

Repair Cycle A.

On-Condition Maintenance (1)

The APU system shall be maintained, subject to the maintenance intervals and periodic inspections contained in the applicable Aircraft Maintenance Planning Document, and the terms of the purchase agreement.

(2)

The turbine wheel and compressor impeller, will be life managed based on "OnCondition" monitoring and shop visit inspection opportunities.

INTRODUCTION Page 2 Jan 15/03

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 8.

List of Abbreviations A.

The following abbreviations/symbols are used in this manual.

Abbreviation

Definition

Abbreviation

Definition

APU

Auxiliary Power Unit

kg

kilograms

BITE

Built-In Test Equipment

kPa

kilopascals

°C

Celsius

lb.

pound

cc

cubic centimeters

min

minute

cm

centimeter

mm

millimeters

CMM

Component Maintenance Manual

N·m

Newton meters

CMC

Central Maintenance Computer

O.D.

Outer Diameter

CPU

Central Processing Unit

PCD

Compressor Discharge pressure

EGT

Exhaust Gas Temperature

pph

pounds per hour

EPROM

Erasable/Programmable Read Only Memory

psi

pounds per square inch

ESU

Electronic Sequence Unit

psia

pounds per square absolute

°F

Fahrenheit

psid

pounds per square differential

FOD

Foreign Object Damage

psig

pounds per square gauge

ft

foot

rpm

revolutions per minute

hr

hour

RTL

Ready To Load

Hz

Hertz

SB

Service Bulletin

I.D.

inner diameter

shp

shaft horsepower

in. Hg

inches of Mercury

U.S.

United States

IPC

Illustrated Parts Catalog

Vdc

Volts direct current

l/hr

liters per hour

±

plus or minus

%

Percent

INTRODUCTION Page 3 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 9.

Consumable Materials A.

Consumable materials required for maintenance and repair of the auxiliary power unit (APU) are listed in Figure 1.

Material

Description/Use

Specification

Source (Vendor Code)

Insulated wire

Fault isolation

MIL-W-22579

Commercially Available

Adhesive

Removal/Installation, Assembly

RTV-106 (917252C1)

General Electric (01139)

Anti-seize compound

Removal/Installation

MolyKote P37

Dow Corning

Anti-seize compound - High Temperature

Removal/Installation

Nickel Ease

Commercially Available

Anti-seize lubricant

Removal/Installation, Assembly

169041 or 51102

Hamilton Sundstrand (55820) or Fel-Pro (73165)

Anti-seize compound -C-5A

Removal/Installation

111007-1

Fel-Pro, Inc. (73165)

Assembly fluid #1

Removal/Installation, Servicing, Assembly

4950515

Hamilton Sundstrand (55820)

Lint free cloth

Removal/Installation, Cleaning, Servicing

Lock wire

Removal/Installation, Servicing

MS20995C20 or MS20995C32

Commercially Available

Safety cable

Removal/Installation

5909034-2B and 5909034-5B

Hamilton Sundstrand (55820)

Cartridge - ferrule

Removal/Installation

5909035-1B and 5909035-2B

Hamilton Sundstrand (55820)

Loctite

Removal/Installation

RC640

Loctite Corp. (05972)

Lubricant - solid film, spray

Removal/Installation, Disassembly, Assembly

Molykote 321R (169015-1)

Dow Corning

Primer Grade N

Removal/Installation, Assembly

MIL-S-22473

Commercially Available

Commercially Available

Consumable Materials List Figure 1 (Sheet 1of 3) INTRODUCTION Page 4 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Material

Description/Use

Specification

Source (Vendor Code)

Sealing compound PST 592

Removal/Installation

112015-1

Loctite Corp. (05972)

Solder

Removal/Installation

SN3WRMAP2 or SN63WRMAP3 or SN63BS

Commercially Available

Tape

Removal/Installation

Cat. No. 27 (950455C1)

3M Corp. (76381)

Engine oil

Removal/Installation, Servicing

Refer to Hamilton Sundstrand Standard Practices Document HSPS 490001 for oil types and restrictions

Hamilton Sundstrand (55820)

Lubricating oil

Cleaning, Disassembly

MIL-PRF-6081 Grade 1010

Commercially Available

TODCO 1060

Cleaning

Petroleum solvent (Cleaning fluid)

Cleaning

Stiff -bristle brush

Cleaning

Dry cleaning solvent

Cleaning

MIL-PRF-680, Type ll

Commercially Available

Cleaning compound (simple green)

Cleaning

13002

Sunshine Makers, Inc. (1Z575)

Gloves

Cleaning

Commercially Available

Goggles

Cleaning

Commercially Available

Mask

Cleaning

Commercially Available

Adhesive, type ll and primer type l

Assembly

MIL-A-46146

Commercially Available

Adhesive, type lll

Assembly

RTV-3145 (5764433 or 22017203)

Dow Corning Corp.

Isopropyl alcohol

Assembly

Locquic primer

Assembly

Commercially Available AMS3160F

Commercially Available Commercially Available

Commercially Available Grade T and Grade N MIL-S-22473 (111009-1)

Loctite Corp.

Consumable Materials List Figure 1 (Sheet 2 of 3) INTRODUCTION Page 5 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Material

Description/Use

Specification

Source (Vendor Code)

Zinc chromate primer

Assembly

Fed. Spec. TT-P-1757

Commercially Available

Barrier material

Storage

MIL-B-131

Commercially Available

Masking tape

Storage

PPP-T-42

Commercially Available

Tag

Storage

Commercially Available

Dry ice

Assembly

Commercially Available

Retaining compound

Assembly

MIL-R-46082, Type ll

Commercially Available

Pipe sealant

Assembly

Loctite 277, Type l, Grade L

Loctite Corp (05972)

Sealing compound

Assembly

Type lll MIL-S-45180

Commercially Available

Gasket compound

Assembly

Form-a-gasket No. 3

Permatex (62377)

Sealant

Assembly

PR-1440

Products Research and Chemical Co. (83574)

Consumable Materials List Figure 1 (Sheet 3 of 3)

INTRODUCTION Page 6 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES AIRWORTHINESS LIMITATIONS 1.

Life Management Plan NOTE:

A.

The Airworthiness Limitations section is Federal Aviation Administration (FAA) approved and specifies maintenance required under sections 43.16 and (91.403) of the Federal Aviation Regulations unless an alternate program has been FAA approved.

Life part inspection or replacement requirements are subject to the data collected as part of the Life Management Plan (LMP). (1)

The LMP is based on the calculated Low Cycle Fatigue (LCF) life, accumulated service experience, and endurance testing of ex-service components. Fleet wide data collection in conjunction with fracture mechanical analyses, and simulations techniques will be used to determine safe operating limits which allow the parts to be withdrawn from service prior to failure.

(2)

Eddy current and Florescent Penetrant Inspection (FPI) inspections of the turbine and compression wheel bore locations, shall be done in accordance with the applicable Inspection and Check sections and Figure 1. The data shall be collected for regular reviews with the FAA. The following are the inspection requirements for the fleet: Component

Location

Minimum Age (Note 1) (Note 2)

Scallop

1000 Cycles

Compressor Wheel

Bore/To be Supplied

5000 Cycles

Compressor Wheel

Backface/FPI

5000 Cycles

Turbine Wheel

Note 1: Perform Eddy Current and FPI inspections on subject wheel when returned for repair at or after the stated life cycle when the APU is disassembled to a level that permits the inspection. Note 2: Inspection interval minimum since last inspection to be 1000 cycles. Inspection Requirements Figure 1 (3)

As the average age of the inspected units moves upwards, life extensions are justified by risk assessment and the continuing health of the inspected engines. The occurrence of cracked hardware will be handled in the same manner, as it would be under a fleet leader program. If an indication is observed, the part will be removed and returned to Hamilton Sundstrand for further evaluation. Hamilton Sundstrand will utilize the data from an in-house test unit to substantiate the crack growth behavior. AIRWORTHINESS Page 1 Jan 15/03

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (4)

This approach relies on the steady occurrence of inspections at shop visits (first opportunity) by Hamilton Sundstrand and Hamilton Sundstrand’s or a Federal Aviation Regulation (FAR) 145 approved repair facilities. If, at any time, a sufficient population (as agreed with the FAA) of the T-62T-40C11 fleet is not being inspected at a rate to support the Life Management Plan (LMP) in risk assessment presented to the FAA during reviews, a notification will be issued to require appropriate inspections. The LMP is a continual process to support the T-62T-40C11 fleet.

(5)

A service information letter (SIL) will be issued periodically to share the fleet results, which specifies the threshold target for continued disassembly for Eddy Current inspections. If any part is found with a crack or if a failure occurs, all operators will be informed. The notification to the operators may also contain updates to the inspection requirement and frequency. As the T62T-40C11 fleet matures, the review will be modified as required to provide sufficient information to the FAA.

(6)

Further details of the LMP may be found in Hamilton Sundstrand Engineering Specification (Radial) (ESR) 0970, “Hamilton Sundstrand Power Systems Model T-62T-40C11 Auxiliary Power Unit Life Management Plan” and Engineering (Radial) Report (ERR) 2396 "Overview of Sundstrand Power Systems Component Life Management Plan." For a copy of the specification or reports, contact your local Hamilton Sundstrand field service representative.

(7)

Low Cycle Fatigue (LCF) Counting

(8)

(a)

Automatic LCF counting is used on the T-62T-40C11 APU to count the accumulated cycles (starts) on the critical components.

(b)

The APU rotating components listed in Figure 1 are subject to LCF due to cyclic operation of the APU. As a result, these parts must be inspected as prescribed by the LMP.

(c)

When the APU or one of the listed components in Figure 1 is replaced, the APU logbook must be updated with the appropriate information.

(d)

Hamilton Sundstrand recommends that the operator provide the accumulated APU hours and cycles to Hamilton Sundstrand, Customer Support Engineering, Department 378, 4400 Ruffin Road, San Diego, California 92186-5757, on a monthly basis or upon removal or replacement of the APU or any of the listed components in Figure 1.

Service Time and Cycles Marking Method (a)

At each removal, the service time and service cycles of the impeller wheels and turbine wheels shall be marked in accordance with the procedures specified in applicable Inspection and Check sections.

AIRWORTHINESS Page 2 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

AUXILIARY POWER UNIT SYSTEM 49-00-00

AUXILIARY POWER UNIT SYSTEM

49-00-00

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THIS PAGE INTENTIONALLY LEFT BLANK

AUXILIARY POWER UNIT SYSTEM

49-00-00

Title, Page 2 Aug 1/01

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES DESCRIPTION AND OPERATION 1.

General NOTE: The Auxiliary Power Unit (APU) System is a source of electrical and pneumatic power for the Embraer 145 and 135 aircraft. The APU System is a model T62T-40C11, manufactured by Hamilton Sundstrand, A United Technologies Company. A.

B.

The APU System consists of the following: (1)

The engine

(2)

The electronic sequence unit (ESU)

(3)

The installation hardware kit

The engine is a gas turbine engine that supplies both shaft power and pneumatic power in the form of compressor bleed air. The engine has: - A reduction drive assembly - A turbine section - A combustor section.

C.

The ESU is a solid state electronic unit that automatically controls the engine start sequence, monitors critical engine parameters during steady state operation, and automatically shuts down the engine in the event these parameters are not within specification limits. The operation limits and parameters are listed in Figure 1. NOTE: When the aircraft is in flight, the ESU will only shut down the engine in the event of a CRITICAL fault, refer to FAULT ISOLATION, Figure 102.

D.

The installation hardware kit consists of an anti-surge valve, a bleed air elbow, a bleed air venturi assembly, and installation clamps and O-rings. The anti-surge valve is always closed on the ground. The anti-surge valve prevents compressor surges and is opened in flight by the ESU during engine starting and when the engine is supplying shaft power only. The remaining components of the kit are used to direct bleed air from the engine to the aircraft pneumatic system.

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Condition Speed

Operation Mode

Limit

Normal operation

100 to 104% (61,565 to 64,028 rpm)

Overspeed shutdown

108% (66,490 rpm)

Underspeed shutdown

Speed goes below 95% (58,487 rpm) after ready to load has been reached

Acceleration

1,604 ± 20°F (873 ± 11°C)

Steady state (100% speed)

1,303 ± 20°F (706 ± 11°C)

High oil temperature

Start initiation or normal operation

330 ± 5°F (166 ± 3°C)

Low oil pressure

Normal operation

6 ± 1.5 psig (41.4 ± 10.3 kPa)

Oil sump capacity

Any

2.5 U.S. quarts (2366 cc)

Bleed duct pressure

APU bleed valve closed

0 psig (0 kPa)

APU bleed valve open

51 psia (352 kPa)

Exhaust gas temperature

Operation Limits and Parameters Figure 1

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES FAULT ISOLATION 1.

2.

Introduction A.

This section lists faults that may occur in the Auxiliary Power Unit (APU) system and the corrective actions to be taken. All corrective actions listed in the fault isolation charts can be performed with the APU system in its installed position. As each corrective action is performed, it is assumed that a restart will be attempted before proceeding to the next action unless otherwise specified.

B.

Faults resulting in an APU system shutdown are determined by APU action and fault messages available from the aircraft Central Maintenance Computer (CMC) or built-in test equipment (BITE) indications in the test cell.

Equipment and Materials A.

Equipment and materials required for fault isolation procedures are listed in Figure 101. NOTE: Equivalent substitutes may be used for items listed.

Item

Equipment/Material

Manufacturer (Vendor Code)

Range

(1)

Insulated wire, MIL-W-22579

Local Supply

N/A

(2)

Digital Multimeter 8060A

Fluke Instrument Company (8S674)

0 to 200 volts

(3)

Pressure gauge

Ashcroft (38056)

0 to 500 psig (0 to 3445 kPag)

(4)

Pressure gauge

Local Supply

0 to 60 psig (0 to 413 kPag)

(5)

Temperature guage

Local Supply

0 to 300°F (0 to 149°C)

Fault Isolation Equipment and Materials Figure 101 3.

Fault Isolation A.

Preliminary Fault Isolation Procedures (1)

Perform fault A tasks before troubleshooting APU.

(2)

Set the APU START switch to ON. The ESU will execute a self-test and output a BITE indication of 1000 for 100 milliseconds. The BITE output will then switch to 0000. If no fault indication is displayed this means that the ESU has reset and is ready for a start sequence.

(3)

If the ESU does not reset, the fault may be in the external electrical system. Perform aircraft or test cell or test cell diagnostic procedures before attempting to troubleshoot the APU. FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (4)

If the APU begins to start when the APU START switch is set to START, and a fault exists, refer to Figure 102; then proceed to the applicable fault isolation chart. The fault categories given in Figure 102 are defined as follows: (a)

ADVISORY - fault message or BITE code displayed only.

(b)

CRITICAL - APU shutdown in all cases.

(c)

MAJOR - APU shutdown only when not in flight.

Fault

CMC Message

ESU failure

APU ESU FAIL

APU general inspection

BITE Code 1000

Fault Category

Fault Description

CRITICAL

Action

The ESU processor has malfunctioned

Replace ESU

NONE

Any fault

Go to A

APU fails to rotate

NONE

APU fails to rotate when start power is applied

Go to B

Bleed valve open

APU BLEED VALVE OPEN

1001

ADVISORY

The bleed valve is open at start initiation

Go to C

No rotation, external short

APU EXTERNAL SHORT

1101

CRITICAL

A short circuit in one of the output circuits: - Fault Signal - Start Command - Anti Surge Valve

Go to D

3% RPM, external short

APU EXTERNAL SHORT

1101

CRITICAL

A short circuit in the output circuit: - Start Fuel Exciter

Go to E

14% RPM, external short

APU EXTERNAL SHORT

1101

CRITICAL

A short circuit in the output circuit: - Main Fuel Exciter

Go to F

Ready to load (RTL), external short

APU EXTERNAL SHORT

1101

CRITICAL

A short circuit in one of the output circuits: - Ready to Load - Maximum Fuel - Cycle Meter

Go to G

Fault Isolation Guide Figure 102 (Sheet 1 of 4) FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Fault

CMC Message

BITE Code

Fault Category

Fault Description

Action

No rotation, fail to start

APU FAIL TO START

0110

CRITICAL

The APU speed has not reached 3% within 8 seconds

Go to H

APU rotates, fail to start 0 to < 14%

APU FAIL TO START

0110

CRITICAL

The APU speed has not reached 14% within 20 seconds

Go to I

APU rotates 14% to 103%

APU FAIL TO START

0110

CRITICAL

The APU speed has not progressed from 14% through 103% within 34 seconds

Go to J

APU fails to carry load

APU UNDERSPEED

1010

CRITICAL

APU shuts down when load applied

Go to K

Shorted oil pressure switch

APU OIL PRESS SW SHORTED

0001

MAJOR

Oil pressure has been detected after the start command has been received, but before cranking the start motor

Go to L

High oil temperature

APU OIL HIGH TEMP

1110

MAJOR

High oil temperature at start initiation or high oil temperature has been detected for twelve seconds after ready to load

Go to M

Low oil pressure

APU OIL LOW PRESS

0100

MAJOR

Go to N

EGT overtemperature

APU EGT OVERTEMP

1100

MAJOR

Low oil pressure for twelve seconds after ready to load The following over temperature limits have been exceeded for 0.5 second: during start (before RTL) 1,604 ± 20°F (873 ± 11°C); steady state (at RTL) 1,300 ± 20°F (704 ± 11°C)

Go to O

Fault Isolation Guide Figure 102 (Sheet 2 of 4) FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault

CMC Message

BITE Code

Fault Category

Fault Description

Action

Overspeed

APU OVERSPEED

0010

CRITICAL

A speed of ≥ 108% has been sensed or a STOP (OVERSPEED TEST) signal has been received after RTL in ground operation

Go to P

Underspeed

APU UNDERSPEED

1010

CRITICAL

A speed of ≤ 95% has been sensed after RTL has been reached

Go to Q

Open thermocouple

APU THERMOCOUPLE OPEN

0011

MAJOR

An EGT ≥ 2,100°F (1,149°C) has been detected for 0.5 second after RTL has been reached

Go to R

Shorted thermocouple

APU THERMOCOUPLE SHORTED

0101

MAJOR

An EGT ≤ 250°F (121°C) has been detected after RTL has been reached

Go to R

Loss of speed data

APU SPEED DATA LOSS

1011

CRITICAL

A speed signal is no longer sensed after 5% has been reached

Go to S

Fault Isolation Guide Figure 102 (Sheet 3 of 4)

FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Fault

CMC Message

BITE Code

Fault Category

Fault Description

Action

Fail to accelerate

APU UNDERSPEED

0111

CRITICAL

Acceleration rate of ≤ 1.0%/second2 is recognized for 2 seconds before 95% speed or speed increases beyond 95% and then falls below 85% before RTL is reached

Go to K

Fail to light

APU FAIL TO LIGHT

1111

CRITICAL

An increase in EGT has not been recognized within 12 seconds after start fuel and exciter have been energized

Go to J

Oil smell in cabin

NONE

Oil smell in cabin

Go to T

Fuel smell in cabin

NONE

Fuel smell in cabin

Go to U

APU will not start in flight. Starts on the ground.

FAIL TO START

APU will not start in flight

Go to V

0110

CRITICAL

Fault Isolation Guide Figure 102 (Sheet 4 of 4)

(5)

The fault isolation diagrams are arranged in a step-by-step logic sequence. The fault isolation diagrams should be used in conjunction with the corresponding fault isolation tables.

FAULT ISOLATION

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FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault A (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Metal on magnetic plug

Bearing failure

A small amount of metal fuzz is acceptable. Metal chunks are not acceptable. Refer to 49-20-00 "INSPECTION/CHECK".

2.

Oil level not correct

Underserviced/ Overserviced sump

Service the oil level to the center of the sight gauge. CAUTION: OVERSERVICE AND UNDERSERVICE OF THE OIL SYSTEM CAN CAUSE HIGH OIL TEMPERATURE AND GEARBOX FAILURE.

3.

Turbine wheel damaged

Overtemperature or rotor rub

Check the turbine wheel for free rotation, no rubbing allowed. Check the turbine wheel for missing blade tips.

4.

Inspection of APU

Various

5.

No CMC Fault messages displayed

Aircraft wiring, ESU, or enable switch

Check the combustor housing V-Band clamp for condition and security. Check the combustor housing for cracks. Check all the LRUs and electrical connectors for security. Review date and time to determine latest fault message. Make sure CMC switch is in enable position for continued troubleshooting. Refer to Fault B.

FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Step 1.

Fault Indication No 28 Vdc at ESU

Probable Cause

Correction

Bad relay, aircraft/test cell wiring, or ESU

Check for 28 Vdc at pins A and E of the ESU when power is applied. If no 28 Vdc indicated, troubleshoot aircraft/test cell wiring and relay (K0280). If 28 Vdc, replace ESU.

FAULT ISOLATION

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FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault C (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Bleed valve open

Bleed valve, ESU, or wiring

Observe bleed valve position indication on bleed valve. If valve indicates open, then go to step 2. If valve indicates closed, go to step 3.

2.

Bleed valve close command

Bleed valve, ESU, or wiring

Shut APU down. Disconnect P309 from bleed valve. Connect 0 to 50 Vdc voltmeter across P309 pins 1(+) to 2(-). Set APU power ON. If 28 Vdc is indicated on meter at pins 1 and 2, replace bleed valve. If no 28Vdc indicated, troubleshoot aircraft/test cell wiring.

CAUTION: USE A HIGH-IMPEDENCE DIGITAL MULTIMETER TO CHECK BLEED VALVE CONTINUITY IN THE FOLLOWING STEPS. THE SWITCH CONTACTS COULD BE DAMAGED IF A LOW-IMPEDENCE METER IS USED. 3.

Bleed valve close commend

Bleed valve, ESU, or wiring

Disconnect P2 from ESU. Check for ground at P2 pin R. If ground, replace ESU. If no ground, go to step 4.

4.

Bleed valve closed signal

Bleed valve or wiring

Disconnect P309. Check continuity from J309 pin 7 to J309 pin 13. If open circuit, replace bleed valve. If continuity, troubleshoot aircraft/test cell wiring.

FAULT ISOLATION

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FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault D (Cont'd) Fault Indication

Probable Cause

1.

Start output shorted to ground

ESU adapter harness, aircraft wiring, or ESU

Disconnect P2 from ESU. Check P2 pins J and C for short to ground. If shorted, troubleshoot aircraft/test cell wiring or start contactor. If ok, replace ESU.

2.

ESU anti-surge valve output shorted to ground

Anti-surge valve, wiring, or ESU

Disconnect P1 and P308. Check P308 pin 1 for short to ground. If shorted, troubleshoot aircraft/APU harness/test cell wiring.

Step

Correction

FAULT ISOLATION

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FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault E (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

ESU start fuel and exciter output shorted to ground

APU harness, ignition exciter, or start fuel valve

Disconnect P303 and P305. Check P4 pins 16 and 21 for short to ground. If shorted, replace APU harness. If ok, then go to step 2.

2.

ESU start fuel and exciter output shorted to ground

Ignition exciter or start fuel valve

Check start fuel valve J305 pins A to B for short. If ok (approx. 29 ohms), replace ignition exciter. If shorted, replace start fuel valve.

3.

ESU start fuel and exciter output shorted to ground

ESU adapter harness, aircraft/test cell wiring, APU harness, ignition exciter, or start fuel valve

Disconnect P4. If P1 pin T is still shorted, troubleshoot aircraft/test cell wiring. If short disappears, go to step 4.

4.

ESU start fuel and exciter output shorted to ground

ESU, ESU adapter Disconnect P1. Check P1 pin T for short harness, test cell to ground. If ok, replace ESU. wiring, APU harness, ignition exciter, or start fuel valve

FAULT ISOLATION

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FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault F (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

ESU main fuel output shorted to ground

ESU, ESU adapter harness, test cell wiring, APU harness, or main fuel valve

Disconnect P1. Check P1 pin J for short to ground. If shorted, go to step 2. If ok, go to step 5.

2.

ESU main fuel output shorted to ground

ESU adapter harness, test cell wiring, APU harness, or main fuel valve

Disconnect 4. If P1 pin J is still shorted, troubleshoot test cell wiring. If short disappears, go to step 3.

3.

ESU main fuel output shorted to ground

APU harness or main fuel valve

Disconnect P306. Check P4 pin 8 for short to ground. If shorted, replace APU harness. If ok, go to step 4.

4.

ESU main fuel output shorted to ground

APU harness or main fuel valve

Check main fuel valve solenoid J306 pins A and B for short (approx. 29 ohms). If shorted, replace main fuel valve. If ok, go to step 5.

5.

ESU faulty

ESU internal fault

Replace ESU.

6.

ESU main fuel output shorted to ground

Hourmeter shorted

Replace hourmeter or harness.

FAULT ISOLATION

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FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault G (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

ESU, max fuel valve or ready-to-load (RTL) outputs

ESU, aircraft/test cell wiring, APU harness, or max fuel valve shorted

Disconnect P1. Check P1 pin R for short to ground. If shorted, go to step 2. If ok, go to step 4.

2.

ESU or max fuel valve shorted

Wiring or APU max fuel valve

Disconnect P4. If P1 pin R is still shorted, troubleshoot aircraft/test cell wiring. If ok, go to step 3.

3.

ESU, max fuel valve, or wiring shorted

APU harness or max fuel valve

Disconnect P307. Check J307 pins A and B for short (approx. 29 ohms). If shorted, replace max fuel valve. If ok, replace APU harness.

4.

Ready-to-load (RTL) output shorted

Aircraft/test cell wiring or ESU

Disconnect P2. Check P2 pin L for short to ground. If shorted, troubleshoot aircraft/test cell wiring. If ok, replace ESU.

5.

Cycle meter shorted

Cycle meter

Replace cycle meter or harness.

FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault H (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Fail to start (APU rotates)

Magnetic pickup

Disconnect P302. Resistance reading of the magnetic pickup should be 1,000 to 1,450 Ohms.

2.

Fail to start (APU rotates)

APU/aircraft/test cell wiring or ESU

Check wiring between ESU and P302.

3.

Fail to start (no rotation)

starter generator

Check for 28 Vdc at starter/generator when APU start switch set to start.

4.

Fail to start (no rotation)

ESU

Check for 28 Vdc at ESU P2 pin J.

5.

Fail to start (no rotation)

APU/aircraft/test cell wiring

Check for 28 Vdc at GCU or start contactor.

FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault I (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Cranking speed

Undetermined

Disconnect the air line at the start purge check valve. Perform an APU start and check for fuel leaking from the check valve.

2.

Speed circuit faulty

ESU or magnetic pickup circuit

Disconnect P1. Check resistance P1 pins M and N (through wiring across magnetic pickup). If ok (1,190 to 1,450 ohms), replace ESU. If not ok, go to FAULT S, loss of speed data.

3.

Slow cranking speed, ESU timed out

Starter/generator, APU, driven equipment, or battery

Disconnect starter/generator from reduction drive. If APU is free to rotate manually, go to step 4. If not free, replace APU.

4.

Slow cranking

Starter/generator or battery

Check battery voltage under load. If ok, replace starter/generator or driven loads. If not ok, replace battery.

FAULT ISOLATION

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FAULT ISOLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault J (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Hung start

Fuel restriction

Check fuel filters for restriction. Clean or replace.

2.

Hung start

Combustor air leak

Check for air leaks at combustor. Repair as necessary.

3.

Hung start

Main fuel solenoid

Check main fuel valve P306 pin A for 28 Vdc at 14% or greater. Repair as necessary.

4.

Hung start

Starter/generator

Refer to FAULT H.

5.

Hung start

Acceleration control

Refer to FAULT V.

6.

Hung start

Fuel pump

Replace fuel pump.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault K (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Inadequate fuel supply

Test cell boost pump

Check test cell fuel boost pump pressure. If ok, go to step 2. If low, repair test cell fuel system.

2.

Starter drop-out

ESU

Check for starter voltage drop-out at starter relay. If 28 Vdc does not drop-out at 70% RPM, replace ESU. If ok, go to step 3.

3.

Restricted fuel flow

Inlet fuel filter or acceleration control

Check fuel inlet filter. If contaminated, replace filter element. If ok, go to step 4.

4.

Restricted fuel flow

fuel pump filter or acceleration control

Check fuel pump filter. If contaminated, clean or replace filter element. If ok, replace acceleration control and fuel pump.

5.

Max fuel flow

Max fuel solenoid

Check for 28 Vdc at P307 pin A. If no 28 Vdc, repair aircraft/test cell wiring. If 28 Vdc, replace max fuel solenoid.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault L (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Short circuit

ESU, APU harness, or LOP switch

Disconnect P1. If p1 pin G is shorted to any other pin, go to step 2. If open, replace ESU.

2.

Short circuit

Test cell wiring, APU harness, or LOP switch

Disconnect P4. If P1 pin G is still shorted, troubleshoot test cell wiring. If open, go to step 3.

3.

Short circuit

APU harness or LOP switch

Disconnect P304. If J304 pins B and C are shorted, replace low oil pressure (LOP) switch. If open, replace APU harness.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault M (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Oil level

Oil level low or high

Check oil level. If not at proper level, service oil. If oil level ok, go to step 2.

2.

Metal on magnetic plug

Bearing failure

A small amount of metal fuzz is acceptable, go to step 3. Metal chunks are not acceptable. Refer to 49-20-00 "INSPECTION/CHECK".

3.

HOT short circuit

HOT SWITCH shorted

Disconnect the HOT SWITCH (A311) at P311. Check for continuity across A311-A to A311-B. If shorted remove and replace HOT SWITCH. If not shorted, go to step 4.

4.

APU HARNESS

APU HARNESS shorted

With A311 disconnected, disconnect APU HARNESS at firewall by disconnecting P4. Check continuity across P4-3 to P4-4; if shorted, remove and replace APU HARNESS. If not shorted, go to step 5.

5.

TEST CELL/AIRCRAFT WIRING

TEST CELL/AIRCRAFT WIRING shorted, ESU inoperative

With P4 disconnected, disconnect P1 at the ESU interface. Check continuity across P1D to P1-E; if shorted, troubleshoot the AIRCRAFT wiring to repair short circuit in HOT circuit. If wiring is not shorted, remove and replace ESU.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault N (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Oil level

Oil level low or high

Check oil level. If not at proper level, service oil. If oil level ok, go to step 2.

2.

Metal on magnetic plug

Bearing failure

A small amount of metal fuzz is acceptable, go to step 3. Metal chunks are not acceptable. Refer to 49-20-00 "INSPECTION/CHECK".

3.

Short circuit, LOP switch

Test cell wiring, LOP switch, or APU harness

Disconnect P1 and P4. If P1 pin G is shorted to ground, repair test cell wiring. If open, go to step 4.

4.

Short circuit, LOP switch

APU harness

If P4 pin 5 is shorted to ground, replace APU harness. If ok go to step 5.

5.

Low oil pressure

ESU, LOP switch, or internal failure

Connect ohmmeter across J304 pins A and B (normally closed contacts of LOP switch). Crank APU while monitoring ohmmeter. This test can also be performed by connecting the LOP switch to regulated shop air. If ohmmeter changes from continuity to open at 6 to 8 psig (41 to 55 kPa), replace ESU. If not, go to step 6. Remove LOP switch. Connect pressure gauge in place of LOP switch. Crank APU and observe pressure gauge.

6.

Low oil pressure

LOP switch or APU

If oil pressure (step 5) reached 6 to 8 psig (41 to 55 kPa), replace LOP switch. If oil pressure low, replace APU.

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EGT

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault O (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Restricted air flow

Air intake

If air intake is restricted, clear intake as required. If ok, go to step 2.

2.

Excessive bleed air during start

Anti-surge valve stuck open

If anti-surge valve is stuck open, replace valve. If ok, go to step 3.

3.

Excessive bleed air after ready-toload (RTL)

Anti-surge valve does not close when bleed valve opens

Restart APU and open bleed valve at RTL. If anti-surge valve does not close when bleed valve opens, go to step 4. If ok, replace acceleration control. Retest APU and if fault continues, replace APU.

4.

Bypass valve does not close

Anti-surge valve, ESU, test cell wiring, or APU harness

Disconnect P308. Connect 0-50 Vdc voltmeter across P308 pins 1(+) and 2(-). Restart APU and open bleed valve at RTL. If 28 Vdc at P308 when bleed valve opens, replace anti-surge valve. If no 28 Vdc, go to step 5.

5.

No 28 Vdc close bypass signal

ESU, test cell wiring, or APU harness

Disconnect P1. If no continuity P1 pin U to P308 pin 1 or no continuity P1V to P308 pin 2, go to step 6. If ok, replace ESU.

