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Engines, Systems & Services

Phoenix, Arizona

TO: HOLDERS OF PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE MAINTENANCE
MANUAL, ATA NO. 49-21-81 REVISED FEBURARY 28, 1996.

THIS REVISED PUBLICATION IS ISSUED FOR USE IN SUPPORT OF THE FOLLOWING AIRCRAFT.

ENGINE/
COMPONENT ENGINE AIRCRAFT
PART NO. MODEL NO. APPLICATION

381276-1 GTCP85-98DHF DC-9


381276-2 GTCP85-98DHF[A] MD-80

REVISION NO. 6 DATED FEBRUARY 14, 2003

This is a COMPLETE revision. The pages revised are listed below together with the Highlights of the revision.
Please discard the entire manual of previous issue(s) and replace with this complete manual.

HIGHLIGHTS

Subject/Page Description of Change

ATA 49-21-81 Manual Changed header all pages. Changed AlliedSignal


references to Honeywell throughout manual. Added
specification AS567 to lockwire procedures. Updated
and added WARNINGs to latest Honeywell
specifications. Changed oil specifications to
MIL-PRF-7808 and MIL-PRF-23699.

Title Page Updated to Revision 6.

Safety/Warranty/Liability Advisory Updated Safety/Warranty/Liability Advisory.

List of Effective Pages Revised to reflect Revision 6.

Record of Revisions Added Revision 6.

Record of Temporary Revisions Added TRs 49-21 through 49-29.

Service Bulletin List Revised to reflect latest Service Bulletin information.

Introduction
Page TC-1/TC-2 Added new Subject titles.

Page INTRO-2 Added paragraph 6.

Pages INTRO-9 and INTRO-10 Added Series 32 through 35.

Pages INTRO-14 and INTRO-15 Added Changes 87 through 102.

Pages INTRO-20 and INTRO-21 Added Changes 53 through 65.

HIGHLIGHTS
ATA NO. 49-21-81 Page 1 of 4
Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Engines, Systems & Services
Phoenix, Arizona

HIGHLIGHTS (CONT)

Subject/Page Description of Change

Introduction (Cont)
Pages INTRO-22 through INTRO-25 Updated Tables 2 and 2A.

Pages INTRO-26 and INTRO-27/INTRO-28 Added Table 3.

49-20-00
Pages 1 and 2 Incorporated TR 49-22 and updated Table 1.

Page 10 Added celsius temperature to first paragraph.

Page 122 Updated Table 101.

Page 126 Updated Table 102.

Page 301 Updated Table 301.

Pages 306 and 307 Incorporated TR 49-29 in Table 302.

Pages 306 through 311/312 Added new APU Lubrication System-Servicing


Section.

Page 401 Updated Table 401 and lubricant specification in Step


1.B. NOTE.

Page 501 Updated Table 501.

Page 509 Revised Figure 502.

Page 510 Deleted reference to Figure 504 in Step 3.B.(5).

Page 512 Incorporated TR 49-21 in Table 502. Updated Table


502.

Page 513 Incorporated TR 49-23 in Table 502.

Page 517 Updated Step 5.A.(6).

Page 519 Updated Figure 506.

Page 520 Incorporated TR 49-24 in Step 5.C.(4). Changed


RPM speed in Step 5.B.(3)(h) NOTE.

Page 521 Incorporated TR 49-25 in Step 5.C.(4).

Page 605 Incorporated TR 49-30 in Table 601.

Page 701 Updated Table 701.

Page 801 Updated Table 801.

HIGHLIGHTS
49-21-81 Page 2
Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Engines, Systems & Services
Phoenix, Arizona

HIGHLIGHTS (CONT)

Subject/Page Description of Change

49-20-00 (Cont)
Page 802 Updated Step 2.

49-20-03
Page 202 Updated Table 201 and Step 1.B.

Page 205 Changed reference for items 10 through 110.

49-20-04
Page 202 Incorporated TR 49-27 in Step B.(1)(b) CAUTION.
Added lubricant specification to Step B.(1)(a).

Page 205 Added lubricant specification to Step 1.B.(2)(b).

49-20-10
Page 202 Updated Table 201.

Page 209 Changed adhesive specification in Step 1.B.(1)(f).

Page 211/212 Added lubricant specification to Step 1.B.(2)(b).

49-30-00
Page 3/4 Changed spelling of word Governor.

49-30-01
Page 202 Updated Table 201.

Pages 204 and 207 Changed fuel specification.

49-30-10
Page 202 Updated Table 201 and Step 1.B.(1).

49-40-01
Page 202 Updated Table 201.

49-50-00
Page 3 Changed spelling of word Governor.

49-50-01
Page 202 Updated Table 201. Added lubricant specification to
Step 1.B.(1).

49-50-07
Page 202 Updated Table 202.

Page 205 Changed MEK specification in Step 3.A.(3).

HIGHLIGHTS
49-21-81 Page 3
Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Engines, Systems & Services
Phoenix, Arizona

HIGHLIGHTS (CONT)

Subject/Page Description of Change

49-60-01
Page 202 Updated Table 201.

49-70-01
Page 202 Updated Table 201.

49-90-01
Page 202 Updated Table 201.

Page 205/206 Changed Alkaline cleaner specification in Step 4.A.

49-90-02
Page 202 Updated Table 201.

Page 205 Added lubricant specification to Step 1.B.(1).

Page 207 Revised Step 1.E.(1).

49-90-04
Page 202 Updated Table 201. Added lubricant specification to
Step 1.B.(1).

HIGHLIGHTS
49-21-81 Page 4
Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Engines, Systems & Services
Phoenix, Arizona

PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE

PART NO.

381276-1/-2

MAINTENANCE MANUAL

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

This publication was prepared by


Honeywell International Inc.
Engines, Systems & Services
Cage Code (99193)
Technical Publications

For assistance call


Customer Support Center
800-421-2133
Outside North America call
602-365-2180

Page T-1
ATA NO. 49-21-81 Aug 1/78
Revised Feb 14/03 No. 6
Copyright 1978, 2003 Honeywell International Inc. All rights reserved.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

SAFETY ADVISORY

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

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

WARRANTY/LIABILITY ADVISORY

WARNING: HONEYWELL ASSUMES NO RESPONSIBILITY FOR ANY HONEYWELL EQUIPMENT


WHICH IS NOT MAINTAINED AND/OR REPAIRED IN ACCORDANCE WITH
HONEYWELL'S PUBLISHED INSTRUCTIONS AND/OR HONEYWELL'S FAA/FAR 36
REPAIR AUTHORIZATION. NEITHER DOES HONEYWELL ASSUME RESPONSIBILITY
FOR SPECIAL TOOLS AND TEST EQUIPMENT FABRICATED BY COMPANIES OTHER
THAN HONEYWELL.

INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS OR


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

Page SWLA-1/SWLA-2
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

RECORD OF REVISIONS

REV ISSUE DATE REV ISSUE DATE


NO. DATE INSERTED BY NO. DATE INSERTED BY

ORIG Aug 1/78

1 Sep 4/81

2 Jul 13/83

3 Jul 20/87

4 Mar 31/92

5 Feb 28/96

6 Feb 14/03

Page RR-1/RR-2
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

RECORD OF TEMPORARY REVISIONS

CHP/SEC INCORPO-
SUBJ RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
49-20-00
49-1 123/124 Aug 27/80 1
49-20-04
49-2 206 Dec 19/83 3
49-20-04
49-3 207/208 Dec 19/83 3
49-20-00
49-4 514 Feb 15/86 3
49-20-00
49-5 603 Apr 15/86 3
49-20-04
49-6 206 Apr 15/86 3
49-40-01
49-7 204 Sep 14/87 4
49-20-00
49-8 515 May 22/89 4
49-40-05
49-9 204 Oct 4/89 4
49-20-04
49-10 202 Oct 4/89 4
49-20-00
49-11 502 Oct 4/89 4
49-20-00
49-12 524 Oct 4/89 4
49-20-00
49-13 603 Jul 18/90 4
49-20-00
49-14 518 Nov 6/92 5
49-20-00
49-15 103 Aug 20/93 5
49-20-00
49-16 118 Aug 20/93 5
49-20-00
49-17 515 Aug 20/93 5
49-20-00
49-18 516 Aug 20/93 5
49-20-00
49-19 517 Aug 20/93 5
49-21-81
49-20 TR-1 Aug 20/93 5
49-20-00
49-21 513 Sep 26/96 6
49-20-00
49-22 1 Mar 28/97 6

Page TR-1
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

RECORD OF TEMPORARY REVISIONS (CONT)

CHP/SEC INCORPO-
SUBJ RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
49-20-00
49-23 514 Mar 28/97 6
49-20-00
49-24 521 Mar 28/97 6
49-20-00
49-25 522 Mar 28/97 6
49-20-00
49-26 307 (Replaced by TR 49-28)
49-20-04
49-27 202 Apr 23/99 6
49-20-00
49-28 307 (Replaced by TR 49-29)
49-20-00
49-29 307 Sep 24/99 6
49-20-00
49-30 605 May 21/02 6

Page TR-2
49-21-81 Feb 14/03
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MAINTENANCE MANUAL
GTCP85-98DHF/[A]

RECORD OF TEMPORARY REVISIONS (CONT)

CHP/SEC INCORPO-
SUBJ RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.

Page TR-3
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

RECORD OF TEMPORARY REVISIONS (CONT)

CHP/SEC INCORPO-
SUBJ RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.

Page TR-4
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST

SB DATE
NO. INCORPORATED TITLE

49-3516, R6 Refer to ATA Relocate Engine Identification Plate


No. 49-23-67

49-3580, R1 Refer to ATA Repair of First Stage Diffuser Assembly


No. 49-23-67 (Part No. 698194-1) Incorporation of
Steel Tip Vanes

49-3655, R4 Refer to ATA Availability of Reconditioned First Stage


No. 49-23-67 Impellers

49-3656, R3 Refer to ATA Availability of Reconditioned Second Stage


No. 49-23-67 Impellers

49-3712, R4 Refer to ATA Incorporation of Combustor Unit (Atomizer


No. 49-26-67 and Liner Assembly) Part Numbers

49-3914, R5 Refer to ATA Product Improvement-Containment


No. 49-23-67 Ring Retention System

49-3926, R3 July 13/83 Incorporation of Hooded Pcd Probe (Without Anti-


Moisture Orifice)

49-5030, R1 Refer to ATA Replace Input Shaft Part No. 892282-1 or 3603685-1
No. 49-23-67 with Flexible Coupling Part No. 3607310-1

49-5070, R2 Refer to ATA Rework Electrical Engine Starters


No. 49-40-01

49-5132 Refer to ATA Availability of Improved Compressor


No. 49-23-67 Interstage Seal Assembly

49-5173 Refer to ATA Replace Compressor Bearing Part No.


No. 49-26-67 693328 or 372435 with Compressor
Bearing Part No. 358649

49-5181, R2 Refer to ATA Rework Electrical Engine Starter to


No. 49-23-67 Incorporate Improved Clutch Plates

49-5192, R3 Refer to ATA Incorporate Improved Automatic Start and


No. 49-23-67 Fuel Holding Relays, Part No. 306366-2

49-5196, R6 Mar 31/92 To Incorporate Timed Acceleration Fuel Control


Improvements in Existing FCU Part No. 3603210,
3609150 and 3603100. Reidentify after Rework as
Part No. 3608000

49-5199, R3 Refer to ATA To Provide Stronger Second Stage Diffuser


No. 49-23-67 Housing to Prevent Cracking

Page SB-1
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5200, R1 Refer to ATA Provide Thicker Turbine Plenum Shim to


No. 49-23-67 Eliminate Leakage

49-5209 Refer to ATA Centrifugal Switch Assembly-Removal of


No. 49-60-33 Retainer Pin Part No. 3601292-1

49-5210, R2 Refer to ATA Replace Packing with Retainer to Prevent


No. 49-23-67 Oil Leakage

49-5230, R2 Refer to ATA Expand Combustion Liner Assembly Exit


No. 49-21-73 Diameter to Reduce Hard Carbon Formation
(CANCELLED)

49-5233, R1 July 13/83 Incorporation of Fuel Conservation EGT


Control System

49-5235 Refer to ATA Rework Multiple Centrifugal Switch and


No. 49-23-67 Wiring Harness Assembly to Incorporate
Threaded Connector

49-5236 Refer to ATA Incorporate Strengthened Exhaust Flange


No. 49-23-67 Assembly to Reduce Exhaust Gas Leakage

49-5304, R2 Refer to ATA Rework Oil Pump Assemblies to Pinned Pump


No. 49-21-83 Configuration

49-5305, R1 Refer to ATA Incorporate Pinned Oil Pump Assembly


No. 49-23-67

49-5307 Refer to ATA Incorporation of Load Control Valve, Part


No. 49-23-67 No. 109382-32

49-5309, R2 Refer to ATA Incorporate Improved Combustion Liner and


No. 49-23-67 Fuel Atomizer Assembly

49-5334, R1 No Effect One Time Inspection of Spare Rear Turbine


Seals, Part No. 977898-1 and Part No.
399987-1

49-5393, R2 No Effect Replacement of Centrifugal Multiple Switch


Pedestal Ball Bearings

49-5417, R1 Refer to ATA Rework Fuel Control Unit, Part No.


No. 49-23-67 3602310-33 to Part No. 3609150-3

Page SB-2
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5418, R1 Refer to ATA Incorporate Fuel Control Unit with Im-


No. 49-23-67 proved Acceleration Limiter

49-5436, R5 Refer to ATA Incorporate Improved Torus Assembly and


No. 49-23-67 Heat Shield

49-5418, R1 Refer to ATA Incorporate Fuel Control Unit with Im-


No. 49-23-67 proved Acceleration Limiter

49-5436, R5 Refer to ATA Incorporate Improved Torus Assembly and


No. 49-23-67 Heat Shield

49-5444 Refer to ATA Replacement of Fuel Atomizer Assembly,


No. 49-23-67 Part No. 3601193-3 with Part No. 3601193-2

49-5456, R1 Refer to ATA Replace/Rework Fan Seal Retainer, Part No.


No. 49-23-67 695343-1 to Part No. 695243-4

49-5460, R1 Refer to ATA Incorporation of Improved Rear Turbine


No. 49-23-67 Seal

49-5471, R2 Refer to ATA Incorporation of Improved Thermocouple,


No. 49-23-67 Part No. 692523-8

49-5472 Jul 20/87 Incorporation of Electrical Engine Starter,


Part No. 3605812-16 and 3605812-17

49-5477 Refer to ATA Rework Electrical Engine Starter Assembly,


No. 49-40-01 Part No. 3605812-13 to 3605812-16 and
Part No. 3605812-14 to 3605812-17

49-5504, R1 Refer to ATA Rework Multiple Centrifugal Switch


No. 49-60-33 Assembly, Part No. 3601030 to Part No.
3609480

49-5505, R1 Refer to ATA Incorporate Multiple Centrifugal Switch


No. 49-23-67 Assembly, Part No. 3609480-X in place of
Part No. 3601030-X

49-5530, R1 No Effect One-Time Inspection of Combustion


Chamber Liner Assembly, Part No. 3605384-3

49-5550, R2 Refer to ATA Rework Improved Combustion Liner


No. 49-23-67 Assembly Ring to Reduce Hard Carbon
Formation

Page SB-3
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5583, R1 Refer to ATA Incorporation of Rear Turbine Seal Part No.