6.

Open wiring

Test cell wiring or APU harness

Disconnect P4. Check continuity from P1 pin U to P4 pin 17 and from P1 pin V to P4 pin 18. If open, troubleshoot test cell wiring. If ok, replace APU harness.

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OVERSPEED

Step

Fault Indication

Probable Cause

Correction

1.

Overspeed

Speed adjustment, acceleration control, fuel pump, or ESU

Attempt to adjust speed with acceleration control speed adjustment to 103% RPM with no load and retry. If successful, return APU to service. If not, go to step 2.

2.

Overspeed

Speed adjustment, acceleration control, fuel pump, or ESU

Replace acceleration control and fuel pump and restart. If ok, return APU to service. If overspeed, replace ESU.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault Q (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Underspeed

Speed adjustment

Restart and observe RPM meter. If speed is less than 103% with no load, go to step 2. If ok, go to step 3.

2.

Underspeed

Speed adjustment

Adjust speed setting on acceleration control to 103% with no load. If adjustment successful, return APU to service. If not, replace acceleration control.

3.

Load or fuel

Premature load, max fuel, ESU, or wiring

If generator load was applied before ready-to-load, return APU to service. If not, go to step 5.

4.

APU fuel pump check

Fuel pump

Start the APU. Apply full load. Turn off the aircraft fuel boost pump. RPM should not drop. If RPM drops, replace fuel pump

5.

Max fuel

Max fuel, ESU, or wiring

Disconnect P307. If 28 Vdc at P307 pin A(+) approximately 7 seconds after 95% RPM, go to step 6. If no 28 Vdc, go to step 7.

6.

Max fuel

Max fuel, ESU, or wiring

Disconnect P307. Apply 28 Vdc (nominal) at P307 pin A(+) and pin B(-). If max fuel valve opens (clicks), go to step 9. If valve does not open, replace max fuel valve.

7.

Open circuit

ESU, APU harness, or test cell wiring

Disconnect P1. If continuity from P1 pin R to P307 pin A and from P1 pin L to P307 pin B, replace ESU. If either is open, go to step 8.

8.

Open circuit

APU harness or test cell wiring

Disconnect P4. If continuity from P4 pin 10 to P307 pin A and from P4 pin 7 to P307 pin B, troubleshoot test cell wiring. If open, replace APU harness.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault Q (Cont'd)

Step

Fault Indication

Probable Cause

Correction

9.

Test cell fuel supply

Boost pump

If aircraft boost pump supplying 5 to 40 psig (34 to 276 kPa) pressure, go to step 10. If low, repair aircraft fuel system.

10.

Fuel supply

Inlet filter, fuel pump filter, acceleration control, or APU

If APU inlet fuel filter is restricted, replace filter. If ok, go to step 11.

11.

Fuel supply

Fuel pump filter, acceleration control, or APU

If fuel pump filter is restricted, clean or replace filter. If ok, go to step 12.

12.

Fuel supply

Acceleration control or APU

Install tee fitting between main manifold and fuel line. Crank APU. Fuel pressure should be approximately 125 psig (862 kPa) when main fuel valve opens at 14%. If fuel pressure is ok, replace APU. If low, go to step 13.

13.

Fuel supply

Acceleration control or APU

Replace acceleration control and restart APU. If ok, return APU to service. If underspeed, replace APU.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Fault R (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Short or Open

ESU, APU harness, or test cell wiring

Disconnect P1. If P1 pin A is shorted to pin B, go to step 2. If open, go to step 3. If ok, replace ESU.

2.

Open circuit

APU harness or test cell wiring

Disconnect P4. If ok, troubleshoot test cell wiring. If P4 pin 1 to pin 2 is open, disconnect thermocouple leads from P4 pins 1 and 2 and connect spare thermocouple leads. If fault still exists, replace thermocouple.

3.

Short circuit

APU harness or test cell wiring

Disconnect P4. If ok, troubleshoot test cell wiring. If P4 pin 1 to pin 2 is shorted, disconnect thermocouple leads from P4 pins 1 and 2 and connect spare thermocouple leads. If fault still exists, replace thermocouple.

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Fault S (Cont'd)

Step

Fault Indication

Probable Cause

Correction

1.

Magnetic pickup short or open

ESU, magnetic pickup, APU harness, or test cell wiring

Disconnect P1. If P1 pin M to N is open, go to step 2. If shorted, go to step 4. If 1,000 to 1,450 ohms, replace ESU.

2.

Open circuit

Magnetic pickup, APU harness, or test cell wiring

Disconnect P302. If J302 pin A to B is ok (1,000 to 1,450 ohms), go to step 6. If open, go to step 3.

3.

Open circuit

APU harness or test cell wiring

Connect P302. Disconnect P4. If P4 pin 11 to 12 is open, replace APU harness. If ok (1,000 to 1,450 ohms), troubleshoot test cell wiring.

4.

Short circuit

Test cell wiring or ESU adapter harness

Disconnect P302. If J302 pin A to B is ok (1,000 to 1,450 ohms), go to step 6. If shorted, go to step 5.

5.

Short circuit

Magnetic pickup, APU harness, or test cell wiring

Connect P302. Disconnect P4. If P4 pin 11 to 12 is shorted, replace APU harness. If ok (1,000 to 1,450 ohms), troubleshoot test cell wiring.

6.

Open or short circuit

Magnetic pickup

Replace magnetic pickup.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES OPERATIONAL CHECK 1.

2.

Introduction A.

This section contains the procedures necessary to perform an operational check of the Auxiliary Power Unit (APU) system. Included in this section are prestarting procedures, starting procedures, bleed air operation, operating limitations, protective shutdowns, and normal shutdown procedures.

B.

The APU is cranked by a starter until self-sustaining speed is attained. Beyond this point, the APU accelerates to rated speed.

C.

During operation, the APU will shut down automatically if the operating limits are either exceeded or not attained within the specified periods outlined in paragraph 2.E.

Operational Check of the APU System A.

Prestarting Procedures (1)

Verify that the MASTER switch is positioned to OFF and the load circuit breaker is closed.

(2)

Check for an adequate fuel supply. Make sure that the fuel supply to the APU system has flow and pressure characteristics as follows: (a)

The minimum fuel boost pressure should be 5 psig (34 kPa) above the true vapor pressure of the fuel, to a maximum of 40 psig (276 kPa) at a maximum fuel flow rate.

(b)

The minimum inlet flow rate should be 250 lb/hr (113.5 kg/hr) to the fuel inlet filter connection.

CAUTION: NEVER ALLOW THE OIL LEVEL TO BE ABOVE THE “FULL” MARK ON THE SIGHT GAUGE. AN OVERFILLED SUMP WILL RESULT IN OIL FOAMING, LOW OIL PRESSURE AND ABNORMAL GEAR WEAR. (3)

Check the oil level on the sight gauge with the APU in a level position. It is essential that the oil level does not exceed FULL.

(4)

If necessary, replenish the oil level with the lubricating oil specified in Figure 1101, SERVICING.

(5)

Check the plumbing and electrical wiring for security.

CAUTION: BE SURE THE AREA AROUND THE APU IS CLEAN AND FREE OF FOREIGN OBJECTS. THE GREATEST HAZARDS TO A TURBINE ENGINE ARE LEAKING FUEL CONNECTIONS AND ENTRY OF FOREIGN MATERIAL INTO THE COMPRESSOR. (6)

Remove any loose objects or material from around the APU, especially objects that may be ingested into the APU during operation. OPERATIONAL CHECK

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B.

Purge the fuel system per SERVICING if: (a)

The fuel system was opened for replacement of components and APU fails to start after three attempts.

(b)

The fuel system was allowed to become empty and APU fails to start after three attempts.

Starting Procedures CAUTION: IT IS POSSIBLE FOR A START TO PRODUCE A ROAR WITH FLAME IN THE EXHAUST. THE CAUSE IS PROBABLY AN ACCUMULATION OF UNBURNED FUEL IN COMBUSTOR FROM PREVIOUS OPERATION. THE APU MUST BE SHUT DOWN AND THE CAUSE INVESTIGATED. WAIT FOR ALL FUEL TO DRAIN FROM COMBUSTOR BEFORE ATTEMPTING ANOTHER START. DURING A START, IF IT APPEARS THAT EXHAUST GAS TEMPERATURE EXCEEDED LIMITS IN FIGURE 201 AFTER “READY FOR SERVICE” INDICATION AND APU DID NOT SHUT DOWN, THIS INDICATES A PROBLEM WITH INSTRUMENTATION. REFER TO FAULT ISOLATION PROCEDURES. CAUTION: DO NOT CONTINUE APU OPERATION IF SHUTDOWN DOES NOT OCCUR AFTER AN OVERSPEED TEST. THIS MAY INDICATE ESU IS NOT SENSING APU SPEED CORRECTLY AND LOSS OF OVERSPEED PROTECTION. DAMAGE TO EQUIPMENT COULD RESULT. NOTE: During an APU fail-to-start condition on a start attempt, every effort should be made to determine the reason for fail-to-start before another start is made. It is recommended that a period of at least 1 minute be allowed between consecutive start attempts to allow fuel to drain from the combustor. If after three consecutive start attempts a fail-to-start condition still occurs, a visual inspection of the APU compartment must be made to inspect for excessive fuel around the tailpipe area, and a cold crank of the APU made to purge fuel from the engine. To accomplish a cold crank, disconnect the electrical connectors from the ignition exciter, start, and main fuel solenoid valves. Motor the APU approximately for 15 seconds with the starter. (1)

Start the APU and allow it to reach rated speed. Perform a simulated overspeed shutdown test by pressing the STOP switch. The APU should shut down. If the APU does not shut down, refer to the FAULT ISOLATION procedures and correct the fault before proceeding.

(2)

Repeat step (1) with the exception of the overspeed test. Observe the RPM and EGT displays during APU acceleration. During a normal start, the RPM display indicates constantly increasing speed until approximately 103% is reached and the EGT display shows a steady temperature rise.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES C.

Bleed Air Operation (1)

D.

Operating Limitations (1)

E.

Allow the APU to run for three minutes to warm up, and then move the bleed air switch to the ON position. This will extract bleed air from the unit.

During APU operation, make sure that the operating limitations in Figure 201 are not exceeded.

Protective Shutdowns (Ground operation) CAUTION: DO NOT ATTEMPT TO OPERATE THE APU BY WIRING AROUND OR DISABLING CIRCUITS TO THE SHUTDOWN OR WARNING DEVICES. A CONDITION THAT PRODUCES AUTOMATIC SHUTDOWN OR WARNING DESERVES ATTENTION. THESE DEVICES ARE INCORPORATED TO PREVENT DAMAGE TO THE APU. (1)

Protective devices in the electrical circuit monitor lubricating oil pressure, high oil temperature, turbine exhaust temperature, APU overspeed, APU underspeed, and sequence failure. The operation of these circuits is described as follows:

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Item Rated Engine Speed

Limitations 61,565 rpm (100% rated speed)

NOTE: The RPM logic circuit is set to shut down the APU at 108% rated speed. The normal no-load speed is approximately 103%. Reduction Drive Axial Pad Speed (Rated)

12,000 rpm

Accessory Drive Pad Speeds Starter Fuel Pump

8,229 rpm 4,235 rpm

Overtemperature Shutdown

1303 ± 20°F (706 ± 11°C) at rated speed or 1,604° ± 20°F (873° ± 11°C) in start sequence

NOTE: The ESU continuously monitors EGT via a thermocouple located in the APU exhaust outlet. EGT temperatures exceeding above limits cause the ESU to automatically shut down the APU for an overtemperature condition. If an automatic shutdown does not occur within five seconds of an observed overtemperature condition, the APU must be shut down manually. Oil Consumption

No evidence of oil consumption after operational check of the APU

Oil Pump Pressure at Rated Speed

15 to 65 psig (103 to 448 kPa)

NOTE: An oil pressure indicator is not provided on the unit, although, provisions for an oil pressure sensor are provided. Automatic shutdown occurs if APU has passed 95% rated speed plus seven seconds and oil pressure drops below 6 ± 1 psig (41.3 ± 6.8 kPa). Operating Limitations Figure 201 Low oil pressure

-

APU shutdown occurs whenever the oil pressure is less than 6 ± 1 psig (41.3 ± 6.8 kPa) after the APU has attained 70% rated speed, plus 5 seconds.

High exhaust gas

-

APU shutdown occurs when the exhaust gas temperature temperature exceeds 1303 ± 20°F (706 ± 11°C) at any time during normal operation, or 1,604° ± 20°F (873° ± 11°C) during start.

High oil temperature -

APU shutdown occurs whenever the oil temperature exceeds 325 to 335°F (163 to 168°C) for twelve consecutive seconds after RTL.

APU overspeed

APU shutdown occurs when speed reaches 108%.

-

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES APU underspeed

-

APU shutdown occurs if speed decreases below 95% after APU has attained ready to load.

Startup failure -

APU shutdown occurs when speed fails to reach 3% speed within 8 seconds, from 3% to 16% speed within 20 seconds, from 16% to 70% within 34 seconds, and from 70% to 95% within 10 seconds.

F.

(2)

The ESU incorporates built-in test equipment (BITE) features to provide visual indications on the aircraft Central Maintenance Computer (CMC) if any of the safe operating parameters has been exceeded, as well as indications of other malfunctions.

(3)

If a protective (malfunction) shutdown occurs: (a)

Note the CMC or BITE indication and go to FAULT ISOLATION to determine the malfunction before attempting a restart.

(b)

Move start/run switch to OFF.

Normal Shutdown Procedures NOTE: No cool down of the APU is required. The APU should be shutdown while under load or immediately after the load is removed. (1)

G.

Allow 30 seconds to elapse after the APU rotor has stopped before moving the offrun-start switch to the OFF position.

Acceleration Control Adjustment CAUTION: DO NOT ADJUST THE APU SPEED UNTIL THE RPM DISPLAY ACCURACY IS ESTABLISHED. ADJUSTING THE APU SPEED WITH THE RPM DISPLAY INDICATING INCORRECTLY MAY RESULT IN UNNECESSARY APU AUTOMATIC SHUTDOWNS. MAKE ADJUSTMENTS WHILE THE APU IS RUNNING. (1)

Rated Speed adjustment (a)

Loosen the speed adjustment jamnut (refer to Figure 202).

(b)

Turn the speed adjustment screw in the required direction to adjust APU speed to 102.5 +/- 0.5% under a no-load condition.

(c)

Turn the speed adjustment screw clockwise to increase or counterclockwise to decrease the speed.

(d)

Hold the speed adjustment screw in place and secure it with the jamnut. Torque the jamnut 24 to 27 pound inches (2.7 to 3.1 N·m).

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Acceleration Control Assembly Adjustments Figure 202

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Acceleration Schedule Adjustment NOTE: The starting time will vary with environmental conditions, but should be in the area of 8 to 15 seconds (0 to 100% speed) on a ‘hot' (recently operated) APU. If acceleration is not satisfactory, adjust according to the following procedure. (a)

Matchmark the acceleration schedule adjustment needle (refer to Figure 202) and housing.

(b)

Loosen the acceleration control jamnut.

(c)

Turn the adjustment needle in the required direction to adjust the acceleration schedule.

NOTE: If the turbine hesitates during acceleration, the acceleration schedule must be increased. The acceleration schedule must be decreased if the turbine rumbles (indication of a hot start) or the EGT is above 1,604° ± 20°F (873° ± 11°C) during acceleration. If the EGT reaches 1,604° ± 20°F (873° ± 11°C) an automatic APU shutdown will occur. NOTE: Turn the adjustment needle clockwise to decrease or counterclockwise to increase the acceleration schedule fuel flow. The adjustment is critical and the initial position should be carefully noted. Make adjustments in 1/8 turn increments. Check the acceleration rate after each adjustment. (d)

Make a minimum of two starts between adjustments, disregarding the characteristics of the first start after adjustment.

(e)

If after one complete turn adjustment, the desired correction is not observed, replace the acceleration control assembly.

(f)

After final adjustment, check and readjust the rated speed if necessary.

(g)

Hold the acceleration schedule adjustment needle in place and secure it with the jamnut. Torque the jamnut 24 to 27 pound inches (2.7 to 3.1 N·m).

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES REMOVAL/INSTALLATION 1. General A.

This section has the procedures for removal and installation of components on the Auxiliary Power Unit (APU) system. Item numbers in the procedures and illustrations are the same as those in the Illustrated Parts Catalog, Document 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001, for general information. NOTE: Alpha-variant items can replace an item when permitted by the effect code for that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

B.

Access to the APU may prevent performance of some procedures while the APU is installed on the aircraft. Refer to the Aircraft Maintenance Manual for access.

C.

A post-maintenance operational check should be performed after doing required maintenance tasks to verify repair. Refer to OPERATIONAL CHECK.

D.

Exercise extreme care to prevent entrance of dirt, dust, and foreign objects into the APU. If a foreign object is dropped into the APU, stop maintenance procedure until the object is located and removed.

E.

Cover large openings with protective covers. Cap or plug open tube assemblies, fittings, and ports. Do not cover tube ends with tape.

F.

All parts attached with lockwire or safety cable prior to removal must be attached with lockwire or safety cable after installation.

G.

When the fuel system has been disturbed for replacement or repair of components, the APU must be operated and checked for fuel leakage. If the APU fails to start after three attempts, purge fuel system of air according to APU maintenance instructions. (Refer to SERVICING).

2. Equipment and Materials A.

Equipment and materials required for removal and installation are listed in Figure 301. NOTE: Equivalent substitutes may be used for items listed. NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or holding other small components in place for ease of assembly and prevention of galling. If necessary, assembly fluid may be diluted with MIL-PRF-7808 or MIL-PRF-23699.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Material

Source (Vendor Code)

Adhesive RTV-106 (917252C1)

General Electric (01139)

Adhesive, Thermosetting 179581

Hamilton Sundstrand (55820)

Anti-seize Compound MolyKote P37

Dow Corning

High Temperature Anti-seize Compound Nickel Ease

Commercially Available

Anti-seize Lubricant 51102 (169041)

Hamilton Sundstrand (55820)

Anti-seize Compound C-5A (111007-1)

Fel-Pro, Inc. (73165)

Assembly Fluid, 4950515

Hamilton Sundstrand (55820)

Connector Pliers, Soft-Jawed TG69

Glenair

Cotton Wipes

Commercially Available

Insulation Sleeving DR-25-1/8 or equivalent

Raychem Corporation (06090)

Isopropyl Alcohol, ASTM D770

Commercially Available

Lacing Tape 4950493-1 or equivalent

Hamilton Sundstrand (55820)

Lint-free Cloth

Commercially Available

Lockwire MS20995C20 and MS20995C32

Commercially Available

or

Hamilton Sundstrand (55820)

Safety Cable 5909034-2B and -5B and

Hamilton Sundstrand (55820)

Cartridge, Ferrule 5909035-1B and -2B Loctite RC640

Loctite Corp. (05972)

Loctite 404 or 480 Instant Adhesive

Loctite Corp.

Lubricant, Solid film, Molykote 321R (Spray)

Dow Corning

Non-metallic Mallet

Commercially Available

Pipe Sealant (4950698)

Hamilton Sundstrand (55820)

Primer Grade N (MIL-S-22473N)

Commercially Available

Single Component Nylon Varnish Nycote 7-11 or equivalent

Nycote Laboratories Corporation

Soft bristled brush

Commercially Available

Solder SN3WRMAP2 or SN63WRMAP3 or SN63BS

Commercially Available

Tape Cat. No. 27 (950455C1)

3M Corp.

Torque Wrench 0 to 25 lb. in. (0 to 2.8 N·m)

Commercially Available

Torque Wrench 25 to 140 lb. in. (2.8 to 15.8 N·m)

Commercially Available

Torque Wrench 140 to 550 lb. in. (15.8 to 62.1 N·m)

Commercially Available

Engine Oil (MIL-PRF-7808 or MIL-PRF-23699)

Commercially Available

Removal/Installation Equipment and Materials Figure 301 REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 3. Removal/Installation Procedures A.

Removal and Installation of Air Inlet Housing Packing (1)

Remove packing (10 or 20, IPC 49-22-00 Figure 1) from air inlet housing.

(2)

Cut new packing (10 or 20) at a 45° angle.

WARNING:

B.

LOCTITE 404 OR 480 ADHESIVE CAUSES INSTANT BONDING OF SKIN OR OTHER HUMAN TISSUE. USE CARE WHEN HANDLING THE ADHESIVE. USE THE ADHESIVE CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ADHESIVE, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0013SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE ADHESIVE, REMOVE YOUR CONTACT LENSES. PUT ON NITRILE OR POLYETHYLENE GLOVES AND SAFETY GLASSES OR CHEMICAL SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ADHESIVE FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(3)

Apply Loctite 404 or 480 adhesive to the two ends.

(4)

Install packing (10 or 20) into the air inlet housing groove with the seam joint at the top of the housing.

(5)

Hold ends together for one minute to ensure adhesive has set.

Removal and Installation of Engine Harness Assembly WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

NOTE: The minimum clearance between tubes, and between tubes and adjacent components must be 0.080 inch (2.032 mm). (1)

Disconnect electrical connectors and remove engine harness assembly as follows:

(a) Disconnect electrical connector (P302) from magnetic pickup (680, IPC 49-20-00 Figure 2). If damaged, remove the connector seal (685) from magnetic pickup (680). Discard the seal. (b) Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC 49-20-00 Figure 3). (c) Disconnect electrical connector (P306) from main fuel solenoid valve (530, IPC 49-20-00 Figure 2). If damaged, remove the connector seal (552) from main fuel solenoid valve (530). Discard the seal.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (d)

Disconnect electrical connector (P305) from start fuel solenoid valve (540). If damaged, remove the connector seal (542) from start fuel solenoid valve (540). Discard the seal.

(e)

Disconnect electrical connector (P307) from maximum fuel solenoid valve (550). If damaged, remove the connector seal (552) from maximum fuel solenoid valve (550). Discard the seal.

(f)

Disconnect electrical connector (P304) from low oil pressure switch (260). If damaged, remove the connector seal (262) from low oil pressure switch (260). Discard the seal.

(g)

Disconnect electrical connector (P311) from high oil temperature switch (690). If damaged, remove the connector seal (685) from high oil temperature switch (690). Discard the seal.

(h)

Disconnect electrical connector (P308) from anti-surge valve (40, IPC 49-0000 Figure 1).

(i)

Disconnect electrical connector (P309) from bleed air valve (100).Remove screws (20, IPC 49-20-00 Figure 1), washers (40), nuts (30), hourmeter (100A) and event counter (110).

NOTE: If the original hourmeter (100A or event counter (110) will not be reinstalled, an entry must be made in the logbook for the APU Hours/Events and the Hours/Events meter readings. (2)

Remove bolts (70), nuts (90), and clamps (45, 50, 60, and 80).

(3)

Remove thermocouple (112) from combustor housing.

(4)

Remove engine harness assembly (10).

(5)

Wrap harness and tubes, as necessary, with tape to be sure of a tight fit in clamps and to obtain minimum gap between fuel lines. NOTE: Harness and tubes shall fit tightly in clamps. Verify installation for fit.

(6)

Install engine harness assembly (10) with clamps (45, 50, 60, and 80), bolts (70), and nuts (90). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (7)

Apply antiseize compound to the threads of thermocouple (112) and attach thermocouple (112) to combustor housing. Torque thermocouple 40 to 50 pound inches (4.5 to 5.6 N·m) and secure with lockwire.

(8)

Install hourmeter (100A) and event counter (110) with screws (20), washers (40), and nuts (30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m).

WARNING:

(9)

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

Clean all harness and component connectors using a soft-bristled brush and cotton wipes moistened with isopropyl alcohol to remove oil, grease, and contamination from the pins and inside of the electrical connectors. Allow connectors to air dry.

(10) If required, install the connector seals as follows: (a)

Connector seal (685, IPC 49-20-00 Figure 2) on magnetic pickup (680).

(b)

Connector seal (552) on main fuel solenoid valve (530). REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (c)

Connector seal (542) on start fuel solenoid valve (540).

(d)

Connector seal (552) on maximum fuel solenoid valve (550).

(e)

Connector seal (262) on low oil pressure switch (260).

(f)

Connector seal (685) on high oil temperature switch (690).

(g)

Slide all connector seals to the base of the connector pins.

(11) Connect engine harness and component connectors as follows: NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (a)

Connect electrical connector (P302) to magnetic pickup (680, IPC 49-20-00 Figure 2).

(b)

Connect electrical connector (P303) of harness assembly (10, IPC 49-20-00 Figure 1) to ignition exciter (200, IPC 49-20-00 Figure 3)

(c)

Connect electrical connector (P306) to main fuel solenoid valve (530, IPC 49-20-00 Figure 2).

(d)

Connect electrical connector (P305) to start fuel solenoid valve (540).

(e)

Connect electrical connector (P307) to maximum fuel solenoid valve (550).

(f)

Connect electrical connector (P311) to high oil temperature switch (690).

(g)

Connect electrical connector (P304) to low oil pressure switch (260).

(h)

Connect electrical connector (P308) to anti-surge valve (40, IPC 49-00-00 Figure 1).

(i)

Connect electrical connector (P309) to bleed valve (100).

(12) Deleted. C.

Removal and Installation of Thermocouple (Refer to Figure 302) WARNING:

MAKE SURE ELECTRICAL POWER SUPPLY IS REMOVED FROM THE APU. ENERGIZED CIRCUITS CAN CAUSE INJURY TO PERSONS.

NOTE: The thermocouple is a dual element type thermocouple (refer to Figure 302). TC1 and TC2 are identical and one of the two may be used. Removal and replacement are the same for TC1 and TC2. (1)

If connected, disconnect electrical connector (P4) (1) from aircraft firewall receptacle (J4)

(2)

Remove bolts (2) and lockwashers (3) and remove clamp (4) from electrical connector (P4) (1). Loosen protective rubber (5). REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (3)

Disconnect wiring from electrical connector (P4) pins 1 and 2 and thermocouple shield wire from P4 shell.

(4)

Remove tie wraps from engine harness assembly to gain access to thermocouple wiring.

(5)

Remove thermocouple (112, IPC 49-20-00 Figure 1) from combustor housing assembly.

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (6)

Coat thermocouple threads with anti-seize compound.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (7)

Install thermocouple (112, IPC 49-20-00 Figure 1) in combustor housing. Torque thermocouple to 40 to 50 pound inches (4.5 to 5.6 N·m) and lockwire thermocouple.

(8)

Connect thermocouple wiring (K1A20-AL, K2A20-CR, and K3A20N) to electrical connector (P4) pins 1 and 2 and P4 shell, respectively.

(9)

Install protective rubber (5, Figure 302) and attach clamp (4) to electrical connector (P4) (1) with bolts (2) and lockwashers (3). Tighten bolts (no torque is required).

(10) Replace tie wraps on engine harness assembly. NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (11) Connect electrical connector (P4) (1) to aircraft firewall receptacle (J4).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Thermocouple Removal and Installation Figure 302

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES D.

Removal and Installation of Event Counter (Pre SB-49-180) WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

NOTE: Manual soldering shall be performed in accordance with the best industry standard practices by certified personnel. The techniques used shall not damage wires or terminals and shall provide solder joints that are free of contamination and provide a reliable electrical connection. NOTE: Tinning of soldering iron tips is accomplished by heating the soldering iron until the tip just reaches the melting point of the solder. Flow the solder, similar to that to used to solder the connection, onto the tip until the tip is fully covered and no base material is exposed. Leave the iron tinned until ready for use. Just prior to soldering (or removing solder), while the iron is still heated, wipe the tip on a wetted sponge. (1)

Desolder harness assembly (10, IPC 49-20-00 Figure 1) wires from event counter (110) as follows: (a)

Remove the 45-degree protective boot from the event counter housing to expose the solder terminals located at the back of the event counter.

(b)

Use a cleaned soldering iron and solder wick to remove solder from terminal M1(+), located at the back of the event counter. Reheat the connection and, while maintaining heat on the connection, apply a light steady pull on the conductor wire until it disengages from the event counter terminal. Use care to prevent splashing the molten solder and to avoid bending or otherwise damaging the terminal.

(c)

Repeat step (b) above for terminal M1(-).

(2)

Remove screws (20), nuts (30), and event counter (110).

(3)

Remove any remaining adhesive from the event counter harness wires.

(4)

Use wire cutters, capable of cutting 20 AWG wire, to cut the exposed conductors off of the wires that were removed from the event counter terminals.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (5)

Use a fixed die hand stripper to strip the ends of the 20 AWG wires to allow an exposed conductor length sufficient to provide ¾ wrap around the event counter terminals. Do not damage the stranded wires. Wires with severed strands are not acceptable.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(6)

Tin the exposed conductors by dipping the leads into liquid flux, followed by coating the leads with solder. Solder shall penetrate the wire to the innermost strands but shall not obscure the outer strands.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(7)

Use isopropyl alcohol to clean the soldered leads to remove any residual flux. There shall be no visible evidence of flux residue.

(8)

Install new 45-degree protective boots over the event counter wires.

(9)

Build up wire bundle at egress using sleeving M23053/5-105-0 or M23053/5-104-0, as required.

(10) Use a pair of rounded needle nose pliers to bend the soldered leads to provide a wrap that will cover ¾ minimum of the event counter terminals.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(11) Connect the wires to the event counter terminals as follows: NOTE: There should be enough solder to ensure that the solder covers the wire over the extent of the wrap. The solder should wet the terminal and wire to form a visible fillet. (a)

Solder wire E26A20 to terminal M1(+) on the event counter.

(b)

Solder wire E27A20N to terminal M1(-) on the event counter.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(12) Use isopropyl alcohol to clean the soldered connections to remove any residual flux. There shall be no visible evidence of flux residue. (13) Use a digital multimeter to verify continuity (0.2 ohm maximum) between the following points: (a)

P0274-24 to M1(+).

(b)

P0274-25 to M1(-).

(14) Use a digital multimeter to check resistance between the event counter terminals and P0274 connector body. The resistance should be 20 megohms minimum. (15) Use a digital multimeter to check resistance between pins P0274-24 and P0274-25. The resistance should be 1,000 ohms minimum. (16) Install the 45-degree boot on the event counter body. Adjust wire sleeving as required. Apply adhesive part number 179581 to ensure fluids resistance at wire egress and event counter body. (17) Install event counter (110) and attach with screws (20) and nuts (30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m). REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (18) In Section 3 of the APU Log Book (Maintenance and Repair Log), record the estimated APU cycles since new (CSN), date of repair, description of work performed and the current reading on the event counter. Future event counter readings should be added to the recorded estimated CSN of the APU. E.

Removal and Installation of Hourmeter (Pre SB-49-180) WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

NOTE: Manual soldering shall be performed in accordance with the best industry standard practices by certified personnel. The techniques used shall not damage wires or terminals and shall provide solder joints that are free of contamination and provide a reliable electrical connection. NOTE: Tinning of soldering iron tips is accomplished by heating the soldering iron until the tip just reaches the melting point of the solder. Flow the solder, similar to that to used to solder the connection, onto the tip until the tip is fully covered and no base material is exposed. Leave the iron tinned until ready for use. Just prior to soldering (or removing solder), while the iron is still heated, wipe the tip on a wetted sponge. (1)

Desolder harness assembly (10, IPC 49-20-00 Figure 1) wires from hourmeter (100A) as follows: (a)

Remove the 45-degree protective boot from the hourmeter housing to expose the solder terminals located at the back of the hourmeter.

(b)

Use a cleaned soldering iron and solder wick to remove solder from terminal M2(+), located at the back of the hourmeter. Reheat the connection and, while maintaining heat on the connection, apply a light steady pull on the conductor wire until it disengages from the hourmeter terminal. Use care to prevent splashing the molten solder and to avoid bending or otherwise damaging the terminal.

(c)

Repeat step (b) above for terminal M2(-).

(2)

Remove screws (20), nuts (30), and hourmeter (110).

(3)

Remove any remaining adhesive from the hourmeter harness wires.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (4)

Use wire cutters, capable of cutting 20 AWG wire, to cut the exposed conductors off of the wires that were removed from the hourmeter terminals.

(5)

Use a fixed die hand stripper to strip the ends of the 20 AWG wires to allow an exposed conductor length sufficient to provide ¾ wrap around the hourmeter terminals. Do not damage the stranded wires. Wires with severed strands are not acceptable.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(6)

Tin the exposed conductors by dipping the leads into liquid flux, followed by coating the leads with solder. Solder shall penetrate the wire to the innermost strands but shall not obscure the outer strands.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(7)

Use isopropyl alcohol to clean the soldered leads to remove any residual flux. There shall be no visible evidence of flux residue.