No. 49-23-67 3609143-3

49-5587, R3 Refer to ATA Incorporate Improved Accessory Cooling Fan


No. 49-23-67 Assembly, Part No. 695227-19

49-5588, R4 Refer to ATA Rework Accessory Cooling Fan Assembly,


No. 49-50-35 Part No. 695227-15 to 695227-19

49-5602, R1 Refer to ATA Availability of Improved Pinion Bearing,


No. 49-23-67 Part No. 3609114-1 for use in Accessory
Drive Gearcase Assembly, Part No.
3603701-1 through -6

49-5624 No Effect Rework of Spare Accessory Drive Gearcase


Housings, Part No. 3603708

49-5629 Refer to ATA Rework of Interstage Housing Assembly, Part


No. 49-23-67 No. 379518 to Part No. 698198-1

49-5630 Refer to ATA Rework Inlet Assembly, Part No. 379713 to


No. 49-23-67 Part No. 698197-1

49-5658, R1 Refer to ATA Incorporate Vent Scupper, Part No. 976703-1


No. 49-23-67 Over Exhaust Pipe Vent on Exhaust Duct Flange
Assembly, Part No. 695140-50/-100

49-5681 Refer to ATA Incorporate Oversize Turbine Nozzle, Part


No. 49-23-67 No. 3601669-13 through -16

49-5689, R5 Refer to ATA Incorporate Turbine Shroud Containment


No. 49-23-67 Augmentation Ring. (Invalid)

49-5699, R2 Refer to ATA Incorporation of MAR-M-247 Turbine Rotor


No. 49-23-67 and Shaft Assembly, Part No. 3842072-1

49-5700, R3 Refer to ATA Incorporation of Hastelloy "S" Turbine Wheel


No. 49-23-67 Shroud Part No. 3611904-1

49-5701, R4 Refer to ATA Incorporate Improved Atomizer Assembly, Part No.


No. 49-23-67 3601193-4/-5/-6 (Reduce Carbon Formation)

Page SB-4
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5709, R2 Refer to ATA Incorporation of Tachometer-Generator Seal,


No. 49-23-67 Part No. 3612194-1

49-5722, R1 Refer to ATA Incorporation of Improved Igniter Plug, Part


No. 49-23-67 No. 3888210-1

49-5733 No Effect One-Time Inspection of Accessory Cooling Fan


Assembly Shaft Nut (Fan End) Part No. 3602177-2

49-5736, R1 No Effect Convert GTCP85-98DHF Engine to GTCP85-


98DCK Configuration

49-5738 Refer to ATA Replace Existing Baffles with Enlarged


No. 49-23-67 Baffles

49-5744, R1 Mar 31/92 Incorporate Shock Mounted Bracket for Ignition Unit

49-5751, R9 Refer to ATA Incorporation of Non-Asbestos Gasket


No. 49-23-67

49-5754, R2 Refer to ATA Incorporation of Spring loaded Turbine Seal


No. 49-23-67 Assembly, Part No. 693616-1 and 3609143-4

49-5762 Refer to ATA Authorize Use of Starter Clutch Plate Assembly,


No. 49-23-67 Part No. 3860692-1

49-5774, R1 Refer to ATA Incorporate Improved Ignition Unit


No. 49-23-67

49-5807, R1 No Effect Conversion of the GTCP85-98DHF to the GTCP85-


98DC[B] and the GTCP85-98DHF[A] to the GTCP85-
98DC[C] Engine Configuration

49-5809 Refer to ATA Incorporation of Non-Asbestos Gaskets


No. 49-23-67

49-5812, R4 Refer to ATA Incorporation of Non-Asbestos Gasket


No. 49-23-67

49-5816 Refer to ATA Rework of Exhaust Duct Flange Assembly


No. 49-23-67 Part No. 695140-50 and 695140-80

49-5834 Refer to ATA Incorporation of Improved Turbine Nozzle,


No. 49-23-67 Part No. 3846484-3 and 3846484-4

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49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5851, R2 Refer to ATA Authorize Use of Combustion Liner, Part No.


No. 49-23-67 3605384-8

49-5862 Refer to ATA Incorporation of Compressor Inlet Assembly,


No. 49-23-67 Part No. 698197-2 (for Commonality)

49-5882, R4 Refer to ATA Rework Existing Second Stage Impeller, Part


No. 49-23-67 No. 379548-50 /966571-1 to Part No. 966569-2 or
Second Stage Impeller, Part No. 698193-4 to Part
No. 966569-1

49-5906, R1 Refer to ATA Authorize Use of Second Stage Impeller,


No. 49-23-67 Part No. 966569-2 in Lieu of Part No. 966569-1

49-5913 Refer to ATA Authorize Use of Torus Assembly Part No.


No. 49-23-67 3830350-1 through -4 in Lieu of Part No. 968959-
28/-22/-23/-26

49-5914 Refer to ATA Replace Insert, Part No. M5932-1-29L with


No. 49-23-67 Insert , Part No. 432-551-0126 on Gearcase,
Part No. 3603708

49-5919, R1 Refer to ATA Rework of TAFCU Acceleration Control Assembly


No. 49-23-67 Part No. 3607680-5 to Part No. 3607680-6 (To
Provide Positive Acceleration Control)

49-5932 Refer to ATA Incorporation of Accessory Drive Housing


No. 49-23-67 Gear Pad Studs, Part No. 682-510-9107 in Place of
Part No. MS51989E107-18

49-5941, R1 Refer to ATA Replacement of MAR-M-247 Turbine Rotor


No. 49-23-67 and Shaft Assembly, Part No. 3842072-1 with Part
No. 3842072-2

49-5974, R1 Refer to ATA Incorporation of Improved Plenum Inlet


No. 49-23-67 Screen Assembly, Part No. 965146-2

49-5996, R1 Refer to ATA Rework Compressor Inlet Assembly, Part No.


No. 49-23-67 698197-1 to Part No. 698197-2

Page SB-6
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-6505 Refer to ATA Inspection and Rework of Interstage Seal


No. 49-23-67 Assembly, Part No. 378854-30 Change Letters L
and M to preclude possible Interference

49-6508, R2 Refer to ATA Replace Oil Temperature Switch, Part No.


No. 49-23-67 375036 with, Part No. 305080-1

49-6534, R2 Mar 31/92 Authorize Use of Turbine Rotor and Shaft Assembly,
Part No. 3842072-3

49-6563, R2 Refer to ATA Incorporate Improved Pinion Bearing, Part No.


No. 49-23-67 3614920-1 in place of Part No. 3609114-1

49-6565, R1 Refer to ATA Incorporation of Load Control Valve, Part No.


No. 49-23-67 109382-35-1

49-A6706, R2 Refer to ATA Incorporate Improved Turbine Shroud Containment


No. 49-23-67 Augmentation Ring, Part No. 3616426-1. SUPERSEDES
SB 49-5689

49-6774 Refer to ATA Incorporate Solid Mounted Bracket Part No.


No. 49-23-67 696069-1 for Ingition Unit

49-6787 Refer to ATA Replace/Rework Atomizer and Liner Assembly


No. 49-23-67 Part No. 3604524-25 with Part No. 3604524-44

49-A6831, R1 Refer to ATA Replace/Rework Exhaust Pipe, Part No. 976987-1,


No. 49-23-67 or Exhaust Duct, Part No. 3607748-1 to Exhaust
Duct, Part No. 3850089-1

49-6860 Refer to ATA Rework First Stage Compressor Impeller, Part Nos.
No. 49-23-67 966570-1 and 379547 to Part No. 966568-1

49-6861 Refer to ATA Replace Spring Washer, Part No. 791-502-9009


No. 49-23-67 with Part No. 3610875-23

49-6863, R1 Refer to ATA Replace Turbine Nozzle, Part No. 3601669-1,


No. 49-23-67 3601669-7 or 3846484-3 with Part No. 3846484-7
and Part No. 3601669-2, 3601669-8 or 3846484-4
with Part No. 3846484-8

49-6864 Refer to ATA Rework Branched Wiring Harness, Part No.


No. 49-23-67 43959-3 to Part No. 43959-5 and Part No. 43959-4
to Part No. 43959-6

Page SB-7
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-6865, R1 Refer to ATA Replace Retaining Nut, Part No. 379523 with
No. 49-23-67 Part No. 379523-1

49-6866, R1 Refer to ATA Replace or Rework Oil Pump, Part No. 379580-650
No.49-23-67 with/to Part No. 379580-700

49-6873 Refer to ATA Rework Plumbing and Electrical Installation by


No. 49-23-67 Replacing Elbow, Part No. 695165-1 with Part No.
695165-2

49-6875 Refer to ATA Rework or Replace Driveshaft Assembly, Part No.


No. 49-23-67 3601031-1 to Part No. 3601031-2

49-6898 Refer to ATA Replace Centrifugal Switch Assembly, Part No.


No. 49-23-67 3609480-5/-10/-13 with Part No. 3615700-5/-10/-13,
Respectively

49-6928, R2 Refer to ATA Replace Timed Acceleration Fuel Control Unit (TAFCU),
No. 49-23-67 Part Nos. 3608000-4/-6/-10 with Part Nos. 3608000-12/-13/
-14

49-6933, R1 Refer to ATA Replace Nut, Part No. 525-580-9003 with Nut,
No. 49-23-67 Part No. S9424-4 which has Improved Retention
Properties

49-6934, R1 Refer to ATA Replace/Rework Acceleration Control Assembly


No. 49-23-67 Part No. 3607680-6 with/to Part No. 3607680-8

49-6960, R1 Refer to ATA Rework Centrifugal Switch Assembly, Part No.


No. 49-23-67 3609480-5/-10/-13 to Part No. 3615700-5/-10/-13
Respectively

49-7103 Refer to ATA Rework/Replace Second Stage Diffuser Housing,


No. 49-23-67 Part No. 698195-1 to/with Part No. 698195-10 and Part
No. 698195-8 to/with Part No. 698195-12

49-7173 Refer to ATA Replace Generator Pad Seal with Rotor, Part No.
No. 49-23-67 377458 with Improved Generator Pad Seal, Part No.
3863237-1 and Rotor, Part No. 3822479-1

49-A7189, R2 Refer to ATA Incorporation of Turbine Wheel Shroud, Containment


No. 49-23-67 Augmentation Ring, Part No. 3616426-3

49-7238, R1 Refer to ATA Remove and Replace Vent Tube Assembly, Part No.
No. 49-23-67 695766-1 With Part No. 3617065-1

49-7301 Refer to ATA Replace Compressor Interstage Seal, Part No. 378854-30
No. 49-23-67 with Compressor Interstage Seal, Part No. 378854-50 on
Compressor and Turbine Assemblies, Part No. 3601835-All

Page SB-8
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-7477 Refer to ATA Replace Second Stage Impeller, Part Nos. 698193-2/-3/-4/-5,
No. 49-23-67 or Part No. 3822481-3 with Second Stage Impeller, Part No.
3822536-1

49-7484, R5 Refer to ATA Replace Fuel Control (FCU), Part No. 3609150-1/-2/-3 and
No. 49-23-67 3608000-4/-6/-10/-12/-13/-14, with FCU Part No. 3617750-1/
-2/-3 and Atomizer and Liner Assembly, Part Nos. 3604524-1/
-19/-21/-25/-29/-44/-45/-46/-47/-48/-49/-50/-51 with Atomizer
and Liner Assembly, Part Nos. 3604524-52/-53/-54/-55/-56/
-57/-58

49-7488, R1 Refer to ATA Replace Turbine Rotor and Shaft Assembly, Part Nos.
No. 49-23-04 3842072-1/-2/-3, or Part No. 3606982-1 with Turbine Rotor
And Shaft Assembly, Part No. 3842360-1

49-7495, R1 Refer to ATA Rework Fuel Control Assembly, Part No. 3609150-1/-2/-3 or
No. 49-23-67 Part No. 3608000-4/-6/-10/-12/-13/-14 to Part No. 3617750-1/
-2/-3

49-7514 Refer to ATA Rework/Replace of Compressor and Turbine Assembly, Part


No. 49-23-04 No. 3601835-30 to/with Part No. 3601835-59

49-7542 Refer to ATA Incorporation of External Shields, Part Nos. 3844911-1 and
No. 49-23-67 3844911-2

49-7572, R1 Refer to ATA Rework/Replace Compressor and Turbine Assembly, Part


No. 49-23-04 No. 3601835-30/-31/-33/-34/-39/-40/-41/-52/-53/-56/-59/-60
to/with Part No. 3601835-62

49-7638, R2 Refer to ATA Rework Second Stage Compressor Diffuser Housing, Part
No. 49-23-67 No. 698195 to Improve Plug Retention Properties

49-7664 Refer to ATA Replaces Turbine Plenum Gasket, Part No. 3612631-4 with
No. 49-23-67 Turbine Plenum Gasket, Part No. 3618086-1

Page SB-9
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

GTE0165, R1 Refer to ATA Improved Fan Shaft Bearings


No. 49-50-35

GTE0167 Refer to ATA Improved Second Stage Diffuser


No. 49-23-67

GTE0170, R1 Refer to ATA Replacement of Existing Washers


No. 49-23-67

GTE0172 Refer to ATA Parts Standardization


No. 49-30-38

GTE0192 Refer to ATA Improved Second Stage Diffuser


No. 49-23-67

GTE0226, R1 Refer to ATA Alternate Oil Pump Filter Element


No. 49-90-33

GTE0253 Refer to ATA Replacement of Shims


No. 49-23-67

GTE0318 Refer to ATA Replacement of Fuel Nozzle Swirl


No. 49-23-67

GTE0357 Refer to ATA Authorizes Installation of Part No.


No. 49-23-67 3601669-1/-2, Turbine Nozzle
(Customer Option)

GTE0362 Refer to ATA Authorizes replacement of Part No.


No. 49-23-67 NAS686-3 with MS21060-3

GTE0368 Refer to ATA Authorizes installation of Part No.


No. 49-23-67 MS9489-24 in place of Part No.
MS9489-25

GTE0531 Refer to ATA Provide Procurable Repair Part


No. 49-23-67

GTE0563 Refer to ATA Availability of Coupling for Repair of


No. 49-23-67 Gearshaft Assembly Part No. 379605

GTE0581 Refer to ATA Authorize use of Aluminum Oil Breather Tube


No. 49-23-67 in Lieu of CRES Tube

Page SB-10
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

GTE0600 Refer to ATA Improved Screw for Lockwire


No. 49-23-67

GTE0648 Refer to ATA Identification Plate


No. 49-23-67

GTE0696, R1 Refer to ATA Authorize Use of Terminal, Part No.


No. 49-23-67 724-505-9013 in Place of Terminal Part
No. 724-505-9008

GTE0697, R1 Refer to ATA Authorize Use of Terminal, Part No.


No. 49-23-67 724-505-9014 in Place of Terminal Part
No. 724-505-9010

GTE0813 Refer to ATA Connectors, Part No. 304805-1/-2/-3/-4/-5


No. 49-23-67

GTE0988 Refer to ATA Authorize use of Ring, Part No. MS16625-1100


No. 49-23-67 in place of Ring, Part No. NAS50-100

GTE0989 Refer to ATA Authorize use of Plug, Part No. AN814-6J in


No. 49-23-67 place of Plug, Part No. AN814-6C

GTE1089 Refer to ATA Authorize use of Turbine Rotor Shaft Assy, Part No.
No. 49-23-67 3616256-1 In place of Turbine Rotor Shaft Assy, Part
No. 696161-13

Page SB-11
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST

SB DATE
NO. INCORPORATED TITLE

49-3232 Refer to ATA Rework Accessory Drive Gearcase to Accept New


No. 49-23-67 High Speed Pinion Bearing Installation

49-3580, R1 Refer to ATA Repair of First Stage Diffuser, Part No.


No. 49-23-67 698194-1 (Incorporation of Steel Tip Vanes)

49-3655, R4 Refer to ATA Availability of Reconditioned First Stage


No. 49-23-67 Impellers

49-3656, R3 Refer to ATA Availability of Reconditioned Second Stage


No. 49-23-67 Impellers

49-5132 Refer to ATA Availability of Improved Compressor Interstage Seal


No. 49-23-67 Assembly

49-5196, R6 Mar 31/92 To Incorporate Timed Acceleration Fuel Control


Improvements in Existing FCU Part No. 3603210,
3609150 and 3603100. Reidentify after Rework as
Part No. 3608000

49-5199, R3 Refer to ATA To Provide Stronger Second Stage Diffuser


No. 49-23-67 Housing to Prevent Cracking

49-5304, R2 Refer to ATA Rework Oil Pump Assemblies to Pinned Pump


No. 49-23-67 Configuration

49-5436, R5 Refer to ATA Incorporate Improved Torus Assembly and Heat Shield
No. 49-23-67

49-5472 Jul 20/87 Incorporation of Electrical Engine Starter, Part No.


3605812-16 and 3605812-17

49-5477 Refer to ATA Rework Electrical Engine Starter Assembly


No. 49-40-01 Part No. 3605812-13 to 3605812-16 and
Part No. 3605812-14 to 3605812-17

49-5504, R1 Refer to ATA Rework Multiple Centrifugal Switch


No. 49-60-33 Assembly, Part No. 3601030 to Part No. 3609480

49-5505, R1 Refer to ATA Incorporate Multiple Centrifugal Switch


No. 49-23-67 Assembly, Part No. 3609480-X in place of
Part No. 3601030-X

49-5550, R2 Refer to ATA Rework Improved Combustion Liner


No. 49-23-67 Assembly Ring to Reduce Hard Carbon Formation

49-5583, R1 Refer to ATA Incorporation of Rear Turbine Seal Part No.


No. 49-23-67 3609143-3

Page SB-12
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5587, R3 Refer to ATA Incorporate Improved Accessory Cooling


No. 49-23-67 Fan Assembly, Part No. 695227-19

49-5588, R4 Refer to ATA Rework Accessory Cooling Fan Assembly,


No. 49-50-35 Part No. 695227-15 to 695227-19

49-5602, R1 Refer to ATA Availability of Improved Pinion Bearing Part


No. 49-23-67 No. 3609114-1 for use in Accessory Drive
Gearcase Assembly, Part No. 3603701-1 thru -6.

49-5624 No Effect Rework of Spare Accessory Drive


Gearcase Housings, Part No. 3603708

49-5629 Refer to ATA Rework of Interstage Housing Assembly, Part


No. 49-23-67 No.379518 to Part No. 698198-1

49-5630 Refer to ATA Rework Inlet Assembly, Part No. 379713 to


No. 49-23-67 Part No. 698197-1

49-5658, R1 Refer to ATA Incorporate Vent Scupper, Part No. 976703-1


No. 49-23-67 Over Exhaust Pipe Vent on Exhaust Duct Flange
Assembly, Part No. 695140-50/-100

49-5681 Refer to ATA Incorporate Oversize Turbine Nozzle, Part


No. 49-23-67 No. 3601669-13 through -16

49-5689, R5 Refer to ATA Incorporate Turbine Shroud Containment


No. 49-23-67 Augmentation Ring. (Invalid)

49-5699, R2 Refer to ATA Incorporation of MAR-M-247 Turbine Rotor


No. 49-23-67 and Shaft Assembly, Part No. 3842072-1

49-5700, R3 Refer to ATA Incorporation of Hastelloy "S" Turbine Wheel


No. 49-23-67 Shroud Part No. 3611904-1

49-5701, R4 Refer to ATA Incorporate Improved Atomizer Assembly,


No. 49-23-67 Part No. 3601193-4/-5/-6 (Reduce Carbon
Formation)

49-5709, R2 Refer to ATA Incorporation of Tachometer-Generator Seal,


No. 49-23-67 Part No. 3612194-1

49-5722, R1 Refer to ATA Incorporation of Improved Igniter Plug, Part


No. 49-23-67 No. 3888210-1

49-5733 No Effect One-Time Inspection of Accessory Cooling Fan


Assembly Shaft Nut (Fan End) Part No. 3602177-2

Page SB-13
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5736, R1 No Effect Convert GTCP85-98DHF Engine to GTCP85-


98DCK Configuration

49-5738 Refer to ATA Replace Existing Baffles with Enlarged


No. 49-23-67 Baffles

49-5744, R1 Mar 31/92 Incorporate Shock Mounted Bracket for


Ignition Unit

49-5751, R9 Refer to ATA Incorporation of Non-Asbestos Gasket


No. 49-23-67

49-5754, R2 Refer to ATA Incorporation of Spring loaded Turbine Seal


No. 49-23-67 Assembly, Part No. 693616-1 and 3609143-4

49-5762 Refer to ATA Authorize Use of Starter Clutch Plate Assembly,


No. 49-23-67 Part No. 3860692-1

49-5774, R1 Refer to ATA Incorporate Improved Ignition Unit


No. 49-23-67

49-5807, R1 No Effect Conversion of the GTCP85-98DHF to the


GTCP85-98DC[B] and the GTCP85-98DHF[A] to the
GTCP85-98DC[C] Engine Configuration

49-5809 Refer to ATA Incorporation of Non-Asbestos Gaskets


No. 49-23-67

49-5812, R4 Refer to ATA Incorporation of Non-Asbestos Gasket


No. 49-23-67

49-5816 Refer to ATA Rework of Exhaust Duct Flange Assembly


No. 49-23-67 Part No. 695140-50 and 695140-80

49-5834 Refer to ATA Incorporation of Improved Turbine Nozzle,


No. 49-23-67 Part No. 3846484-3 and 3846484-4

49-5851, R2 Refer to ATA Authorize Use of Combustion Liner, Part No.


No. 49-23-67 3605384-8

49-5862 Refer to ATA Incorporation of Compressor Inlet Assembly,


No. 49-23-67 Part No. 698197-2 (for Commonality)

Page SB-14
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5882, R4 Refer to ATA Rework Existing Second Stage Impeller, Part


No. 49-23-67 No. 379548-50 /966571-1 to Part No. 966569-2 or
Second Stage Impeller, Part No. 698193-4 to Part
No. 966569-1

49-5906, R1 Refer to ATA Authorize Use of Second Stage Impeller,


No. 49-23-67 Part No. 966569-2 in Lieu of Part No. 966569-1

49-5913 Refer to ATA Authorize Use of Torus Assembly Part No.


No. 49-23-67 3830350-1 through -4 in Lieu of Part No. 968959-
28/-22/-23/-26

49-5914 Refer to ATA Replace Insert, Part No. M5932-1-29L with


No. 49-23-67 Insert , Part No. 432-551-0126 on Gearcase,
Part No. 3603708

49-5919, R1 Refer to ATA Rework of TAFCU Acceleration Control Assembly


No. 49-23-67 Part No. 3607680-5 to Part No. 3607680-6 (To
Provide Positive Acceleration Control)

49-5932 Refer to ATA Incorporation of Accessory Drive Housing


No. 49-23-67 Gear Pad Studs, Part No. 682-510-9107 in Place of
Part No. MS51989E107-18

49-5941, R1 Refer to ATA Replacement of MAR-M-247 Turbine Rotor


No. 49-23-67 and Shaft Assembly, Part No. 3842072-1 with Part
No. 3842072-2

49-5974, R1 Refer to ATA Incorporation of Improved Plenum Inlet


No. 49-23-67 Screen Assembly, Part No. 965146-2

49-5996, R1 Refer to ATA Rework Compressor Inlet Assembly, Part No.


No. 49-23-67 698197-1 to Part No. 698197-2

49-6505 Refer to ATA Inspection and Rework of Interstage Seal


No. 49-23-67 Assembly, Part No. 378854-30 Change Letters L
and M to preclude possible Interference

Page SB-15
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-6508, R2 Refer to ATA Replace Oil Temperature Switch, Part No.


No. 49-23-67 375036 with, Part No. 305080-1

49-6534, R2 Mar 31/92 Authorize Use of Turbine Rotor and Shaft Assembly,
Part No. 3842072-3

49-6563, R2 Refer to ATA Incorporate Improved Pinion Bearing, Part No.


No. 49-23-67 3614920-1 in place of Part No. 3609114-1

49-6565, R1 Refer to ATA Incorporation of Load Control Valve, Part No.


No. 49-23-67 109382-35-1

49-A6706, R2 Refer to ATA Incorporate Improved Turbine Shroud Containment


No. 49-23-67 Augmentation Ring, Part No. 3616426-1. SUPERSEDES
SB 49-5689

49-6774 Refer to ATA Incorporate Solid Mounted Bracket Part No.


No. 49-23-67 696069-1 for Ingition Unit

49-6787 Refer to ATA Replace/Rework Atomizer and Liner Assembly


No. 49-23-67 Part No. 3604524-25 with Part No. 3604524-44

49-A6831, R1 Refer to ATA Replace/Rework Exhaust Pipe, Part No. 976987-1,


No. 49-23-67 or Exhaust Duct, Part No. 3607748-1 to Exhaust
Duct, Part No. 3850089-1

49-6860 Refer to ATA Rework First Stage Compressor Impeller, Part Nos.
No. 49-23-67 966570-1 and 379547 to Part No. 966568-1

49-6861 Refer to ATA Replace Spring Washer, Part No. 791-502-9009


No. 49-23-67 with Part No. 3610875-23

49-6863, R1 Refer to ATA Replace Turbine Nozzle, Part No. 3601669-1,


No. 49-23-67 3601669-7 or 3846484-3 with Part No. 3846484-7
and Part No. 3601669-2, 3601669-8 or 3846484-4
with Part No. 3846484-8

49-6864 Refer to ATA Rework Branched Wiring Harness, Part No.


No. 49-23-67 43959-3 to Part No. 43959-5 and Part No. 43959-4
to Part No. 43959-6

49-6865, R1 Refer to ATA Replace Retaining Nut, Part No. 379523 with
No. 49-23-67 Part No. 379523-1

Page SB-16
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-6866, R1 Refer to ATA Replace or Rework Oil Pump, Part No. 379580-650
No. 49-23-67 with/to Part No. 379580-700

49-6873 Refer to ATA Rework Plumbing and Electrical Installation by


No. 49-23-67 Replacing Elbow, Part No. 695165-1 with Part No.
695165-2

49-6875 Refer to ATA Rework or Replace Driveshaft Assembly, Part No.


No. 49-23-67 3601031-1 to Part No. 3601031-2

49-6898 Refer to ATA Replace Centrifugal Switch Assembly, Part No.


No. 49-23-67 3609480-5/-10/-13 with Part No. 3615700-5/-10/-13,
Respectively

49-6928, R2 Refer to ATA Replace Timed Acceleration Fuel Control Unit (TAFCU),
No. 49-23-67 Part Nos. 3608000-4/-6/-10 with Part Nos. 3608000-12/-13/
-14

49-6933, R1 Refer to ATA Replace Nut, Part No. 525-580-9003 with Nut,
No. 49-23-67 Part No. S9424-4 which has Improved Retention
Properties

49-6934, R1 Refer to ATA Replace/Rework Acceleration Control Assembly


No. 49-23-67 Part No. 3607680-6 with/to Part No. 3607680-8

49-6960, R1 Refer to ATA Rework Centrifugal Switch Assembly, Part No.


No. 49-23-67 3609480-5/-10/-13 to Part No. 3615700-5/-10/-13
Respectively

49-7103 Refer to ATA Rework/Replace Second Stage Diffuser Housing,


No. 49-23-67 Part No. 698195-1 to/with Part No. 698195-10 and Part
No. 698195-8 to/with Part No. 698195-12

49-7173 Refer to ATA Replace Generator Pad Seal with Rotor, Part No.
No. 49-23-67 377458 with Improved Generator Pad Seal, Part No.
3863237-1 and Rotor, Part No. 3822479-1

49-A7189, R2 Refer to ATA Incorporation of Turbine Wheel Shroud, Containment


No. 49-23-67 Augmentation Ring, Part No. 3616426-3

49-7238, R1 Refer to ATA Remove and Replace Vent Tube Assembly, Part No.
No. 49-23-67 695766-1 With Part No. 3617065-1

49-7301 Refer to ATA Replace Compressor Interstage Seal, Part No. 378854-30
No. 49-23-67 with Compressor Interstage Seal, Part No. 378854-50 on
Compressor and Turbine Assemblies, Part No. 3601835-All

49-7477 Refer to ATA Replace Second Stage Impeller, Part Nos. 698193-2/-3/-4/-5,
No. 49-23-67 or Part No. 3822481-3 with Second Stage Impeller, Part No.
3822536-1

Page SB-17
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-7484, R5 Refer to ATA Replace Fuel Control (FCU), Part No. 3609150-1/-2/-3 and
No. 49-23-67 3608000-4/-6/-10/-12/-13/-14, with FCU Part No. 3617750-1/
-2/-3 and Atomizer and Liner Assembly, Part Nos. 3604524-1/
-19/-21/-25/-29/-44/-45/-46/-47/-48/-49/-50/-51 with Atomizer
and Liner Assembly, Part Nos. 3604524-52/-53/-54/-55/-56/
-57/-58

49-7488, R1 Refer to ATA Replace Turbine Rotor and Shaft Assembly, Part Nos.
No. 49-23-04 3842072-1/-2/-3, or Part No. 3606982-1 with Turbine Rotor
And Shaft Assembly, Part No. 3842360-1

49-7495, R1 Refer to ATA Rework Fuel Control Assembly, Part No. 3609150-1/-2/-3 or
No. 49-23-67 Part No. 3608000-4/-6/-10/-12/-13/-14 to Part No. 3617750-1/
-2/-3

49-7514 Refer to ATA Rework/Replace of Compressor and Turbine Assembly, Part


No. 49-23-04 no. 3601835-30 to/with Part No. 3601835-59

49-7542 Refer to ATA Incorporation of External Shields, Part No's 3844911-1 and
No. 49-23-67 3844911-2

49-7572, R1 Refer to ATA Rework/Replace Compressor and Turbine Assembly, Part


No. 49-23-04 No. 3601835-30/-31/-33/-34/-39/-40/-41/-52/-53/-56/-59/-60
to/with Part No. 3601835-62

49-7638, R2 Refer to ATA Rework Second Stage Compressor Diffuser Housing, Part
No. 49-23-67 No. 698195 to Improve Plug Retention Properties

49-7664 Refer to ATA Replaces Turbine Plenum Gasket, Part No. 3612631-4 with
No. 49-23-67 Turbine Plenum Gasket, Part No. 3618086-1

Page SB-18
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

GTE0192 Refer to ATA Improved Second Stage Diffuser


No. 49-23-67

GTE0226, R1 Refer to ATA Alternate Oil Pump Filter Element


No. 49-90-33

GTE0318 Refer to ATA Replacement of Fuel Nozzle Swirl


No. 49-23-67

GTE0357 Refer to ATA Authorizes Installation of Part No.


No. 49-23-67 3601669-1/-2, Turbine Nozzle
(Customer Option)

GTE0362 Refer to ATA Authorizes Replacement of Part No.


No. 49-23-67 NAS686-3 with MS21060-3

GTE0368 Refer to ATA Authorizes Installation of Part No.


No. 49-23-67 MS9489-24 in place of Part No.
MS9489-25

GTE0531 Refer to ATA Provide Procurable Repair Part


No. 49-23-67

GTE0563 Refer to ATA Availability of Coupling for Repair of


No. 49-23-67 Gearshaft Assembly Part No. 379605

GTE0581 Refer to ATA Authorize use of Aluminum Oil Breather Tube


No. 49-23-67 in Lieu of CRES Tube

GTE0600 Refer to ATA Improved Screw for Lockwire


No. 49-23-67

GTE0648 Refer to ATA Identification Plate


No. 49-23-67

GTE0696, R1 Refer to ATA Authorize Use of Terminal, Part No.


No. 49-23-67 724-505-9013 in Place of Terminal Part
No. 724-505-9008

GTE0697, R1 Refer to ATA Authorize Use of Terminal, Part No.