(8)

Install new 45-degree protective boots over the hourmeter wires.

(9)

Build up wire bundle at egress using sleeving M23053/5-105-0 or M23053/5-104-0, as required.

(10) Use a pair of rounded needle nose pliers to bend the soldered leads to provide a wrap that will cover ¾ minimum of the hourmeter terminals.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(11) Connect the wires to the hourmeter terminals as follows: NOTE: There should be enough solder to ensure that the solder covers the wire over the extent of the wrap. The solder should wet the terminal and wire to form a visible fillet. (a)

Solder wire E17A20 to terminal M2(+) on hourmeter.

(b)

Solder wire E16A20N to terminal M2(-) on hourmeter.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(12) Use isopropyl alcohol to clean the soldered connections to remove any residual flux. There shall be no visible evidence of flux residue. (13) Use a digital multimeter to verify continuity (0.2 ohm maximum) between the following points: (a)

P0274-13 to M2(+).

(b)

P0274-15 to M2(-).

(14) Use a digital multimeter to check resistance between the hourmeter terminals and P0274 connector body. The resistance should be 20 megohms minimum. (15) Install the 45-degree boot on the hourmeter body. Adjust wire sleeving as required. Apply adhesive part number 179581 to ensure fluids resistance at wire egress and hourmeter body. (16) Install hourmeter (100A) and attach with screws (20) and nuts (30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (17) In Section 3 of the APU Log Book (Maintenance and Repair Log), record the estimated APU time since new (TSN), date of repair, description of work performed and the current reading on the hourmeter. Future hourmeter readings should be added to the recorded estimated TSN of the APU. F.

Removal and Installation of Hour Meter/Event Counter (Post SB-49-180) WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

NOTE: Manual soldering shall be performed in accordance with the best industry standard practices by certified personnel. The techniques used shall not damage wires or terminals and shall provide solder joints that are free of contamination and provide a reliable electrical connection. NOTE: Tinning of soldering iron tips is accomplished by heating the soldering iron until the tip just reaches the melting point of the solder. Flow the solder, similar to that to used to solder the connection, onto the tip until the tip is fully covered and no base material is exposed. Leave the iron tinned until ready for use. Just prior to soldering (or removing solder), while the iron is still heated, wipe the tip on a wetted sponge. (1)

(2)

Desolder harness assembly (10, IPC 49-20-00 Figure 1) wires from hourmeter /event counter (111) as follows: (a)

Remove the heat shrink boot from the hourmeter/event counter housing to expose the solder terminals located at the back of the hourmeter/event counter.

(b)

Use a cleaned soldering iron and solder wick to remove solder from terminal M1(+), located at the back of the hourmeter/event counter. Reheat the connection and, while maintaining heat on the connection, apply a light steady pull on the conductor wire until it disengages from the hourmeter terminal. Use care to prevent splashing the molten solder and to avoid bending or otherwise damaging the terminal.

(c)

Repeat step (b) above for terminal M1(-).

Remove and discard screws (20, IPC 49-20-00 Figure 1), washers (40), and nuts (30) from the hourmeter/event counter (111).

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (3)

Pull the hourmeter/event counter (111) from the fuel filter/meters bracket assembly (300, IPC 49-20-00, Figure 2).

(4)

Remove any remaining adhesive from the hourmeter/event counter harness wires.

(5)

Use wire cutters, capable of cutting 20 AWG wire, to cut the exposed conductors off of the wires that were removed from the hourmeter/event counter terminals.

(6)

Use a fixed die hand stripper to strip the ends of the 20 AWG wires to allow an exposed conductor length sufficient to provide ¾ wrap around the hourmeter/event counter terminals. Do not damage the stranded wires. Wires with severed strands are not acceptable.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(7)

Tin the exposed conductors by dipping the leads into liquid flux, followed by coating the leads with solder. Solder shall penetrate the wire to the innermost strands but shall not obscure the outer strands.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(8)

Use isopropyl alcohol to clean the soldered leads to remove any residual flux. There shall be no visible evidence of flux residue.

(9)

Slide heat shrink boot over the harness assembly and make sure the large end is facing the cut end of the wires.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(10) Connect the wires to the hourmeter/event counter terminals as follows: REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES NOTE: There should be enough solder to ensure that the solder covers the wire over the extent of the wrap. The solder should wet the terminal and wire to form a visible fillet. (a)

Solder wire E26A20 to terminal M1(+) on hourmeter/event counter.

(b)

Solder wire E27A20N to terminal M1(-) on hourmeter/event counter.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(11) Use isopropyl alcohol to clean the soldered connections to remove any residual flux. There shall be no visible evidence of flux residue. (12) Use a digital multimeter to verify continuity (0.2 ohm maximum) between the following points: (a)

P0274-24 to M1(+).

(b)

P0274-25 to M1(-).

(13) Use a digital multimeter to check resistance between the hourmeter terminals and P0274 connector body. The resistance should be 20 megohms minimum. (14) Use a digital multimeter to check resistance between pins P0274-24 and P0274-25. The resistance should be 1,000 ohms minimum. (15) Install the heat shrink boot on the hourmeter/event counter body. Adjust wire sleeving as required. Apply adhesive part number 179581 to ensure fluids resistance at wire egress and hourmeter/event counter body. (16) Install hourmeter/event counter (111) and attach with screws (20) and nuts (30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m) (17) In Section 3 of the APU Log Book (Maintenance and Repair Log), record the estimated APU time since new (TSN) and cycles since new (CSN), date of repair, description of work performed and the current reading on the event counter. Future hourmeter/event counter readings should be added to the recorded estimated TSN and CSN of the APU.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES G. Removal and Installation of Hour Meter and Event Counter (Post SB-49-189) WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

NOTE: Removal and installation of the fuel filter/meters bracket assembly (300, IPC 49-20-00, Figure 2) involve the removal and re-installation of the fire detection system. Removal and re-installation of the fire detection system and/or any work on attaching hardware or the airframe itself must be performed in accordance with the aircraft maintenance manual (AMM). Any questions or issues relative to the AMM must be referred directly to the aircraft manufacturer. (1) Refer to the AMM for the procedures necessary to remove the fire detection system on the fuel filter/meters bracket assembly (300). (2) Remove the screws (20, IPC 49-20-00, Figure 1), the washers (40), and the nuts (30). Remove the hourmeter (100A). (3) Remove the screws (20), the washers (40), and the nuts (30). Remove the event counter (110). (4) Remove the bolts (180, IPC 49-20-00, Figure 2) and the fuel filter assembly (170) from the fuel filter/meters bracket assembly (300). (5) Remove the bolts (310), the washers (320), and the fuel filter/meters bracket assembly (300). (6) Install the fuel filter/meters bracket assembly (300) with the bolts (310) and the washers (320). (7) Install the fuel filter assembly (170) onto the fuel filter/meters bracket assembly (300) with the bolts (180). (8) Install the event counter (110, IPC 49-20-00, Figure 1) with the screws (20), the washers (40), and the nuts (30). (9) Install the hourmeter (100A) with the screws (20), the washers (40), and the nuts (30). (10) Refer to the AMM for the procedures necessary to install the fire detection system on the fuel filter/meters bracket assembly (300, IPC 49-20-00, Figure 2).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

H. Removal and Installation of Anti-Surge Valve and Bleed Air Elbow WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

(1)

Disconnect electrical connector (P308) from anti-surge valve (40, IPC 49-00-00 Figure 1).

(2)

Disconnect the aircraft ducts connected to the anti-surge valve (40) and bleed air elbow (10).

(3)

Remove V-band clamp (50) and packing (60). Discard the packing. Remove anti-surge valve (40) from bleed air elbow (10).

(4)

Remove V-band clamp (20), packing (30) and bleed air elbow (10). Discard the packing.

(5)

Install bleed air elbow (10) with V-band clamp (20) and packing (30). Torque clamp locknut 33 to 37 pound inches (3.7 to 4.1 N·m).

(6)

Install anti-surge valve (40) with V-band clamp (50) and packing (60). Torque clamp locknut 23 to 27 pound inches (2.5 to 3.0 N·m).

(7)

Connect aircraft ducts to bleed air elbow (10) and anti-surge valve (40).

(8)

Connect electrical connector (P308) to anti-surge valve (40).

NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. I.

Removal and Installation of Bleed Air Valve and Filter (1)

Disconnect electrical connector (P309) from bleed air valve (100, IPC 49-00-00 Figure 1).

(2)

Disconnect aircraft ducts from bleed air valve (100) and remove bleed air valve.

(3)

Remove plug (10, IPC 49-00-00 Figure 2), packing (20), filter (30), spring (40), and filter retainer (50). Discard packing (20) and filter (30).

(4)

Install packing (20) on plug (10). Install filter retainer (50), spring (40), filter (30), and plug into actuator housing of bleed air valve (100, IPC 49-00-00 Figure 1).

(5)

Connect aircraft ducts to bleed air valve (100).

(6)

Connect electrical connector (P309) to bleed air valve (100).

NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES J. Removal and Installation of Ignition Cable(s) WARNING:

(1)

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

Pre-SB-49-150 configuration:

(a) Disconnect ignition cable (130, IPC 49-20-00 Figure 3) from igniter plug (170). (b) Remove bolt (150), nut (160), and clamp (140). (c) Disconnect ignition cable from exciter (200) and remove cable. (d) Remove and replace washers (137), if damaged. WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (e) Connect ignition cable (130) to igniter plug (170). Torque B-nut 40 to 60 pound inches (4.5 to 6.8 N·m) and secure with lockwire. (f) Put clamp (140) around cable and attach to bracket (180) with bolt (150) and nut (160). Torque nut 24 to 27 pound inches (2.7 to 3.1 N·m). (g) Connect ignition cable (130) to exciter (200). Torque B-nut 40 to 60 pound inches (4.5 to 6.8 N·m). (2)

Post-SB-49-150 configuration:

(a) Disconnect ignition cables (130 and 135, IPC 49-20-00 Figure 3) from igniter plugs (170A). (b) Remove bolts (155 and 157), nuts (160A), and clamps (145 and 147). (c) Disconnect ignition cables from exciter (200A) and remove cables. (d) Remove and replace washers (137), if damaged.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (e) Connect ignition cable (130 and 135) to igniter plugs (170A). Torque B-nuts 40 to 60 pound inches (4.5 to 6.8 N·m) and secure with lockwire. (f) Put clamps (145) around cables and clamp (147) around main fuel valve to manifold tube assembly (90, IPC 49-20-00 Figure 2). Attach clamps with bolts (155 and 157, IPC 49-20-00 Figure 3) and nuts (160A). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m). (g) Connect ignition cables (130 and 135) to exciter (200A). Torque B-nut 40 to 60 pound inches (4.5 to 6.8 N·m). K. Removal and Installation of Igniter Plug(s) WARNING:

(1)

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

Pre-SB-49-150 configuration:

(a) Disconnect ignition cable (130, IPC 49-20-00 Figure 3) from igniter plug (170) and remove plug. WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION:

ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO THE TIP OF THE IGNITER OR DAMAGE TO THE PLUG WILL OCCUR.

(b) Apply anti-seize (169041) to the threads of igniter plug (170). REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (c) Install igniter plug (170) in combustor housing. Torque plug 108 to 132 pound inches (12 to 15 N·m). Connect ignition cable (130) to igniter plug. Torque B-nut 40 to 60 pound inches (4.5 to 6.8 N·m). (2)

Post-SB-49-150 configuration:

(a) Disconnect ignition cables (130 and 135, IPC 49-20-00, Figure 3) from igniter plugs (170A) and remove plugs. WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION:

ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO THE TIP OF THE IGNITER OR DAMAGE TO THE PLUG WILL OCCUR.

(b) Apply anti-seize (169041) to the threads of igniter plug (170A). (c) Install igniter plugs (170A) in combustor housing. Torque plugs 108 to 132 pound inches (12 to 15 N·m). (d) Connect ignition cables (130 and 135) to igniter plugs. Torque B-nuts 40 to 60 pound inches (4.5 to 6.8 N·m). L. Removal and Installation of Ignition Exciter WARNING:

(1)

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

Pre-SB-49-150 configuration:

(a) Disconnect electrical connector (P303) from ignition exciter (200, IPC 49-20-00, Figure 3). (b) Disconnect ignition cable (130) from ignition exciter (200). (c) Remove bolts (210 and 215), lockwashers (220), brackets (230 and 240), and ignition exciter (200). (d) Install ignition exciter (200) and brackets (230 and 240) with bolts (210 and 215) and lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (e) Connect ignition cable (130) to ignition exciter (200). Torque B-nut 40 to 60 pound inches (4.5 to 6.8 N·m) and secure with lockwire. (f) Connect electrical connector (P303) to ignition exciter (200). NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (2)

Post-SB-49-150 configuration:

(a) Disconnect electrical connector (P303) from ignition exciter (200A, IPC 49-20-00 Figure 3). (b) Disconnect ignition cables (130 and 135) from ignition exciter (200A). (c) Remove bolts (210A), lockwashers (220), brackets (240B), and ignition exciter (200A). NOTE:

Bolts (150A), clamps (148), and nuts (160A) do not have to be removed from brackets (240B).

(d) If required, remove bolts (210A), lockwashers (220), and exciter bracket (193). (e) If removed, install exciter bracket (193) with bolts (210A) and lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m). (f) Install ignition exciter (200A) and brackets (240B) with bolts (210A) and lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (g) Connect ignition cables (130 and 135) to ignition exciter (200A). Torque B-nuts 40 to 60 pound inches (4.5 to 6.8 N·m) and secure with lockwire. (h) Connect electrical connector (P303) to ignition exciter (200A). NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (3)

Post-SB-49-185 configuration:

(a) Disconnect electrical connector (P303) from ignition exciter (200A, IPC 49-20-00 Figure 3). (b) Disconnect ignition cables (130 and 135) from ignition exciter (200A). (c) Remove bolts (195). (d) Remove washers (197). (e) Remove the exciter mounting bracket assembly (193, 49-20-00, Figure 3). (f) Install isolators (199) on exciter mounting bracket assembly (-193A). (g) Install exciter mounting bracket assembly (-193A). (h) Install washers (-198). (i) Install bolts (-196). (j) Torque bolts (-196) to 55 to 70 pound inches (6.2 to 7.9 N.m). (k) Install ignition exciter (200A) with bolts (210A) and lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (l) Connect ignition cables (130 and 135) to ignition exciter (200A). Torque B-nuts 40 to 60 pound inches (4.5 to 6.8 N·m) and secure with lockwire. (m) Connect electrical connector (P303) to ignition exciter (200A). NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. M. Removal and Installation of Start Fuel Nozzle(s) (1)

Pre and Post SB-49-124 configuration: NOTE: On pre-SB-49-124 configuration APU, one start nozzle tube assembly (145, IPC 49-20-00 Figure 2) and one of the start fuel nozzle holder assemblies (380, IPC 49-20-00 Figure 3) will not be present.

(a) Loosen start nozzle tube assemblies (140 and 145, IPC 49-20-00, Figure 2) at tee (350, IPC 49-20-00, Figure 3). (b) Disconnect tube assemblies (140 and 145, IPC 49-20-00, Figure 2) from start fuel nozzle holder assemblies (380, IPC 49-20-00, Figure 3) and remove the start fuel nozzle holder assemblies (380). (c) Remove fitting (390) and nozzle (400) from each start fuel nozzle holder (380). (2)

Pre SB-49-152 configuration:

(a) Assembly of start fuel nozzle assembly (380):

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE LOCQUIC PRIMER GRADE T, CORRECTLY. THE PRIMER IS FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE PRIMER, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0135SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE PRIMER, PUT ON CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES (BUTYL RUBBER). MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE PRIMER FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT 1

Apply primer Grade T to three threads closest to nozzle (410) hex. Allow 3 to 4 minutes for primer to dry. WARNING: USE LOCTITE RC640, CORRECTLY. THE COMPOUND IS FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0067SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT

(3)

2

Apply Loctite RC640 to the same area on the fuel nozzle.

3

Install fuel nozzle into fitting (390). Torque nozzle 55 to 60 pound inches (6.2 to 6.7 N·m).

Post SB-49-152 configuration:

(a) Loosen start nozzle tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2) at tee (350, 350A, 350B, or 350C, IPC 49-20-00, Figure 3) and fitting (352). (b) Disconnect tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2) from start fuel nozzle holder assemblies (380, IPC 49-20-00, Figure 3) and remove the start fuel nozzle holder assemblies (380). (c) Remove fitting (390) and nozzle (400) from each start fuel nozzle holder (380). (d) Assembly of start fuel nozzle assembly (380A, 380B or 380C): 1

Install nozzle (400A) into fitting (390 or 390A) or nozzle (400B) into fitting (390B). Torque nozzle 55 to 60 pound inches (6.2 to 6.7 N·m). REMOVAL/INSTALLATION

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Stake nozzle (400A or 400B) and fitting (390, 390A or 390B) three places as shown in Figure 306. NOTE:

Staking is limited to a maximum of six places.

Staking Of Start Fuel Nozzle Assembly Figure 306 CAUTION:

DO NOT INTERCHANGE START FUEL NOZZLE HOLDERS. ONLY USE A START FUEL NOZZLE HOLDER WITH A NOTCHED HEX HEAD IN A THREE-START FUEL NOZZLE CONFIGURATION. IN A ONE OR TWOSTART FUEL NOZZLE CONFIGURATION ONLY USE A START FUEL NOZZLE HOLDER WITH NO NOTCH ON THE HEX HEAD. INSTALLATION OF AN INCORRECT START FUEL NOZZLE HOLDER MAY RESULT IN AN OVER TEMPERATURE OR HUNG START CONDITION.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (4)

Pre and Post SB-49-124 configuration:

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION:

NOTE:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN THE THREADS OF THE START NOZZLE HOLDER AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL CONTAMINATE THE START NOZZLE HOLDER.

On pre-SB-49-124 configuration APU, one start nozzle tube assembly (145, IPC 49-20-00, Figure 2) and one of the start fuel nozzle holder assemblies (380, IPC 49-20-00, Figure 3) is not used.

(e) Apply a light coat of anti-seize lubricant (part number 169041) to the threads of the nozzle holder assemblies (380) and the mating threads of the combustor housing. (f) Install fitting (390) and nozzle (400) to each start fuel nozzle holder (380). (g) Install start fuel nozzle holder assemblies (380) in combustor housing. Torque fittings 50 to 55 pound inches (5.6 to 6.2 N·m). (h) Connect start nozzle tube assemblies (140 and 145, IPC 49-20-00, Figure 2) to tee (350, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 N·m). (i) Connect start nozzle tube assemblies (140 and 145, IPC 49-20-00, Figure 2) to start fuel nozzle holder assemblies (380, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 N·m).

REMOVAL/INSTALLATION

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Post SB-49-152 configuration:

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN THE THREADS OF THE START NOZZLE HOLDER AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL CONTAMINATE THE START NOZZLE HOLDER.

(a) Apply a light coat of anti-seize lubricant (part number 169041) to the threads of the nozzle holder assemblies (380C) and the mating threads of the combustor housing. (b) Install start fuel nozzle holder assemblies (380C) in combustor housing. Torque fittings 50 to 55 pound inches (5.6 to 6.2 N·m). (c) Connect start nozzle tube assemblies (140, 145 and 147, IPC 49-20-00 Figure 2) to tee (350, IPC 49-20-00 Figure 3) and fitting (352). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 N·m). (d) Connect start nozzle tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2) to start fuel nozzle holder assemblies (380C, IPC 49-20-00, Figure 3). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 N·m). (5)

Post SB-49-190 configuration:

(a) Disconnect tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2) from start fuel nozzle holder assemblies (380, IPC 49-20-00, Figure 3). (b) Remove Start Fuel Nozzle Holder Assembly (-380D, IPC 49-20-00, Figure 3) or Start Fuel Nozzle Holder Assembly (-380E) (c) Remove nozzle (400). (d) Remove tabbed washer (-382, IPC 49-20-00, Figure 3) and discard. (e) Install new tabbed washer (-382) and Start Fuel Nozzle Holder Assembly (-380D), or Start Fuel Nozzle Holder Assembly (-380E) (f) Install nozzle (400). (g) Install Start Fuel Nozzle Holder Assembly (-380D, IPC 49-20-00, Figure 3) or Start Fuel Nozzle Holder Assembly (-380E)

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (h) Install tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2). (6)

Post SB-49-181 configuration:

WARNING:

USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

CAUTION:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN THE THREADS OF THE START FUEL NOZZLE HOLDER AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL CONTAMINATE THE START FUEL NOZZLE HOLDER.

(a) Loosen tube assemblies (140B and 147) at 90°-elbow (350D, IPC 49-20-00, Figure 3). (b) Disconnect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) from the two start fuel nozzle holder assemblies (380F, IPC 49-20-00, Figure 3) and remove the start fuel nozzle holder assemblies. (c) If necessary, remove plug (385). (d) Remove fitting (390D) and injector (400C) from each start fuel nozzle holder assembly (380F). (e) Apply a light coat of anti-seize lubricant (51102) to the threads of the two start fuel nozzle holder assemblies (380F) and the mating threads of the combustor housing. (f) Install fitting (390D) and injector (400C) to each start fuel nozzle holder assembly (380F). (g) Install the two start fuel nozzle holder assemblies (380F) in combustor housing. Torque fittings to 50 to 55 pound inches (5.6 to 6.2 N•m). (h) If removed, install plug (385). (i) Connect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) to 90°-elbow (350D, IPC 49-20-00, Figure 3). Torque B-nuts to 75 to 85 pound inches (8.5 to 9.6 N•m). (j) Connect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) to the two start fuel nozzle holder assemblies (380F, IPC 49-20-00, Figure 3). Torque B-nuts to 75 to 85 pound inches (8.5 to 9.6 N•m).

REMOVAL/INSTALLATION

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Post SB-49-191 configuration:

WARNING:

USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

CAUTION:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN THE THREADS OF THE START FUEL NOZZLE HOLDER AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL CONTAMINATE THE START FUEL NOZZLE HOLDER.

(a) Loosen tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) at tee (350B, IPC 49-20-00, Figure 3). (b) Disconnect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) from the three start fuel nozzle holder assemblies (380E, IPC 49-20-00, Figure 3) and remove the start fuel nozzle holder assemblies. (c) Remove fitting (390C) and injector (400B) from each start fuel nozzle holder assembly (380E). (d) Apply a light coat of anti-seize lubricant (51102) to the threads of the three start fuel nozzle holder assemblies (380E) and the mating threads of the combustor housing. (e) Install fitting (390C) and injector (400B) to each start fuel nozzle holder assembly (380E). (f) Install the three start fuel nozzle holder assemblies (380E) in combustor housing. Torque fittings to 50 to 55 pound inches (5.6 to 6.2 N•m). (g) Connect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) to tee (350B, IPC 49-20-00, Figure 3). Torque B-nuts to 75 to 85 pound inches (8.5 to 9.6 N•m). (h) Connect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) to the three start fuel nozzle holder assemblies (380E, IPC 49-20-00, Figure 3). Torque Bnuts to 75 to 85 pound inches (8.5 to 9.6 N•m).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES N.

O.

Removal and Installation of Purge Check Valve (1)

Disconnect tube assembly (150, IPC 49-20-00, Figure 2) from union (330, IPC 4920-00, Figure 3).

(2)

Remove bolt (300), nut (310), and clamp (290) from check valve (280).

(3)

Remove check valve (280) from reducer (360).

(4)

Remove union (330) and packing (340) from check valve (280). Discard packing.

(5)

Install packing (340) and union (330) on check valve (280). Torque union 75 to 85 pound inches (8.5 to 9.6 N·m).

(6)

Install check valve (280) on reducer (360). Torque reducer 75 to 85 pound inches (8.5 to 9.6 N·m).

(7)

Install clamp (290) on check valve (280) with bolt (300) and nut (310). Torque nut 25 to 30 pound inches (2.8 to 3.4 N·m).

(8)

Connect tube assembly (150, IPC 49-20-00 Figure 2) to union (330, IPC 49-20-00, Figure 3). Torque B-nut 135 to 150 pound inches (15 to 17 N·m).

Removal and Installation of Fuel Manifold Assembly (1)

Disconnect tube assembly (90, IPC 49-20-00, Figure 2) from union (560, IPC 49-2000, Figure 3).

(2)

Remove bolts (480), nuts (490), and washers (500).

(3)

Unscrew B-nuts of fuel manifold assembly (470) from combustor housing assembly and remove fuel manifold.

(4)

Remove union (560) and packing (570) from fuel manifold assembly (470). Discard packing.

(5)

Remove bolts (520), nuts (530), washers (540), clamps (510), and cushions (550) from fuel manifold assembly (470).

(6)

Install cushions (550) and clamps (510) on fuel manifold assembly (470) with bolts (520), nuts (530), and washers (540). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

(7)

Install union (560) and packing (570) on fuel manifold assembly (470). Torque union 75 to 85 pound inches (8.5 to 9.6 N·m).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION: ANTI-SEIZE COMPOUNDS CONTAINING LEAD ARE HARMFUL TO THE COMBUSTOR LINER AND HOUSING ASSEMBLIES. DO NOT APPLY ANTI-SEIZE COMPOUNDS CONTAINING LEAD TO THESE COMPONENTS.

P.

Q.

(8)

Apply a light coat of anti-seize compound to fuel manifold assembly B-nuts and to manifold collars.

(9)

Install fuel manifold assembly (470) on combustor assembly. Tighten B-nuts evenly in the following sequence: 3 and 9 o’clock positions, 2 and 7 o’clock, and 5 and 11 o’clock. Torque B-nuts 55 to 65 pound inches (6.2 to 7.3 N·m).

Removal and Installation of Combustor Drain Check Valve Assembly (1)

Disconnect aircraft fuel drain tube from check valve assembly (250, IPC 49-20-00, Figure 3).

(2)

Remove check valve assembly (250) and packing (260) from reducer (270). Discard packing.

(3)

Install check valve assembly (250), with the flow arrow pointing forward, and packing (260) on reducer (270). Torque check valve assembly 75 to 100 pound inches (8.5 to 11.3 N·m).

(4)

Connect aircraft fuel drain tube to check valve assembly (250).

Removal and Installation of Fuel Inlet Filter Element WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. (1)

Position a container or drip pan under APU to catch spilled fuel.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (2)

Remove filter bowl (190, IPC 49-20-00, Figure 2), filter element (200), packing (205), and backing ring (208) from fuel filter assembly (170). Discard filter element and packing.

(3)

Install packing (205) and backing ring (208) on filter element (200) and install filter element in filter bowl (190).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (4) R.

Install filter bowl (190) on fuel filter assembly (170). Torque filter bowl 20 to 60 pound inches (2.3 to 6.8 N·m) and install lockwire.

Removal and Installation of Fuel Pump Filter Element (1)

Remove screws (20, IPC 49-20-00, Figure 4), cover (10), and packing (30). Discard packing.

(2)

Remove filter element (40) and packing (50). Discard packing. NOTE: Do not discard reusable filter element unless damaged.

S.

(3)

Put packing (50) on filter element (40) and install filter element.

(4)

Put packing (30) on cover (10) and install cover. Attach cover with screws (20). Torque screws 24 to 27 pound inches (2.7 to 3.1 N·m).

Removal and Installation of Fuel Solenoid Valves WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

(1)

Position a container or drip pan under APU to catch spilled fuel.

(2)

Disconnect tube assemblies, as required, from the following components: NOTE: Be sure caps and plugs are installed on all open lines, fittings, and ports. (a)

Disconnect tube assembly (130, IPC 49-20-00, Figure 1) from start valve bolt fitting (420, IPC 49-20-00, Figure 2) and from fuel control assembly (250, IPC 49-20-00, Figure 1).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (b) Disconnect tube assembly (240, IPC 49-20-00, Figure 1) from reducer (490, IPC 4920-00, Figure 2) and from fuel control assembly (250, IPC 49-20-00, Figure 1). (c) Disconnect tube assembly (140, IPC 49-20-00, Figure 1) from union (510, IPC 49-20-00, Figure 2) and from fuel control assembly (250, IPC 49-20-00, Figure 1). (d) Disconnect tube assemblies (90 and 130, IPC 49-20-00, Figure 2) from reducers (490). (3)

Disconnect electrical connectors, as required, from the following:

(a) Connector (P306) from main fuel solenoid valve (530). If damaged, remove connector seal (552) from main fuel solenoid valve (530). (b) Connector (P305) from start fuel solenoid valve (540). If damaged, remove connector seal (542) from start fuel solenoid valve (540). (c) Connector (P307) from maximum fuel solenoid valve (550). If damaged, remove connector seal (552) from maximum fuel solenoid valve (550). (4)

Remove bolts (560), nuts (570), and fuel solenoid valves (530, 540, and 550), as required.

(5)

Disassemble fuel solenoid valves as follows:

(a) Remove fittings (420, 450, and 480) and packings (430, 440, 460, and 470). Discard packings. (b) Remove reducers (490) and packings (500). Discard packings. (c) Remove union (510) and packing (520). Discard packing. (6)

Install fuel solenoid valves (530, 540, and 550) as follows: NOTE:

During installation, be sure main fuel and start fuel solenoid valves (530 and 540) are installed with flow arrows pointed away from fitting (480). Be sure maximum fuel solenoid valve (550) is installed with flow arrow pointed towards fitting (480).

(a) Put packing (430) on fitting (420) and packing (460) on fitting (450). Put packings (440 and 470) on fitting (480). Install fitting (480) on start fuel and maximum fuel solenoid valves (540 and 550) and attach with fitting (420) in start fuel solenoid valve (540) and fitting (450) in maximum fuel solenoid valve (550). Torque fittings (420 and 450) 135 to 150 pound inches (15 to 17 N·m). (b) Put packings (500) on reducers (490) and install reducers into main and start solenoid valves (530 and 540). Torque reducers 135 to 150 pound inches (15 to 17 N·m). (c) Put packing (520) on union (510) and install union into maximum fuel solenoid valve (550). Torque union 135 to 150 pound inches (15 to 17 N·m). REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (d) Install fuel solenoid valves (530, 540, and 550) with bolts (560) and nuts (570). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m). (7)

Connect tube assemblies to the following components:

(a) Connect tube assembly (130, IPC 49-20-00, Figure 1) to start valve bolt fitting (420, IPC 49-20-00, Figure 2) and to fuel control assembly (250, IPC 49-20-00, Figure 1). Torque B-nuts 95 to 105 pound inches (10.7 to 11.9 N·m). (b) Connect tube assembly (240, IPC 49-20-00, Figure 1) to reducer (490, IPC 49-2000, Figure 2) and to fuel control assembly (250, IPC 49-20-00, Figure 1). Torque Bnuts 75 to 85 pound inches (8.5 to 9.6 N·m). (c) Connect tube assembly (140, IPC 49-20-00, Figure 1) to union (510, IPC 49-20-00, Figure 2) and to fuel control assembly (250, IPC 49-20-00, Figure 1). Torque B-nuts 95 to 105 pound inches (10.7 to 11.9 N·m). (d) Connect tube assemblies (90 and 130, IPC 49-20-00, Figure 2) to reducers (490). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 N·m). (8)

Connect electrical connectors, as required, as follows:

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (a) Clean engine control harness assembly electrical connectors P306, P305 and P307 and the electrical connector on the main fuel solenoid valve (530), start fuel solenoid valve (540) and maximum fuel solenoid valve (550) using a soft-bristled brush and cotton wipes moistened with isopropyl alcohol to remove oil, grease, and contamination from the pins and inside of the electrical connectors. Allow connectors to air dry. (b) If required, install the connector seals (552) in the main fuel solenoid valve (530) connector, (542) in the start fuel solenoid valve (540) connector, and (552) in the maximum fuel solenoid valve (550) connector. Press the seals over the connector pins to the base of the pins. NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (c) Connector (P306) to main fuel solenoid valve (530). (d) Connector (P305) to start fuel solenoid valve (540).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (e) Connector (P307) to maximum fuel solenoid valve (550). T. Removal and Installation of Fuel Control Assembly, Acceleration Control, and Fuel Pump. WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. (1)

Position a container or drip pan under APU to catch spilled fuel.

(2)

Disconnect tube assemblies from the following components: NOTE: Be sure caps and plugs are installed on all open lines, fittings, and ports.

(a) Disconnect tube assembly (130, IPC 49-20-00, Figure 1) from union (420) and from start valve bolt fitting (420, IPC 49-20-00, Figure 2). (b) Disconnect tube assembly (240, IPC 49-20-00, Figure 1) from reducer (440) and from reducer (490, IPC 49-20-00, Figure 2). (c) Disconnect tube assembly (140, IPC 49-20-00, Figure 1) from reducer (380) and from union (510, IPC 49-20-00, Figure 2). (d) Disconnect tube assembly (120, IPC 49-20-00, Figure 1) from union (490) and from elbow (230, IPC 49-20-00, Figure 2). (e) Disconnect tube assembly (180, IPC 49-20-00 Figure 1) from union (360) and from elbow (20, IPC 49-20-00, Figure 3). (f) Disconnect aircraft drain tube from elbow (460, IPC 49-20-00, Figure 1). (3)

Remove bolts (260, IPC 49-20-00, Figure 1), washers (270), and assembled fuel control assembly (250). Remove gasket (280) and discard.

(4)

Remove bolts (300), washers (310), and fuel pump (320). Remove packings (330, 340, and 350) and discard.

(5)

Remove elbow (460), nut (480), and packing (470). Discard packing.

(6)

Remove unions (360, 380, 420, 440, and 490) and packings (370, 390, 430, 450, and 500). Discard packings.

(7)

Remove plug (400) and packing (410). Discard packing.

(8)

Mate fuel pump (320) to acceleration control (290) without packings. The faces should mate with no clearance and without force. If force is necessary, separate and inspect splines. Remove all foreign material and burrs.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (9)

Put packings (330, 340, and 350) on acceleration control (290) and mate to fuel pump (320). Attach with bolts (300) and washers (310). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

(10) Install elbow (460), packing (470) and nut (480). Torque nut 180 to 200 pound inches (20.3 to 22.6 N·m). (11) Install unions (360, 380, 420, and 440) and packings (370, 390, 430, and 450). Torque unions 90 to 100 pound inches (10.2 to 11.3 N·m). (12) Install union (490) and packing (500). Torque union 135 to 150 pound inches (15 to 17 N·m). (13) Install plug (400) and packing (410). Torque plug 135 to 150 pound inches (15 to 17 N·m). (14) Install assembled fuel control assembly (250) and gasket (280) and attach with bolts (260) and washers (270). Torque bolts 55 to 70 pound inches (6.2 to 7.9 N·m). (15) Connect tube assemblies to the following components: (a) Connect tube assembly (130) to union (420) and to start valve bolt fitting (420, IPC 49-20-00, Figure 2). Torque B-nuts 135 to 150 pound inches (15.2 to 16.9 N·m). (b) Connect tube assembly (240, IPC 49-20-00, Figure 1) to reducer (440) and to reducer (490, IPC 49-20-00, Figure 2). Torque B-nuts 50 to 60 pound inches (5.6 to 6.8 N·m). (c) Connect tube assembly (140, IPC 49-20-00 Figure 1) to reducer (380) and to union (510, IPC 49-20-00, Figure 2). Torque B-nuts 135 to 150 pound inches (15.2 to 16.9 N·m). (d) Connect tube assembly (120, IPC 49-20-00, Figure 1) to union (490) and to elbow (230, IPC 49-20-00, Figure 2). Torque B-nuts 270 to 300 pound inches (30.5 to 33.9 N·m). (e) Connect tube assembly (180, IPC 49-20-00, Figure 1) to union (360) and to elbow (20, IPC 49-20-00, Figure 3). Torque B-nuts 135 to 150 pound inches (15.2 to 16.9 N·m). (f) Connect aircraft drain tube to elbow (460, IPC 49-20-00, Figure 1). U. Removal and Installation of High Oil Temperature Switch WARNING:

(1)

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

Disconnect electrical connector (P311) from high oil temperature switch (690, IPC 49-20-00 Figure 2). If damaged, remove the connector seal (685) from high oil temperature switch (690). Discard the seal.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES. WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (2)

Place a container under the reduction drive to catch oil and remove high oil temperature switch (690) and packing (700). Discard packing. Put packing (700) on high oil temperature switch (690) and install switch. Torque switch 55 to 75 pound inches (6.2 to 8.5 N·m) and secure with lockwire.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (3)

Clean engine control harness assembly electrical connector P311 and the electrical connector on the high oil temperature switch (690) using a soft-bristled brush and cotton wipes moistened with isopropyl alcohol to remove oil, grease, and contamination from the pins and inside of the electrical connectors. Allow connectors to air dry.

(4)

If required, install the connector seal (685) in the high oil temperature switch (690) connector. Press the seal over the connector pins to the base of the pins.

NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (5)

Connect electrical connector (P311) to high oil temperature switch (690).

(6)

Service APU with oil (refer to SERVICING).

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES V. Removal and Installation of Magnetic Pickup WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

(1)

Disconnect electrical connector (P302) from magnetic pickup (680, IPC 49-20-00 Figure 2). If damaged, remove the connector seal (685) from magnetic pickup (680). Discard the seal.

(2)

Loosen nut and remove magnetic pickup (680). NOTE:

(3)

To aid removal of pickup, it may be necessary to apply heat around boss to soften thread sealant.

Insert a 7/16 Allen wrench in the starter gear of the accessory drive assembly. Use the wrench to manually turn the gear until one tooth of the starter gear is in line with the center of the speed pickup mounting hole.

WARNING:

USE LOCQUIC PRIMER GRADE N, MIL-S-22473N, CORRECTLY. THE PRIMER IS FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE PRIMER, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0135SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE PRIMER, PUT ON CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES (BUTYL RUBBER). MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE PRIMER FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

WARNING:

USE TEFLON SEALANT, PST 592, CORRECTLY. THE COMPOUND IS FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0067SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT

(4)

Apply MIL-S-22473N Primer Grade "N" to threads of magnetic pickup (680) and allow to dry for 5 minutes. Apply Pipe Sealant with Teflon (PST 592) to threads of magnetic pickup.

(5)

Rotate Accessory Drive Gear until top of one of the Gear Teeth is in line with center of Magnetic Pick-up mounting hole.

(6)

Install Magnetic Pick-up (680) by hand into Accessory Drive until contact with Gear is made. REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (7)

Using key in electrical connector as a reference, back off magnetic pickup (680) one quarter (1/4) turn (0.14 inch or 0.356 mm) and tighten Jam Nut into housing. Torque Jam Nut to 75-100 pound inches (8.5 to 11.3 N.m). NOTE: Gap between pole of speed pickup and gear tooth is 0.012 to 0.016 inch (0.305 to 0.406 mm).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (8)

Use the Allen wrench to manually turn the starter gear through a complete revolution. Make sure speed pickup does not touch the gear. Secure jam nut with lockwire or safety cable and ferrule.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (9)

Clean engine control harness assembly electrical connector P302 and the electrical connector on the magnetic pickup (680) using a soft-bristled brush and cotton wipes moistened with isopropyl alcohol to remove oil, grease, and contamination from the pins and inside of the electrical connectors. Allow connectors to air dry.

(10) If required, install the connector seal (685) in the magnetic pickup (680) connector. Press the seal over the connector pins to the base of the pins. (11) Connect the engine control harness assembly electrical connector P302 to the magnetic pickup (680). NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector.

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES W. Removal and Installation of Low Oil Pressure Switch WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

(1)

Disconnect electrical connector (P304) from low oil pressure switch (260, IPC 4920-00, Figure 2). If damaged, remove the connector seal (262) from low oil pressure switch (260). Discard the seal.

(2)

Remove low oil pressure switch (260) and packing (270). Discard packing.

(3)

Put packing (270) on low oil pressure switch (260) and install switch. Torque switch 40 to 60 pound inches (4.5 to 6.7 N·m).

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (4)

Clean engine control harness assembly electrical connector P304 and the electrical connector on the low oil pressure switch (260) using a soft-bristled brush and cotton wipes moistened with isopropyl alcohol to remove oil, grease, and contamination from the pins and inside of the electrical connectors. Allow connectors to air dry.

(5)

If required, install the connector seal (262) in the low oil pressure switch (260) connector. Press the seal over the connector pins to the base of the pins.

(6)

Connect electrical connector (P304) to low oil pressure switch (260).

NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES X. Removal and Installation of Oil Sight Plug WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES. (1)

Drain oil below level of sight plug (580, IPC 49-20-00, Figure 2) according to SERVICING.

(2)

Remove oil sight plug (580) and packing (590) from nut (610). Discard packing.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (3)

Put packing (590) on oil sight plug (580) and install plug into nut (610). Torque plug 65 to 85 pound inches (7.3 to 9.6 N·m) and secure to nut (610) with lockwire or safety cable and ferrule.

(4)

Service APU with oil (refer to SERVICING).

Y. Removal and Installation of Oil Filter Element WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES. (1)

Position a container under oil filter bowl (332, IPC 49-20-00, Figure 2) to catch spilled oil.

(2)

Remove oil filter bowl (332), backup ring (334), packing (335), filter element (340), and packing (350). Discard filter element and packings.

(3)

Put packing (350) in filter element (340).

(4)

Put backup ring (334) and packing (336) on oil filter bowl (332).

(5)

Put filter element (340) into oil filter bowl (332) and install bowl.

(6)

Service APU with oil (refer to SERVICING).

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Z. Removal and Installation of Magnetic Plug / Magnetic Drain Plug WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES. (1)

Position a container under the APU to catch spilled oil.

(2)

Remove magnetic drain plug (10, IPC 49-23-00, Figure 1), and packing (20). Allow oil to drain into container. Discard packing.

(3)

Remove magnetic plug (30) and packing (40). Discard packing.

(4)

Put packing (20) on magnetic drain plug (10) and install plug. Torque plug 40 to 50 pound inches (4.5 to 5.7 N·m).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (5)

Put packing (40) on magnetic plug (30) and install plug. Torque plug 15 to 20 pound inches (1.6 to 2.2 N·m). Secure plugs (10 and 30) with lockwire.

(6)

Service APU with oil (refer to SERVICING).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES CLEANING 1.

Introduction A.

This section has the procedures for cleaning the Auxiliary Power Unit (APU) system components. Item numbers in the procedures and illustrations are the same as those in the Illustrated Parts Catalog (IPC), Document 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001, for general information. NOTE: Alpha-variant items can replace an item when permitted by the effect code for that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Cleaning Materials A.

Cleaning materials are listed in Figure 601. NOTE: Equivalent substitutes may be used for items listed. Material

Source (Vendor Code)

Lint-free cloth

Commercially Available

Lubricating oil MIL-PRF-6081, Grade 1010

Commercially Available

TODCO 1060

Commercially Available

Cleaning Solution MIL-PRF-85704 Type II or Type II RTU

Commercially Available

Isopropyl Alcohol, ASTM D770

Commercially Available

Cotton Wipes, A-A-51025

Commercially Available

Soft-bristle Brush

Commercially Available

Stiff-bristle brush

Commercially Available

Dry cleaning Solvent (Federal Specification MIL-PRF-680, Type II)

Commercially Available

Cleaning Compound (Simple Green, 13002) or equivalent alkaline cleaner with a pH of 8-9.

Sunshine Makers, Inc. (1Z575)

Ultrasonic Cleaner, B-2200-R-1

Branson Ultrasonics Corp. (10042)

Gloves

Commercially Available

Goggles

Commercially Available

Mask

Commercially Available

Spray Gun

Commercially Available

Q-Tip or rounded toothpick

Commercially Available

Razor Knife

Commercially Available

Oil (Federal Specification VV-L-800)

Commercially Available Cleaning Materials Figure 601 CLEANING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 3.

Cleaning Procedures A.

General (1)

B.

When considerable time may elapse between cleaning and inspection or reassemble, apply a light coat of lubricating oil to components and mating surfaces. Place cleaned parts in clean plastic bags to prevent contamination.

Cleaning (1)

Cleaning requirements are listed in Figure 602. Component

Cleaning Method

Fuel pump filter (40, IPC 49-20-00 Figure 4) Fuel pump (320, IPC 49-20-00 Figure 1)

Wash and flush. Clean by ultrasonic method. Wipe with clean, lint-free cloth soaked in dry- cleaning solvent.

Acceleration control (290, IPC 49-20-00 Figure 1)

Wipe with clean, lint-free cloth soaked in dry- cleaning solvent.

Low oil pressure switch (260, IPC 49-20-00 Figure 2)

Wipe with clean lint-free, dry cloth.

Thermocouple (112, IPC 49-20-00 Figure 1)

Wipe with clean lint-free, dry cloth.

Ignition exciter (200 or 200A, IPC 49-20-00 Figure 3)

Wipe clean with lint-free, dry cloth. NOTE: Cap electrical receptacles or connections as required before cleaning.

Hourmeter (100A, IPC 49-20-00 Figure 1)

Wipe clean with lint-free, dry cloth.

Event counter (110, IPC 49-20-00 Figure 1)

Wipe clean with lint-free, dry cloth.

Anti-surge valve (40, IPC 49-00-00 Figure 1)

Wipe clean with lint-free, dry cloth.

High oil temperature switch (690, IPC 49-20-00 Figure 2)

Wipe clean with lint-free, dry cloth.

Solenoid valves (530, 540, and 550, IPC 49-20-00 Figure 2)

Wipe clean with lint-free, dry cloth. CAUTION: TO PREVENT DAMAGE, DO NOT USE CONVENTIONAL ABRASIVE OR IGNITER PLUG CLEANER.

Igniter plug (170 or 170A, IPC 49-20-00 Figure 3)

Use a dry, stiff-bristle brush and wipe with clean, lint-free, dry cloth.

Magnetic pickup (690, IPC 49-20-00 Figure 2)

Wipe clean with lint-free, dry cloth.

Start Fuel Nozzle (380C and 380E, IPC 49-20-00 Figure 3)

Refer to steps 6.A. thru 6.I. NOTE: Refer to APS 500C/I/R Cleaning number 5 as an alternate cleaning method.

Cleaning Requirements Figure 602 CLEANING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (2)

Cleaning/Checking of Combustor Drain Check Valve Assembly WARNING: USE CLEANING SOLVENT (ALSO KNOWN AS DRY CLEANING SOLVENT, STODDARD SOLVENT, MINERAL SPIRITS, NAPHTHA, PETROLEUM SPIRITS, MIL-PRF-680 TYPE II, ASTM D235 TYPE II, OR AMS3160) CORRECTLY. THE SOLVENT IS FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE SOLVENT, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0158SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE SOLVENT, PUT ON CHEMICALSPLASH GOGGLES, AND SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SOLVENT FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (a)

Wash and flush check valve assembly (250, IPC 49-20-00 Figure 3) thoroughly with dry-cleaning solvent.

(b)

Connect a source of regulated air pressure to bulkhead end of check valve assembly. NOTE: The line length must be 4 to 5 feet (1.2 to 1.5m) with pressure gage placed right next to check valve assembly.

4.

(c)

Slowly apply air. Valve must close when 25 psig (172.5 kPa) air pressure is applied to the inlet. Valve leakage not to exceed 0.01 psig (0.07 kPa) per minute. Replace check valve assembly if ball valve does not seat properly.

(d)

Return air pressure to 0 psig (0 kPa).

(e)

Remove check valve from air source.

(f)

Pour dry-cleaning solvent into bulkhead end of check valve assembly. Solvent must flow freely from valve. Replace check valve assembly if solvent flow is restricted.

Turbine Assembly Water Wash CAUTION: THE COMPRESSOR WHEEL IS OF TITANIUM CONSTRUCTION. DO NOT USE WATER SOLUBLE CLEANERS CONTAINING CHLORINATED HYDROCARBONS. CHLORINATED HYDROCARBONS ARE DETRIMENTAL TO TITANIUM. A.

Prepare to Clean NOTE: Cap or plug all open lines and ports. (1)

Remove components as necessary to gain access to air inlet screen (770, IPC 49-20-00 Figure 3). Do not remove screen. CLEANING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (2)

Disconnect electrical connectors (P305, P306, and P307) from solenoid valves (530, 540, and 550, IPC 49-20-00 Figure 2).

(3)

Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC 49-20-00 Figure 3).

(4)

Disconnect tube assembly (180, IPC 49-20-00 Figure 1) from elbow (20, IPC 49-2000 Figure 3). NOTE: This will prevent cleaning solution reaching acceleration control.

(5)

Mix 1 part cleaning solution MIL-PRF-85704 Type II to 4 parts distilled water. NOTE: Cleaning solution MIL-PRF-85704 Type II requires no dilution.

(6) B.

Fill a suitable spray gun with cleaning solution mixture.

Clean the Turbine Rotor Assembly (1)

Set master switch to START for approximately 5 seconds and release. Allow engine RPM to build up. Set master switch to OFF.

(2)

Spray cleaning solution into air inlet while engine is rotating. NOTE: Cleaning solution that is ingested during slow rotation of the turbine will be most effective for cleaning operation.

C.

(3)

Repeat steps (1 and 2) until cleaning solution has been ingested.

(4)

Allow engine to stand for approximately 15 minutes to allow deposits to be dissolved.

(5)

Fill a suitable spray gun with one quart (1 liter) of distilled or demineralized water.

(6)

Repeat steps (1 and 2) and spray water into air inlet while engine is rotating. Repeat steps (1 and 2) until all water has been ingested.

Reassembly (1)

Allow engine to stand until all water has drained from the check valve assembly (250, IPC 49-20-00 Figure 3). Inspect check valve assembly (250) and clean as necessary.

(2)

Connect tube assembly (180, IPC 49-20-00 Figure 1) to elbow (20, IPC 49-20-00 Figure 3). Torque B-nut 135 to 150 pound inches (15 to 17 N·m).

(3)

Connect electrical connector (P303) to ignition exciter (200 or 200A, IPC 49-20-00 Figure 3) and secure with lockwire.

(4)

Connect electrical connector (P305) to solenoid valve (530, IPC 49-20-00 Figure 2), (P306) to solenoid valve (540), and (P307) to solenoid valve (550) and secure with lockwire.

(5)

Install components removed to gain access to the inlet screen. CLEANING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 5.

6.

Cleaning the Fuel Pump Filter Element A.

Clean filter element (40, IPC 49-20-00 Figure 4) using the ultrasonic cleaning method.

B.

The filter element should remain in ultrasonic tank for about 5 minutes.

C.

Wipe surfaces with clean, lint-free cloth.

Cleaning the Fuel Nozzle and Components WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION. A.

Place the cleaning compound in the cleaning tank at 40 to 50% of tank capacity and heat the solution to 120° to 140° F (49° to 60° C).

CAUTION: DO NOT ALLOW PARTS TO REMAIN IN CLEANING SOLUTION FOR EXTENDED PERIODS OF TIME OR RUST SPOTS CAN FORM. IF PARTS ARE NOT INSPECTED IMMEDIATELY AFTER CLEANING, DIP THEM IN CLEAN LUBRICATING OIL TO PREVENT FORMATION OF RUST. B.

Place the part to be cleaned in the cleaning tank for 15 to 20 minutes.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET MEDICAL ATTENTION. C.

Pressure rinse the part with the hand gun for three to five minutes.

D.

Using a stainless steel brush or Scotch Brite, and hot water, brush areas which might exhibit oxidation. NOTE: A Q-tip and a round tooth pick may be used to remove any remaining contaminants from the fuel nozzle body. If necessary, use a razor knife to remove contaminants from the slots in the face of the distributor.

CLEANING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION. E.

Place the cleaning compound in the cleaning tank to 40 or 50% of tank capacity and heat the solution to 120° to 140° F (49° to 60° C) until all traces of varnish or carbon have been removed.

CAUTION: DO NOT ALLOW PARTS TO REMAIN IN CLEANING SOLUTION FOR EXTENDED PERIODS OF TIME OR RUST SPOTS CAN FORM. IF PARTS ARE NOT INSPECTED IMMEDIATELY AFTER CLEANING, DIP THEM IN CLEAN LUBRICATING OIL TO PREVENT FORMATION OF RUST. F.

Place the part to be cleaned in the cleaning tank for five to ten minutes.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET MEDICAL ATTENTION. G.

Pressure rinse the part with the hand gun for three to five minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION. H.

Rinse the part in the hot rinse tank for three to five minutes.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET MEDICAL ATTENTION. I.

Use compressed air at 29 psi (200 kPa) or lower to dry part.

CLEANING

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Page 606 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES INSPECTION/CHECK 1.

General A.

This section provides procedures to determine serviceability of the Auxiliary Power Unit (APU) system. Item numbers in the procedures are the same as those in the Illustrated Parts Catalog (IPC), Document 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001, for general information. NOTE: Alpha-variant items can replace an item when permitted by the effect code for that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

B.

Overtemperature Inspection (1)

The measured continuous exhaust gas temperature (EGT) shall not exceed 1303 ± 20°F (706 ± 11°C). In the event the temperature exceeds these limits, an overtemperature shutdown should occur. If the APU does not shutdown automatically, it must be manually shutdown immediately. A notation of the temperature reached and the duration of operating time in an overtemperature condition should be entered in the log book. The following checks shall be performed if the corrective actions suggested by FAULT ISOLATION procedures do not correct the condition: (a)

Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC 49-20-00 Figure 3).

(b)

Crank APU to maximum cranking speed and allow to coastdown. Carefully listen for unusual noises or vibration during runup and coastdown.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDESHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (c)

Connect electrical connector (P303) to ignition exciter (200 or 200A, IPC 49-20-00 Figure 3) and secure with lockwire.

INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

C.

(d)

Start APU and accelerate to 50% rated speed and shutdown APU. Carefully listen for unusual noises or vibration during runup and coastdown.

(e)

If all conditions appear normal, start APU and accelerate to rated speed. If APU operation is normal, apply partial load. At each change of load, allow EGT to stabilize to determine if APU operation is normal before applying additional load.

(f)

If all conditions appear normal at rated speed and load, the APU can be returned to service. However, if over-temperature continues, remove APU for repair.

APU Inspection (1)

Refer to Figure 801 for the APU inspection limits. (a)

Operationally check APU for proper starting (refer to OPERATIONAL CHECK).

INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Nomenclature

Inspection Limits

Corrective Action

Loop Clamps

Check for condition and security. No deterioration permitted.

Replace damaged clamps.

Brackets (730, IPC 49-20-00 Figure 2)

Check for condition, security, and cracks.

Replace bracket.

Check for corrosion.

Remove corrosion.

Check for chafing, cracks, or leakage. Nicks or gouges in excess of 10% of wall thickness. Kinks not allowed.

Reposition support clamps to prevent chaffing. Replace cracked or leaking tubes with nicked/gouged in excess of 10%.

Visually check B-nuts for cracks and/or damaged.

Replace tube assembly.

Check for corrosion.

Remove corrosion.

Check for minimum clearance of 0.080 inch (2.032 mm) between external rigid tubing.

Reposition tubing.

Check for cracked, broken, or blockage of screen mesh.

Remove blockage. Remove screen to check for possible foreign object damage (FOD). If FOD is suspected, remove turbine assembly for further investigation.

Check screen for condition of lacing hooks.

Replace screen if damaged.

Check for crazing, fracture, delamination, erosion, chips and resin starvation (dryness) in composite areas of top and bottom halves.

Refer to INSPECTION 104 (4922-01) of Document APS500C/I/R.

Check for wear, crazing, fracture and erosion through the laminate of top and bottom halves [less than or equal to 1 inch (25.4 mm) in diameter].

Refer to INSPECTION 104 (4922-01) of Document APS500C/I/R.

Check for damaged or missing piece(s) in composite radial closure and/or flanges.

Refer to INSPECTION 104 (4922-01) of Document APS500C/I/R.

Tube Assemblies

Air Inlet Screen (770, IPC 49-20-00 Figure 3)

Air Inlet Duct Assembly (10, IPC 49-20-00 Figure 3)

APU Inspection Limits Figure 801 (Sheet 1 of 5) INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Nomenclature

Inspection Limits

Corrective Action

Check for crazing, fracture or erosion of multiple layers of plies [less than or equal to 3 square inches (19.35 square centimeters)]

Refer to INSPECTION 104 (4922-01) of Document APS500C/I/R.

Check for damage or evidence of cracks in housing.

Replace APU.

Check for corrosion.

Remove corrosion.

Turbine wheel should rotate easily. No rubbing or unusual noise is permitted.

Replace APU.

Preformed Packing (10 and 20, IPC Figure 1, 49-22-00)

Inspect preformed packing for damage (worn), nicks and cuts.

Refer to REPAIR 26 (49-22-01) of Document APS500C/I/R.

Harness Assembly (10, IPC 49-20-00 Figure 1)

Check for condition and security.

Replace harness.

Check heat shrink tubing for deterioration.

Replace damaged tubing.

Check for harness chafing.

Reposition harness and clamps as necessary.

Check terminal lugs for damage.

Replace damaged terminal lugs.

Ignition Cables (130 and 135, IPC, 49-20-00 Figure 3)

Check for frayed braiding.

Replace ignition cable.

Exciter (200 or 200A, IPC 49-20-00 Figure 3)

Check housing and mounting bracket for nicks, burrs, or scratches.

Blend out minor nicks, burrs, or scratches.

Check housing for dents, distortion, or cracks.

Replace exciter.

Check mounting bracket for distortion.

Straighten mounting bracket to original contour.

Check mounting bracket for cracks.

Replace exciter.

Check connectors for corrosion.

Remove corrosion.

Turbine Assembly (780, IPC 49-20-00 Figure 3)

APU Inspection Limits Figure 801 (Sheet 2 of 5) INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Nomenclature

Inspection Limits

Corrective Action

Check mounting bracket for cracks.

Replace exciter.

Check connectors for corrosion.

Remove corrosion.

Thermocouple (112, IPC 49-20-00 Figure 1)

Check sheath and shielding for damage.

Replace thermocouple.

Magnetic Pickup (680, IPC 49-20-00 Figure 2)

Check for security and damage.

Replace magnetic speed pickup.

Test Magnetic Pickup according to paragraph 1.I.

Replace magnetic pickup if test failed.

Check for mechanical damage.

Replace igniter plug if it shows impact damaged, if connector well or firing end insulator is cracked or loose, or if connector pin is badly bent or broken.

Check firing end shell for chafing or fretting wear.

Replace igniter plug if wear exceeds 0.015 inch (0.38 mm) or if wear is more than one-half the circumference of the shell.

Check for swollen or distorted shell body.

Replace igniter plug.

Check for electrical erosion.

Replace igniter plug if erosion exceeds limit shown in figure 802.

High Oil Temperature Switch (690, IPC 49-20-00 Figure 2)

Check for security and damage.

Replace high oil temperature switch.

Low Oil Pressure Switch (260, IPC 49-20-00 Figure 2)

Check for corrosion.

Remove corrosion.

Main, Start, and Maximum Fuel Solenoid Valves (530, 540, and 550, IPC 49-20-00 Figure 2)

Check connector and valve body for corrosion.

Remove corrosion.

Igniter Plugs (170 or 170A, IPC 49-20-00 Figure 3)

APU Inspection Limits Figure 801 (Sheet 3 of 5)

INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Nomenclature

Inspection Limits

Corrective Action

Check for movement between valve body and housing.

If the valve body is cast, torque screws 6 to 8 pound inches (0.68 to 0.90 N·m). If the valve body is solid, torque screws 4.7 to 5.3 pound inches (0.53 to 0.59 N·m).

Check mounting flange gasket for damage. A minimum of 0.150 inch (3.81 mm) gasket around the connector is acceptable.

Replace solenoid valve.

Fuel Manifold (470, IPC 49-20-00 Figure 3)

Check for condition, security, and evidence of fuel leakage.

Torque B-nuts. Replace manifold if fuel leakage continues.

Fuel Control Assembly (250, IPC 49- 20-00 Figure 1)

Check for condition, security, and evidence of fuel leakage.

Disassemble and replace packings.

Acceleration Control (280, IPC 49-20-00 Figure 1)

Check for evidence of fuel leakage. A maximum of 6 drops per minute is allowed.

Replace acceleration control.

Fuel Pump (320, IPC 49-20-00 Figure 1)

Check for evidence of fuel leakage. A maximum of 6 drops per minute is allowed.

Replace fuel pump.

Anti-Surge Valve (40, IPC 49-00-00 Figure 1)

Check for condition and security.

Replace anti-surge valve.

Check mounting flange for evidence of gas leakage.

Replace packing.

Check for oil leakage.

Tighten connections as needed. Replace APU.

Check for cracks in housing.

Replace APU.

Check for corrosion.

Remove corrosion.

Check for chipped or worn paint.

Repair according to REPAIR-59 (49-26-01) of Document APS500C/I/R

Reduction Drive Assembly (820, IPC 4920-00 Figure 3)

Accessory Drive Cover Assembly (70, IPC 49-23-00 Figure 2)

APU Inspection Limits Figure 801 (Sheet 4 of 5) INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Nomenclature

Fuel Nozzle (400, IPC 49-20-00 Figure 3)

Inspection Limits

Corrective Action

Check for loose or missing paint.

For aesthetic purposes, intumescent coating may be touched up or repainted.

Check for security and damage.

Replace nozzle assembly.

Test according to paragraph 1.J.

Replace nozzle assembly if test is failed.

APU Inspection Limits Figure 801 (Sheet 5 of 5)

Igniter Plug Figure 802

INSPECTION/CHECK

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THIS PAGE INTENTIONALLY LEFT BLANK

INSPECTION/CHECK

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Page 806B Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES D.

Magnetic Plug (Chip Detector) Inspection WARNING: DO NOT TOUCH THE COMPONENTS OF THE OIL SYSTEM IF THE APU IS HOT. THESE COMPONENTS STAY HOTTER THAN OTHER COMPONENTS. HOT COMPONENTS CAN BURN YOU. WARNING: HOT OIL MAY CAUSE BURNS TO EYES AND SKIN. PUT ON SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION. WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES. CAUTION:

(1)

DO NOT OIL GET ON THE ENGINE OR OTHER COMPONENTS. IMMEDIATELY CLEAN THE OIL WHEN IT FALLS ON THEM. OIL CAN CAUSE DAMAGE TO PAINT AND RUBBER.

Remove the magnetic plug (30, IPC 49-23-00, Figure 1) from the magnetic drain plug (10).

NOTE: It is not necessary to drain the oil when you examine the magnetic drain plug. The magnetic drain plug has a valve that closes when the magnetic element is removed. (2)

Remove the preformed packing (40) from the magnetic plug (30). Discard the preformed packing.

(3)

Examine the magnetic plug (30) for contamination. (a)

If the plug is free of contamination, wipe with a clean, lint-free cloth, install new packing (40), and reinstall it into the APU.

NOTE: Occasionally, new or overhauled APU's may produce a small amount of fuzz, flakes, or splinters during initial operation. (b)

If contamination is found, refer to Figure 803 for contamination criteria.

INSPECTION/CHECK

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Page 807 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES E.

Oil Contamination Inspection (1)

If particles are found in the reduction drive oil, refer to Figure 803 for contamination criteria.

Contamination Type Magnetic

Particle Form/Quantity (Note 1) Fuzz (Finewear)

Magnetic or Nonmagnetic

Small Flakes or Granules Flakes smaller than 0.060 square inch (0.387 square cm), or approximately 0.25 x 0.25 inches (0.64 x 0.64 cm) Quantity of flakes does not cover an area larger than 0.060 square inch (0.387 square cm), or approximately 0.25 x 0.25 inches (0.64 x 0.64 cm) Splinters (1 to 3 pieces)

Disposition Change oil and filter. Clean magnetic plug and return APU to service. Change oil and filter (Refer to SERVICING). Clean the oil sump, visually inspect the gearbox, and perform Step 1 below. Step 1. Operate the APU normally for approximately 1 hour and recheck the magnetic drain plug and filter. If no particles are found during the recheck, return the APU to service and normally scheduled maintenance. If fewer particles are found than were originally seen before the 1 hour period, change the oil and filter again and perform Step 2 below. (Notes 2, 3, and 4). If more or larger particles are found than were originally seen before the 1 hour period, remove the APU. Step 2. Operate the APU normally for approximately 25 hours and recheck the magnetic drain plug and filter. If no particles are found during the recheck, return the APU to service. If fewer particles are found than were originally seen before the twenty-five hour period, change the oil and filter again and perform Step 1 above. (Notes 2, 3, and 4). If more or larger particles are found than were originally seen before the 25 hour period, remove the APU.