No. 49-23-67 724-505-9014 in Place of Terminal Part
No. 724-505-9010

GTE0813 Refer to ATA Connectors, Part No. 304805-1/-2/-3/-4/-5


No. 49-23-67

Page SB-19
49-21-81 Feb 14/03
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
MAINTENANCE MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

GTE0988 Refer to ATA Authorize use of Ring, Part No. MS16625-1100


No. 49-23-67 in place of Ring, Part No. NAS50-100

GTE0989 Refer to ATA Authorize use of Plug, Part No. AN814-6J in


No. 49-23-67 place of Plug, Part No. AN814-6C

GTE1089 Refer to ATA Authorize use of Turbine Rotor Shaft Assy, Part No.
No. 49-23-67 3616256-1 In place of Turbine Rotor Shaft Assy, Part
No. 696161-13

Page SB-20
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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page T-1 Feb 14/03 Introduction


TC-1 Feb 14/03
Safety/ TC-2 Blank
Warranty/ INTRO-1 Feb 14/03
Liability INTRO-2 Feb 14/03
Advisory SWLA-1 Feb 14/03 INTRO-3 Feb 14/03
SWLA-2 Blank INTRO-4 Feb 14/03
INTRO-5 Feb 14/03
Record of INTRO-6 Feb 14/03
Revisions RR-1 Feb 14/03 INTRO-7 Feb 14/03
RR-2 Blank INTRO-8 Feb 14/03
INTRO-9 Feb 14/03
Record of INTRO-10 Feb 14/03
Temporary INTRO-11 Feb 14/03
Revisions TR-1 Feb 14/03 INTRO-12 Feb 14/03
TR-2 Feb 14/03 INTRO-13 Feb 14/03
TR-3 Feb 14/03 INTRO-14 Feb 14/03
TR-4 Feb 14/03 INTRO-15 Feb 14/03
INTRO-16 Feb 14/03
Service INTRO-17 Feb 14/03
Bulletin List SB-1 Feb 14/03 INTRO-18 Feb 14/03
SB-2 Feb 14/03 INTRO-19 Feb 14/03
SB-3 Feb 14/03 INTRO-20 Feb 14/03
SB-4 Feb 14/03 INTRO-21 Feb 14/03
SB-5 Feb 14/03 INTRO-22 Feb 14/03
SB-6 Feb 14/03 INTRO-23 Feb 14/03
SB-7 Feb 14/03 INTRO-24 Feb 14/03
SB-8 Feb 14/03 INTRO-25 Feb 14/03
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SB-10 Feb 14/03 INTRO-27 Feb 14/03
SB-11 Feb 14/03 INTRO-28 Blank
SB-12 Feb 14/03
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108 Feb 14/03

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LIST OF EFFECTIVE PAGES

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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

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TC-1 Feb 14/03
49-20-04 TC-1 Feb 14/03 TC-2 Blank
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49-30-00 TC-1 Feb 14/03
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LIST OF EFFECTIVE PAGES

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LIST OF EFFECTIVE PAGES

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49-90-02 (Cont) 206 Feb 14/03


207 Feb 14/03
208 Feb 14/03

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203 Feb 14/03
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TABLE OF CONTENTS

CHAPTER/
SECTION/
SUBJECT SUBJECT

INTRODUCTION 49-21-81

ENGINE SECTION 49-20-00

ENGINE FUEL AND CONTROL SECTION 49-30-00

IGNITION/STARTING SECTION 49-40-00

AIR SECTION 49-50-00

ENGINE CONTROLS SECTION 49-60-00

INDICATING SECTION 49-70-00

OIL SECTION 49-90-00

REFER TO APPLICABLE SECTION/SUBJECT FOR EXPANDED CONTENTS.

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GTCP85-98DHF/[A]

INTRODUCTION

TABLE OF CONTENTS

SECTION/
SUBJECT SUBJECT PAGE

General INTRO-1

Equipment Identification /Configuration INTRO-1

Applicable Publications INTRO-2

Materials, Equipment, Compounds and Special Tools INTRO-2

Illustrated Parts Catalog Reference INTRO-2

Geometric Tolerance Symbols INTRO-3

Equipment Identification List (Table 1, 1A) INTRO-4

Applicable Publications List (Table 2, 2A) INTRO-22

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GTCP85-98DHF/[A]

INTRODUCTION

1. General

This publication provides instructions for the equipment listed in Table 1 and 1A, Equipment
Identification List, manufactured by Honeywell Engines, Systems & Services, P.O. Box 52170,
Phoenix, AZ 85072-2170.

This publication is prepared in accordance with Air Transport Association Specification No. 100.
Definition of words and terms used in this publication are as stipulated therein.

2. Equipment Identification/Configuration

The exact identification of the equipment may be determined by noting the part number, model
number, series number and change number (s) stamped on the identification plate.

The Equipment Identification List (Table 1, 1A) provides the following information.

A. The part number, series number and change number(s) which comprise the equipment.

B. A listing of overhaul and repair changes. These are product improvement and/or repair type
changes which may be incorporated in the equipment.

C. Service bulletins incorporating the production and/or overhaul repair change.

NOTE: Overhaul and repair changes incorporated by service bulletins which were later
incorporated as production changes will be listed twice under two different change
numbers. The earlier change number reflects the change being incorporated at
time of overhaul or repair. The later change number reflects the change being
incorporated at time of production.

Work procedure differences between configurations of the equipment covered in this


publication are identified in the text by the insertion of the applicable service bulletin (Pre or
Post SB ) or part number (PN ), at the beginning of the paragraph or procedural step which
describes the changed procedure. Illustrations applicable to a particular modification or
configuration are identified by the insertion of the applicable service bulletin (Pre or Post SB _ )
part number (PN _ ), preceding the illustration title. Procedures and illustrations not identified
by service bulletins or part numbers are applicable to all configurations of the equipment.

Page INTRO-1
49-21-81 Feb 14/03
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GTCP85-98DHF/[A]

3. Applicable Publications

The nomenclature, part number, and publication report number(s) of accessories covered in separate
publications are listed in Table 2, Applicable Publications List.

4. Materials, Equipment, Compounds and Special Tools

Materials, equipment and compounds will be listed at the heading of each section. Special tools will be
listed in appropriate section as required. Consult these lists so that the materials, equipment,
compounds and special tools may be gathered prior to starting maintenance or repair.

5. Illustrated Parts Catalog Reference

IPC item numbers are used throughout the manual where feasible. Reference to applicable IPC figure
(including sections when required) are included in the applicable figure key. In cases where use of IPC
item numbers are not feasible, reference to IPC item numbers are included. For example,

KEY TO FIGURE 201

10. COUPLING (IPC FIG. 1)


20. PACKING
30. COMBUSTOR UNIT

In this case all items in the KEY TO FIGURE 201 are listed in IPC Figure 1 of corresponding section.

KEY TO FIGURE 203

10. SCREW (210, IPC FIG. 2, 49-20-00) 160. BOLT


20. WASHER (220, IPC FIG. 2, 49-20-00) 170. WASHER (150, IPC FIG. 6,
30. BRACKET (200, IPC FIG. 2, 49-20-00 49-20-00)
40. NUT (60, IPC FIG. 4, 49-20-00) 180. WASHER (50, IPC FIG. 7,
50. WASHER (70, IPC FIG. 4, 49-20-00) 49-20-00)
60. SPACER WASHER (80, IPC FIG. 4, 190. PANEL ASSY (170, IPC
49-20-00) FIG. 6, 49-20-00)
70. BOLT (90, IPC FIG. 4, 49-20-00) 200. SCREW (40, IPC FIG. 6,
80. BRACKET (50, IPC FIG. 4, 49-20-00) 49-20-00)
90. SCREW (IPC FIG. 5, 49-20-00) 210. WASHER (50, IPC FIG. 6,
100. WASHER 49-20-00)
110. PACKING W/RTNR 220. MOUNT ASSY (60, IPC
120. CLAMP (70, IPC FIG. 5, 49-20-00) FIG. 6, 49-20-00)
130. BRACKET (80, IPC FIG. 5, 230. MOUNT ASSY (60, IPC
49-20-00) FIG. 6, 49-20-00)
140. BOLT (IPC FIG. 6, 49-20-00) 230. GROMMET (60, IPC FIG. 7,
150. WASHER 49-20-00)

In this case items in the KEY TO FIGURE 203 are listed in the IPC Figure and section as indicated.

Page INTRO-2
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6. Geometric Tolerance Symbols

If applicable, geometric symbols are used on illustrations in CHECK and REPAIR sections of the
manual. These symbols are shown in Table 3.

Page INTRO-3
49-21-81 Feb 14/03
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Table 1. Equipment Identification List for Part No. 381276-1

Series Change Service


No. No. Description Bulletin

1 - Original Configuration

2 2 Flight Test Configuration (Serial


No. P-1 only)

3 2, 10

10 Incorporation of Hooded Pcd Probe 49-3926


(Without Anti-Moisture Orifice)

4 2, 7, 10

7 Rework Electrical Engine Starter 49-5181


to Incorporate Improved Clutch Plates

5 2, 7, 10, 11

11 Rework Multiple Centrifugal Switch 49-5235


and Wiring Harness Assembly to
Incorporate Threaded Connector

6 2, 7, 10, 11, 12

12 Product Improved-Containment Ring 49-3914


Retention

7 2, 7, 10 thru 13
13 Incorporate Strengthened Exhaust 49-5236
Flange Assembly to Reduce Exhaust
Gas Leakage

8 2, 7, 10 thru 13,
19

19 Replace CRES Scavenge Tube with


Aluminum

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

9 2, 7, 10 thru 13,
19, 21

21 Incorporation of Combustor Unit 49-5309


(Atomizer and Liner Assembly) Part
Numbers

10 2, 7, 10 thru 13,
19, 20, 21

20 Incorporation of Load Control Valve 49-5307


Part No. 109382-32

11 2, 7, 10 thru 13,
19, 21 and 25

25 Incorporate New Fuel Control Unit 49-5418


with Improved ACCELERATION Limiter

12 2, 7, 10 thru 13,
19, 21, 24, 25
and 26

24 Incorporate Improved Torus Assembly 49-5436


and Heat Shield Part No. 3609467-1

26 Replace Fuel Atomizer Assembly 49-5444


Part No. 3601193-3 with Part No.
3601193-2

13 2, 7, 10 thru 13,
19, 21, 24, 25,
26 and 28

28 Incorporate Improved Thermocouple 49-5471

14 2, 7, 10 thru 13,
19, 21, 24, 25,
26, 28 and 29

29 Incorporate Pinned Oil Pump 49-5304/


Assembly -5305

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MAINTENANCE MANUAL
GTCP85-98DHF/[A]

Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

15 2, 7, 10 thru 13,
19, 21, 24, 25, 26
28, 29 and 31

31 To Provide Stronger Second Stage 49-5199


Diffuser Housing to Prevent Cracking

16 2, 7, 10 thru 13,
19, 21, 24, 25, 26
28, 29, 31 and 35

35 Incorporate Improved Torus 49-5436


Assembly and Heat Shield Part
No. 968959-22

17 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35 and
39

39 Incorporate Improved Accessory 49-5587


Cooling Fan Assembly Part No.
695227-19

18 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39
and 41

41 Incorporate Multiple Centrifugal 49-5505


Switch Assembly Part No.
3609480-13 in place of Part No.
3601030-13

19 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41 and 43

43 Incorporate Correct Seal Retainer 49-5587


Which Results in a Properly Installed
Carbon Face on Fan Assembly

Page INTRO-6
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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

20 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43 and 49

49 Incorporate Containment Ring to 49-5689


Ensure Turbine Wheel/Shroud
Containment Integrity

21 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 49 and 52

52 Incorporate Extended Baffles for 49-5738


Increased Performance

22 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 49, 52 and
48

48 Incorporate Stronger Shroud for 49-5700


Increased Reliability

23 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52
and 53

53 Incorporate Customer Requested 49-5744


Shock Mounted Ignition Unit

24 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53 and 61

61 Incorporate New Bracket Assembly -

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GTCP85-98DHF/[A]

Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

25 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61 and 62, 64

62 Incorporate Improved Oil Pump -


Assembly

64 Incorporate Exhaust Duct Flange with 49-5658


Scupper at Oil Vent

26 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
and 69

67 Incorporate Improved Screen 49-5974


with resistance Welded Wire

69 Incorporate Improved Shut-off 49-6565


Valve

27 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68 and 69

68 Increase Temperature Set 49-6508


Point of Oil Temperature Switch

28 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69 and 72

72 Provide Hard Mount for Ignition 49-6774


Unit

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

29 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72 and 73

73 Provide Improved Altitude Starting 49-6787

30 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73
and 74

74 Reroute Thermocouple and Ignitor -


Lead to Protect from Combustor

31 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81 and 83

81 Provide Improved Hi-Speed 49-6563


Pinion Bearing

83 Provide T-Wheel Axial 49-6831


Retention

32 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81, 83, 84 and 88

84 Provide Improved Nut 49-6933


Part No. S9424-4

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

32 (Cont) 88 Incorporate Improved Housing 49-7514


Assembly Part No. 698195-12

33 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81, 83, 84 and 88

89 Authorize the use of Seal 49-7173


Part No. 3863237-1 and
Rotor Part No. 3822479-1

34 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81, 83, 84, 88 and 89

93 Incorporate Improved Vent Tube 49-7238


Part No. 3617065-1

94 Incorporate Improved 49-A7189


Hastelloy "S" Augmentation
Ring Part No. 3616426-3

35 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81, 83, 84, 88, 89,
93 and 94

95 Incorporate Improved Seal 49-7301


Assembly Part No. 378854-50

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 1 Rework Electrical Engine Starter 49-5070

3 Repair of First Stage Diffuser Part 49-3580


No. 698194-1 (Incorporation of Steel
Tip Vanes)

4 Availability of Reconditioned First 49-3655


Stage Impeller

5 Availability of Reconditioned Second 49-3656


Stage Impeller

6 Availability of Improved Compressor 49-5132


Interstage Seal Assembly

8 Incorporation of Fuel Conservation 49-5233


EGT Control System

9 Authorize Use of Timed Acceleration 49-5196


Fuel Control Unit Part No. 3608000-8

14 Authorize Use of Turbine Wheel -


Assembly Part No. 3604604-3

15 Authorize Use of Second Stage -


Diffuser Part No. 892290-1

16 Authorize Use of Turbine Wheel -


Assembly Part No. 3604604-1

17 Authorize Use of Turbine Wheel -


Assembly Part No. 3604604-2

18 Incorporate Pinned Oil Pump 49-5305


Assembly (See Chg
29)

22 Authorize Use of Fuel Control -


Unit Part No. 3602310-10

23 Incorporate Gearcase Housing, Part -


No. 977831-5 in Lieu of Part No.
3603708-2

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 27 Incorporate Multiple Centrifugal 49-5505


(Cont) Switch Assembly, Part No. 3609480-13 (See Chg
in place of Part No. 3601030-13 41)

30 Authorize Use of Diffuser 49-5199


Housing Part No. 698195-7 (See Chg
or -8 31)

33 Incorporation of Electrical Engine 49-5472


Starter, Part No. 3605812-16
and 3605812-17

34 Incorporate Improved Torus 49-5436


Assembly and Heat Shield (See Chg
Part No. 968959-22 35)

37 Incorporate Improved Accessory 49-5487


Cooling Fan Assembly, Part No. (See Chg
695227-19 39)

38 Relocate Engine Identification 49-3516


Plate

40 Incorporate Modification of Name 49-5233


Plate Bracket

42 Incorporate Fan Assembly, Part No. 49-5587


695227-19 in Lieu of Part No. 695227 (See Chg
-15 43)

44 Incorporate Turbine Shroud Containment 49-5689


Augmentation Ring (See Chg
49)

46 Incorporate MAR-M-247 Turbine Rotor 49-5699


and Shaft Assembly Part No. 3842072-1 (See Chg
45)

47 Incorporate Hastilloy "S" Turbine Wheel 49-5700


Shroud Part No. 3611904-1 (See Chg
48)

50 Incorporate Igniter Plug Part No. 49-5722


3888210-1 with Hastilloy Shell

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 56 Incorporate Combustion Liner, 49-5851


(Cont) Part No. 3605384-8 in Lieu of Part
No. 3605384-3

57 Authorize Use of MAR-M-247 Turbine 49-5834


Nozzle

60 Authorize Rework of Atomizer Part 49-5701


No. 3601193-2 to Part No. 3601193-5

63 Authorize Use of Shims Part No. 49-5436


3614844-1/-2/-3 to Obtain Clearance
Between Torus and Shroud

65 Authorize Use of Torus, Part No. 49-5436


3830350-2 in Lieu of Part No. 968959-22

71 Authorize use of Part No. 3616252-1

72 Authorize use of Ignition Unit Hard 49-6774


Mount Part No. 696069-1 in Lieu of
Shock Mount Part No. 3614647-1

75 Authorize use of Augmentation Ring -


Part No. 3616426-1

76 Authorize use of Composite Cooling -


Fan Part No. 3616496-1

77 Authorize use of Wiring Harness -


Part No. 43959

78 Authorize the MCP Upgrade VIA 49-6809


Parts Kit 3616233-1

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 82 Authorize use of T-Wheel/Shaft


Assembly Part No. 3842072-3

84 Authorize use of Improved Nut 49-6933


Part No. S9424-4

85 Authorize use of Fuel Control 49-6928


Part No. 3608000-14 for Field
Evaluation of a Non-Metallic
Drive Coupling

86 Authorize use of Switch Assembly 49-6898


Part No. 3615700-13

87 Authorize use of Turbine and


Compressor Assembly Part No.
3601835-60

94 Authorize the use of Hastelloy 49-A7189


"S" Augmentation Ring,
Part No. 3616426-3

96 Authorize use of Improved 49-7477


Impeller Part No. 3822536-1

97 Authorize use of Fuel Control 49-7484


Unit Part No. 3617750-2

98 Provide ID for Units to Incorporate 49-7477


and Authorize use of Improved
HFC Life Impeller Part No.
3822536-1

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont.)