Contamination Criteria (Small Sized Particles) Figure 803 (Sheet 1 of 3)

INSPECTION/CHECK

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Page 808 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Contamination Type Magnetic or Nonmagnetic

Particle Form/Quantity (Note 1) Large Flakes or Granules

Disposition

Flakes larger than 0.060 square inch (0.387 square cm), or approximately 0.25 x 0.25 inches (0.64 x 0.64 cm) Quantity of smaller flakes covers an area larger than 0.060 square inch (0.387 square cm), or approximately 0.25 x 0.25 inches (0.64 x 0.64 cm) Splinters (3 or more pieces)

Change oil and filter (Refer to SERVICING). Clean the oil sump or perform flush and drain (refer to SERVICING), visually inspect the gearbox, and perform Step 1 below. CAUTION: IF A PARTICLE IS FOUND WHICH IS RECOGNIZABLY A PIECE OF AN INTERNAL GEARBOX COMPONENT, SUCH AS A GEAR TOOTH, REMOVE THE APU. Step 1. Resume normal APU operation to accumulate between thirty (30) minutes and no more than one (1) APU operating hour and recheck the magnetic plug and filter. If no particles are found during the recheck, return the APU to service and perform Step 2 below. (Notes 2, 3, and 4) If particles are found, remove the APU. Step 2. Resume normal APU operation to accumulate no more than fifteen (15) APU operating hours and recheck the magnetic plug and filter. If no particles are found during the recheck, return the APU to service. If particles are found, remove the APU.

Contamination Criteria (Large Sized Particles) Figure 803 (Sheet 2 of 3)

INSPECTION/CHECK

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Page 809 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Notes Note 1: Definition of particle forms: Flake: thin flat piece or layer Fuzz (Finewear): light particles or fibers Granular: consisting of or appearing to consist of grains Splinter: thin pieces or sliver split off lengthwise Note 2: Contamination evidence should be removed from the magnetic drain plug and/or oil sump and preserved by encapsulating the evidence in a piece of clear plastic tape placed in a clean, new plastic bag. The oil filter should be removed and placed in a clean, new plastic bag. An oil sample should be taken and stored in an oil sample kit. Record the date, APU serial number, and APU hours and cycles since new or since last oil check. Include this information with the items sent for analysis. It is recommended that this information be recorded in the APU logbook. Return evidence, the oil filter, and oil sample with the removed APU for analysis. Note 3: Perform a Spectrographic Oil Analysis Program (SOAP) analysis of the oil and material removed (refer to Figure 804). The presence of M50 material in the results of the analysis is cause for removal. (M50 material contains approximately 90% iron, 4% chromium, 4% molybdenum, 1% vanadium, 0.8% carbon, and 0.2% silicon.) Note 4: Confirmation of the findings should be communicated to either Hamilton Sundstrand Customer Service, Field Service, or an authorized Hamilton Sundstrand Service Center before APU removal.

Contamination Criteria Figure 803 (Sheet 3 of 3)

INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Magnetic Chip Detector Inspection Figure 804

INSPECTION/CHECK

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Page 811 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Spectrographic Oil Analysis Program (SOAP) NOTE: Samples for SOAP analysis may be submitted to any qualified laboratory. Hamilton Sundstrand does not recommend nor require any specific facility be used. NOTE: It is necessary to establish a baseline for SOAP analysis for each APU and watch for changes from that baseline as an indicator of a possible problem. NOTE: These guideline levels are not considered as ultimate limits for oil analysis; they are strictly target watch levels used to develop a trend. Element

Watch Limits in parts per million (ppm)

Iron (Fe)

5

Copper (Cu)

5

Chromium (Cr)

5

Aluminum (Al)

5

Nickel (Ni)

5

Silicon (Si)

10

Boron (B)

10

Sodium (Na)

10

Phosphorous (Ph)

10

Zinc (Zn)

60

Magnesium (Mg)

5

Molybdenum (Mo)

5

Silver (Ag)

5

1.

If an element value is exceeded on first analysis, check magnetic plug and resample.

2.

If an element value is exceeded on the second check, change the oil, oil filter, and change the inspection interval to one half normal period.

3.

If an element value is exceeded on the third check, contact Hamilton Sundstrand Customer Service, Field Service, or an authorized Hamilton Sundstrand Service Center. Spectrographic Oil Analysis Program Figure 805

INSPECTION/CHECK

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Page 812 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES F.

Borescope Inspection (1)

G.

Remove the necessary components and insert the probe of a borescope through the following openings in the APU to gain access to the internal components of the turbine assembly. Refer to Figure 801 for inspection limits. (a)

Start fuel nozzle (380, IPC 49-20-00 Figure 3) opening. Provides access to the combustor liner.

(b)

Igniter plug (170 or 170A, IPC 49-20-00 Figure 3) opening. Provides access to the combustor liner.

(c)

Air inlet screen (770, IPC 49-20-00 Figure 3). Provides access to the compressor wheel and diffuser.

(d)

Anti-surge valve (40, IPC 49-00-00 Figure 1) opening. Provides access to the diffuser.

(e)

Exhaust end of the combustor housing (640, IPC 49-20-00 Figure 3). Provides access to the turbine wheel and turbine nozzle.

APU Shutdown Check NOTE: The thermocouple (112, IPC 49-20-00 Figure 1) is a dual element component with two sets of alumel and chromel wires (T/C 1 and T/C 2). T/C 1 wires go to pins A, and B, T/C 2 wires got to pins D, and E. The electronic sequence unit (ESU) reads only signals from pins A, and B. To eliminate an intermittent thermocouple shutdown problem, use T/C 2 connector. NOTE: Before you change the thermocouple wires, determine if the wire change will correct the APU shutdowns. Use adapter harness (part number 4504950 or equivalent) to do check procedure. (1)

Disconnect the APU harness connector J4 from the aircraft bulkhead connector P4.

(2)

Connect the APU harness connector J4 to adapter harness connector P4.

(3)

Connect opposite end of adapter harness J4 to the aircraft bulkhead connector P4.

(4)

Do several APU cycles in an attempt to duplicate the APU shutdown (refer to Aircraft Operation Manual).

(5)

If the shutdowns continue, the cause(s) of the auto shutdowns are most likely not related to the thermocouple. Proceed to paragraph (6). If the shutdowns stop, do procedures in paragraph G.

(6)

Disconnect the adapter harness from the aircraft bulkhead connector P4 and from the APU harness connector J4.

(7)

Connect the APU harness connector J4 to the aircraft bulkhead connector P4.

INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES H.

Thermocouple Wire Change (1)

Disconnect the APU harness connector J4 from the aircraft bulkhead connector P4.

(2)

Remove the backshell.

CAUTION: MAKE SURE TO MARK WIRES CORRECTLY AND DOCUMENT PROCEDURES SO THAT THE HARNESS CAN BE RETURNED TO THE ORIGINAL CONFIGURATION.

I.

(3)

Remove the harness pins A, and B and mark them. Move pins out of the way and secure.

(4)

Remove harness pins D, and E and mark them.

(5)

Insert pins D, and E into slots A and B respectively.

(6)

Attach the backshell.

(7)

Connect the APU harness connector J4 to the aircraft bulkhead connector P4.

Magnetic Pickup Test (1)

Remove the magnetic pickup (680, IPC 49-20-00 Figure 2) (refer to 49-00-00, Removal/Installation).

(2)

Use an ohmmeter to measure the resistance between pins A and B of the magnetic pickup (680) connector (this is the coil resistance). The coil resistance shall be between 1,000 and 1,300 ohms at ambient temperature.

(3)

Install the magnetic pickup (680) (refer to 49-00-00, Removal/Installation).

INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES J.

Fuel Nozzle Inspection NOTE: Use a microscope (10X) and a bright light to check the parts. Nomenclature

Inspection Limits

Corrective Action

Nozzle Assemblies

Check orifice erosion. Flow test, refer to Figure 807.

Replace nozzle.

Spring Retainer (-440, IPC 4920-00 Figure 3)

Check for obstructed fuel passage and damage

Reclean or replace retainer.

Nozzle Body (-400B, IPC 4920-00 Figure 3)

Check for nicks, burrs on threads. Check for wear or erosion on surface of tapered cone. Check for nicks or scratches on exterior especially at fuel outlet. Check for nicks or scratches on seal surface. Check for nicks or scratches in retaining ring grove.

Replace nozzle assembly.

Distributor

Check for wear, erosion, or scratches on front face or slots. Check for contaminants on front face or slots.

Replace nozzle assembly.

Retaining Ring (-420, IPC 4920-00 Figure 3)

Check for nicks or burrs on edges. Check for correct shape.

Replace retaining ring.

Screen (-430, IPC 49-20-00 Figure 3)

Check screen for contamination. Check for correct shape.

Clean or replace screen.

Spring (-410, IPC 49-20-00 Figure 3)

Check for free height o 0.265± 0.015 inch (6.73± 0.38 mm).

Replace spring.

Reclean distributor.

Fuel Nozzle Inspections Limits Figure 806 (1)

Install holder assembly in fuel nozzle flow fixture TM90190 or ST92300B. NOTE: If staking is required per the applicable APU repair manual, stake after successful flow check.

INSPECTION/CHECK

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Page 815 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Fuel Nozzle Figure 807 WARNING: USE CLEANING SOLVENT (ALSO KNOWN AS DRY CLEANING SOLVENT, STODDARD SOLVENT, MINERAL SPIRITS, NAPHTHA, PETROLEUM SPIRITS, MIL-PRF-680 TYPE II, ASTM D235 TYPE II, OR AMS3160) CORRECTLY. THE SOLVENT IS FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE SOLVENT, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0158SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE SOLVENT, PUT ON CHEMICALSPLASH GOGGLES, AND SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SOLVENT FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (2)

Use solvent at the specific pressure and verify that flow is between the maximum and minimum values with a nominal specific gravity at 80°F (26.7°C) as shown in Figure 808.

INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Part Number 169046-1 169111-2, 4951965

Pressure psig (kPa)

Flow-pph Minimum

Maximum

100-400 (689-2,756)

8.4

17.1

198-202 (1,365-1,393)

10.5

12.0

340-360 8.6 10.0 (2,344-2,482) Fuel Nozzle Flow Rate Figure 808 Measure the spray angle approximately 0.5 inch (12.7 mm) downstream of the nozzle and make sure the values are within the limits specified in Figure 809. 4951277

(3)

Part Number

Spray Angle

Pressure psig (kPa)

Minimum

Maximum

169046-1

100-400 (689-2,756)

70°

N/A

169111-2

198-202 (1,365-1,393)

70°

100°

4951277

340-360 (2,344-2,482)

70°

100°

198-202 98° 112° (1,365-1,393) Fuel Nozzle Spray Angle Figure 809 There should be no streaks, spitting dribbling, or variations in the spray pattern. 4951965

(4)

Streaks Spitting Dribbling (5)

Variations in spray density Large irregular drops occurring intermittently Sluggish dripping and large drops of unatomized fluid forming on nozzle tip

If inspection limits are not met, replace the fuel nozzle (400 and 400A, IPC 49-20-00, Figure 3). Nozzle holder assemblies (-380E and -380F) and fuel nozzle (-400B and -400C) are repairable (refer to 49-00-00 REPAIR).

INSPECTION/CHECK

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES REPAIR 1.

General A.

This section provides procedures for repair of the Auxiliary Power Unit (APU) system. Item numbers in the procedures are the same as those in the Illustrated Parts Catalog (IPC), Document 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001, for general information. NOTE: Alpha-variant items can replace an item when permitted by the effect code for that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Repair Do a repair of the components as follows: A.

Return the nozzle holder assembly (-380E or -380F, IPC 49-20-00 Figure 3) to Hamilton Sundstrand for repair (according to HSPS Proprietary Repair Number XXX).

B.

Return the fuel nozzle (-400B or -400C) to Hamilton Sundstrand for repair (according to HSPS Proprietary Repair Number XXX).

REPAIR

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REPAIR

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES SERVICING 1.

General A.

This section has the procedures for flushing of the Auxiliary Power Unit (APU) system lubricating oil system, purging the fuel system of air, and reading the data from the hourmeter and event counter. Item numbers in the procedures are the same as those in the Illustrated Parts Catalog (IPC), Bulletin 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001, for general information. NOTE: Alpha-variant items can replace an item when permitted by the effect code for that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

B.

Access to the APU may prevent performance of some procedures while the APU is installed on the aircraft. Refer to the Aircraft Maintenance Manual for access.

C.

Exercise extreme care to prevent entrance of dirt, dust, and foreign objects into the APU. If a foreign object is dropped into the APU, stop maintenance procedure until the object is located and removed.

D.

Cover large openings with protective covers. Cap or plug open tube assemblies, fittings, and ports. Do not cover tube ends with tape. NOTE: Refer to Standard Practices Manual (SPM), Document HSPS 490001 for a listing of all protective covers used on the APU for shipment and/or storage.

E. 2.

All parts attached with lockwire prior to removal must be re-attached with lockwire after installation.

Equipment and Materials A.

Equipment and materials required for servicing are listed in Figure 1101. NOTE: Equivalent substitutes may be used for items listed. NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or holding other small components in place for ease of assembly and prevention of galling. If necessary, assembly fluid may be diluted with MIL-PRF-7808 or MIL-PRF-23699. Material

Source (Vendor Code)

Assembly Fluid, 4950515

Hamilton Sundstrand (99167)

Container 1 Gallon (3.8 liters)

Commercially Available

Drain Line

Commercially Available Servicing Equipment and Materials Figure 1101 (Sheet 1 of 2) SERVICING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Material

Source (Vendor Code)

Lint-free Cloth

Commercially Available

Lockwire MS20995C20 and MS20995C32

Commercially Available

Lubricating Oil, Refer to Hamilton Sundstrand Standard Practices Document HSPS 490001 for oil types and restrictions

Hamilton Sundstrand (55820)

Torque Wrench 25 to 140 lb. in. (2.8 to 15.8 Commercially Available N·m) Data Reader Model 1170 (P/N M7793-12-1) or

Curtis Instruments, Inc. (18583)

Meter Reader (P/N 4951807)

Oxley (K0066)

Connector Pliers, Soft-Jawed TG69

Glenair

Servicing Equipment and Materials Figure 1101 (Sheet 2 of 2) 3.

Flushing the APU Oil System The flushing procedure is used whenever the oil becomes contaminated or is being changed to a different brand. WARNING: DO NOT TOUCH THE COMPONENTS OF THE OIL SYSTEM IF THE APU IS HOT. THESE COMPONENTS STAY HOTTER THAN OTHER COMPONENTS. HOT COMPONENTS CAN BURN YOU. WARNING: HOT OIL MAY CAUSE BURNS TO EYES AND SKIN. PUT ON SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION. WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES. CAUTION: DO NOT LET OIL GET ON THE ENGINE OR OTHER COMPONENTS. IMMEDIATELY CLEAN THE OIL WHEN IT FALLS ON THEM. OIL CAN CAUSE DAMAGE TO PAINT AND RUBBER. A.

B.

Drain APU Lubrication Oil (1)

Place a container of approximately 1 gallon (3.8 liters) capacity beneath the magnetic drain plug (10, IPC 49-23-00 Figure 1).

(2)

Remove magnetic drain plug (10) from reduction drive assembly (820, IPC 49-20-00 Figure 3). Drain the oil from the reduction drive assembly oil sump.

Replenish APU Lubrication Oil (1)

Install magnetic drain plug (10, IPC 49-23-00 Figure 1) into reduction drive assembly (820, IPC 49-20-00 Figure 3). Torque magnetic drain plug 40 to 50 pound inches (4.5 to 5.7 N·m).

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (2)

Remove plug (870).

CAUTION: DO NOT ALLOW THE OIL LEVEL TO BE ABOVE THE "FULL" MARK ON THE SIGHT GLASS. AN OVERFILLED SUMP WILL RESULT IN OIL FOAMING AND LOW OIL PRESSURE AND/OR OVERTEMPERATURE. (3)

Fill the reduction drive assembly oil sump with 2.5 quarts (2366 cc) of approved oil. Check the sump oil level on oil level sight plug (580, IPC 49-20-00 Figure 2). Do not exceed the FULL mark.

(4)

Install the plug (870, IPC 49-20-00 Figure 3) in oil fill cap assembly (860).

C.

Start APU and allow it to stabilize at 100% for 10 minutes.

D.

Shut down APU and allow it to coast to a stop.

E.

Drain reduction drive assembly sump (step A above).

F.

Install new preformed packings as follows:

G.

(1)

Remove packing (20, IPC 49-23-00 Figure 1) from magnetic drain plug (10). Discard packing.

(2)

Apply assembly fluid to a new packing (20) and install packing on magnetic drain plug (10).

(3)

Remove plug (870, IPC 49-20-00 Figure 3) and packing (910). Discard packing.

(4)

Apply assembly fluid to a new packing (910) and install packing on plug (870).

Replenish APU Lubrication Oil (1)

Install magnetic drain plug (10, IPC 49-23-00 Figure 1) into reduction drive assembly (820, IPC 49-20-00 Figure 3). Torque magnetic drain plug 40 to 50 pound inches (4.5 to 5.7 N·m) and secure with lockwire.

CAUTION: DO NOT ALLOW THE OIL LEVEL TO BE ABOVE THE "FULL" MARK ON THE SIGHT GLASS. AN OVERFILLED SUMP WILL RESULT IN OIL FOAMING AND LOW OIL PRESSURE AND/OR OVERTEMPERATURE.

4.

(2)

Fill the reduction drive assembly oil sump with 2.5 quarts (2366 cc) of approved oil. Check the sump oil level on oil level sight plug (580, IPC 49-20-00 Figure 2). Do not exceed the FULL mark.

(3)

Install the plug (870, IPC 49-20-00 Figure 3) in oil fill cap assembly (860).

Purge Fuel System of Air A.

The APU fuel system must be purged of air after the following conditions: (1)

After initial installation of the APU. SERVICING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

B.

(2)

When the system has been disturbed for replacement of components and the APU fails to start after three attempts.

(3)

When the fuel system has become empty and the APU fails to start after three attempts.

Purge APU fuel system of air as follows: WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED. (1)

Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC 49-20-00 Figure 3).

(2)

Disconnect start nozzle tube assemblies (140 and 145, IPC 49-20-00 Figure 2) from start nozzle holder assemblies (380, IPC 49-20-00 Figure 3). Connect drain lines to the open tubes.

(3)

Disconnect main fuel tube assembly (90, IPC 49-20-00 Figure 2) from fuel manifold (470, IPC 49-20-00 Figure 3). Connect a drain line to the open tube.

(4)

Place open end of drain lines into a container.

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. (5)

Be sure there is an adequate fuel supply in the storage tanks. Turn on the fuel supply and check for leaks and correct as necessary.

(6)

Set MASTER switch to ON, set START-STOP-RUN switch momentarily to START, and release to RUN. Check fuel flow from drain lines. Be sure an air- free flow of fuel is obtained. After 15 seconds, set START-STOP-RUN switch to STOP. NOTE: It may be necessary to repeat this step to obtain an air-free flow of fuel.

(7)

Set MASTER switch to OFF.

(8)

Remove drain lines and connect start fuel tube assemblies (140 and 145, IPC 4920-00 Figure 2) to start nozzle holder assemblies (380, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 N·m).

(9)

Remove drain line and connect main fuel tube assembly (90, IPC 49-20-00 Figure 2) to fuel manifold (470, IPC 49-20-00 Figure 3). Torque B-nut 75 to 85 pound inches (8.5 to 9.6 N·m). SERVICING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (10) Connect electrical connector (P303) to ignition exciter (200 or 200A, IPC 49-20-00 Figure 3) and secure with lockwire. (11) Start and operate APU and check all fuel line connections for leakage. Shut down APU. 5.

Hourmeter and Event Counter Data Readout A.

Prepare for Data Readout

NOTE: Refer to Figure 1102 for reader and meter compatibility.

B.

C.

(1)

Remove the protective covers from the hourmeter (100A, IPC Figure 1) and event counter (110) or hourmeter/event counter (111).

(2)

Connect the reader to the connector on either the hourmeter (100A) or event counter (110) or hourmeter/event counter (111).

Data Readout (Curtis Reader) (1)

Depress the reader center button. The reader will self test for approximately 5 seconds. A vertical marker will appear to indicate which reading is being given, either events (left side of display) or hours (right side of display).

(2)

Record the number shown in the reader display window.

(3)

Repeat this procedure for the other solid state device.

Restore APU to Normal (1)

Disconnect the reader from the last solid state device read.

(2)

Install the protective covers on the hourmeter (100A) and event counter (110).

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES D.

Data Readout (Oxley Reader) NOTE: Oxley Reader must be plugged into the solid state meter before the Reader is switched ON or inaccurate reading may occur.

E.

(1)

Press and hold the left-mouse button on the button panel of the Reader for a moment to switch the Reader to ON. The Reader will display "INTERROGATING ETT" in the LCD display panel. The STATUS lamp will flash red. The Reader will display the type indicator, e.g., "INTERROGATING _________". The STATUS lamp stays green. Hours and Events are displayed on the LCD display panel.

(2)

Record the number shown in the reader display window.

(3)

Hours and Events may be stored in the Reader by pressing the right-mouse button on the Reader button panel. The LCD display panel will state "STORE READING?" Press the right-mouse button again to store.

Restore APU to Normal (1)

Press the left-mouse button on the Reader button panel to turn the Reader OFF.

(2)

Disconnect the Reader from the last solid state device read.

(3)

Install the protective cover on the hourmeter/event counter (111).

Reader M7793-2-1 (Curtis) 1170-001 1170-003 1170-004 4951807 (Oxley)

4950077(A-E) X X X X X

4950077(F) X X X X

Meter (Revision Letter) 4950135(A-E) 4950135(F) X X X X X X

4951559

X X X X

Reader and Meter Compatibility Figure 1102

SERVICING

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ENGINE 49-20-00

ENGINE

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ENGINE

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES DESCRIPTION AND OPERATION 1. General (Refer to Figure 1) A.

The engine is a gas turbine engine that supplies both shaft power and pneumatic power in the form of compressor bleed air.

B.

The engine has: - The reduction drive assembly - The turbine section - The combustor section. The engine also has: - A fuel system - An ignition/starting system - An air system - APU controls - An oil system.

C.

The engine gets ambient air, which is compressed in the compressor of the turbine section. The compressed air flows into the combustor section where it mixes with fuel which then burns. The burned fuel and air mixture moves through the turbine section to give power to turn the turbine rotor and to drive the reduction drive assembly.

2. Component Description (Refer to Figure 2) A.

Combustor section (1) The combustor section is the part of the engine where the fuel mixes with air and burns. (2) The combustor section is attached to the turbine section. (3) The combustor is an annular type that has: - A combustor housing with an integral bleed air scroll - A combustor liner - The igniter plugs (one, pre-SB-49-150; two, post SB-49-150) - A combustor drain valve - A fuel manifold - The start fuel nozzle assemblies, (one, pre SB-49-124; two, post SB 49-124 and three, post SB-49-152).

B.

Turbine section (1) The turbine section gives the power to drive the reduction drive assembly. (2) The turbine section provides compressed air to the combustor section for bleed air supply. DESCRIPTION AND OPERATION

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Engine Modular Sections Figure 1 (3) The turbine section is installed between the reduction drive assembly and the combustor section. (4) The turbine section has: - An air inlet housing - A rotor assembly - A diffuser - A turbine nozzle assembly - An input pinion.

DESCRIPTION AND OPERATION

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A-68079 Engine Cross Section Figure 2

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES C.

Reduction drive assembly (1) The reduction drive assembly transmits shaft power from the turbine section to the accessories during APU operation. It also transmits start power to the compressor during starting. (2) The reduction drive assembly is attached to the turbine section. (3) The reduction drive assembly has: - An accessory drive assembly - An oil filler cap - A low oil pressure switch - A high oil temperature switch - An integral oil sump.

3. Engine Operation A.

Initially, the starter/generator turns the engine. When the engine turns, the compressor pulls in the air through the air intake ducting. This air is then compressed and sent to the diffuser. From the diffuser, the air goes to the combustor section.

B.

In the combustor the air is mixed with atomized fuel from the start fuel nozzles and fuel manifold venturies. The igniter starts the ignition of the start fuel. The combustor then burns main and max fuel continuously. When the fuel is burned, the gases from the combustor are sent through the turbine nozzle onto the blades of the turbine wheel. From the turbine wheel, the gases go through the center of the combustor housing to the exhaust.

C.

The turbine wheel provides power to the compressor and the reduction drive assembly.

4. Fuel System A.

The fuel system consists of components that function automatically to provide proper APU acceleration and maintain a near constant operating speed under varying load conditions. These components are the acceleration control/fuel pump, start, main, and maximum fuel solenoid valves, fuel filter assembly, fuel manifold, start fuel nozzles, check valve, and interconnecting tubing assemblies. Fuel must be supplied to the APU from the aircraft fuel supply which provides fuel to a 10 micron nominal (25 micron absolute) fuel filter at a pressure at least 5 psi (34 kPa) over the true vapor pressure.

B.

Acceleration Control/Fuel Pump (1) The acceleration control/fuel pump is mounted on the accessory pad of the reduction drive assembly. The fuel pump is a positive-displacement, gear- type unit. (2) The acceleration control consists of three major components secured together. These are the governor housing, the governor housing cover, and the bellows cover assembly.

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (3) A cleanable fuel pump outlet filter (25-micron filtration, nominal) is installed in the pump housing. The fuel pump splined shaft fits into a drive in the reduction drive assembly. The other end of the fuel pump drive shaft is spline-coupled to the drivehead assembly of the acceleration control. (4) Adjustment to APU governed speed is made by turning the speed adjustment screw in or out. This changes the position of the governor tension lever, which increases or decreases the force of the governor control spring against the rotating drivehead assembly. (5) The governor characteristics are designed to provide 3% droop. When adjustments are required, the no-load speed is set at 103%. This setting will provide 100% rated speed at full load. C.

Start Purge Valve (1) The purge system consists of a check valve downstream of the start fuel solenoid that is connected to the compressor discharge. When the solenoid is turned off, this compressor discharge pressure purges the start fuel nozzles and fuel lines.

D.

Fuel Inlet Filter Assembly (1) The low pressure fuel inlet filter protects the fuel system from contamination. The filter is a full flow type with a disposable 10 micron nominal (25 micron absolute) fuel filter element. The fuel filter assembly has provision for an impending filter bypass differential pressure sensor and bypass relief valve. The bypass relief valve has a cracking pressure not less than 3 psid (21 kPa) with full bypass at a differential pressure of 7 psid (48 kPa) maximum. The bypass relief valve is designed to prevent the discharge of fuel filter contaminants when bypassing fuel around a clogged filter.

E.

Fuel Manifold (1) The fuel manifold provides fuel to the six equally spaced main fuel nozzles around the circumference of the combustor. Fuel is supplied to the fuel manifold through the main and maximum fuel solenoid valves. (2) Fuel flow to the fuel manifold assembly is controlled by the flyweight assembly in the acceleration control to limit the speed of the APU. Increasing rotor speed above the set speed causes the free ends of the fly weights to pivot away from the axis of the rotating drivehead assembly. The pivoting action of the flyweights against the bearing plate of the piston/valve assembly, compresses the governor control spring, and moves the fuel metering valve in a direction to reduce fuel flow to the APU. This action results in near constant speed over the APU operating range.

F.

Start Fuel Nozzles (1) The start fuel nozzles project radially into the combustor. Fuel atomized by the nozzles is ignited by the igniter plug located on the combustor directly in line with the start fuel nozzles. The nozzles incorporate integral screens with hole diameters of 0.005 - 0.009 inch (0.127 - 0.228 mm) to provide additional filtration. DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES NOTE: The pre-SB-49-124 configuration has one start fuel nozzle, the post-SB49-124 configuration has two start fuel nozzles and the post-SB-49-152 has three start fuel nozzles. G.

Start, Main, and Maximum Fuel Solenoid Valves (1) The fuel solenoid valves are operated by a nominal electrical input of 28 Vdc from the ESU. The three fuel solenoid valves are bolted to a bracket on the reduction drive assembly adjacent to the acceleration control/fuel pump. The fuel system components are interconnected with stainless steel tubing. (2) The start fuel solenoid valve is energized to the open position by the ESU at start initiation (if air borne) or at 3% rated speed (if on the ground) to supply fuel to the start fuel nozzle(s). At 70% rated speed, the valve is de-energized. In the deenergized condition, the valve shuts off the fuel flow to the start fuel nozzle(s) and the check valve opens to allow compressor discharge pressure (Pcd) to flow through the nozzle(s). This clears the nozzle(s) and lines of fuel to prevent coking of the start fuel nozzle(s). (3) Fuel is supplied to the fuel manifold assembly through the main and maximum fuel solenoid valves. The main fuel solenoid valve is energized to the open position by the ESU at 14% rated speed. De-energizing this valve produces a normal shutdown of the APU. (4) The maximum fuel solenoid valve is energized at 95% rated speed, plus 7 seconds, bypassing the acceleration orifice and allowing maximum fuel flow for governing at rated APU speeds and loads.

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 5. Fuel System Operation (Refer to Figure 3) A.

The fuel system consists of components that function automatically to provide proper APU acceleration and maintain a near constant operating speed under varying load conditions. At initiation of start and in proper sequence, the ESU actuates the start fuel solenoid valve to the open position, and energizes the ignition circuit. Fuel is then directed through the start fuel solenoid valve to the start fuel nozzles. After combustion ignition, at 14% rated APU speed, the main fuel solenoid valve is activated by the ESU and fuel is directed through the fuel manifold, in addition to the start fuel nozzles. Main and maximum fuel is supplied to the combustor fuel nozzles by the fuel manifold and is atomized by venturies for normal operation. Combustion ignition takes place in the combustor when atomized fuel from the start fuel nozzles is ignited by the igniter plug. All fuel flow to the combustor during the acceleration phase is controlled by APU compressor discharge pressure acting on the diaphragm in the delta-P (∆P) regulator chamber of the acceleration control assembly. One side of the diaphragm is ported through the compressor pressure line to compressor outlet pressure; the other side is ported to ambient air pressure. Compressor discharge pressure, acting on the diaphragm, controls the setting of the ∆P regulator. The ∆P regulator, in turn, controls the differential pressure across the orifice and governor.

B.

As compressor discharge pressure increases, the ∆P regulator lowers the governor outlet pressure, thus increasing the pressure drop across the governor. This increase in pressure drop results in an increase in fuel flow to the APU. Fuel flow to the main fuel nozzles is increased in proportion to increasing compressor discharge pressure. Between 14% and 70% rated APU speed, the ESU also pulses the main fuel solenoid valve on and off. This is done to prevent an overtemperature shutdown of the APU. At approximately 70% rated APU speed, the fuel flow to the start fuel nozzles is cut off, and the main fuel nozzles continue to supply fuel for combustion. At 95% rated APU speed, plus 7 seconds, the maximum fuel solenoid valve is opened (energized) allowing maximum fuel flow for speed governing at rated speed and varying load conditions.

C.

Ambient air pressure varies inversely with altitude. The diaphragm in the ∆P regulator chamber, in conjunction with an aneroid bellows and a lever, reacts to changes in ambient air pressures, causing a reduction in fuel flow as altitude is increased.

D.

A minimum fuel flow orifice, installed in the acceleration control housing bypassing the governor, allows a small amount of fuel under pump pressure to flow to the fuel nozzles even if fuel flow through the governor has been greatly reduced. In the event the load is removed suddenly, the setting of the minimum fuel flow orifice maintains adequate fuel flow to sustain combustion.

E.

Drain provisions for the fuel system are as follows: (1) An acceleration control/fuel pump drain and vent provides overboard drain of leakage within the acceleration control/fuel pump. (2) A combustor drain located on the bottom of the combustor provides drain for the combustion chamber. It consists of a spring-loaded ball valve (check valve assembly) which is held open until approximately 45 percent engine speed is attained when compressor discharge pressure overcomes the spring pressure.

DESCRIPTION AND OPERATION

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APU Fuel System Schematic Figure 3

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 6. Ignition/Starting System (Refer to Figure 4) A.

The ignition/starting system initially turns the engine, provides acceleration assistance and starts the ignition of the fuel-air mixture in the combustor.

B.

The ignition/starting system has: - An ignition exciter - One or two ignition cables - One or two igniter plugs - A starter/generator (not supplied with the APU). NOTE: The pre-SB-49-150 configuration has one ignition cable and one igniter plug. The post SB-49-150 configuration has two ignition cables and two igniter plugs.

C.

The ignition/starting system also uses: - The electronic sequencing unit (ESU).

D.

When the APU is operated, the ignition/starting system is fully automatic in operation. The starter portion of the starter/generator turns the engine through the reduction drive assembly to get sufficient air flow for combustion. Then the ignition exciter supplies a high energy current to the igniter plug for ignition. When the engine gets to a set speed the ignition/starting system is automatically deenergized.