Series Change Service


No. No. Description Bulletin

99 Provide ID for Units to Incorporate 49-7514


and Authorize use of Turbine and
Compressor Assembly Part No.
3601835-59

100 Authorize the use of External Shields, 49-7542


Part Nos. 3844911-1 and 3844911-2

101 Turbine and Compressor Assembly, 49-7572


Part No. 3601835-62, Replaces
Turbine and Compressor Assembly,
Part No. 3601838-59

102 Wheel and Shaft Assembly, Part No. 49-7488


3842360-1, Replaces Wheel and
Shaft Assembly, Part No. 3842350-1

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Table 1A. Equipment Identification List for Part No. 381276-2

Series Change Service


No. No. Description Bulletin

1 - Original Configuration

2 4 Incorporate Improved Torus 49-5436


Assembly and Heat Shield

3 3, 4

3 Incorporate Improved 49-5587/


Accessory Cooling Fan 49-5588
Assembly Part No.
695227-19

4 3, 4 and 8

8 Incorporate Improved Three 49-5505


Speed Switch

5 3, 4, 8 and 9

9 Incorporate Correct Seal Retainer 49-5587


Which Results in a Properly Installed
Carbon Face on Fan Assembly

6 3, 4, 8, 9 and
15

15 Incorporate Containment Ring to 49-5689


Ensure Turbine Wheel/Shroud
Containment Integrity

7 3, 4, 8, 9, 15
and 14, 18

14 Incorporate Stronger Shroud for 49-5700


Increased Reliability

18 Incorporate Extended Baffles for 49-5738


Increased Performance

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont)

Series Change Service


No. No. Description Bulletin

8 3, 4, 8, 9, 14,
15, 18 and 19

19 Incorporate Customer Requested 49-5744


Shock Mounted Ignition Unit

9 3, 4, 8, 9, 14,
15, 18, 19 and
24

24 Incorporate New Bracket Assembly -


Part No. 3614647-1

10 3, 4, 8, 9, 14,
15, 18, 19, 24
and 27,29

27 Incorporate Improved Oil Pump -


Assembly

29 Incorporate Exhaust Duct Flange with 49-5658


Scupper at Oil Vent

11 9, 14, 15, 18,


19, 24, 27,
29, 32 and 34

32 Incorporate Improved Screen with 49-5974


Resistance Welded Wire Part No.
695146-2

34 Incorporate Improved Shut-Off Valve 49-6565


Part No. 109382-35

12 9, 14, 15,18,
19, 24, 27,
29, 32, 33 and
34

33 Authorize the use of Oil Temp Switch 49-5699


Part No. 305080-1

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont)

Series Change Service


No. No. Description Bulletin

13 9, 14, 15, 18,


19, 24, 27, 29,
32, 33, 34
and 37

37 Incorporate Hard Mount for 49-6774


Ignition Unit

14 9, 14, 15, 18,


19, 24, 27, 29,
32, 33, 34, 37,
thru 39

38 Incorporate Improved Atomizer 49-6787


and Liner Assembly Part No.
3604524-44

39 Reroute Thermocouple and Ignitor -


Leads

15 9, 14, 15, 18,


19, 24, 27, 29,
32, 33, 34, 37,
thru 39,45,
and 47

45 Incorporate Improved Hi-Speed 49-6563


Pinion Bearing Part No. 3614920-1

47 Incorporate Improved Exhaust Duct 49-6831


Part No. 3850089-1

16 9, 14, 15, 18,


19, 24, 27, 29,
32, 33, 34, 37,
thru 39,45, 47,
and 48

48 Incorporate Improved Nut Part No. 49-6933


S9424-4

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 2 Incorporation of Electrical Engine 49-5472

Starter, Part No. 3605812-16 and


3605812-17

6 Incorporate Improved Accessory 49-5587


Cooling Fan Assembly, Part No. (See Chg
695227-19 3)

10 Incorporate Turbine Containment 49-5689


Augmentation Ring (See Chg
15)

12 Incorporate MAR-M-247 Turbine Rotor 49-5699


and Shaft Assembly Part No. 3842072-1 (See Chg
11)

13 Incorporate Hastilloy "S" Turbine 49-5700


Shroud

16 Incorporate Igniter Plug Part No. 49-5722


3888210-1 with Hastilloy Shell

20 Incorporate Combustion Liner, 49-5851


Part No. 3605384-8 in Lieu of Part
No. 3605384-3

21 Authorize Use of MAR-M-247 Turbine 49-5834


Nozzle

23 Incorporate Combustion Liner, 49-5851


Part No. 3605384-8 in Lieu of Part
No. 3605384-3

25 Authorize Rework of Atomizer Part 49-5701


No. 3601193-2 to Part No. 3601193-5

26 Authorize Use of Shims Part No. 49-5436


3614844-1/-2/-3 to Obtain Clearance
Between Torus and Shroud

28 Incorporate Gearcase Housing, Part -


No. 977831-5 in Lieu of Part No.
3603708-2

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont.)

Series Change Service


No. No. Description Bulletin

No Series 30 Authorize Use of Torus, Part No. -


(Cont) 3830350-2 in Lieu of Part No. 968959-22

36 Incorporate the use of Part No. -


3616252-1

37 Authorize the use of Ignition Unit 49-6774


Hard Mount Part No. 696069-1

40 Authorize the use of Augmentation -


Ring Part No. 3616426-1

41 Authorize the use of Composite -


Cooling Fan Part No. 3616496-1

42 Authorize the use of Wiring Harness -


Part No. 43959-4

43 Authorize MCP Upgrade VIA Parts 49-6809


Kit 3616233-1

46 Authorize the use of T-Wheel/Shaft -


Assembly Part No. 3842072-3

50 Authorize the use of Switch Assembly 49-6898


Part No. 3615700-13

51 Authorize the use of Turbine and -


Compressor Assembly Part No.
3601835-60

52 Incorporate Improved Housing -


Assembly Part No. 698195-12

53 Authorize the use of Seal 49-7173


Part No. 3863237-1 and
Rotor Part No. 3822479-1

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont.)

Series Change Service


No. No. Description Bulletin

No Series 56 Incorporate Improved Tube 49-7238


(Cont) Assembly Part No. 3617065-1

57 Authorize the use of Hastelloy "S" 49-A7189


Augmentation Ring Part No.
3616426-3

58 Authorize the use of Seal Assembly 49-7301


Part No. 378854-50

59 Authorize use of Improved Impeller 49-7477


Part No. 3822536-1

60 Provide ID for Units to Incorporate 49-7477


and Authorize use of Improved HFC
Life Impeller Part No. 3822536-1

61 Provide ID for Units to Incorporate 49-7514


and Authorize use of Turbine and
Compressor Assembly Part No.
3601835-59

62 Provide identification for units 49-7484


incorporating new FCU and
Atomizer and Liner Assembly

63 Authorize the use of External 49-7542


Shields, Part Nos. 3844911-1 and
3844911-2

64 Turbine and Compressor Assembly, 49-7572


Part No. 3601835-62, replaces
Turbine and Compressor Assembly,
Part No. 3601838-59

65 Wheel and Shaft Assembly, Part 49-7488


No. 3842360-1, replaces Wheel
And Shaft Assembly, Part No.
3842350-1

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Table 2. (GTCP85-98DHF) Applicable Publications List

Nomenclature Part No. Publication Type

Gas Turbine Engine 381276-1 49-21-83 OH


49-21-73 IRM
49-23-67 IPC

Accessory Cooling Fan Assembly 695227-15 49-50-35 OH/IPL


695227-19

Air Pressure Regulator 108032-8 49-50-07 OH/IPL

Centrifugal Multiple Switch 3601030-11 49-60-33 OH/IPL


Assembly 3601030-13
3609480-13 49-60-47 CMM/IPL

Check Valve (Oil) 899766-1 49-90-41 OH/IPL

Electrical Engine Starter 372697-21-1 49-40-01 OH/IPL


3605812-10
3605812-14
3605812-17

Fuel Atomizer Assembly 3601193-3 49-30-38 OH/IPL


3601193-2

Fuel Control Unit 3602310-14-1 49-30-49 OH/IPL


3602310-33
3609150-3-1 49-30-69 OH/IPL
3608000-10 49-31-17 CMM/IPL

Igniter Plug Lead 369259-20 49-41-05 OH/IPL

Ignition Unit 3603281-3/-7 49-40-33 CMM/IPL

Load Control Valve 109382-28 49-50-40 OH/IPL


109382-32

Oil Cooler Assembly 152050-5 49-20-10 CMM/IPL

Oil Tank Assembly 899320-1 49-90-35 OH/IPL

Oil Pump Assembly 379580-300 49-90-33 OH/IPL


379580-650
379580-700

Pneumatic Solenoid Valve (NC) 692993 49-60-41 OH/IPL

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Table 2. (GTCP85-98DHF) Applicable Publications List (Cont)

Nomenclature Part No. Publication Type

Pneumatic Thermostat 129552-1 49-70-39 OH/IPL

Pressure Relief Valve 373048-3 49-90-01 OH/IPL


(Component of Oil Pump Assembly)

Sequencing Oil Pressure Switch 692525-9 49-60-06 OH/IPL

Solenoid Shutoff Valve (NC) 692545-3 49-30-67 OH/IPL


(Component of Fuel Control Unit)

Solenoid (Three-Way) Shutoff 320362-2 24-09-71 CMM/IPL


Valve

Standard Practices Manual - 20-00-02/


70-00-01

Gas Turbine Engine Tester 290122-400 49-GE-03 GEM


Assembly (For Mechanical 290122-500 49-GE-03 GEM
Speed Switch) 290270-1-1 8A-80 OSI

Thermostat Calibration 290417-2-1 290417MM MM


Test Set

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Table 2A. (GTCP85-98DHF[A]) Applicable Publications List

Nomenclature Part No. Publication Type

Gas Turbine Engine 381276-2 49-23-67 IPC


49-21-73 IRM
49-21-83 OH

Accessory Cooling Fan Assembly 695227-15 49-50-35 OH/IPL


695227-19

Air Pressure Regulator 108032-8 49-50-07 OH/IPL

Centrifugal Multiple Switch 3601030-13-1 49-60-47 CMM/IPL


Assembly 3609480-13

Check Valve (Oil) 899766-1 49-90-41 OH/IPL

Electrical Engine Starter 3605812-14 49-40-01 OH/IPL


3605812-17

Fuel Atomizer Assembly 3601193-2 49-30-38 OH/IPL

Fuel Control Unit 3609150-3-1 49-30-69 OH/IPL


3608000-10 49-31-17 CMM/IPL

Igniter Plug Lead 369259-20 49-41-05 OH/IPL

Ignition Unit 3603281-3/-7 49-40-33 CMM/IPL

Load Control Valve 109382-32 49-50-40 OH/IPL

Oil Cooler Assembly 152050-5 49-20-10 CMM/IPL

Oil Tank Assembly 899320-1 49-90-35 OH/IPL

Oil Pump Assembly 379580-650 49-90-33 OH/IPL


379580-700

Pneumatic Solenoid Valve (NC) 692993 49-60-41 OH/IPL

Pneumatic Thermostat 129552-1 49-70-39 OH/IPL

Pressure Relief Valve 373048-3 49-90-01 OH/IPL


(Component of Oil Pump Assembly)

Sequencing Oil Pressure Switch 692525-9 49-60-06 OH/IPL

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Table 2A. (GTCP85-98DHF[A]) Applicable Publications List (Cont)

Nomenclature Part No. Publication Type

Solenoid Shutoff Valve (NC) 692545-3 49-30-67 OH/IPL


(Component of Fuel Control Unit)

Solenoid (Three-Way) Shutoff 320362-2 24-09-71 CMM/IPL


Valve

Standard Practices Manual - 20-00-02/


70-00-01

Gas Turbine Engine Tester 290122-400 49-GE-03 GEM


Assembly 290122-500
290270-1-1 8A-80 OSI

Thermostat Calibration 290417-2-1 290417MM MM


Test Set

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Table 3. Geometric Tolerance Symbols

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Table 3. Geometric Tolerance Symbols (Cont)

Page INTRO-27/INTRO-28
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ENGINE SECTION

TABLE OF CONTENTS

SECTION
SUBJECT SUBJECT PAGE

DESCRIPTION AND OPERATION 49-20-00


Description and Operation 1
Trouble Shooting 101
Servicing 301
Removal/ Installation 401
Adjustment/Test 501
Inspection/Check 601
Cleaning/Painting 701
Approved Repairs 801
EXTERNAL PARTS INSTALLATION 49-20-03
Maintenance Practices 201
COMBUSTION AND EXHAUST SECTION 49-20-04
Maintenance Practices 201
ACCESSORY GEARCASE SEALS 49-20-10
Maintenance Practices 201

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1. General

The pneumatic and shaft power gas turbine engine is designed for ground level and airborne auxiliary
power. The engine provides mechanical shaft power for driving aircraft accessories such as an
alternator, provides pneumatic bleed-air power for starting main aircraft engines and for aircraft cabin
air-conditioning and pressurization, and provides cooling air for engine lubricating oil and for the engine
enclosure at all times.

The physical and operational characteristics of the pneumatic and shaft power gas turbine engine are
listed in Table 1.