E.

The ESU controls the ignition/starting system. The electrical supply for the starter motor is 28 Vdc from the aircraft electrical system.

7. Ignition/Starting System Operation A.

When the ESU gets a start signal from the APU Panel, it automatically controls the ignition/starting cycle. (1) The ESU energizes the start contactor and gives a start signal to the starter/generator. (2) The starter/generator rotation turns the gear train in the reduction drive assembly, allowing the APU to get sufficient air flow for combustion. (3) When the engine speed is 0% during airborne operation or 3% for ground operation, the ESU energizes the ignition exciter and start fuel solenoid valve. The ignition exciter then supplies an intermittent high energy current to the igniter plug(s). Then the igniter plug(s) make(s) sparks to start and sustain the ignition of the fuel-air mixture in the combustion housing. (4) At 14% engine speed, the main fuel solenoid valve is energized. Between 14% and 70% engine speed, the ESU pulses the main fuel solenoid valve on and off to prevent an overtemperature shutdown. If ignition is not detected by the ESU, the starter is disengaged until 8% engine speed then re-engaged (swing start). Swing start is limited to one time per start attempt.

DESCRIPTION AND OPERATION

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APU Wiring Diagram (Pre SB-49-180) Figure 4 DESCRIPTION AND OPERATION

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APU Wiring Diagram (Post SB-49-180) Figure 5

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (5) The starter portion of the starter/generator continues to help the engine acceleration. When the engine speed is about 70%, the starter contactor, start fuel solenoid valve, and ignition exciter are de-energized. The sparks from the igniter plug(s) then stop(s) and self-sustained combustion continues. (6) When the engine speed is 95%, the ESU starts a 7-second timer. At the end of the 7 seconds, the maximum fuel solenoid valve, the ready-to-load signal, and event counter are energized. 8. Air System A.

The APU air system supplies bleed air to the aircraft main engine start (MES) system and bypass air to prevent compressor surge during in-flight APU starting and operation.

B.

The main components of the APU air system are: - the bleed valve - the anti-surge valve - the flow-limiting venturi.

9. Air System Operation A.

Air enters the APU through the APU air inlet duct. From the duct, the air passes through the compressor and into the combustor housing. Bleed air for the aircraft ECS and APU surge protection is tapped off the compressor via the combustor housing bleed scroll.

B.

The anti-surge valve provides additional discharge capability to keep the compressor out of surge during periods when the APU is started in flight or is operating in flight with exclusively shaft loads. When not in flight the valve is always energized closed.

C.

The bleed valve drive control is provided directly by the aircraft through the ESU. Bleed air can be selected after the RTL signal has been provided by the ESU. The ESU monitors the status of the bleed valve via a position switch ("closed"), which is used to generate an "advisory" fault BITE out put during the APU start sequence and is used to control anti-surge valve usage. A second position switch in the bleed valve is used for aircraft pneumatic systems control.

10. APU Controls A.

The APU controls system is required for control, monitoring, and protection of the APU during stating, operation, and shutdown.

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES B.

The APU controls system consists of: - an electronic sequence unit (ESU) - a low oil pressure switch - a high oil temperature switch - a magnetic speed pickup - an EGT thermocouple.

C.

Electrical power for the APU controls system is obtained from the battery +28Vdc.

D.

During operation, the ESU receives signals from the magnetic speed sensor probe, low oil pressure switch, EGT thermocouple, and the high oil temperature switch; all of which monitor critical engine parameters. These signals provide data which enable the ESU to operate APU primary protective circuits of: - Overspeed (engine rpm at or above 108.3% rated speed) - Underspeed (engine rpm 95% or less rated speed) - Low oil pressure (6 ± 1.5 psig, 41.4 ± 10.3 kPa) - Overtemperature (1303 ± 20°F, 706 ± 11°C) - High oil temperature (330 ± 5°F, 165.6 ± 2.8 °C).

E.

Electronic Sequence Unit (ESU) (Refer to Figure 6) (1) The ESU is located in the bay just forward of the APU compartment. (2) The ESU is a solid-state electronic control unit that controls the APU. The ESU controls the start up and shut down sequences of the APU, monitors the APU for proper operational parameters, powers down the APU in case of malfunction, and isolates failures of the APU through four built-in test equipment (BITE) discrete outputs to the aircraft central maintenance computer.

F.

Low Oil Pressure Switch (1) The low oil pressure switch is remotely mounted and is located on the left side of the reduction drive assembly (lubrication oil sump). (2) The switch has two positions: normal and low oil pressure. When the oil pressure increases above 6 ± 1.5 psig (41.4 ± 10.3 kPa), the switch is set to the normal position, which causes the hourmeter to run. If the oil pressure falls below 6 ± 1.5 psig (41.4 ± 10.3 kPa), the switch sends a low oil pressure signal (ground) to the ESU. The ESU begins checking for low oil pressure once the APU speed has reached 95% plus 7 seconds.

G.

High Oil Temperature Switch (1) The high oil temperature switch is located on the lower, aft face of the reduction drive assembly (lubrication oil sump). (2) The normally open switch closes when the oil temperature exceeds 330 ± 5°F (165.6 ± 2.8°C).

DESCRIPTION AND OPERATION

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A-69858 Electronic Sequence Unit Figure 6

H.

Thermocouple (1) The dual-element chromel/alumel thermocouple is mounted to the combustor assembly and extends into the exhaust stream. One element of the thermocouple is used to sense APU exhaust gas temperature and the other element is a spare. (2) The millivolt output of the thermocouple is transmitted to the ESU, which analyzes the signal for an overtemperature condition.

I.

Magnetic Speed Pickup (1) The magnetic speed pickup is installed into the accessory drive housing of the reduction drive assembly. (2) The magnetic speed pickup is threaded into the housing and aligns with the teeth on the accessory drive gear. (3) The magnetic speed pickup generates a sinusoidal signal which is transmitted to the ESU, where it is used for start sequencing, speed sensing (overspeed and underspeed conditions), and output to the aircraft EICAS. DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 11. APU Controls Operation (Refer to Figures 7 and 8) A.

APU start sequencing is based upon information received from the magnetic speed pickup. The ESU uses this information to sequence and control, through preprogrammed logic, the energizing of the fuel solenoid valves and the ignition exciter.

B.

Information from the magnetic speed pickup is also used by the ESU for monitoring the APU for an overspeed or underspeed condition. The ESU shuts down the APU for an overspeed condition anytime the rotor speed exceeds 108%. An underspeed shutdown occurs only after the rotor speed reaches 95% and then drops below this speed, when a normal shutdown command has not been received.

C.

The ESU uses signals received from the thermocouple to monitor the APU for an overtemperature condition. The ESU will shutdown the APU when the exhaust gas temperature exceeds 1604°F ± 20°F (873°C ± 11° C) during acceleration or 1303°F ± 20°F (706°C ± 11°C) after ready-to-load.

12. APU Oil System A.

The oil system lubricates and cools all the bearings, gears, and shaft components in the APU.

B.

The oil system includes (Refer to Figure 9): - An oil filler cap - An oil pump - An oil sump - A pressure relief valve - An oil filter - A magnetic drain plug - An oil level sight glass.

C.

A high oil temperature switch and a low oil pressure switch are installed in the oil system. The system also uses: - The drain system - The reduction drive assembly - The electronic sequencing unit (ESU).

DESCRIPTION AND OPERATION

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A-69859 APU Control Sequence Figure 7

DESCRIPTION AND OPERATION

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APU Control Schematic Figure 8

DESCRIPTION AND OPERATION

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APU Lubrication System Components Figure 9 D.

The oil system is contained in or installed on the reduction drive assembly. The pressure pump supplies the pressurized oil from the reduction drive sump. The internal passages through the engine supply the oil to lubricate the movable components. The oil then returns to the reduction drive sump.

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (1) Oil Filler Cap (a) The oil filler cap is used to fill the reduction drive sump. (b) The cap is installed on the right side of the reduction drive assembly. (2) Oil Pump (a) The oil pump is a gear-type pump assembly that is internal to the reduction drive assembly. It is driven by the reduction gear train. (3) Oil Sump (a) The oil sump is integral with the lower portion of the reduction drive assembly housing. It has a capacity of 2.5 US quarts (2366 cc). (4) Pressure Relief Valve (a) The pressure relief valve is a spring-loaded, ball-type relief valve, internally mounted in the reduction drive assembly. The valve regulates the system oil pressure at 15 to 40 psig (103 to 276 kPa). When the valve opens, excess oil is directed against the inside surface of the air inlet housing to cool the oil. The oil then drains to the sump. (5) Oil Filter (a) The oil filter assembly is remotely installed on a bracket near the left side of the reduction drive assembly. (b) The oil filter assembly has a disposable 10 micron filter element installed in a removable bowl. (c) The oil flows through the pressure filter element to the lubrication system. A differential pressure indicator is installed on the filter housing and extends to show when the filter element is becoming clogged and requires replacement. (6) Magnetic Drain Plug (a) The magnetic drain plug catches the metal particles, which may cause internal damage to the APU. (b) The magnetic drain plug is installed in the reduction drive sump. (c) It has two parts: - A drain plug at the base of the reduction drive sump - A magnetic insert installed in the plug. (d) Removal of the magnetic insert will not cause loss of oil. DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (7) Oil Level Sight Glass (a) An oil level sight glass is used to check the oil level. (b) The oil level sight glass is installed on the left side of the reduction drive assembly. (c) Oil should be added when the oil level is at the base of the sight glass. The dot on the sight glass indicates that the sump is full. 13. APU Oil System Operation (Refer to Figure 10) A.

The pump draws oil out of the sump and through internal drilled passages and external lubrication lines to the oil filter. Oil enters the oil filter housing, passes through the filter element from outside to inside, and is returned to the internal passages of the reduction drive housing by the external lubrication lines.

A-69861 APU Lubrication System Schematic Figure 10

DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES B.

If the oil filter becomes clogged, oil will bypass the filter element. The differential pressure indicator extends and locks in position if the pressure differential across the filter reaches 85 to 95 psig (586 to 655 kPa). The filter bypass valve opens when the differential pressure across the filter reaches 110 to 120 psid (758 to 827 kPa), permitting the oil to bypass a restricted filter.

C.

High-pressure oil from the oil filter is returned to the reduction drive into a passage leading to four oil jets and the system relief valve. Three of the oil jets direct oil spray to the points where the high-speed reduction drive input pinion meshes with the three planetary gears. The other jet directs an oil spray between the end of the output shaft and the input pinion to create a mist for lubrication of the rotor shaft bearings. The remainder of the gears and gear shaft bearings are lubricated by oil spray created when oil strikes the planetary gears and the input pinion.

D.

The air-oil mist for rotor shaft bearing lubrication is supplied through another oil jet adjacent to the oil jet ring. This jet directs oil spray to the aft end of the output shaft. It is then directed through a hole in the center of the input pinion and flows aft through the hollow rotor shaft. Near the end of the rotor shaft, mist passes through a hole in the rotor shaft wall and reverses direction to flow forward through the roller bearing, around the outside of the rotor shaft, through the ball bearing, and out of the oil slinger nut into the reduction drive assembly housing.

E.

The system relief valve regulates system oil pressure at 15-40 psid (103-172 kPa) by bypassing a portion of the pump output directly into the reduction drive assembly housing. The bypassed oil is directed against the inside surface of the air inlet housing to cool the oil. The oil then flows to the sump by gravity flow through an opening in the bottom of the planetary gear carrier assembly.

DESCRIPTION AND OPERATION

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DESCRIPTION AND OPERATION

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES DISASSEMBLY 1.

General A.

This section has the procedures for disassembly of the engine. Item numbers in the procedures are the same as those in the Illustrated Parts Catalog (IPC), Document 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001, DISASSEMBLY, for general disassembly information. NOTE: Alpha-variant items can replace an item when permitted by the effect code for that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Equipment and Materials A.

Equipment and materials required for disassembly are listed in Figure 501. NOTE: Equivalent substitutes may be used for items listed. Equipment and Material

Source (Vendor Code)

Lubricating Oil MIL-PRF-6081, Grade 1010

Commercially Available

Molycote 321R (169015-1)

Commercially Available

ST91125, Combustor Assembly Puller

Hamilton Sundstrand (99167)

ST70396, Assembly Fixture

Hamilton Sundstrand

ST70137, Rotor Fixture

Hamilton Sundstrand Equipment and Materials Figure 501

3.

Preparation A.

General Procedure (1)

Place each disassembled part on a clean workbench in the order of disassembly in preparation for cleaning and inspection. Keep hardware and small parts together in trays.

(2)

Provide proper coverings or supports to protect shafts, gears, studs, and projecting parts from damage.

(3)

Do not use steel or lead hammers directly on assemblies or their parts. Use cellulose-tipped hammers and fiber or rawhide mallets as specified. Do not clamp parts directly in the steel jaws of a bench vise. Use a vise having micarta jaws or equivalent.

(4)

After disassembly, spray steel parts with lubricating oil. Cover all parts with clean paper or suitable coverings unless cleaning and inspection is to be accomplished immediately. DISASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (5)

Do not disassemble tube assemblies, hose assemblies, wiring harness assemblies, riveted assemblies, staked, or press-fit parts. Do not remove nameplates, modification plates, lubrication plates, decals, studs, stud lockrings, or thread inserts, unless specifically required in the text or necessary for replacement of a part. If disassembly or removal is necessary, proceed in accordance with current procedures.

(6)

Always keep ports, bores, and passages of assemblies or components sealed with suitable closure between repair procedures. Cover large openings with covers retained in place. NOTE: Do not use tape to cover openings or connections on fuel or lubrication system components.

B.

(7)

During disassembly, examine all parts and assemblies for signs of scoring, burning, or other damage. Note physical conditions which will not be apparent after cleaning. Tag involved parts before they are cleaned and laid out for detail inspection. Check for evidence of damage caused by improper repair procedures. Report such damage in accordance with current practice.

(8)

Record manner of lockwiring for duplication at reassembly.

(9)

All seals, gaskets, preformed packings, tabwashers, lockpins, and lockwire are to be discarded when removed and replaced with new items.

Preparation for Disassembly (1)

If the engine is mounted in a shipping container, crate, or other support unit, transfer it to assembly fixture ST70396.

(2)

If necessary, drain lubrication oil from the reduction drive assembly. (Refer to 4900-00, SERVICING). NOTE: Retain lubrication oil for inspection for evidence of metal particles or other foreign matter.

4.

Removal of Engine Components NOTE: Determine fault isolation indication, recorded malfunction, and total operating time to establish the condition of the engine or most probable cause of its malfunction. This is to determine the extent of disassembly required to accomplish repairs. A.

Engine Harness Assembly

WARNING: MAKE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. MAKE SURE ALL COMPONENTS CAPABLE OF RETAINING AN ELECTRICAL CHARGE HAVE BEEN GROUNDED. (1)

Disconnect electrical connectors and remove engine harness assembly as follows: DISASSEMBLY

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(2)

(a)

Disconnect electrical connector (P302) from magnetic pickup (680, IPC 49-20-00 Figure 2).

(b)

Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC 49-20-00 Figure 3).

(c)

Disconnect electrical connector (P306) from main fuel solenoid valve (530, IPC 49-20-00 Figure 2).

(d)

Disconnect electrical connector (P305) from start fuel solenoid valve (540).

(e)

Disconnect electrical connector (P307) from maximum fuel solenoid valve (550).

(f)

Disconnect electrical connector (P304) from low oil pressure switch (260).

(g)

Disconnect electrical connector (P311) from high oil temperature switch (690).

(h)

Disconnect electrical connector (P308) from anti-surge valve (40, IPC 49-0000 Figure 1).

(i)

Disconnect electrical connector (P309) from bleed air valve (100).

Remove screws (20, IPC 49-20-00 Figure 1), washers (40), nuts (30), hourmeter (100A) and event counter (110). NOTE: If the original hourmeter (100A) or event counter (110) will not be reinstalled, an entry must be made in the logbook for the APU Hours/Events and the Hours/Events meter readings.

B.

(3)

Remove bolts (70), nuts (90), and clamps (45, 50, 60, and 80).

(4)

Remove thermocouple (112) from combustor housing.

(5)

Remove engine harness assembly (10).

Sensors (1)

Loosen nut and remove magnetic pickup (680, IPC 49-20-00 Figure 2). NOTE: To aid removal of pickup, it may be necessary to apply heat around boss to soften thread sealant.

(2)

If damaged, remove the connector seal (685) from magnetic pickup (680). Discard the seal.

(3)

Remove low oil pressure switch (260) and packing (270). Discard packing.

(4)

If damaged, remove the connector seal (262) from low oil pressure switch (260). Discard the seal.

(5)

Remove high oil temperature switch (690) and packing (700). Discard packing.

DISASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (6) If damaged, remove the connector seal (685) from high oil temperature switch (690). Discard the seal. C.

Tube Assemblies (1)

Remove bolt (70, IPC 49-20-00 Figure 1), nut (90), and loop clamps (50 and 220) from tube assemblies (120 and 130).

(2)

Remove bolts (160 and 200), nuts (170 and 210), and loop clamps (150, 190, and 220) from tube assemblies (140 and 180).

(3)

Remove bolts (40, 520, and 525, IPC 49-20-00 Figure 2), nuts (50 and 530), and loop clamps (30, 70 and 510) from tube assemblies (10, 20, and 80).

(4)

Remove bolts (110), nuts (120), and loop clamps (30, 100, and 160) from tube assemblies (90, 130, 145, and 150).

(5)

Post SB-49-152: Remove bolt (157A, IPC 49-20-00 Figure 3), nut (160A), and loop clamp (147A) from tube assembly (147, IPC 49-20-00 Figure 2).

(6)

Post SB-49-181: Remove bolt (110B), washer (115), and loop clamp (100C) from tube assembly (147).

(7)

Post SB-49-191: (a)

Remove bolt (110B), washer (115), and loop clamp (100C) from tube assembly (147).

(b)

Remove bolt (163), nut (164), and loop clamps (161 and 162) from tube assemblies (145A and 140B).

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES. (8)

Position a container or drip pan under engine to catch spilled fuel and oil.

(9)

Disconnect tube assemblies from the following components and remove tube assemblies: (a)

Disconnect tube assembly (130, IPC 49-20-00 Figure 1) from union (420) and from start valve bolt fitting (420, IPC 49-20-00 Figure 2).

(b)

Disconnect tube assembly (240, IPC 49-20-00 Figure 1) from reducer (440) and from reducer (490, IPC 49-20-00 Figure 2). DISASSEMBLY

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(c)

Disconnect tube assembly (140, IPC 49-20-00 Figure 1) from reducer (380) and from union (510, IPC 49-20-00 Figure 2).

(d)

Disconnect tube assembly (120, IPC 49-20-00 Figure 1) from union (490) and from elbow (230, IPC -49-20-00 Figure 2).

(e)

Disconnect tube assembly (180, IPC 49-20-00 Figure 1) from union (360) and from elbow (20, IPC 49-20-00 Figure 3).

(f)

Disconnect tube assembly (10, IPC 49-20-00 Figure 2) from union (60) and tee (360).

(g)

Disconnect tube assembly (20) from elbow (400) and reducer (50, IPC 49-2300 Figure 1).

(h)

Disconnect tube assembly (80, IPC 49-20-00 Figure 2) from union (60) and reducer (50, IPC 49-23-00 Figure 1).

(i)

Disconnect tube assembly (90, IPC 49-20-00 Figure 2) from reducer (490) and union (560, IPC 49-20-00 Figure 3).

(j)

Disconnect tube assembly (130, IPC 49-20-00 Figure 2) from reducer (490) and tee (350, IPC 49-20-00 Figure 3).

(k)

Disconnect start fuel nozzle tube assemblies: 1

Pre and Post SB-49-124 configuration: a

2

Post SB-49-152 configuration: a

3

Disconnect tube assemblies (140, 145 and 147, IPC 49-20-00 Figure 2) from tee (350, IPC 49-20-00 Figure 3), fitting (352) and start fuel nozzle holder assemblies (380C).

Post SB-49-181 configuration: a

4

Disconnect tube assemblies (140 and 145, IPC 49-20-00 Figure 2) from tee (350, IPC 49-20-00 Figure 3) and start fuel nozzle holder assemblies (380).

Disconnect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) from 90°-elbow (350D, IPC 49-20-00, Figure 3) and from the two start fuel nozzle holder assemblies (380F).

Post SB-49-191 configuration: a

Disconnect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) from tee (350B, IPC 49-20-00, Figure 3) and from the three start fuel nozzle holder assemblies (380E).

DISASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (l) D.

E.

F.

G.

Disconnect tube assembly (150B, IPC 49-20-00 Figure 2) from union (330, IPC 49-20-00 Figure 3).

Fuel Control Assembly, Acceleration Control, and Fuel Pump (1)

Remove bolts (260, IPC 49-20-00 Figure 1), washers (270), and assembled fuel Remove bolts (300), washers (310), and fuel pump (320). Remove packings (330, 340, and 350) and discard.

(2)

Remove elbow (460), nut (480), and packing (470). Discard packing.

(3)

Remove unions (360, 380, 420, 440, and 490) and packings (370, 390, 430, 450, and 500). Discard packings.

(4)

Remove plug (400) and packing (410). Discard packing.

Fuel Solenoid Valves (1)

Remove bolts (560, IPC 49-20-00 Figure 2), nuts (570), and fuel solenoid valves (530, 540, and 550).

(2)

Remove fittings (420 and 450), packings (430, 440, 460, and 470) and fitting (470). Discard packings.

(3)

Remove reducers (490), union (510), and packings (500 and 520). Discard packings.

(4)

If damaged, remove connector seals (542 and 552) from fuel solenoid valves (530, 540, and 550). Discard seals.

Fuel Filter Assembly (1)

Remove bolts (180) and fuel filter assembly (170).

(2)

Remove bowl (190) and element (200), packing (205), and backing ring (208). Discard packing and backing ring.

(3)

Remove union (210) and packing (220). Discard packing.

(4)

Remove elbow (230), packing (240), and nut (250). Discard packing.

Oil Filter Assembly (1)

Remove reducer (280) and packing (290). Discard packing.

(2)

Remove bolts (310), washers (320), bracket (300), and oil filter/pressure indicator (330).

(3)

Remove filter bowl (332), backup ring (334), packing (336), filter element (340) and packing (350). Discard packings and backup ring. DISASSEMBLY

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H.

I.

J.

5.

(4)

Remove tee (360), retainer (370), packing (380), and nut (390). Discard packing.

(5)

Remove elbow (400) and packing (410). Discard packing.

Accessory Bracket and Components (1)

Remove oil level sight plug (580) and packing (590). Discard packing.

(2)

Remove nut (610), screws (620 and 660), washers (630 and 670), spacer (640), and accessory bracket (600).

(3)

Remove oil level sight spacer (710) and packing (590). Discard packing.

(4)

Remove support bracket (650) by removing bolt (210, IPC 49-23-00 Figure 1) and washer (240).

(5)

Reinstall bolt (210) and washer (240) in reduction drive assembly. Torque bolt 24 to 27 pound inches (2.7 to 3.1 N·m).

Lifting Brackets (1)

Remove bolt (790, IPC 49-20-00 Figure 2), nut (800), washer (810), clamp (770), and sensor bushing (780).

(2)

Remove bolts (740), washers (750), and brackets (730 and 760).

Fire Control Loop Brackets and Clamps (1)

Remove bolts (520), nuts (530), clamps (510), and sensor bushings (540).

(2)

Remove one bolt (210, IPC 49-23-00 Figure 1) and washer (605, IPC 49-20-00 Figure 1) from the reduction drive assembly and remove bracket (600).

(3)

Reinstall bolt (210, IPC 49-23-00 Figure 1) with washer (240) in reduction drive assembly. Torque bolt 24 to 27 pound inches (2.7 to 3.1 N·m).

(4)

Remove bolt (590, IPC 49-20-00 Figure 1) and bracket (580).

(5)

Remove bolt (560), nut (570), and bracket (550).

Engine Module Disassembly A.

Air Inlet Duct and Engine Mount (1)

Loosen captive fasteners and remove air inlet duct (10, IPC 49-20-00 Figure 3).

(2)

Remove elbow (20), union (30), and packing (40). Discard packing.

(3)

Remove bolt (120) and engine mount (110).

DISASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES B.

Ignition Cable(s) WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED. (1)

(2)

C.

Pre-SB-49-150 configuration: (a)

Disconnect ignition cable (130) from igniter plug (170).

(b)

Remove bolt (150), nut (160), and clamp (140). Disconnect ignition cable from exciter (200) and remove cable.

(c)

Remove and discard washers (137), if damaged.

Post-SB-49-150 configuration: (a)

Disconnect ignition cables (130 and 135) from igniter plugs (170A).

(b)

Remove bolts (155 and 157), nuts (160A), and clamps (145 and 147).

(c)

Disconnect ignition cables from exciter (200A) and remove cables.

(d)

Remove and discard washers (137), if damaged.

Ignition Exciter WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED. (1)

Pre-SB-49-150 configuration: (a)

(2)

(3)

Remove bolts (210 and 215), lockwashers (220), brackets (230 and 240), and ignition exciter (200).

Post-SB-49-150 configuration: (a)

Remove bolts (210A), lockwashers (220), brackets (240B), and ignition exciter (200A).

(b)

Remove bolts (150A), clamps (148), sensor bushings (149), and nuts (160A) from brackets (240B).

(c)

Remove bolts (210A), lockwashers (220), and exciter bracket (193).

Post-SB-49-185 configuration: (a)

Disconnect electrical connector (P303) from ignition exciter (200A, IPC 49-20-00 Figure 3). DISASSEMBLY

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D.

F.

Disconnect ignition cables (130 and 135) from ignition exciter (200A).

(c)

Remove safety wire, part number MS20995C32, and bolts (196)

(d)

Remove washers (-198)

(e)

Remove the exciter mounting bracket assembly (193, 49-20-00 Figure 3)

(f)

Remove isolators (193A) from the exciter mounting bracket assembly (193).

Igniter Plugs (1)

E.

(b)

Remove igniter plug(s) (170 or 170A) from combustor housing.

Purge Check Valve (1)

Remove bolt (300), nut (310), check valve (280), and brackets (320). Remove loop clamp (290).

(2)

Remove union (330), tee(s) (350), reducer (360), and packings (340 and 370). Discard packings.

Start Fuel Nozzles (1)

Pre and Post SB-49-124 configuration: NOTE: On pre-SB-49-124 configuration APU, one start nozzle tube assembly (145, IPC 49-20-00 Figure 2) and one of the start fuel nozzle holder assemblies (380, IPC 49-20-00 Figure 3) will not be present.

(2)

(a)

Loosen start nozzle tube assemblies (140 and 145, IPC 49-20-00, Figure 2) at tee (350, IPC 49-20-00, Figure 3).

(b)

Disconnect tube assemblies (140 and 145, IPC 49-20-00, Figure 2) from start fuel nozzle holder assemblies (380, IPC 49-20-00, Figure 3) and remove the start fuel nozzle holder assemblies (380).

(c)

Remove fitting (390) and nozzle (400) from each start fuel nozzle holder (380).

Post SB-49-190 configuration: (a)

Remove Start Fuel Nozzle Holder Assembly (-380D, IPC Figure 3, 49-20-00) or Start Fuel Nozzle Holder Assembly (-380E).

(b)

Remove tabbed washer (-382, IPC Figure 3, 49-20-00) and discard.

DISASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (3)

(4)

G.

H.

Post SB-49-181 configuration: (a)

Loosen tube assemblies (140B and 147, IPC 49-20-00, Figure 2) at 90°-elbow (350D, IPC 49-20-00, Figure 3).

(b)

Disconnect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) from the two start fuel nozzle holder assemblies (380F, IPC 49-20-00, Figure 3) and remove the start fuel nozzle assemblies.

(c)

If necessary, remove plug (385).

(d)

Remove fitting (390D) and injector (400C) from each start fuel nozzle holder assembly (380F).

Post SB-49-191 configuration: (a)

Loosen tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) at tee (350B, IPC 49-20-00, Figure 3).

(b)

Disconnect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) from the three start fuel nozzle holder assemblies (380E, IPC 49-20-00, Figure 3) and remove the start fuel nozzle holder assemblies.

(c)

Remove fitting (390C) and injector (400B) from each start fuel nozzle holder assembly (380E).

Fuel Manifold (1)

Unscrew B-nuts of fuel manifold (470) from combustor housing assembly (640).

(2)

Remove bolts (480), nuts (490), washers (500), and assembled fuel manifold (470).

(3)

Remove bolts (520), nuts (530), washers (540), loop clamps (510) and cushions (550) from fuel manifold (470).

(4)

Remove union (560) and packing (570). Discard packing.

(5)

Remove filter assembly (590) and packing (580) from fuel manifold (470).

(6)

Remove retaining ring (600) and filter (610) from filter housing (620).

Combustor Housing and Liner WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING EXHAUST DEPOSITS INTO OPEN WOUNDS. (1)

Remove spacers (630) and slide containment ring (670) towards the reduction drive assembly (820).

DISASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

I.

(2)

Remove V-band clamp (650), use combustor puller and remove combustor housing (640), preformed packing (660), and containment ring (670). Discard packing.

(3)

Remove radial pins (680) or liner holder plug (680A), brackets (690) (if installed), sensor bushings (700) (if installed), and combustor liner assembly (710).

(4)

Remove packings (720) and discard.

Turbine Assembly (1)

Remove bolts (740), washers (750), cover (730), and gasket (760). Discard gasket.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.

J.

(2)

Cut lockwire and remove inlet screen (770).

(3)

Remove bolts (790) and washers (800). Separate turbine assembly (780) from reduction drive assembly (820) and remove gasket (810). Discard gasket.

Modification and Identification Plates (1)

Do not remove modification plate (830) unless damaged. If necessary, remove plate.

(2)

Do not remove identification plate (850) unless damaged. If necessary, remove plate.

DISASSEMBLY

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DISASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES ASSEMBLY 1.

General A.

This section has the procedures for assembly of the engine. Item numbers in the procedures are the same as those in the Illustrated Parts Catalog (IPC), Document 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001, ASSEMBLY, for general assembly information. NOTE: Alpha-variant items can replace an item when permitted by the effect code for that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Equipment and Materials WARNING: OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN USING CONSUMABLES. TO AVOID INJURY, WEAR NECESSARY PROTECTIVE GEAR DURING HANDLING AND USE. MAKE CERTAIN CONSUMABLES AND THEIR VAPORS ARE KEPT AWAY FROM HEAT, SPARK, AND FLAME. A.

Equipment and materials required for assembly are listed in Figure 1001. NOTE: Equivalent substitutes may be used for items listed. Equipment and Material

Source (Vendor Code)

Adhesive, Type II and Primer, Type I MIL-A46146

Commercially Available

Adhesive , Type III RTV3145 (576443-3 or 22017203)

Dow Corning Corp.

Adhesive, Thermosetting 179581

Hamilton Sundstrand (55820)

Anti-seize compound 169041-1 or 51102

Hamilton Sundstrand (55820) or Fel-Pro, Inc (73165)

Assembly fixture, ST78601

Hamilton Sundstrand (55820)

Assembly fluid, 4950515

Hamilton Sundstrand (55820)

Connector Pliers, Soft-Jawed TG69

Glenair

Combustor assembly puller, ST91125

Hamilton Sundstrand (55820)

Cover, 162400-200

Hamilton Sundstrand (55820)

Insulating Compound #4

Dow Corning Corp.

Isopropyl Alcohol, ASTM D770

Commercially available

Lint-free cloth

Commercially available

Equipment and Materials Figure 1001 (Sheet 1 of 2) ASSEMBLY

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Page 1001 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Equipment and Material

Source (Vendor Code)

Lockwire MS20995C20 and MS20995C32 Or Safety Cable 5909034-2B and -5B and Cartridge, Ferrule 5909035-1B and -2B Locquic primer, Grade T and Grade N MIL-S22473 (111009-1)

Commercially available

Loctite retaining compound, RC640

Loctite Corp. (05972)

Lubricating oil MIL-PRF-6081, Grade 1010

Commercially Available

Non-metallic mallet

Commercially available

Pipe Sealant (4950698)

Hamilton Sundstrand (55820)

Soft-bristled Brush

Commercially available

Tape Cat No. 27 (950455C1)

3M Corp. (76381)

Tape Silicone - Self-Bonding (MIL-I-46852C, Type 1)

Commercially available

Zinc chromate primer Fed. Spec. TT-P-1757

Commercially available

Engine oil MIL-PRF-7808 or MIL-PRF-23699

Commercially available

Hamilton Sundstrand (55820) Loctite Corp. (05972)

Equipment and Materials Figure 1001 (Sheet 2 of 2) 3.