Table 1. Leading Particulars

Engine General
Weight (dry) Part No. 381276-1 .................................................................................................... 340 lb max
Part No. 381276-2 .................................................................................................... 343 lb max
Engine Ratings (min) at 630C (1166F) Turbine discharge
Temperature (Ratings apply at the following conditions)
Inlet Air Total Temperature ......................................................................................................... 39C (103F)
Inlet Air Total Pressure ......................................................................................................... 29.92 in. Hg abs
Turbine Discharge Static Pressure ....................................................................................... 29.92 in. Hg abs
Combined Mechanical and Pneumatic Power Output
Shaft Horsepower .......................................................................................................................... 60 3 shp
Bleed-air Flow .................................................................................................................................103.0 ppm
Bleed-air Total Pressure ....................................................................................................... 101.5 in. Hg abs
Bleed-air Total Temperature .............................................................................. 214 to 253 C (418 to 488 F)
Engine Speeds
Turbine Wheel
No-Load, Steady-state ................................................................................................... 42,500 100 rpm
Full-bleed Load (Droop) ......................................................................................................... 400 rpm min
1000 rpm max
Output Drive Shaft
(at 42,000 rpm turbine speed) ........................................................................................................ 6,000 rpm
Tachometer-generator Drive Shaft
(at 42,000 rpm turbine speed) ...................................................................................................... 42,000 rpm
Gear Ratio (turbine wheel speed to
tachometer-generator speed) .............................................................................................................. 10:1
Fuel System
Fuel Specification ..........................................................................Fuel specification authorized for operation
of aircraft main engines are authorized for
APU operation.

CAUTION: ANTI-SMOKE ADDITIVE SHELL CI-2 IS NOT APPROVED FOR USE. THIS ADDITIVE
FORMS MAGNESIUM DEPOSITS WHICH REDUCE TURBINE LIFE.

Fuel; Additives
Fuel additives approved for use with this engine.

Purpose Brand/Specification/Remarks

Anti-icing Phillips PF55 or any additive which com-


plies with MIL-I-27688. Concentration, 0.15
percent maximum by volume.

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Table 1. Leading Particulars (Cont)

Purpose Brand/Specification/Remarks

Anti-corrosion Santolene C. Concentration, 56.0 PPM


maximum by weight.

Anti-static Shell ASA3. Concentration, 1.0 PPM or a


conductivity of 300 pico mhos/m. 3.0 PPM
maximum.

Biocide, Anti-microbial All including Biobor JF. Concentration, 270


or Fungicide PPM maximum by weight.

Fuel Thermal Stability Improver Additive

NOTE: Thermal stability improver additive can be added to all approved fuels.

The maximum concentration for use is 256 mg/L for all the above brand names of the additive.

MIL-DTL-83133 Grade JP-8+100 is acceptable for use (JP-8+100 is military JP-8 turbine fuel
which contains GE Betz Spec-Aid 8Q462 or Shell Aviation APA101 at a maximum concentration
of 256 mg/L).

The additive should be injected following manufacturers recommendations including:

An additive injection pump should be used to meter the additive concentration during
fueling (mixing additive in aircraft fuel tanks is not recommended).

The additive should be injected downstream of any airport fuel/water separators (additive
can disarm some filter/separators).

The APU inlet fuel filter should be closely monitored during initial use of additized fuel, and
replaced as required - the additive may dislodge particulates accumulated in ground of aircraft
fuel systems sending them downstream to the engine inlet filter.

APU performance should be monitored following initial use of the additive - any particulates
accumulated in the engine fuel system may be dislodged by the additive and sent to downstream
fuel system components.

GE Betz Spec-Aid 8Q462

GE Betz Turboline FS100C

Shell Aviation Aero Shell Performance Additive


101(APA 101)

Lubrication System
Lubrication Specification ..................................................................... Refer to Section 49-20-00, Table 302
Electrical System
Voltage ............................................................................................................................................ 26 2 vdc
Amperage (momentary) ............................................................................................................ 400 amp max

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MAINTENANCE MANUAL
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2. Description

The pneumatic and shaft power gas turbine is essentially a self-contained power source and requires
only a source of fuel and electrical power for operation. The starting, acceleration, and operation of the
engine is controlled by an integral system of automatic and coordinated pneumatic and electro-
mechanical controls. A minimum of customer-furnished external controls are used for initiating engine
starts and for observing engine operation.

Engine power is developed through compression of ambient air by a two-stage centrifugal compressor.
The compressed air, mixed with fuel and ignited, drives a radial inward-flow turbine wheel. The
rotating shaft power of the drive turbine wheel drives the compressor, the accessories, and the output
drive shaft.

Engine power is developed through compression of ambient air by a two-stage centrifugal compressor.
The compressed air, mixed with fuel and ignited, drives a radial inward-flow turbine wheel. The
rotating shaft power of the turbine wheel drives the compressor, the accessories, and the output drive
shaft.

For convenient description, the engine is divided into seven main sections. The engine section
includes an accessory and gearcase assembly located at the front of the engine and a compressor and
turbine assembly located at the rear. The remaining sections are an engine and fuel control section,
an ignition/starting section, an air section, an engine control section, an indicating section, and an oil
section. (Refer to Figure 1.)

The engine section mounts and drives certain engine accessories, an accessory cooling fan assembly,
and the engine output drive shaft. The accessory and gearcase assembly consists of a gearcase
assembly and the following engine accessories: fuel control unit, oil pump assembly, centrifugal switch
assembly, electrical starter, and tachometer-generator.

The gearcase assembly encloses a reduction gear system. A torsion shaft couples the compressor
turbine main shaft to the main drive gear in the gearcase assembly. The main drive gear transmits
power through the reduction gear system to drive the accessories at the required speed for each
accessory. The arrangement of the accessory gear train permits the starter to drive all the accessories
in addition to driving the compressor impellers and turbine wheel during engine starting.

KEY TO FIGURE 1

1,5. GAS TURBINE ENGINE (REFER TO SECTION 49-20-00)


10. ENGINE SECTION (REFER TO SECTION 49-20-VARIOUS)
20. ENGINE FUEL AND CONTROL SECTION (REFER TO SECTION 49-30-00)
30. IGNITION/STARTING SECTION (REFER TO SECTION 49-40-00)
40. AIR SECTION (REFER TO SECTION 49-50-00)
50. ENGINE CONTROLS SECTION (REFER TO SECTION 49-60-00)
60. INDICATING SECTION (REFER TO SECTION 49-70-00)
70. OIL SECTION (REFER TO SECTION 49-90-00)

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Gas Turbine Engine Sections


Figure 1

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The compressor and turbine assembly develops the pneumatic and shaft power absorbed during
operation of the engine. The assembly consists of a two-stage centrifugal compressor and a single-
stage turbine wheel assembly rotating on a common shaft. The compressor is enclosed by a
compressor inlet plenum assembly. The first and second stage compressor impellers are
pneumatically connected through interstage ducts. The turbine plenum assembly encloses the turbine
components and provides a receiver for compressed air from the compressor discharge housing. A
combustion chamber liner assembly provides a combustion area and is perforated to provide the
correct air-to-fuel mixture and burning rate. A turbine torus assembly directs combustion products to a
turbine nozzle assembly which encompasses the turbine wheel blades. A shroud encloses the turbine
wheel blades and directs the exhaust gases to the turbine exhaust pipe (Refer to Figure 2 for cross
sectional view with air-flow schematic and location of accessory mounting pads.)

3. Operation

The engine incorporates control components in the fuel, air and electrical systems which automatically
control engine functions and maintain required engine speed and safe temperature from initiation of
start through operation of full load. Some of the control components require interconnection with
certain customer-furnished switches and relays for proper operation.

When the starter is energized, the rotating starter drive pawls engage a jaw in the accessory gearcase
and start driving the gear train. The gear train drives the compressor and turbine rotating parts, the oil
pump assembly (and attached tachometer-generator), the fuel control unit, and the centrifugal switch
assembly. The low oil pressure switch electrical circuit remains normally closed.

As the compressor and turbine rotating parts start turning, ambient air is drawn through the inlet into
the compressor section. The air is compressed by the compressor first stage impeller for further
compression. The compressed air is discharged into a vaned deswirl assembly and from there is
directed into the turbine plenum. (Clean bleed-air may be withdrawn from an outlet in the plenum
through a bleed-air load control valve when the engine reaches governed speed.) From the turbine
plenum, the compressed air enters the combustion chamber.

When engine speed reaches its required value, rising oil pressure actuates the sequencing oil
pressure switch, which completes a circuit to the fuel solenoid valve and to the ignition unit. The fuel
solenoid valve is energized to open to permit fuel flow to the fuel atomizer assembly. The fuel atomizer
assembly sprays fuel of proper pattern and flow into the combustion chamber where the fuel and
compressed air mix. The ignition unit causes the igniter plug to ignite the fuel and air mixture in the
combustion chamber.

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Engine Cross Section


Figure 2

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Combustion increases the energy content of the air-fuel mixture. The gases flow into the turbine torus
assembly and through the turbine nozzle assembly to the blades of the turbine wheel. The energy of
the gases is absorbed by the rotation of the turbine wheel. The spent gases are discharged through
the turbine exhaust. A portion of the power developed at the turbine wheel is used to drive the
compressor impellers, the accessory gear train, and the drive accessories. The remainder of the
power is available for output shaft power to drive customer equipment when no-load governed speed is
attained.

Acceleration of the engine continues through the combined force of the starter and energy of the hot
gases. when engine speed reaches its required value, the 35-percent switch in the centrifugal switch
assembly open, this opens the circuit to the starter. Starter rotation ceases and the starter drive pawls
disengage from the accessory gear train. When engine oil pressure reaches a preset value, the low
oil pressure switch electrical circuit is opened.

The engine continues to accelerate under turbine power. When engine speed reached its required
value, the 95-percent switch in the centrifugal switch assembly closes, this opens a circuit to the
ignition unit and closes a circuit to the hourmeter. The igniter plug ceases firing, and combustion is
self-sustaining. The hourmeter starts recording operating time. Acceleration continues until the no-
load governed speed is reached.

After steady state no-load governed speed is attained, shaft power loads or bleed-air loads may be
imposed within the ranges specified in Table. 1.

Engine speed and exhaust temperature are automatically controlled within established limits by
metering of fuel flow by the fuel control unit.

Smooth and proper acceleration is controlled by action of the acceleration limiter valve in the fuel
control unit. The valve references compressor air discharge pressure to fuel pressure, then pressure-
actuated diaphragms operate a poppet valve to bypass more or less fuel to maintain the required ratio
of fuel flow to compressor air pressure. During starting, when compressor air pressure is insufficient,
the poppet valve is restrained from bypassing fuel by an adjustable spring pressure against the
actuating diaphragm. The fuel pressure at which the spring pressure is overcome is the cracking
pressure setting of the fuel control unit.

Turbine discharge temperature is controlled by action of a single dual purpose pneumatic thermostat.
If turbine discharge temperature exceeds a preset value at any time during acceleration or operation
above 95-percent before actuation of the bleed-air switch, the ball valve in the pneumatic thermostat
opens to bleed some of the compressor air from the fuel control unit limiter valve through the three-way
solenoid shutoff valve, which allows the poppet valve to open and bypass fuel, thus reducing the
turbine discharge temperature. When the temperature is reduced below the preset value, the
pneumatic thermostat closes and stops bleeding the compressor air from the acceleration limiter valve.
(Refer to Section 49-30-00, Figure 2.)

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(Post SB 49-5233/-98DHF[A]) The fuel conservation system operation does not affect APU starting.
During a start, the thermostat controls the APU EGT to 630C (1166F) to retain maximum start
reliability and full bleed airflow capability for aircraft main engine starting. System operation is initiated
by selection of the cockpit "economy" switch to energize the 2-way "economy" solenoid and vent LCV
actuator pressure through the preset adjustable orifice. EGT then is reduced, resulting in reduced fuel
consumption and economical APU operation.

Engine speed is controlled by action of the governor in the fuel control unit. The flyweight-type
governor is driven by the main fuel pump drive shaft, which in turn is driven through the accessory gear
train. Then engine speed exceeds the preset governed speed, the governor flyweights move outward
to open a slide valve to bypass fuel and so decrease engine speed. when engine speed drops, as
when load is applied, governor flyweights move inward to close the slide valve to permit greater fuel
flow and so increase engine speed.

Engine loading during bleed-air loading or combination shaft and bleed-air loading is automatically
controlled within established limits by modulation of the load control valve buttterfly position.

Overloading and consequent excessive turbine discharge temperature above 95-percent speed with
the bleed-air switch in addition to opening the load control valve, energizes the three-way solenoid
shutoff valve which shuts off compressor discharge pressure to the pneumatic thermostat. (Refer to
Section 49-30-00, Figure 2.) If turbine discharge temperature reaches a preset value, the ball valve in
the pneumatic thermostat opens to bleed some of the control air from the load control valve actuator
which causes the actuator mechanism to move the butterfly valve toward a more closed position, thus
reducing the load and the discharge temperature. When the temperature is reduced below the preset
valve, the pneumatic thermostat closes and stops bleeding the control air from the actuator.

The engine is provided with certain safety devices which shut down the engine or complete warning
circuit in the event of overspeeding, excessively high oil temperature, or low oil pressure. Other safety
devices, operating in conjunction with the engine systems, may be installed by the customer.

If engine speed approaches 110-percent of governed speed, and governing devices in the fuel control
unit have not metered fuel sufficiently to reduce speed, the flyweight-actuated overspeed switch in the
centrifugal switch assembly will close, which opens a circuit to the fuel solenoid valve is de-energized,
it closes and shuts off fuel flow to the combustion chamber, thus stopping the engine.

If engine oil temperature exceeds a preset value, the high oil temperature thermostatic switch electrical
circuit will close.

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MAINTENANCE MANUAL
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ENGINE - TROUBLE SHOOTING

1. General

The following trouble shooting procedures are based on performance of the engine operational test
and are presented in a tree-type format. When all steps in the OK condition path check out, the engine
is operable.

When a test does not check out, follow the NOT OK line to the box containing the trouble symptom.
Turn to the procedure indicted and continue to follow a single line by analyzing the results of each test
until the required corrective action is determined. Perform the specified corrective action, then repeat
the test at which the failure was encountered.

All trouble shooting procedures are based on the assumption that wiring is OK and that electrical
power is available. If the corrective action in the procedure does not correct the problem, check wiring
using the wiring diagram. Refer to Table 101 or 102 for electrical data (Refer to Figure 101).

Use schematic diagrams provided for aid in performing engine trouble shooting. (Refer to Section
49-30-00, 49-50-00 or 49-90-00.)

2. Engine Trouble Shooting

Engine trouble shooting is divided into two parts: Start and governed-speed operation.

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2. A. Engine Start Trouble Shooting

INITIATE ENGINE START. IF-

ENGINE START IS INITIATED, OBSERVE ENGINE START DOES NOT INITIATE,


STARTER OPERATION. IF- CHK POWER SUPPLY

SW IS RELEASED - PROCEDURE 1. STARTER ROTATES ONLY UNTIL


START

OK-OBSERVE FOR COMBUSTION AT STARTER ROTATES BUT CRANKS


2.5 TO 3.5 OIL PRESSURE. IF- ENGINE SLOWLY OR NOT AT ALL -
PROCEDURE 2.

OK-OBSERVE FOR ACCELERATION TO COMBUSTION DOES NOT OCCUR -


NO-LOAD GOVERNED SPEED. IF- PROCEDURE 3,4.

FLAMES EMIT FROM EXHAUST


DURING ACCELERATION -
PROCEDURE 5.

ENGINE CONTINUES TO ACCELERATE ACCELERATION SLOW OR SPEED


TO NO-LOAD GOVERNED SPEED. DOES NOT REACH NO-LOAD
START IS OPERATIVE. GOVERNED SPEED - PROCEDURE 6.

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2. B. Engine Governed Speed Operation Trouble Shooting

OPERATE ENGINE AT NO-LOAD


GOVERNED SPEED. IF-

ENGINE HAS HIGH OIL CONSUMPTION


OR NOTICEABLE SMOKE FROM
EXHAUST - PROCEDURE 7.

ENGINE EXCEEDS NO-LOAD GOVERNED


SPEED THEN SHUTS DOWN. ADJUST
GOVERNOR OR REPLACE FUEL CONTROL
UNIT.

OK-APPLY BLEED LOAD. IF-

OIL SMELL/MIST IN APU BLEED AIR-


PROCEDURE 11.

BLEED LOAD CAN NOT BE APPLIED-


PROCEDURE 8.

SPEED DROOP EXCESSIVE WHEN BLEED


LOAD IS APPLIED - PROCEDURE 9.

GOVERNED SPEED SYSTEM EXCESSIVE EGT OR NO CONTROL DURING


OPERATIVE BLEED LOAD APPLICATION - PROCEDURE
10.

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PROCEDURE 1

STARTER ROTATES ONLY UNTIL


STARTER SWITCH IS RELEASED.
CHECK OPERATION OF HOLDING
RELAY. PRESS AND RELEASE
STARTER SWITCH. IF-

RELAY IS NOT ENERGIZED,


REPLACE HOLDING RELAY.
(REFER TO SECTION 49-60-05)

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PROCEDURE 2

STARTER ROTATES BUT CRANKS


ENGINE SLOWLY OR NOT AT ALL,
CHECK VOLTAGE AT STARTER
MOTOR. IF-

OK-CHK STARTER MOTOR CLUTCH NOT OK-CORRECT POWER SUPPLY.


AND PAWL. IF-

OK-CHK ACCESSORY DRIVE NOT OK-REPLACE STARTER. (REFER


GEARCASE ASSY GEAR TRAIN. IF- TO SECTION 49-40-01).

OK-CHK FOR DEFECTIVE NOT OK-REPLACE ENGINE.


COMPRESSOR TURBINE ASSY. IF-

NOT OK-REPLACE ENGINE.

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PROCEDURE 3

COMBUSTION DOES NOT OCCUR,


CHK FIRING OF IGNITOR. IF-

OK-CHK FUEL SUPPLY PRESSURE TO NOT OK-CHK VOLTAGE AT IGNITION


FUEL CONTROL UNIT. IF- UNIT PRIMARY TERMINAL (8 VDC). IF-

OK-CHK FUEL NOT OK-CHK


PRES THROUGH FUEL SUPPLY OK-REPLACE NOT OK-CHK
FUEL ATOMIZER. IGNITER PLUG, VOLTAGE AT
IF- IGN LEAD (REFER SEQ OIL PRES
TO SECTION 49- SW.
40-02) OR IGN UNIT
(REFER TO SEC-
TION 49-40-05) AS
REQUIRED.

NOT-OK REFER
TO PROCEDURE
4

OK-CHK 95 PERCENT SWITCH. IF- NOT OK-REPLACE SEQ OIL PRESSURE


SW. (REFER TO SECTION 49-60-03)

OK-CHK HOLDING RELAY. IF- NOT OK-REPLACE SWITCH

OK-REPAIR OR REPLACE FAULTY NOT OK-REPLACE RELAY. (REFER TO


WIRING. SECTION 49-60-05)

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PROCEDURE 4

IMPROPER FUEL PRESSURE THROUGH


FUEL ATOMIZER, CHK FUEL FLOW TO
FUEL ATOMIZER. IF-

OK-CHK FUEL PRESSURE TO NOT OK-CHK VOLTAGE TO FUEL SOLENOID


FUEL ATOMIZER. IF- VALVE. IF-

OK-CHK FUEL NOT OK-(PRE


ATOMIZER SB 49-5196 ADJ OK-REPLACE FUEL NOT OK-CHK SEQ
SCREEN. IF- ACCELERATION SOLENOID VALVE OIL PRESS SW.
LIMITER (REFER TO SEC- IF-
CRACKING TION 49-30-01).
PRESS. IF
PRESS CANNOT
BE ADJ, OR
(POST
SB 49-5196), CHK
FUEL CONTROL
UNIT FUEL
FILTER. IF-

OK-REPLACE SEQ NOT OK-REPAIR


OIL PRESS SW. OR REPLACE OIL
(REFER TO PUMP ASSY
SECTION 49-60-03). (REFER TO
SECTION 49-90-02).

OK-REPLACE NOT OK- CLEAN OK-REPAIR OR NOT OK-


FUEL ATOMIZER OR REPLACE REPLACE FUEL REPLACE FUEL
OR COMBUSTOR FUEL ATOMIZER CONTROL UNIT FILTER (REFER
UNIT (REFER TO SCREEN. (REFER TO SEC- TO SECTION
SECTION 49-20-04). TION 49-30-01). 49-30-01).

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PROCEDURE 5

FLAMES EMIT FROM EXHAUST DURING


ACCELERATION, CHK FUEL SUPPLY
PRESSURE TO FUEL CONTROL UNIT. IF-

OK-CHK ACCELERATION LIMITER NOT OK-(PRE SB 49-5196) ADJ ACC-


CRACKING PRESSURE SETTING. IF- ELERATION LIMITER CRACKING
PRESS SETTING. IF SETTING
CANNOT BE ADJ OR (POST SB
49-5196) REPLACE FUEL CONTROL
UNIT.

OK-REPLACE FUEL ATOMIZER ASSY


OR COMBUSTER UNIT (REFER TO
SECTION 49-20-04).

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PROCEDURE 6

ACCELERATION SLOW OR ENGINE DOES


NOT REACH ON-LOAD GOVERNED SPEED,
CHK VOLTAGE TO STARTER MOTOR. IF-

OK-CHK FUEL SUPPLY PRESS TO NOT OK-VOLTAGE IS BELOW 14 VDC


FUEL INLET. IF- DURING IN RUSH OF CURRENT, CORRECT
POWER SUPPLY.

OK-CHK CONTROL AIR PRESS, NOT OK-CHK FUEL SUPPLY.


FUEL PRESS AND TURBINE
DISCHARGE TEMPERATURE
ON START. IF-

CONTROL AIR AND FUEL PRESS NORM CONTROL AIR AND FUEL PRESS
BUT TURBINE DISCHARGE TEMP HIGH, NORMAL AND TURBINE DISCHARGE
CHK FOR UNUSUAL NOISE OR RAPID TEMP LOW, CHK FUEL ATOMIZER
DECELERATION, IF NOT OK, CHK FOR SCREEN. IF-
DEFECTIVE COMPRESSOR AND
TURBINE ASSY.

OK-REPLACE FUEL NOT OK-CLEAN


ATOMIZER/ OR REPLACE
COMBUSTOR UNIT SCREEN.
(REFER TO SECTION
49-20-04).
CONTROL AIR PRESS, FUEL PRESS
AND TURBINE DISCHARGE TEMP LOW.
CHK ACCELERATION LIMITER VALVE

Cont

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PROCEDURE 6 (CONT)

Cont

OK-CHK CONTROL AIR PRESS LINES. NOT OK-RESET CRACKING PRESSURE.


IF-

OK-CHK PNEUMATIC THERMOSTAT NOT OK-TIGHTEN OR REPLACE LINES.


SETTING. IF-

OK-CHK CONTROL AIR PICKUP TEE NOT OK-ADJ THERMOSTAT SETTING.


ASSY FOR CORRECT ORIFICE SIZE
OR CONTAMINATION; ORIFICE SIZE
MUST BE 0.030 IN. DIA. IF-

OK-CHK INSTALLATION OF THREE-WAY NOT OK-CLEAN OR REPLACE TEE


VALVE (REFER TO SECTION 49-50-28). ASSY.

OK-REPLACE VALVE NOT OK-REINSTALL VALVE.

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PROCEDURE 7

ENGINE HAS HIGH OIL CONSUMPTION OR


NOTICEABLE SMOKE FROM EXHAUST, CHK
OIL LEVEL IN TANK. IF-

OK-DISCONNECT OIL TANK VENT LINE NOT OK-CHK OIL CHECK VALVE FOR
AT EXHAUST VENT PROBE AND PLACE PROPER OPERATION. IF-
LINE IN CONTAINER, OPERATE ENGINE.
IF-

OK-SERVICE NOT OK-


OIL TANK REPLACE OIL
CHECK VALVE.

SMOKING CONTINUES FROM EXHAUST SMOKING STOPS AND OIL IS


CHK ACCESSORY GEAR CASE PRESS BLOWING INTO CONTAINER,
PORT PLUG AND PACKING. IF- REPLACE PACKINGS ON OIL TUBES
AND BREATHER FITTING ASSY.

OK-CHK NOT OK-


ACCESSORY GEAR TIGHTEN PLUG
CASE CAVITY OR REPLACE
PRESS. IF- PACKING

Cont

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PROCEDURE 7 (CONT)

Cont

OK-REPLACE ENGINE NOT OK-CHK FOR EVIDENCE OF OIL


LEAKAGE FROM FUEL CONTROL.

OK-REPLACE NOT OK-


ENGINE. REPLACE FUEL
CONTROL SEAL
(REFER TO
SECTION
49-30-01).

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PROCEDURE 8

BLEED LOAD CANNOT BE APPLIED, CHK


ACTUATION OF 95% SW (LOAD LIGHT ON).
IF-

OK-CHK BLEED LOAD SYSTEM NOT OK-REPLACE CENTRIFUGAL SW


AIR PRESS LINES. IF- ASSY (REFER TO SECTION 49-60-01).

OK-CHK VOLTAGE TO LOAD CONTROL NOT OK-REPAIR OR REPLACE FAULTY


VALVE. IF- LINE.

OK-CHK AIR PRESS REGULATOR NOT OK-CHK LOAD SWITCH. IF-


OUTPUT PRESS. IF-

OK-REPAIR OR NOT OK-


REPLACE WIRING REPLACE
LOAD SWITCH.

OK-REPLACE LOAD CONTROL VALVE NOT OK-CHK AIR PRESS REGULATOR


(REFER TO SECTION 49-50-06). PICKUP CONNECTION OR TEE ASSY
FOR CORRECT ORIFICE SIZE OR
CONTAMINATION; ASSY MUST BE
FREE FROM FOREIGN MATTER. IF-

Cont

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PROCEDURE 8 (CONT)
Cont

OK-CHK PRESS REGULATOR FILTER NOT OK-CLEAN CONNECTOR OR


ELEMENT (REFER TO SECTION 49- TEE ASSY.
50-07). IF-

OK-ADJUST OR REPLACE PRESSURE NOT OK-CLEAN OR REPLACE FILTER


REGULATOR (REFER TO SECTION ELEMENT (REFER TO SECTION
49-50-07). IF- 49-50-07).

LOAD CANNOT BE APPLIED, REPLACE


LOAD CONTROL VALVE (REFER TO
SECTION 49-50-06).

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PROCEDURE 9

SPEED DROOP EXCESSIVE WHEN BLEED


LOAD IS APPLIED. CHK-

IF TURBINE DISCHARGE TEMP LOAD CONTROL VALVE OPENING RATE


EXCEEDS SPECIFIED LIMITS: CHK IF-
AIR PRESSURE REGULATOR
OUTPUT PRESSURE. IF-

OK-ADJ OR NOT OK-ADJ OR NOT OK-ADJ


REPLACE REPLACE REGU- RATE OR RE-PLACE
PNEUMATIC LATOR (REFER VALVE (REFER
THERMOSTAT TO SECTION TO SECTION
(REFER TO 49-50-07). 49-50-06).
SECTION
49-50-04).

IF TURBINE DISCHARGE TEMP IS


BELOW SPECIFIED LIMITS WHEN
SPEED DROOPS: CONNECT PRESS
GAGE TO MEASURE CONT UNIT
LIMITER, THEN WITH ENGINE
OPERATING ACTUATE BLEED-
LOAD SW AND CHK CONTROL
AIR PRESSURE. IF-

CONT AIR PRESS LOW, CHK LINES


IN CONT AIR SYS FOR LEAKS. IF-

Cont
Cont

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PROCEDURE 9 (CONT)

Cont Cont

OK-CHK THREE NOT OK- CONTROL AIR PRESS NORM AND FUEL
WAY SOLENOID REPLACE PRESS INCREASES WHEN RPM DROOPS,
VALVE (REFER FAULTY CHK FUEL ATOMIZER SCREEN. IF-
TO SECTION LINE
49-50-28).

NOT OK- OK-REPLACE FUEL NOT OK-CLEAN


REPLACE ATOMIZER/COM- OR REPLACE
VALVE BUSTOR UNIT (REFER SCREEN.
TO SECTION
49-20-40).

CONTROL AIR PRESS AND


FUEL PRESS REMAIN CONSTANT
WHEN RPM DROOPS, CHK
FUEL SUPPLY PRESS. IF-

OK-CHK FUEL FILTER ELMENT NOT OK-CORRECT FUEL SUPPLY


(REFER TO SECTION 49-30-01). PRESS.
IF-

OK-CHK FUEL SHUTOFF SOL NOT OK-REPLACE ELEMENT (REFER


VALVE FOR OBSTRUCTION OR TO SECTION 49-30-10).
IF FULL OPEN (REFER TO
SECTION 49-30-01). IF-

OK-REPLACE FUEL CONTROL NOT OK-REPLACE FUEL SHUTOFF


UNIT (REFER TO SECTION SOL VALVE (REFER TO SECTION
49-30-01). 49-30-01).

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PROCEDURE 10

EXCESSIVE EGT OR NO CONTROL DURING


BLEED LOAD APPLICATION. CHK-

INSTALLATION AND OPERATION OF


THREE-WAY, SOLENOID VALVE. IF-

OK-CHK PRESS REGULATOR NOT OK-REINSTALL OR REPLACE


OUTPUT PRESSURE (REFER TO VALVE (REFER TO SECTION
SECTION 49-50-07). IF- 49-50-28).

OK-CHK AND ADJUST PNEUMATIC NOT OK-ADJUST OR REPLACE


THERMOSTAT (REFER TO SECTION REGULATOR (REFER TO SECTION
49-50-04). IF- 49-50-07).

OK-REPLACE LOAD CONTROL NOT OK-REPLACE PNEUMATIC


VALVE (REFER TO SECTION THERMOSTAT (REFER TO SECTION
49-50-06). 49-50-04).

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GTCP85-98DHF/[A]

PROCEDURE 11

OIL SMELL/MIST IN APU BLEED AIR. CHECK


THAT OIL IS NOT INSIDE OR OUTSIDE APU
INLET. IF-

OK-CHECK THAT SMELL/MIST IS NOT OK-CHECK THAT OIL IS


ONLY ON START UP. IF- NOT LEAKING FROM GEARCASE
OVERBOARD VENT. IF-

OK-PERFORM NOT OK-CHECK OK-PERFORM NOT OK-CHECK


AIRCRAFT THAT COMPRESSOR AIRCRAFT GEARCASE
TROUBLE SEAL IS NOT LEAKING TROUBLE PRESSURE
SHOOTING INTO FIRST STAGE SHOOTING PORT PLUG
PROCEDURES. IMPELLER. IF- PROCEDURES. AND
PACKING. IF-

OK-PERFORM NOT OK-REPLACE APU OK-CHECK NOT OK-


AIRCRAFT GEARCASE TIGHTEN PLUG
TROUBLE EXTERNAL SEALS, AND/OR
SHOOTING REPLACE AS REPLACE
PROCEDURES. NECESSARY. PACKING.