Engine Module Assembly NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or holding other small components in place for ease of assembly and prevention of galling. If necessary, assembly fluid may be diluted with MIL-PRF-7808 or MIL-PRF-23699. A.

Modification and Identification Plates (1)

Install new modification plate as follows: (a)

Mark new plate (830, IPC 49-20-00 Figure 3) with the information found on the old plate.

ASSEMBLY

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Page 1002 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE SILICONE ADHESIVE/SEALANT, DOW CORNING 3145, CORRECTLY. KEEP THE SEALANT AWAY FROM WATER OR MOIST AIR. THE SEALANT CAN REACT WITH WATER OR MOIST AIR TO MAKE METHYL ALCOHOL GAS. METHYL ALCOHOL GAS IS VERY FLAMMABLE AND CAN BE EXPLOSIVE. DO NOT SWALLOW THE SEALANT, IT CAN MAKE METHYL ALCOHOL THAT CAN CAUSE DEATH OR BLINDNESS. BEFORE YOU USE THE SEALANT, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0202SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(2)

(b)

Apply RTV 3145 adhesive to back of plate.

(c)

Attach plate to reduction drive assembly (820).

Install new identification plates as follows: (a)

Mark new plate (850) with the information found on the old plates.

WARNING: USE SILICONE ADHESIVE/SEALANT, DOW CORNING 3145, CORRECTLY. KEEP THE SEALANT AWAY FROM WATER OR MOIST AIR. THE SEALANT CAN REACT WITH WATER OR MOIST AIR TO MAKE METHYL ALCOHOL GAS. METHYL ALCOHOL GAS IS VERY FLAMMABLE AND CAN BE EXPLOSIVE. DO NOT SWALLOW THE SEALANT, IT CAN MAKE METHYL ALCOHOL THAT CAN CAUSE DEATH OR BLINDNESS. BEFORE YOU USE THE SEALANT, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0202SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (b)

Apply RTV 3145 adhesive to back of plates.

(c)

Attach plate (850) to reduction drive assembly (820) and containment ring (670).

ASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES B.

Turbine Assembly (1)

Place reduction drive assembly (820) with turbine mounting surface facing up.

(2)

Put gasket (810) on reduction drive assembly mating surface with rubber side facing reduction drive. NOTE: Do not use any form of lubricant when installing the gasket.

(3)

Install turbine assembly (780) and attach with bolts (790) and washers (800). Tighten bolts evenly in a criss-cross pattern. Torque bolts in a criss- cross pattern 65 to 75 pound inches (7.34 to 8.47 N·m). Make sure turbine input pinion shaft meshes with reduction drive star gear.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.

C.

(4)

Install inlet screen (770) and attach with lockwire. Install cover 162400-200.

(5)

Put gasket (760) on turbine assembly. Install cover (730) with bolts (740) and washers (750). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

Combustor Housing Assembly Components WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING EXHAUST DEPOSITS INTO OPEN WOUNDS. (1)

Apply a light coat of assembly fluid on packings (720) and install packings into atomizer fittings of liner (710).

CAUTION: DO NOT USE A SHARP TOOL WHEN INSERTING PACKINGS. A SMALL STRAIGHT PUNCH OR EQUIVALENT MAY BE USED. (2)

Insert a 0.125 inch (3.18 mm) diameter rod with a rounded, tapered end into each atomizer fitting to make sure that packings (720) are seated in their grooves.

ASSEMBLY

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Page 1004 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION: ANTI-SEIZE COMPOUNDS CONTAINING LEAD ARE HARMFUL TO THE COMBUSTOR LINER AND HOUSING ASSEMBLIES. DO NOT APPLY ANTISEIZE COMPOUNDS CONTAINING LEAD TO THESE COMPONENTS.

D.

(3)

Apply a light coating of antiseize compound to mating surfaces of combustor housing assembly (640) and combustor liner assembly (710).

(4)

Place combustor housing assembly vertical, exhaust flange down. Position combustor liner in housing. Make sure of correct alignment of start fuel nozzle and ignitor plug bosses in combustor housing and liner assemblies.

(5)

Apply a light coating of antiseize compound to threads of radial pins (680) or liner holder plug (680A). Install radial pins (680) or liner holder plug (680A), as appropriate for the engine configuration. If brackets (690) are required for the configuration, install them, making sure of free entry into liner. Do not tighten radial pins or liner holder plug at this time.

(6)

If necessary, install sensor bushings (700) into brackets (690).

Fuel Manifold Assembly (1)

If necessary, install filter (610) into housing (620) and secure with retaining ring (600).

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (2)

Apply a light coat of antiseize compound to fuel manifold (470) B-nuts and manifold collars. ASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

E.

(3)

Install fuel manifold (470). Tighten B-nuts evenly in the following sequence: 3 and 9 o'clock positions, 2 and 7 o'clock positions, and 5 and 11 o'clock positions. Torque B-nuts 55 to 65 pound inches (6.2 to 7.3 N·m).

(4)

Apply a light coat of assembly fluid to packings (570 and 580).

(5)

Put packing (580) and filter housing (590) on fuel manifold (470) and attach manifold with bolts (480), washers (500), and nuts (490). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

(6)

Put packing (570) on union (560) and install union. Torque union 25 to 35 pound inches (2.8 to 3.9 N·m).

(7)

Put cushions (550) in loop clamps (510) and install clamps. Attach loop clamps with bolts (520), washers (540), and nuts (530). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

Combustor Assembly WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION: ANTI-SEIZE COMPOUNDS CONTAINING LEAD ARE HARMFUL TO THE COMBUSTOR LINER AND HOUSING ASSEMBLIES. DO NOT APPLY ANTISEIZE COMPOUNDS CONTAINING LEAD TO THESE COMPONENTS. (1)

Position turbine assembly (780) vertical. Apply a light coating of antiseize compound to mating surfaces of combustor housing assembly (640) and turbine nozzle.

(2)

Put containment ring (670) over turbine assembly. Install packing (660) on combustor housing assembly (640).

(3)

Apply a small amount of lubricant to inside of V-band clamp (650) and install loosely over combustor housing assembly (640).

(4)

Install combustor puller on combustor housing assembly (640) and install turbine assembly with combustor drain at 6 o’clock position. Be sure that matchmarks on combustor housing assembly (640) and turbine assembly are aligned.

(5)

Position V-band clamp (650) on combustor housing. Align clamp nut at 8 o'clock position and torque clamp nut 45 to 55 pound inches (5.1 to 6.2 N·m). ASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (6)

Remove combustor assembly puller.

(7)

Slide containment ring (670) up onto turbine assembly and attach with spacers (630). Torque spacers 97 to 107 pound inches (11 to 12 N·m).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (8)

Tighten radial pins (680) or liner holder plug (680A). Torque pins or plug 140 to 150 pound inches (16 to 20 N·m) and secure with lockwire or safety cable and ferrule.

WARNING:

(9)

USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

Apply a light coating of antiseize compound to threads of elbow (450).

(10) Install nut (460) and elbow (450). Torque nut 90 to 100 pound inches (10.2 to 11.3 N·m). F.

Start Fuel Nozzles (1)

Pre SB-49-150 configuration: (a)

For start fuel nozzle holder assembly (380), assemble fitting (390) and nozzle (400) as follows:

ASSEMBLY

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Page 1007 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE LOCQUIC PRIMER GRADE T, CORRECTLY. THE PRIMER IS FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE PRIMER, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0135SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE PRIMER, PUT ON CHEMICALSPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES (BUTYL RUBBER). MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE PRIMER FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT 1

Apply Grade T primer to three threads closest to nozzle (410) hex. Allow 3 to 4 minutes for primer to set.

WARNING: USE GRADE T PRIMER AND LOCTITE RC640 SEALANT, CORRECTLY. THE COMPOUND IS FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0067SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT 2

(2)

Apply Loctite RC640 to the same area on nozzle. Install nozzle into fitting (390). Torque nozzle 55 to 60 pound inches (6.2 to 6.7 N·m).

Post SB-49-150 configuration: (a)

For start fuel nozzle holder assembly (380A, 380B, 380C), assemble fitting (390 or 390A) and nozzle (400A) or fitting (390B) and nozzle (400B) as follows: 1

Install nozzle (400A) into fitting (390 or 390A) or (400B) into fitting (390B) Torque nozzle 55 to 60 pound inches (6.2 to 6.7 N·m).

2

Stake nozzle (400A or 400B) and fitting (390, 390A or 390B) three places as shown in Figure 1002. NOTE:

Staking is limited to a maximum of six places.

ASSEMBLY

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Page 1008 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES CAUTION: DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN THE THREADS OF THE START NOZZLE HOLDER AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL CONTAMINATE THE START NOZZLE HOLDER. WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (3)

Apply a light coat of antiseize lubricant to the threads of the start nozzle holder assembly fitting (380) and the mating threads of the combustor housing.

CAUTION: DO NOT INTERCHANGE START FUEL NOZZLE HOLDERS. ONLY USE A START FUEL NOZZLE HOLDER WITH A NOTCHED HEX HEAD IN A THREE-START FUEL NOZZLE CONFIGURATION. IN A ONE OR TWOSTART FUEL NOZZLE CONFIGURATION ONLY USE A START FUEL NOZZLE HOLDER WITH NO NOTCH IN THE HEX HEAD. INSTALLATION OF AN INCORRECT START FUEL NOZZLE HOLDER MAY RESULT IN AN OVER TEMPERATURE OR HUNG START CONDITION. (4)

For pre-SB-49-124 configuration, install assembled holder assembly (380 or 380A) in combustor housing assembly (640). Torque holder 50 to 55 pound inches (5.6 to 6.2 N·m).

(5)

For post-SB-49-124 configuration, install two assembled holder assemblies (380B) in combustor housing assembly (640). Torque holder 50 to 55 pound inches (5.6 to 6.2 N·m).

(6)

For post-SB-49-152 configuration, install three assembled holder assemblies (380C) in combustor housing assembly (640). Torque holder 50 to 55 pound inches (5.6 to 6.2 N·m).

ASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Staking Of Start Fuel Nozzle Assembly Figure 1002 (7)

Post SB-49-190 configuration: (a)

Install tabbed washer (-382, IPC Figure 3, 49-20-00).

(b)

Install Start Fuel Nozzle Holder Assembly (-380D, IPC Figure 3, 49-20-00) or Start Fuel Nozzle Holder Assembly (-380E).

ASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (8)

Post SB-49-181 configuration: WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OILRESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN THE THREADS OF THE START FUEL NOZZLE HOLDER AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL CONTAMINATE THE START FUEL NOZZLE HOLDER.

(a)

Apply a light coat of anti-seize lubricant (51102) to the threads of the two start fuel nozzle holder assemblies (380F) and the mating threads of the combustor housing.

(b)

Install fitting (390D) and injector (400C) to each start fuel nozzle holder assembly (380F).

(c)

Install the two start fuel nozzle holder assemblies (380F) in combustor housing. Torque fittings to 50 to 55 pound inches (5.6 to 6.2 N•m).

(d)

If removed, install plug (385).

ASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (9)

Post SB-49-191 configuration: WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OILRESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION:

G.

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN THE THREADS OF THE START FUEL NOZZLE HOLDER AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL CONTAMINATE THE START FUEL NOZZLE HOLDER.

(a)

Apply a light coat of anti-seize lubricant (51102) to the threads of the three start fuel nozzle holder assemblies (380E) and the mating threads of the combustor housing.

(b)

Install fitting (390C) and injector (400B) to each start fuel nozzle holder assembly (380E).

(c)

Install the three start fuel nozzle holder assemblies (380E) in combustor housing. Torque fittings to 50 to 55 pound inches (5.6 to 6.2 N•m).

Purge Check Valve (1)

Apply light coat of assembly fluid on packings (370 and 340).

(2)

Put packing (370) on reducer (360) and install reducer into check valve (280). Torque reducer 40 to 55 pound inches (4.5 to 6.2 N·m).

(3)

Put packing (340) on union (330) and install union into check valve (280). Torque union 135 to 150 pound inches (15.2 to 17 N·m).

(4)

Install tee (350) into reducer (360). Torque tee 40 to 55 pound inches (4.5 to 6.2 N·m).

(5)

For post SB-49-124 configuration, install tee (350B or 350C) onto tee (350). Torque tee 40 to 55 pound inches (4.5 to 6.2 N·m).

(6)

Put loop clamp (290) on check valve (280). Install clamp, check valve, and brackets (320) with bolt (300) and nut (310). Torque bolt 24 to 27 pound inches (2.7 to 3.1 N·m).

ASSEMBLY

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES H.

I.

Combustor Drain Check Valve (1)

Install reducer (270) in combustor housing assembly (640). Torque reducer 75 to 100 pound inches (8.5 to 11.3 N·m).

(2)

Apply light coat of assembly fluid on packing (260).

(3)

Put packing (260) on check valve (250) and install valve. Torque valve 75 to 100 pound inches (8.5 to 11.3 N·m).

Ignition Exciter (1)

Pre-SB-49-150 configuration: (a)

(2)

(3)

Install ignition exciter (200) and brackets (230 and 240) with bolts (210 and 215) and lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

Post-SB-49-150 configuration: (a)

Install exciter bracket (193) with bolts (210A) and lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1N·m).

(b)

Install ignition exciter (200A) and brackets (240B) with bolts (210A) and lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1N·m).

(c)

Install clamps (148) and sensor bushings (149) with bolts (150A) and nuts (160A). Torque bolts 24 to 27 pound inches (2.7 to 3.1N·m).

Post-SB-49-185 configuration: (a)

Install isolators (199, IPC 49-20-00, Figure 3) on exciter mounting bracket assembly (-193A).

(b)

Install exciter mounting bracket assembly (-193A).

(c)

Install washers (-198).

(d)

Install bolts (-196).

(e)

Torque bolts (-196) to 55 to 70 pound inches (6.2 to 7.9 N.m).

ASSEMBLY

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Page 1013 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDESHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (4) J.

Secure bolts (-196) with safety cable and ferrule cartridge or safety wire.

Igniter Plugs (1)

Pre-SB-49-150 configuration:

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION:

ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO TIP OF IGNITER PLUG OR DAMAGE TO THE PLUG WILL OCCUR.

(a)

Apply a light coat of antiseize compound to both threaded ends of ignitor plug (170).

(b)

Install igniter plug (170) in combustor housing. Torque plug 108 to 132 pound inches (12 to 15 N·m).

ASSEMBLY

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Page 1014 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (2)

Post-SB-49-150 configuration:

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. CAUTION:

K.

ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO TIP OF IGNITER PLUG OR DAMAGE TO THE PLUG WILL OCCUR.

(a)

Apply a light coat of antiseize compound to both threaded ends of ignitor plugs (170A).

(b)

Install igniter plugs (170A) in combustor housing. Torque plugs 108 to 132 pound inches (12 to 15 N·m).

Ignition Cables (1)

(2)

Pre-SB-49-150 configuration: (a)

If removed, install washers (137).

(b)

Install bracket (180) with bolt (190). Torque bolt 55 to 70 pound inches (6.2 to 7.9 N·m).

(c)

Connect ignition cable (130) to igniter plug (170). Torque B-nut 40 to 60 pound inches (4.5 to 6.8 N·m) and secure with lockwire or safety cable and ferrule.

(d)

Put clamp (140) around cable and attach to bracket (180) with bolt (150) and nut (160). Torque nut 24 to 27 pound inches (2.7 to 3.1 N·m).

(e)

Connect ignition cable (130) to exciter (200). Torque B-nut 40 to 60 pound inches (4.5 to 6.8 N·m)

Post-SB-49-150 configuration: (a)

If removed, install washers (137).

ASSEMBLY

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Page 1015 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDESHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (b)

Connect ignition cables (130 and 135) to igniter plugs (170A). Torque B-nuts 40 to 60 pound inches (4.5 to 6.8 N·m) and secure with lockwire or safety cable and ferrule.

(c)

Put clamps (145) around cables at two locations. Attach clamps with bolts (155) and nuts (160A). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m). NOTE: The center two clamps (145) and clamp (147) are not installed at this time.

(d) L.

4.

Connect ignition cables (130 and 135) to exciter (200A). Torque B-nut 40 to 60 pound inches (4.5 to 6.8 N·m).

Engine Mount and Air Inlet Duct (1)

Install engine mount (110) with bolt (120). Torque bolt 100 to 130 pound inches (11.3 to 14.6 N·m).

(2)

Install elbow (20) and torque 135 to 150 pound inches (15.2 to 17 N·m).

(3)

Put packing (40) on union (30) and install in elbow (20). Torque union 135 to 150 pound inches (15.2 to 17 N·m).

(4)

Remove cover 162400-200 and install air inlet duct (10) with captive fasteners.

Engine Assembly A.

Lifting Brackets (1)

Install brackets (730 and 760, IPC 49-20-00 Figure 2) with bolts (740) and washers (750). Torque bolts 55 to 70 pound inches (6.2 to 7.9 N·m).

(2)

Install sensor bushing (780) and clamp (770) with bolt (790), nut (800), and washer (810). Torque bolt 24 to 27 pound inches (2.7 to 3.1 N·m).

ASSEMBLY

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Page 1016 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES B.

High Oil Temperature Switch WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (1)

C.

Apply a light coat of assembly fluid on packing (700) and install packing on high oil temperature switch (690) and install switch. Torque switch 55 to 75 pound inches (6.2 to 8.5 N·m) and secure with lockwire or safety cable and ferrule.

Speed Pickup (1)

Insert a 7/16 Allen wrench in the starter gear of the accessory drive assembly. Use the wrench to manually turn the gear until one tooth of the starter gear is in line with the center of the speed pickup mounting hole.

WARNING: USE ANAEROBIC RETAINING COMPOUND, MIL-R-46082, CORRECTLY. THE COMPOUND IS FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0067SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (2)

Apply MIL-S-22473N Primer Grade "N" to threads of magnetic pickup (680) and allow to dry for 5 minutes. Apply Pipe Sealant with Teflon (PST 592) to threads of magnetic pickup.

(3)

Rotate Accessory Drive Gear until top of one of the Gear Teeth is in line with center of Magnetic Pick-up mounting hole.

(4)

Install Magnetic Pick-up (680) by hand into Accessory Drive until contact with Gear is made.

(5)

Using key in electrical connector as a reference, back off magnetic pickup (680) one quarter (1/4) turn (0.14 inch or 0.356 mm) and tighten Jam Nut into housing. Torque Jam Nut to 75-100 pound inches (8.5 to 11.3 N.m). NOTE: Gap between pole of speed pickup and gear tooth is 0.012 to 0.016 inch (0.305 to 0.406 mm). ASSEMBLY

49-20-00

Page 1017 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (6)

D.

Use the Allen wrench to manually turn the starter gear through a complete revolution. Make sure speed pickup does not touch the gear. Secure jam nut with lockwire or safety cable and ferrule.

Oil Level Sight Plug and Accessory Bracket (1)

Install bracket (650) with screw (210, IPC 49-23-00 Figure 1) and washer (240). Torque screw 20 to 22 pound inches (2.2 to 2.5 N·m).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (2)

Apply a light coat of assembly fluid on packing (590, IPC 49-20-00 Figure 2) and install packing on spacer (710). Install spacer and torque 150 to 200 pound inches (16.9 to 22.6 N·m). Secure spacer to oil cap (74, IPC 49-23-00 Figure 1) with lockwire or safety cable and ferrule.

(3)

Install accessory bracket (600, IPC 49-20-00 Figure 2) with screws (620 and 660), washers (630 and 670), and spacer (640). Torque screws 20 to 22 pound inches (2.2 to 2.5 N·m).

ASSEMBLY

49-20-00

Page 1018 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.

E.

F.

(4)

Install nut (610) and torque 95 to 115 pound inches (10.7 to 13.0 N·m). Secure nut to bracket (600) with lockwire or safety cable and ferrule.

(5)

Apply a light coat of assembly fluid on packing (590) and install packing on oil level sight plug (580) and install plug. Torque plug 65 to 85 pound inches (7.3 to 9.6 N·m) and secure to nut (610) with lockwire or safety cable and ferrule.

Solenoid Valves (1)

Put solenoid valve (550) on bolts (560) so that flow arrow will face forward when installed on the engine.

(2)

Put solenoid valve (540) on bolts (560) so that flow arrow will face aft when installed on the engine.

(3)

Put solenoid valve (530) on bolts (560) so that flow arrow will face aft when installed on the engine.

(4)

Install assembled valves in bracket (600) and attach with nuts (570). Torque bolts 25 to 30 pound inches (2.8 to 3.3 N·m).

(5)

Apply a light coat of assembly fluid on packing (520) and install packing on union (510) and install union. Torque union 135 to 150 pound inches (15.1 to 16.9 N·m).

(6)

Apply a light coat of assembly fluid on packings (500) and install packings on reducers (490) and install reducers. Torque reducers 135 to 150 pound inches (15.1 to 16.9 N·m).

(7)

Apply a light coat of assembly fluid on packings (430 and 460) and install packings on fittings (420 and 450). Put fittings (420 and 450) into fitting (480) and install packings (440 and 470). Install assembled fitting (480) into solenoid valves (540 and 550). Torque fittings 135 to 150 pound inches (15 to 17 N·m).

Oil Filter/Pressure Indicator (1)

Apply a light coat of assembly fluid on packing (410) and install packing on elbow (400) and install elbow in oil filter/pressure indicator (330). Torque elbow 60 to 80 pound inches (6.7 to 9.0 N·m).

(2)

Install retainer (370), nut (390), and packing (380) on tee (360). Install tee and torque 75 to 100 pound inches (8.5 to 11.3 N·m). ASSEMBLY

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Page 1019 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

G.

(3)

Install oil filter/indicator (330) and bracket (300) and attach with bolts (310) and washers (320). Torque bolts 108 to 120 pound inches (12.2 to 13.5 N·m).

(4)

Apply a light coat of assembly fluid on packing (336) and install packing (336) and backup ring (334) in filter bowl (332).

(5)

Apply a light coat of assembly fluid on packing (350) and install packing in filter element (340) and install element in filter bowl (332). Install filter bowl to oil filter/pressure indicator (330).

Low Oil Pressure Switch (1)

Apply a light coat of assembly fluid on packings (290 and 270) and install packing (290) into reducer (280) and packing (270) on low oil pressure switch (260).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (2) H.

I.

Install reducer and switch on tee (360). Torque reducer and switch 135 to 150 pound inches (15.2 to 17 N·m) and secure with lockwire or safety cable and ferrule.

Fuel Filter Assembly (1)

Apply a light coat of assembly fluid on packing (240) and install nut (250) and packing on elbow (230) and install elbow in fuel filter assembly (170). Torque elbow 95 to 105 pound inches (10.7 to 11.8 N·m).

(2)

Apply a light coat of assembly fluid on packing (220) and install packing on union (210) and install union in fuel filter assembly (170). Torque union 95 to 105 pound inches (10.7 to 11.8 N·m).

(3)

Put backing ring (208), packing (205), and element (200) in bowl (190) and install bowl. Torque bowl 40 to 60 pound inches (4.5 to 6.7 N·m).

(4)

Install assembled fuel filter (170) with bolts (180). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

Fire Control Loop Brackets and Clamps (1)

Remove one bolt (210, IPC 49-23-00 Figure 1) and washer (240) from the reduction drive assembly. Discard washer.

(2)

Install bracket (600, IPC 49-20-00 Figure 1) and washer (605) with the bolt previously removed in step (1). Torque bolt 24 to 27 pound inches (2.7 to 3.1 N·m).

ASSEMBLY

49-20-00

Page 1020 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

J.

(3)

Install bracket (580) with bolt (590). Torque bolt 190 to 230 pound inches (21.5 to 25 N·m).

(4)

Install bracket (550) with bolt (560) and nut (570). Torque bolt 24 to 27 pound inches (2.7 to 3.1 N·m).

(5)

Install clamps (510) and sensor bushings (540) and with bolts (520) and nuts (530). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

Fuel Control Assembly (1)

Apply a light coat of assembly fluid on packing (500). Install packing on union (490) and install union. Torque union 180 to 200 pound inches (20.3 to 22.6 N·m). Apply a light coat of assembly fluid on packing (470). Put nut (480) and packing (470) on elbow (460) and install elbow. Torque elbow 95 to 105 pound inches (10.7 to 11.8 N·m).

(2)

Apply a light coat of assembly fluid on packing (450). Install packing on reducer (440) and install reducer. Torque reducer 40 to 55 pound inches (4.5 to 6.2 N·m).

(3)

Apply a light coat of assembly fluid on packing (430). Install packing on union (420) and install union. Torque union 40 to 55 pound inches (4.5 to 6.2 N·m)

(4)

Apply a light coat of assembly fluid on packing (410). Install packing on plug (400) and install plug. Torque plug 40 to 55 pound inches (4.5 to 6.2 N·m).

(5)

Apply a light coat of assembly fluid on packing (390). Put packing on reducer (380) and install reducer. Torque reducer 25 to 35 pound inches (2.8 to 3.9 N·m).

(6)

Apply a light coat of assembly fluid on packing (370). Install packing on union (360) and install union. Torque union 40 to 55 pound inches (4.5 to 6.2 N·m).

(7)

Mate fuel pump (320) to acceleration control (290) without installing packings. The faces should mate with no clearance and with no force required. If force is necessary, separate and inspect splines. Remove all foreign material and burrs.

(8)

Separate fuel pump from acceleration control.

(9)

Apply a light coat of assembly fluid on packings (330, 340, and 350). Install packings on acceleration control (290).

(10) Install fuel pump (320) on acceleration control (290) with bolts (300) and washers (310). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m). (11) Install gasket (280) and fuel control assembly (250) with bolts (260) and washers (270). Torque bolts 55 to 70 pound inches (6.2 to 7.9 N·m). K.

Tube Assemblies NOTE: The minimum clearance between tubes and between tubes and adjacent components must be 0.080 inch (2.03 mm). (1)

Connect tube assemblies to the following components:

ASSEMBLY

49-20-00

Page 1021 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (a)

Connect tube assembly (130) to union (420) and to start valve bolt fitting (420, IPC 49-20-00 Figure 2). Torque B-nuts 135 to 150 pound inches (15.1 to 16.9 N·m).

(b)

Connect tube assembly (240, IPC 49-20-00 Figure 1) to reducer (440) and to reducer (490, IPC 49-20-00 Figure 2). Torque B-nuts 50 to 60 pound inches (5.6 to 6.8 N·m).

(c)

Connect tube assembly (140, IPC 49-20-00 Figure 1) to reducer (380) and to union (510, IPC 49-20-00 Figure 2). Torque B-nuts 135 to 150 pound inches (15.1 to 16.9 N·m).

(d)

Connect tube assembly (120, IPC 49-20-00 Figure 1) to union (490) and to elbow (230, IPC 49-20-00 Figure 2). Torque B-nuts 135 to 150 pound inches (15.1 to 16.9 N·m).

(e)

Connect tube assembly (180, IPC 49-20-00 Figure 1) to union (360) and to elbow (20, IPC 49-20-00 Figure 3). Torque B-nuts 135 to 150 pound inches (15.1 to 16.9 N·m).

(f)

Connect tube assembly (10, IPC 49-20-00 Figure 2) to union (60) and to tee (360). Torque B-nuts 270 to 300 pound inches (30.5 to 33.9 N·m).

(g)

Connect tube assembly (20) to elbow (400) and to reducer (50, IPC 49-23-00 Figure 1). Torque B-nuts 95 to 105 pound inches (10.7 to 11.8 N·m).

(h)

Connect tube assembly (80, IPC 49-20-00 Figure 2) to union (60) and to reducer (50, IPC 49-23-00 Figure 1). Torque B-nuts 95 to 105 pound inches (10.7 to 11.8 N·m).

(i)

Connect tube assembly (90, IPC 49-20-00 Figure 2) to reducer (490) and to union (560, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 N·m).

(j)

Connect tube assembly (130, IPC 49-20-00 Figure 2) to reducer (490) and to tee (350, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 N·m).

(k)

Connect start fuel nozzle tube assemblies: 1

Pre and Post SB-49-124 configuration: a

2

Connect tube assemblies (140 and 145, IPC 49-20-00 Figure 2) to tee (350, IPC 49-20-00 Figure 3) and to start fuel nozzle holder assemblies (380). Torque B-nuts 40 to 50 pound inches (4.5 to 5.6 N·m).

Post SB-49-152 configuration: a

Connect tube assemblies (140, 145 and 147, IPC 49-20-00 Figure 2) to tee (350, IPC 49-20-00 Figure 3), fitting (352) and to start fuel nozzle holder assemblies (380C). Torque B-nuts 40 to 50 pound inches (4.5 to 5.6 N·m).

ASSEMBLY

49-20-00

Page 1022 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 3

Post SB-49-181 configuration: a

4

Post SB-49-191 configuration: a

(l)

Connect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) to 90°-elbow (350D, IPC 49-20-00, Figure 3) and to the two start fuel nozzle holder assemblies (380F). Torque B-nuts to 40 to 50 pound inches (4.5 to 5.6 N•m).

Connect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) to tee (350B, IPC 49-20-00, Figure 3) and to the three start fuel nozzle holder assemblies (380E). Torque B-nuts to 40 to 50 pound inches (4.5 to 5.6 N•m).

Connect tube assembly (150, IPC 49-20-00 Figure 2) to union (330, IPC 4920-00 Figure 3). Torque B-nut 135 to 150 pound inches (15.1 to 16.9 N·m).

(2)

Install loop clamps (30, 100, and 160, IPC 49-20-00 Figure 2) on tube assemblies (90, 130, 145, and 150) with bolts (110) and nuts (120). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

(3)

Install loop clamp (147A, IPC 49-20-00 Figure 3) on tube assembly (147, IPC 4920-00 Figure 2) with bolt (157A, IPC 49-20-00 Figure 3) and nut (160). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

(4)

Install loop clamps (30, 70 and 510) on tube assemblies (10, 20, and 80) with bolts (40, 520, and 525, ) and nuts (50 and 530). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m).

(5)

Install loop clamps (150, 190, and 220, IPC 49-20-00 Figure 1) on tube assemblies (140 and 180) with bolts (160 and 200) and nuts (170 and 210). Torque bolts 24 to 27 pound inches (2.7 to 3.1 N·m). Install loop clamps (50 and 220) on tube assemblies (120 and 130) with bolt (70) and nut (90). Torque bolt 24 to 27 pound inches (2.7 to 3.1 N·m).

(6)

For post SB-49-150 configuration, install loop clamps (145, IPC 49-20-00 Figure 3) (middle set of clamps) on ignition cables (130 and 135). Install loop clamp (147) on tube assembly (90, IPC 49-20-00 Figure 1). Attach all three loop clamps with bolt (157, IPC 49-20-00 Figure 3) and nut (160A). Torque bolt 24 to 27 pound inches (2.7 to 3.1 N·m).

(7)

For Post SB-49-181 configuration, install loop clamp (100C, IPC 49-20-00, Figure 2) with bolt (110B) and washer (115) to tube assembly (147).

(8)

Post SB-49-191 configuration: (a)

Install loop clamp (100C) with bolt (110B) and washer (115) to tube assembly (147).

(b)

Install loop clamps (161 and 162) with bolt (163) and nut (164) to tube assemblies (145A and 140B).

ASSEMBLY

49-20-00

Page 1023 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES L.

Engine Harness Assembly (Pre SB 49-180) (1)

Wrap harness and tubes, as necessary, with tape to be sure of a tight fit in clamps and to obtain minimum gap between fuel lines. NOTE: Harness and tubes shall fit tightly in clamps. Verify installation for fit. NOTE: The minimum clearance between tubes, and between tubes and adjacent components must be 0.080 inch (2.03 mm).

(2)

Install engine harness assembly (10) with clamps (45, 50, 60, and 80), bolts (70), and nuts (90). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m).

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE. (3)

Apply antiseize compound to the threads of thermocouple (112) and attach thermocouple to combustor housing. Torque thermocouple 40 to 60 pound inches (4.5 to 6.8 N·m) and secure with lockwire or safety cable and ferrule.

(4)

Install hourmeter (100A) and event counter (110) with screws (20), washers (40), and nuts (30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m).

ASSEMBLY

49-20-00

Page 1024 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (5)

Clean all harness and component connectors using a soft-bristled brush and cotton wipes moistened with isopropyl alcohol to remove oil, grease, and contamination from the pins and inside of the electrical connectors. Allow connectors to air dry.

(6)

If required, install connector seals (262, 542, 552, and 685, IPC 49-20-00 Figure 2) in the connectors of low oil pressure switch (260), fuel solenoid valves (530, 540 and 550), and magnetic pickup (680). Press the seals over the connector pins to the base of the pins.

(7)

Connect harness assembly electrical connectors to the following components: NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (a) Connect electrical connector (P302) to magnetic pickup (680, IPC 49-20-00 Figure 2). (b)

Connect electrical connector (P303) of harness assembly (10, IPC 49-20-00 Figure 1) to ignition exciter (200, IPC 49-20-00 Figure 3) as follows: Apply self-bonding tape onto the harness, connector, and connector backshell. (Refer to Figure 1003).

1

NOTE:

When installing self-bonding tape, the overlapping and stretching instructions must be followed to correctly install tape.

a

Apply tape onto harness, connector, and connector backshell by wrapping the tape, with the blue stripe on the outside, in a clockwise rotation onto ZONE A.

b

Start at the connector end near the strain relief screws.

c

Stretch the tape as it is being applied so that the width of the tape decreases by approximately 25-percent.

d

Begin by wrapping two layers of 100-percent coverage for a tight seal.

e

Continue wrapping the tape with a 50-percent overlap through ZONE A and onto ZONE B.

f

Finish wrapping onto ZONE B with two layers of 100-percent coverage. ASSEMBLY

49-20-00

Page 1025 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES g

Allow tape to cure according to manufacturer’s instructions. NOTE:

The tape cures to an airworthy condition in approximately one hour. It fully cures in 48 hours at an ambient temperature of 70 to 80 F (21 to 27 C).

Wrapping Harness and Connectors with Self-Bonding Tape Figure 1003 (c)

Connect electrical connector (P306) to main fuel solenoid valve (530, IPC 49-20-00 Figure 2).

(d)

Connect electrical connector (P305) to start fuel solenoid valve (540).

(e)

Connect electrical connector (P307) to maximum fuel solenoid valve (550).

(f)

Connect electrical connector (P311) to high oil temperature switch (690).

(g)

Connect electrical connector (P304) to low oil pressure switch (260).

(h)

Connect electrical connector (P308) to the anti-surge valve (40, IPC 49-00-00 Figure 1).

NOTE: Electrical connector (P308) is connected to the anti-surge valve and (P309) is connected to the bleed air valve during finally assembly of the APU.

ASSEMBLY

49-20-00

Page 1026 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (i)

Connect electrical connector (P309) of harness assembly (10, IPC 49-20-00 Figure 1) to bleed air valve (100, IPC 49-00-00 Figure 1) as follows: WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT

M.

1

Clean the harness, connector, and connector backshell with isopropyl alcohol and a lint free cloth.

2

Apply self-bonding tape onto the harness, connector, and connector backshell following the procedures oulined in step 4.L.(5)(c)2. (Refer to Figure 1003).

Installation of Engine Harness Assembly (Post SB 49-180) (1)

Wrap harness and tubes, as necessary, with tape to be sure of a tight fit in clamps and to obtain minimum gap between fuel lines. NOTE: Harness and tubes shall fit tightly in clamps. Verify installation for fit. NOTE: The minimum clearance between tubes, and between tubes and adjacent components must be 0.080 inch (2.03 mm).

(2)

Install engine harness assembly (10) with clamps (45, 50, 60, and 80), bolts (70), and nuts (90). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m).

(3)

Route the engine harness assembly as shown in Figures 1004 and 1005.

(4)

Install the clamps (quantity 2) (190), bolt (200) removed in step 3 (b) above with new nut (210), at the location and positions shown. Torque bolt 20 to 22 pound inches (2.2 to 2.4 N.m).

(5)

The clamp holding the engine harness assembly wires was positioned downward and is now positioned upward.

(6)

Reinstall the sensor bushing (230), clamp (220), clamp (190) and bolt removed in step 3 (b) above as originally located, along with a new nut (210) and the clamp (65), removed in step 2 (a) above. Torque bolt to 20 to 22 pound inches (2.2 to 2.4 N.m).

ASSEMBLY

49-20-00

Page 1027 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (7)

Apply antiseize compound to the threads of thermocouple (112) and attach thermocouple (112) to combustor housing. Torque thermocouple 40 to 50 pound inches (4.5 to 5.6 N·m) and secure with lockwire.

(8)

Install hourmeter/event counter (111) with screws (20), washers (40), and nuts (30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 N·m).

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (9)

Clean all harness and component connectors using a soft-bristled brush and cotton wipes moistened with isopropyl alcohol to remove oil, grease, and contamination from the pins and inside of the electrical connectors. Allow connectors to air dry.

(10) If required, install connector seals (262, 542, 552, and 685, IPC 49-20-00 Figure 2) in the connectors of low oil pressure switch (260), fuel solenoid valves (530, 540 and 550), and magnetic pickup (680). Press the seals over the connector pins to the base of the pins. (11) Connect engine harness and component connectors as follows: NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (a)

Connect electrical connector (P302) to magnetic pickup (680, IPC 49-20-00 Figure 2).

(b)

Connect electrical connector (P303) of harness assembly (10, IPC 49-20-00 Figure 1) to ignition exciter (200, IPC 49-20-00 Figure 3).

ASSEMBLY

49-20-00

Page 1028 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (c)

Connect electrical connector (P306) to main fuel solenoid valve (530, IPC 49-20-00 Figure 2).

(d)

Connect electrical connector (P305) to start fuel solenoid valve (540).

(e)

Connect electrical connector (P307) to maximum fuel solenoid valve (550).

(f)

Connect electrical connector (P311) to high oil temperature switch (690).

(g)

Connect electrical connector (P304) to low oil pressure switch (260).

(h)

Connect electrical connector (P308) to anti-surge valve (40, IPC 49-00-00 Figure 1).

(i)

Connect electrical connector (P309) to bleed valve (100).

(12) Use a lint free cloth and remove any visible insulating compound.

ASSEMBLY

49-20-00

Page 1029 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Top View - Engine Control Harness Installation (Post SB 49-180) Figure 1004 ASSEMBLY

49-20-00

Page 1030 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Side View - Engine Control Harness Installation (Post SB 49-180) Figure 1005

49-20-00

ASSEMBLY Page 1031 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

ASSEMBLY

49-20-00

Page 1032 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES STORAGE 1.

General A.

This section details the requirements necessary to prepare the engine for on-wing and off-wing storage. It also provides depreservation procedures for the engine from storage. Refer to ASTM D-3951-82 for general requirements of industrial packaging. Item numbers in the procedures are the same as those in the Illustrated Parts Catalog (IPC), Document 40C11-3. Refer to Standard Practices Manual, Document HSPS 490001, for general information. NOTE: Alpha-variant items can replace an item when permitted by the effect code for that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Equipment and Materials NOTE: Refer to Standard Practices Manual, Document HSPS 490001, ASSEMBLY for a list of protective covers used on the engine for shipment or storage. A.

Preservation, storage and depreservation equipment and materials are listed in Figure 1201. (1)

Equivalent substitutes may be used for items listed. Material

Source (Vendor Code)

VCI - 121

Cortec Corporation (44695)

MIL-I-2210C (1 pak per each cubic foot of bag volume)

Cortec Corporation (44695)

Barrier bag (optional), 165151-1 or 165151-2

Hamilton Sundstrand (55820)

Barrier material MIL-B-131

Commercially Available

Bracket assembly, 164174-100 and 165166-102 Hamilton Sundstrand (55820) Cleaning Compound (Simple Green, 13002) or equivalent alkaline cleaner with a pH of 8 - 9

Sunshine Makers (1Z575)

Connector Pliers, Soft-Jawed TG6

Glenair

Container 1 gallon (3.8 liter)

Commercially Available

Desiccant (88 units), MIL-D-3464

Commercially Available

Desiccant Cor - Pak™ 1-MUL

Commercially Available

Heat seal machine

Commercially Available

Humidity indicator card

Commercially Available

Label

Commercially Available

Lint-free cloth

Commercially Available

Lubricating oil MIL-PRF-6081, Grade 1010

Commercially Available

Masking tape PPP-T-42

Commercially Available

Preservation and Storage Equipment and Materials Figure 1201 (Sheet 1 of 2) STORAGE

49-20-00

Page 1201 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Material

Source (Vendor Code)

Protective caps and plugs, MIL-C-5501

Commercially Available

Shipping container Tag

Hamilton Sundstrand (55820) Commercially Available

Tube assembly

Commercially Available

Vacuum machine (air)

Commercially Available

Vacuum tube

Commercially Available

Water vapor proof barrier material, MIL-B-131

Commercially Available

Solvent resistant gloves

Commercially Available

Engine exhaust cover, 4951923-1

Hamilton Sundstrand (55820)

Air inlet duct cover, 4951924

Hamilton Sundstrand (55820)

Preservation and Storage Equipment and Materials Figure 1201 (Sheet 2 of 2) 3.

Preservation and Storage - OFF WING A.

Fuel System Preservation (1)

Connect a tube assembly to fuel inlet at union (210, IPC 49-20-00 Figure 2).

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES. (2)

Connect a gravity-feed oil supply to tube assembly.

WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED. (3)

Disconnect electrical connectors (P305 and P306) from solenoid valves (530 and 540).

(4)

Apply 28 Vdc to solenoid valve electrical connectors (J305 and J306).

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. (5)

Place container under combustor drain check valve (250, IPC 49-20-00 Figure 3) to catch spilled fuel. STORAGE

49-20-00

Page 1202 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (6)

Turn turbine rotor clockwise looking at turbine wheel from exhaust of APU. Rotor will turn freely if starter-generator is not on gearbox. NOTE: If there is a starter-generator on APU, turn turbine rotor counter clockwise from gearbox accessory pad using a wrench.

(7)

Disconnect 28 Vdc from solenoid valves and install connectors (P305 and P306).

NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (8)

Disconnect gravity-feed oil supply from tube assembly and remove tube assembly from fuel inlet at union (210, IPC 49-20-00 Figure 2).

(9)

Install protective caps and plugs in all open ports and fittings.

(10) Attach a tag warning that fuel system has been preserved. B.

General Preservation NOTE: The following procedure will allow the engine to be stored for a maximum of 90 days. (1)

Install air inlet cover on air inlet duct (10, IPC 49-20-00 Figure 3).

(2)

Clean external surfaces of APU with a lint-free cloth dampened with Simple Green.

(3)

Wipe off residual Simple Green with a dry, lint-free cloth.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.

C.

(4)

Remove magnetic drain plug (10, IPC 49-23-00 Figure 1) as an assembly and allow lubricating oil to drain from reduction drive assembly into container.

(5)

Install magnetic drain plug (10) in reduction drive assembly and torque 180 to 200 pound inches (20.3 to 22.6 N·m).

(6)

Attach a tag to engine warning that oil system has been drained.

(7)

Cover all open connections, ports, and openings including anti-surge valve, bleed air valve, and exhaust outlet with barrier material and masking tape.

Preparation for Storage or Shipment NOTE: The following procedure will allow the engine to be stored for a maximum of 12 months. (1)

Cover all open connections, ports, and openings, including start bypass valve, bleed air valve, and exhaust outlet with barrier material and masking tape.

(2)

Hoist APU from assembly stand. STORAGE

49-20-00

Page 1203 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (3)

Attach bracket assemblies to APU. NOTE: When possible; bracket assemblies, support assembly, attaching hardware, and other items supplied with APU shipping container, shall be reused to ship or store identical APU model.

(4)

Position barrier material around APU and shipping frames to form a barrier bag.

(5)

Hoist APU onto shipping container skid.

(6)

Cut small holes in barrier bag to allow bolts to protrude.

(7)

Lift barrier bag and place gaskets on each protruding bolt. Apply adhesive around bolts and gaskets.

(8)

Place gaskets on bolts from inside of barrier bag.

(9)

Secure bracket assemblies to shipping container skid with nuts and washers.

(10) Install humidity indicator card on inside of barrier bag so as to coincide with shipping container window. (11) Using masking tape, secure cellular cushioning material around APU to prevent protruding corners and edges from cutting barrier bag. (12) Place fresh desiccants in barrier bags as required. (13) Position top of barrier bag over APU and align seam edges. Apply staples around edge of barrier bag to keep seams even. (14) Seal barrier bag seam around APU, except for one opening small enough to permit installation of vacuum tube, using heat seal machine. NOTE: When using heat seal machine, use care to prevent wrinkles in barrier bag seams and fabric pulling which will cause leaks. (15) Place vacuum tube in small opening of barrier bag and attach air vacuum machine to tube. (16) Operate air vacuum machine to remove air from barrier bag until bag clings snugly to APU. (17) Remove air vacuum machine and tube from barrier bag and immediately seal the small opening. (18) Apply masking tape around barrier bag. (19) Attach APU records and applicable documents to barrier bag. (20) Position shipping container cover so that window in cover coincides with humidity indicator card attached to barrier bag. Secure cover to skid with bolts. STORAGE

49-20-00

Page 1204 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (21) Attach applicable records, documents, and markings to exterior of shipping container. 4.

Preservation and Storage - ON WING A.

Fuel System Preservation (1)

Disconnect the fuel inlet tube from the fuel inlet on the fuel control assembly.

(2)

Connect a tube assembly to fuel inlet.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES (3)

Connect a gravity-feed supply of lubricating oil, MIL-PFR-6081, Grade 1010 to the tube assembly.

WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED. (4)

Disconnect electrical connectors from solenoid valve.

(5)

Apply 28 Vdc to solenoid valve electrical connectors.

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. (6)

Place container under combustor fuel tube assembly drain hose to catch spilled fuel.

(7)

Turn turbine rotor counterclockwise until fuel-free oil flows from drain hose.

(8)

Disconnect 28 Vdc from solenoid valve and install connectors.

NOTE: When possible, connectors should be tightened with a pair of soft-jawed connector pliers. Tighten until the soft-jawed pliers slip on the connector. (9)

Disconnect the gravity-feed oil supply from the tube assembly and remove the tube assembly from the fuel inlet on the fuel control assembly.

(10) Install protective caps and plugs in all open ports and fittings. B.

Drain all oil from the gearbox assembly

C.

Continue preserving the APU engine assembly for on wing storage as follows

STORAGE

49-20-00

Page 1205 Mar 15/04

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (1)

Attach a tag to the oil filler cap with the information that follows: (a)

(2)

“WARNING - No Oil in Gearbox”.

Attach a tag to the fuel supply hose with the information that follows: WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES (a)

The fuel system of this engine has been preserved with lubricating oil MILPRF-6081, Grade 1010.

(b)

This preservation is valid until MM/DD/YY NOTE: Date should be 90 days from beginning of preservation of the APU engine assembly.

(3) 5.

Install protective covers on the APU engine assembly exhaust, air inlet duct and bleed control valve duct.

Depreservation of the APU Engine Assembly from Storage A.

Remove the APU engine assembly from storage.

B.

Prepare the APU engine assembly for test.

C.

Remove the protective covers from the APU engine assembly exhaust, air inlet duct, bleed air valve, and anti-surge valve.

D.

Remove any tags from the fuel supply hose.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES. E.

Drain all oil from the fuel system.

F.

Connect the fuel supply to the inlet on the fuel control assembly and open the fuel supply valve.

G.

Remove any tags from the gearbox assembly oil filler cap.

H.

Fill the gearbox assembly with oil.

I.

Operate the APU engine assembly for a minimum of 3 minutes.

J.

Shut down the APU engine assembly.

K.

Do a visual inspection of the APU engine assembly for fuel leaks or for oil leaks at the output pads, seals, fittings and connections.

STORAGE

49-20-00

Page 1206 Nov 15/07

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES TESTING 1.

Introduction A.

2.

This section details the test procedures required to evaluate the engine operational efficiency after repair. Refer to 49-00-00, FAULT ISOLATION for corrective actions if the engine fails during test.

Test Cell Requirements A.

Equipment and Instrumentation (1)

Test cell equipment and instrumentation are listed in Figure 1301. NOTE: Equivalent substitutes may be used for listed items.

B.

Fuel and Lubrication Oil Criteria (1)

Fuel used during test shall conform to MIL-T-5624 (Grade JP-4 or JP-5 or JP-8) or ASTM D-1655 (Type A or A-1).

(2)

Lubrication oil used shall conform to MIL-PRF-23699 specification or the commercial equivalent.

(3)

Fuel boost pressure shall be 5 to 40 psig (34.47 to 275.79 kPa).

(4)

The fuel flowrate (pph) shall be measured with a calibrated flowmeter.

(5)

The following procedures are required when using a turbine meter flowmeter: NOTE: Direct flow measurement maybe accomplished using a Micromotion massflowmeter, therefore, specific gravity and temperature measurements are not required.

(6)

(a)

The actual fuel specific gravity (S.G. ACT) at the time of the acceptance tests, for use in determining the actual fuel flowrate, will be determined indirectly by measuring the actual fuel temperature (TFUEL ACT.) at the time of test, along with the type-fuel specific gravity curve.

(b)

The S.G. ACT. and TFUEL ACT. shall be recorded on the test data sheet.

Oil level change shall be measured and recorded during the initial and final acceptance tests, using the following procedures: NOTE:

Evidence of oil consumption after test shall be cause for rejection.

(a)

The reduction drive assembly oil sump shall be filled with room-temperature oil, to the full mark on the oil level sight glass, prior to starting tests.

(b)

Mark oil level on sight glass with a grease pencil before starting tests. TESTING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Name

Number

Manufacturer (Vendor Code)

Use

Clock

Commercially Available

Test timing

Stop watch

Commercially Available

Recording starting cycle time

Starting motor

Model MT50

Delco-Remy (16764)

Test setup

Water dynamometer

101-080

Kahn (33980)

Test setup

Dynamometer Load 0-100 pounds (0-45 Kg)

3397

Lebow (60012)

Measure shaft load

Digital frequency counter (0 to 5 kHz)

TACTROL-3

Airpax (82227)

Magnetic speed pickup

Torque arm length

Kahn

Test setup

Drain line (2)

Commercially Available

Test setup

Filler cap thermometer

Modified 117851-1

Hamilton Sundstrand (99167)

Test setup

Accelerometer

2221F

Endevco (97896)

Vibration measurement

Vibration meter

6634M10

Endevco

Vibration measurement

Vibration filter (@ rotor frequency)

AB193-1046

TTE (07766)

Band pass filter

Pressure gauge 0 to 100 psig (0 to 690 kPa) (quantity 4)

118

Viatran (27385)

Measure oil pressure

Thermometer 32 to 450°F (0 to 232°C) .125” x 6”, Type “K”, ungrounded, single element

M1212CSU6

C-Temp (6X013)

Measure oil temperature

Exhaust gas temperature test probe 0 to 2,000°F (0 to 1,093°C)

M2512CSE6

C-Temp

Measure exhaust temperature

Test Cell Equipment and Instrumentation Figure 1301 (Sheet 1 of 2) TESTING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Name

Number

Manufacturer (Vendor Code)

Use

Hamilton Sundstrand (99167)

Measure compressor inlet temperature

Orifice plate 2.5924 in. (65.85 mm) diameter

Commercially Available

Measure bleed air flow

Variable/Controllable Air Load Valve

Commercially Available

Regulates (Controls) bleed air flow

Air inlet temperature probe 0 to 150°F (0 to 113°C)

MT574

Electronic sequence unit

4501974

Hamilton Sundstrand

Test setup

Bleed air shutoff valve, slave

4950699

Hamilton Sundstrand

Test setup

Barometer pressure gauge 28 to 32 in. Hg (95 to 108 kPa)

125-K094

Robinson/Halpern

Measure barometric pressure

Flowmeter 0 to 200 pph

D12

Micro Motion (63985)

Mass flowmeter

Bleed air static pressure 0 to 100 psig (0 to 689 kPa)

118

Viatran (27385)

Measure pressure

Compressor discharge pressure 0 to 100 psig (0 to 689 kPa)

118

Viatran

Measure compressor discharge pressure

Test probe 0 to 500°F (0 to 360°C)

M2512CSE6

C-Temp (6X013)

Measure bleed air temperature

Pressure gauge 0 to 200 inch H2O

123

Viatran

Measure bleed air delta pressure

Exhaust duct pressure 123 Viatran Measure exhaust duct 0 to -10 inch H2O pressure NOTE: All instrumentation and equipment used in APU testing shall be calibrated to provide a static accuracy within 3 percent of the values obtained when the APU is operating at maximum output Test Cell Equipment and Instrumentation Figure 1301 (Sheet 2 of 2)

TESTING

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Page 1303 Jul 1/00

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

C.

(c)

The change in oil level, as indicated on the oil level sight glass, is to be measured with a scale (inches) immediately after shutdown of the last run.

(d)

Record oil temperature at the time of measurement.

Facilities (1)

A fuel supply system incorporating a 10 micron filter and boost pump capable of delivering 250 pph (237 l/hr) at 5 to 40 psig (34.5 to 276 kPa).

(2)

Fuel source capable of maintaining test procedure for a minimum of three hours (675 US gallons, 565 UK gallons, 2,700 liters approximately).

(3)

Exhaust ducting system shall not recirculate APU exhaust gases into the compressor inlet.

(4)

Orifice plate 2.5924 inch (65.85 mm) diameter installed in bleed duct to measure air bleed from bleed valve.

(5)

Refer to Figure 1302 for additional control panel facilities required. NOTE: A position switch may be used to simulate open/closed position of a load valve.

TESTING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Test Interconnection Diagram (Pre SB-49-180) Figure 1302

TESTING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES

Test Interconnection Diagram (Post SB-49-180) Figure 1303 TESTING

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Page 1307/1308 Jan 15/03

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES D.

Glossary (1)

The following terms and abbreviations are used in the test procedures:

P1

Measured engine inlet total pressure (psia[kPa]). The test cell barometric pressure (P0) may be used for this measurement

δ

(P1, psia[kPa])/14.7

T1

Measured engine inlet temperature

EGTmeas

Measured exhaust gas temperature using a 6 point rake. The EGT shall be measured in the engine exhaust duct. NOTE: The ∆Pexh and EGT measurements shall not be taken in the same locations.

SHPmeas

Shaft power measured at the reduction drive output shaft (dyno horsepower)

SHPmeas/δ

Shaft power measured at the reduction drive output shaft corrected for barometric pressure

RPMmeas

Rotor speed measured at the set-point

∆Pexh = (∆Pexh,meas)/δ

Measured exhaust gas static pressure, inches (millimetres) of water (gage pressure relative to P0), corrected to standard ambient pressure. This pressure shall be measured at the engine exhaust using static pressure taps. This pressure will be recorded as a negative number if the static pressure is less than P1 or recorded as a positive number if the static pressure is greater than P1

WBmeas

Measured bleed flow (pounds [kilograms] per minute)

WBmeas/δ

Measured bleed flow corrected for barometric pressure

Pcdmeas

Measured compressor discharge pressure (psia [kPa])

Pcdmeas/δ

Measured compressor discharge pressure corrected for barometric pressure

SHPset

Dyno load set-point as defined in acceptance test

EGTset

T1 biased EGT set-point as defined in acceptance test

RPMset

Rotor speed set-point as defined in acceptance test

P0

Test cell barometric pressure

TESTING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 3.

Preparation for Test A.

Installation of Engine in Test Cell (1)

Install engine in test cell mounting attachment points.

(2)

Connect fuel supply line to fuel inlet filter.

(3)

Install fuel pump seal and turbine drain lines.

(4)

Connect exhaust ducting to combustor housing.

(5)

Connect the bleed air line to the engine bleed air port.

(6)

Connect start by-pass air duct to anti-surge valve.

(7)

Connect the electrical test harness to connector (P4).

(8)

Remove oil filler cap. Fill reduction drive assembly with oil to full mark on sight glass. Note oil level before starting test. Install filler cap modified 117851-1 complete with oil temperature thermometer and oil pressure gauge line.

(9)

Make sure exhaust gas temperature thermocouple test probes ST91172 are connected.

(10) Install compressor air inlet temperature probe MT574. (11) Remove lifting eye from air inlet housing and install vibration pickup adapter bolt, vibration pickup, and cable. Check all equipment for security. Remove all loose articles from the test area. Ensure that the air inlet screen and exhaust outlet are free from obstructions. (12) Make sure that the test cell downstream bleed valve is fully closed. B.

Slave Devices (1)

The engine shall be operated with ESU (4501974 Series) or electronically equivalent unit.

(2)

A slave bleed air valve, 4950699, must be electrically wired into the ESU control system to run the engine. NOTE: A position switch may be used to simulate the valve position.

(3)

The bleed air valve indication must be in the fully closed position to start the engine. It must be in the full open position to close the start-bypass valve during engine operation.

(4)

The hourmeter and event counter should be installed and operating for both the initial and final tests. TESTING

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HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES (5) 4.

The bleed flow limiting venturi, 4502368, shall not be used during the tests.

Test Operation A.

B.

Starting Power (1)

The engine shall be started using a Delco-Remy electric starting motor, model MT50 (or equivalent), driving through the water dynamometer.

(2)

A 24 to 28 Vdc power source shall be used to supply electrical power to the starter motor.

Conditions Requiring Shutdown of Engine CAUTION: SHOULD ANY OF THE FOLLOWING CONDITIONS OCCUR DURING TESTING, THE ENGINE SHALL BE SHUT DOWN. THE TEST SHALL NOT CONTINUE UNTIL THE CONDITION IS CORRECTED. (1)

Evidence of oil, fuel, or air leaks, including evidence of fuel control drain leakage in excess of 4 drops per minute.

(2)

Abnormal noise, smoking, or exhaust flaming.

(3)

Vibration in excess of 0.2 mil (peak-to-peak) at rotor frequency.

(4)

Oil pressure below 18 psig (124.1 kPa) or greater than 100 psig (689.5 kPa) for more than 30 seconds at 100 percent speed.

(5)

Oil sump temperature exceeding 275°F (135°C).

(6)

Surge during operation or acceleration.

(7)

Exhaust gas temperature exceeding 1,624°F (885°C) during a start.

(8)

Exhaust gas temperature exceeding 1,323°F (718°C) during steady state operation.

(9)

Governor droop greater than 4 percent from no load to full bleed load or from no load to 60 shaft horsepower.

(10) Speed oscillation in excess of +0.5 percent at steady state conditions. C.

Engine Shut Down Procedure (1)

Set the control panel OFF-RUN-START switch to OFF.

(2)

Set test cell fuel boost pump off.

(3)

Allow the engine to run down and stop.

(4)

Close the main fuel supply valve to the engine. TESTING

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Page 1311 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES D. 5.

Record test data in accordance with Figure 1304.

Preliminary Check and Safety Test A.

B.

Preliminary Check (1)

Verify for fully closed bleed valves.

(2)

Inspect installation of engine in test cell and security of all connections to the engine.

Safety Test (1)

Electrically disable connectors P305 start and P306 main fuel solenoid valves and P303 ignition exciter.

(2)

Open the engine main fuel supply valve.

(3)

Crank the engine for approximately 30 seconds. Record maximum engine oil pressure down-stream of the oil filter.

(4)

Set OFF-RUN-START switch OFF.

(5)

Set fuel boost pump to ON.

(6)

Purge the fuel system of air (refer to 49-00-00, SERVICING).

TESTING

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Page 1312 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Test Step

Test Data 5.B

7.C

7.D

7.E

7.F

7.G

Operating time (hours) via hourmeter Start cycles via event counter Barometric pressure (in. Hg) Start time (initiation of cranking to rated speed) (seconds) Maximum exhaust gas temperature during start (°F) (°C) Magnetic pickup (Hz) Engine speed and/or accessory drive pad speed (rpm) Torque arm length (Ft) (m) Dynamometer load (lbs) (kg) Calculated output horsepower (hp) (corrected for barometric pressure) Fuel flow (pph) Fuel boost pressure (psig) (kPa) Fuel temperature at flowmeter (°F) (°C)* Fuel specific gravity (S.G. ACT.)* Ambient temperature (°F) (°C) Exhaust duct pressure (in. H2O) Compressor inlet temperature (°F) (°C) *Required when using turbine flow meter. Test Data Sheet Figure 1304 (Sheet 1 of 2)

TESTING

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Page 1313 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES Test Step

Test Data 5.B

7.C

7.D

7.E

7F

7G

Exhaust gas temperature, performance average Exhaust gas temperature, EGT probe (°F) (°C) Bleed air temperature (°F) (°C) Bleed air static pressure (psia) (kPa) Bleed air delta P (in. H2O) Bleed air flow (ppm) Compressor discharge pressure (psig) (kPa) Oil sump temperature (°F) (°C) Oil pump discharge pressure (psig) (kPa) Oil level change (in.) (mm) Engine vibration (mils) (Pk to Pk) Gearbox pressure (measured at the filler cap with a 1/8 in. orifice at the vent) (in. H2O) Engine rundown time (seconds) Fuel type

Test Data Sheet Figure 1304 (Sheet 2 of 2)

(7)

Connect electrical connectors (P305 and P306) to start and main fuel solenoid valves.

(8)

Connect electrical connector (P303) to ignition exciter.

TESTING

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Page 1314 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES CAUTION: IF A FALSE START OCCURS, ALLOW AT LEAST ONE MINUTE FOR RESIDUAL FUEL TO DRAIN THROUGH COMBUSTOR FUEL DRAIN CHECK VALVE BEFORE ATTEMPTING TO RESTART. (9)

Set OFF-RUN-START switch momentarily to START and release to RUN.

(10) Allow the engine to accelerate to 50 percent rpm, (2,400 Hz), then set OFF-RUNSTART switch to OFF. Note operation of all instruments. Check engine for oil and/or fuel leaks. (11) Start the engine. Record the time for acceleration from initiation of cranking to stabilized, ready to load engine running. CAUTION: ACCELERATION ADJUSTMENT IS CRITICAL. THE INITIAL NEEDLE POSITION MUST BE CAREFULLY NOTED BEFORE ANY ADJUSTMENT IS MADE. MAKE ADJUSTMENTS IN INCREMENTS OF 1/8-TURN. CHECK ACCELERATION RATE AFTER EACH ADJUSTMENT. (12) Adjust acceleration needle of the acceleration control unit to increase fuel flow if a smooth acceleration is not achieved, or to decrease fuel flow if a hot start occurs during acceleration. Torque paint acceleration needle on completion. (13) Operate the APU at governed speed. (14) Adjust acceleration control unit governor rpm adjuster to control engine speed at 101.5% - 102.5%N (4872 - 4920 Hz) with no shaft load and bleed valve closed. (15) Run the engine at governed speed, no load, for 5 minutes. Check for proper operation of hourmeter and event counter. Inspect for oil, air, or fuel leaks. Record data. (16) Ensure that the combustor drain check valve is fully closed. 6.

System Malfunction Checks A.

System Check NOTE: System malfunction check must be made with the strut switch in the “ground” position. (1)

System malfunction check shall be conducted in accordance with the following procedures: (a)

Operate engine with no load at governed speed. Adjust, if necessary, to 101.5 - 102.5 +1/-0 percent rpm (4,872 to 4,920 Hz).

(b)

Check the engine low oil pressure (high oil temperature) circuit by removing the connector (P304) from the oil pressure switch. This shall cause the unit to shut down. Check BITE indications on ESU to be sure of correct operation.

TESTING

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Page 1315 May 1/02

HAMILTON SUNDSTRAND ENGINE MANUAL PART NUMBER 4501966 SERIES 7.

Performance Tests A.

Test Data (1)

B.

Record test data in accordance with Figure 1303.

Test Steps CAUTION: DURING TEST STEPS, A RUMBLING NOISE MAY BE HEARD. RUMBLE IS AN ACCEPTABLE ENGINE CONDITION. RUMBLE MUST NOT BE CONFUSED WITH SURGE. SURGE IS VERY APPARENT AS A LOUD, SHARP REPORT OR “BANG” EITHER SINGLY OR IN RAPID SUCCESSION. SURGE IS HARMFUL AND WILL CAUSE APU DAMAGE IF ALLOWED TO CONTINUE. NOTE: During test, the engine shall be loaded by a water dynamometer. The air bleed shall be measured from the bleed port by an orifice or nozzle conforming to current ASME standards. NOTE: No degradation is allowed for Run No. 2, EGT. All other performance runs are allowed 1.5% degradation.

C.

Test Step 1 - BLEED FLOW ONLY (1)

Operate for a minimum of 5 minutes “on-point” at: Speed = 60,023 to 62,181 rpm (97.5 - 101.0%N) (Speed drop as result of loading) EGTset = 1,300 ± 10°F (704 ± 6°C) SHPset/δ =