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Wiring Diagram for Wiring Harness Assembly


PN 439595-2/-3
Figure 101

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Table 101. Electrical Wiring Data (Refer to Figure 101)

From To
Wire Awg Length Location Term or Location Term or Wire
No. Size (in.) No. Pin No. No. Pin No. Specification

3X8K18 18 32.75 P1-1108 D T1-29 X1 MS17411


3X8L18 18 10.25 T1-28 X1 T1-29 X1 MS17411
3X8M18 18 6.50 T1-27 X1 T1-28 X1 MS17411
3X9G18 18 31.50 P1-1108 A T1-29 X2 MS17411
3X10G18 18 28.75 P1-1108 B T1-28 X2 MSA7411
3X11G18 18 27.75 P1-1108 C T1-27 X2 MS17411
E576C18 18 83.25 P1-1108 B P1-126 B MS17411
E577C18 18 83.25 P1-1108 H P1-126 A MS17411
E579A18 18 83.25 P1-1108 G P1-126 C MS17411
E605G16 16 18.75 P1-126 E S3-44 2 MS17411
E605H16 16 51.25 P1-1108 E S3-44 2 MS17411
E605J18 18 51.25 P1-1108 F S3-44 2 MS17411
E605K20 20 61.75 P1-149 E S3-44 2 MS17411
*E605K20 20 61.75 P1-149 3 S3-44 2 MS17411
E606A16 16 19.25 P1-264 D S3-44 1 MS17411
E606B20 20 62.25 P1-149 B S3-44 1 MS17411
*E606B20 20 62.25 P1-149 4 S3-44 1 MS17411
E606D18 18 51.75 P1-1108 C S3-44 1 MS17411
E607B20 20 58.75 S3-44 7 P1-149 D MS17411
*E607B20 20 58.75 S3-44 7 P1-149 5 MS17411
E607C18 18 67.00 S3-44 7 P1-101 E MS17411
E607D20 20 15.71 S3-44 7 P1-264 B MS17411
E608A18 18 17.00 P1-264 A SE-44 5 MS17411
E608B18 18 71.00 P1-148 A S3-44 5 MS17411
E608C18 18 39.50 P1-150 A S3-44 5 MS17411
E608C16 16 72.50 P1-156 A S3-44 5 MS17411
E608E18 18 18.75 HR-MTR NEG (-) S3-44 6 MS17411
E608F18 18 45.00 P1-262 B S3-44 6 MS17411
E608G16 16 49.50 P1-1108 M S3-44 6 MS17411
E608J20 20 43.25 S3-44 6 P1-155 H MS17411
E608L18 18 77.75 S3-44 4 P1-490 A MS17411
**E608N18 18 78.25 P1-767 A S3-44 4 MS17411
E609A18 18 35.50 P1-1108 D P1-116 C MS17411
E618A16 16 39.75 P1-1108 X SPLICE - MS17411
*3618J20 20 52.50 P1-149 1 CB - MS17411
E618J20 20 50.25 P1-149 A SPLICE - MS17411
E618K16 16 3.50 SPLICE - CB LINE MS17411
E621C16 16 93.50 P1-1108 V P1-263 E MS17411

8 Denotes wiring harness assembly Part No. 43959-3.


** Denotes Post SB 49-5233.

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Table 101. Electrical Wiring Data (Refer to Figure 101) (Cont)

From To
Wire Awg Length Location Term or Location Term or Wire
No. Size (in.) No. Pin No. No. Pin No. Specification

E621C16 16 93.50 P1-1108 V P1-263 E MS17411


E625D20 20 42.75 P1-1108 U P1-155 B MS17411
E628G16 16 48.50 P1-1108 P S3-44 8 MS17411
E628H18 18 70.50 S3-44 8 P1-156 B MS17411
E628H18 18 75.50 S3-44 8 P1-149 B MS17411
**E631D18 18 101.25 P1-1108 J P1-767 B MS17411
E633C18 18 69.00 P1-1108 M P1-262 A MS17411
E640A18 18 93.50 P1-1108 T P1-263 C MS17411
E641A18 18 12.00 HR-MTR POS(+) CB LOAD MS17411
E642A18 18 85.75 P1-1108 K P1-265 B MS17411
*E644A20 20 77.00 P1-149 7 P1-116 A MS17411
E644A20 20 77.00 P1-149 C P1-116 A MS17411
E645A18 18 64.75 P1-265 A S3-44 3 MS17411
E645B18 18 18.50 P1-264 H S3-44 3 MS17411
E645C18 18 50.50 P1-1108 K S3-44 3 MS17411
E646A18 18 67.25 P1-264 G P1-263 D MS17411
E650A18 18 68.25 P1-101 B P1-150 B MS17411
E651A20 20 28.25 P1-149 F P1-101 A MS17411
*E651A20 20 28.25 P1-149 2 P1-101 A MS17411
E652A18 18 18.50 P1-101 C P1-148 B MS17411
CR-WHITE 18 104.00 P1-1108 S TCPL CR MIL-W-5846
AL-GREEN 18 104.00 P1-1108 A TCPL AL MIL-W-5846

* Denotes wiring harness assembly Part No. 43959-3


** Denotes Post SB 49-5233.

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Wiring Diagram for Wiring Harness Assembly


PN 43959-4
Figure 102

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Table 102. Electrical Wiring Data (Refer to Figure 102)

From To
Wire Awg Length Location Term or Location Term or Wire
No. Size (in.) No. Pin No. No. Pin No. Specification

3X8K18 18 32.75 P1-1108 D T1-29 X1 MS17411


3X8L18 18 10.25 T1-28 X1 T1-29 X1 MS17411
3X8M18 18 6.50 T1-27 X1 T1-28 X1 MS17411
3X9G18 18 31.500 P1-1108 A T1-29 X2 MS17411
3X10G18 18 28.75 P1-1108 B T1-28 X2 MS17411
3X11G18 18 27.25 P1-1108 C T1-27 X2 MS17411
E576C18 18 83.75 P1-1108 B P1-126 B MS17411
E577C18 18 83.25 P1-1108 H P1-126 A MS17411
E579A18 18 83.25 P1-1108 G P1-126 C MS17411
E605G16 16 18.75 P1-264 E S3-44 2 MS17411
E605H16 16 51.25 P1-1108 E S3-44 2 MS17411
E605J18 18 51.25 P1-1108 F S3-44 2 MS17411
E605K20 20 61.75 P1-149 3 S3-44 2 MS17411
E606A16 16 19.25 P1-264 D S3-44 1 MS17411
E606B20 20 62.25 P1-149 4 S3-44 1 MS17411
E606D18 18 51.75 P1-1108 C S3-44 1 MS17411
E607B20 20 58.75 P1-149 5 P1-149 5 MS17411
E607C18 18 67.00 S3-44 7 P1-101 E MS17411
E607D20 20 15.75 S3-44 7 P1-264 B MS14711
E608A18 18 17.00 P1-264 A S3-44 5 MS17411
E608B18 18 71.00 P1-148 A S3-44 5 MS17411
E608C18 18 39.50 P1-150 A S3-44 5 MS17411
E608D16 16 72.50 P1-156 A S3-44 5 MS17411
E608E18 18 18.75 HR-MTR NEG(-) S3-44 6 MS17411
E608F18 18 45.00 P1-262 B S3-44 6 MS17411
E608G16 16 49.50 P1-1108 M S3-44 6 MS17411
E608J20 20 43.25 S3-44 6 P1-155 H MS17411
E608L18 18 77.75 S3-44 4 P1-490 A MS17411
E608N18 18 78.25 P1-767 A S3-44 4 MS17411
3609A17 18 35.50 P1-1108 D P1-116 C MS17411
E618A16 16 39.75 P1-1108 X SPLICE - MS17411
E618J20 20 52.50 P1-149 1 CB LINE MS17411
E618K16 16 3.50 SPLICE - CB LINE MS17411
E621C16 16 73.50 P1-1108 V P1-263 E MS17411
E622A18 18 88.00 P1-263 B P1-155 C MS17411
E624C20 20 42.00 P1-155 A PL-1108 N MS17411
E625D20 20 42.75 P1-1108 U P1-155 B MS17411

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Table 102. Electrical Wiring Data (Refer to Figure 102) (Cont)

From To
Wire Awg Length Location Term or Location Term or Wire
No. Size (in.) No. Pin No. No. Pin No. Specification

E628G16 16 48.50 P1-1108 P S3-44 8 MS17411


E628H18 18 70.50 S3-44 8 P1-156 B MS17411
E628J18 18 75.50 S3-44 8 P1-490 B MS17411
E631D18 18 101.25 P1-1108 J P1-767 B MS17411
E633C18 18 69.00 P1-1108 M P1-262 A MS17411
E640A18 18 93.50 P1-1108 T P1-263 C MS17411
E641A18 18 12.00 HR-MTR POS(+) CB LOAD MS17411
E643A18 18 85.75 P1-1108 K P1-265 B MS17411
E644A20 20 77.00 P1-149 7 P1-116 A MS17411
E645A18 18 64.75 P1-265 A S3-44 3 MS14711
E645B18 18 18.50 P1-264 H S3-44 3 MS17411
E645C18 18 50.50 P1-1108 K S3-44 3 MS17411
E646A18 18 67.25 P1-264 G P1-263 D MS17411
E650A18 18 P1-101 B P1-150 B MS17411
E651A20 20 28.25 P1-149 2 P1-101 A MS17411
E652A18 18 18.50 P1-101 C P1-148 B MS17411
CR-WHITE 18 104.00 P1-1108 S TCPL DR MIL-W-5846
AL-GREEN 18 104.00 P1-1108 A TCPL AL MIL-W-5846

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ENGINE - SERVICING

1. Preparation for Use

Table 301. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Preservation oil (MIL-L-6081, Grade Commercially available


1005 or 1010)

Oil (Refer to Table 302) Commercially available.

A. Prepare Engine for Service

NOTE: No depreservation procedures are required other than the normal preparation for
use procedures.

Oil leakage/seepage at tailpipe may be evident if engine has been stored or left in other than a
horizontal position. This condition may occur but does not necessarily indicate failure of
internal seals. Clean oil accumulation and check for presence of oil after completion of engine
run.

(1) Fill oil tank assembly to operating level with an approved engine oil (Table 302)
observing applicable instructions given in Step 3. Engine Lubricating System Service.

(2) Remove cap from oil pressure connection at ground checkout panel and connect an
oil line from a pre-oil boost pump serviced with same brand of oil as used to service oil
tank in step (1). Apply approximately five psig pressure with boost pump, roll engine
over by hand several times to ensure engine pre-oil. Remove pre-oil boost pump and
replace cap when engine pre-oil is assured.

(3) Provide a source of fuel (Table 1) to the fuel inlet connection port on engine fuel
control.

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CAUTION: NEVER ATTEMPT AN ENGINE START UNLESS AN ADEQUATE SUPPLY


OF FUEL IS AVAILABLE TO THE FUEL CONTROL UNIT. FUEL CONTROL
UNIT LUBRICATION IS PROVIDED BY FUEL.

1. A. (4) Remove cap from low fuel pressure connection at ground check out panel to bleed air
from plumbing and ensure a ready supply of fuel to the fuel control unit. Replace cap
when ready supply of fuel is assured.

(5) Provide a source of electrical power (26 2 volts dc).

(6) Start engine following procedure established by installation. Allow engine to


accelerate to no-load governed speed. Operate engine at no-load governed speed for
three to five minutes.

(7) Stop engine following procedure established by installation. After engine has come to
a complete stop, shut off fuel supply to engine fuel control unit.

(8) Carefully inspect all lubrication lines and fuel lines and their connection points for any
evidence of oil leakage or fuel leakage.

(9) Remove fuel filter element from fuel control unit and oil filter element from oil pump
assembly and replace both filters with new filters.

(10) Engine is now ready for normal operation.

2. Preservation and Storage

CAUTION: PRESERVATION AND STORAGE OF THE ENGINE SHALL BE IN ACCORDANCE


WITH MIL-E-5595 AND MIL-E-5607, EXCEPT THE COMPRESSOR SECTION
SHALL NOT BE SPRAYED WITH ANY CORROSION PREVENTIVE COMPOUNDS.
NO HYDROCARBONS OR OILS SHALL EVER BE INTRODUCED INTO THE
COMPRESSOR SECTION; A POSSIBILITY OF UNCONTROLLED COMBUSTION
MAY RESULT.

A. Follow Preservation and Storage Instructions for Installed Engines with Periods of Idleness up
to 180 Days.

(1) Operate engine at no-load governed speed for at least five minutes every two weeks.

(2) Maintain oil level in oil tank at correct level.

(3) Make sure that all engine openings and exhaust doors are closed, except during
engine operation to prevent entrance of water or foreign material.

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NOTE: At the end of a one year period, the engine should be placed in service or removed
and stored. If this is not feasible, contact Honeywell Engines, Systems & Services,
P.O. Box 52170, Phoenix, AZ 85072-2170 for further instructions.

2. B. Preservation and Storage Instructions for Installed Engines with Periods of Idleness from 181
to 365 Days

(1) Operate engine for at least five minutes at no-load governed speed, then shut down
and accomplish steps (2) through (17) while engine is still hot.

(2) Disconnect, drain and cap fuel supply line to engine and leave disconnected while
engine is inactive.

(3) Disconnect electrical harness from ignition unit.

(4) Place battery and master control switch to "ON" position.

(5) Disconnect and drain high pressure fuel line from fuel solenoid valve.

(6) Connect a 1/4 inch diameter hose to fuel solenoid valve connection and drain engine
fuel system overboard.

(7) Connect a 3/8 inch diameter hose (approximately three feet long) to engine fuel inlet
port. Supply preserving oil (MIL-L-6081, Grade 1005 or 1010) to engine.

CAUTION: DO NOT EXCEED STARTER DUTY CYCLE OF ONE MINUTE ON, FOUR
MINUTES OFF.

(8) Motor engine by means of the starter for 15 to 20 seconds or until oil is seen to flow
from overboard drain hose.

(9) Remove and discard fuel filter.

(10) Disconnect 1/4 inch diameter hose from fuel solenoid valve connection and reconnect
high pressure fuel line.

(11) Disconnect 3/8 inch diameter hose from fuel inlet port. Cap port tightly.

(12) Remove oil tank drain plug and oil filter from oil pump. Drain lubricating system,
including oil tank. Allow engine to stand until all oil has drained, then reseal engine.

(13) Place master control switch to "OFF" position.

(14) Connect wiring harness to ignition unit.

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CAUTION: DO NOT USE TAPE TO COVER FUEL SYSTEMS PORTS OR


CONNECTIONS.

2. B. (15) Plug, cap, or seal all external pressure taps, ports, fittings, and other openings on the
engine, including the following.

(a) Fuel inlet port.

(b) Fuel bypass port.

(c) Fuel and oil drain fittings.

(d) Gearcase pressure gage connection.

(e) Fuel and oil pressure gage connections.

(16) Close inlet and exhaust doors to prevent entrance of water or foreign material.

(17) Tag engine as being preserved and not in operable condition.

C. Preservation and Storage Instructions for Engines Removed from Installation and Placed in
Storage Containers

NOTE: Use of a corrosion-preventive mixture in the engine lubrication system is


not required. Engine oil (MIL-PRF-7808) is a satisfactory corrosion-
preventive. If oil (MIL-PRF-23699) is used in engine, do not store engine
longer than 120 days. Use oil (MIL-PRF-7808) for preservation of engines
that are stored longer than 120 days.

(1) Remove cap from high pressure fuel connection at test panel assembly and connect a
line to drain overboard.

(2) Disconnect fuel supply line at fuel inlet connection of fuel control unit and connect a
supply of preservation oil (MIL-L-6081, Grade 1005 or 1010). Supply oil under slight
pressure if necessary, until action of fuel pump gears is established.

CAUTION: DO NOT EXCEED STARTER DUTY CYCLE OF ONE MINUTE ON, FOUR
MINUTES OFF.

(3) Disconnect ignition unit primary lead, depress start switch momentarily, and rotate
engine by use of starter for 15 to 20 seconds. The fuel solenoid valve shall
automatically open, allowing oil to flow overboard. Maintain flow until clean oils flow
overboard.

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2. C. (4) Remove drain cap from oil supply line and allow all oil to drain. Disconnect scavenge
line at breather fitting and allow excess oil to drain. Allow oil to drain from fuel pump
and fuel lines.

(5) Replace cap at high pressure fuel connection on test panel assembly, reconnect oil
scavenge line to breather fitting, reinstall oil drain cap, and reconnect ignition.

(6) Remove fuel filter and discard. Flush new filter with preservation oil (MIL-L-6081,
Grade 1005 or 1010), then install filter in fuel control unit.

(7) Disconnect customer ducts, harness receptacle, and plumbing lines from engine as
required. Remove attaching hardware securing engine to installation.

(8) Using a suitable lifting sling, adjust sling as required to support engine in normal
horizontal position. Attach a hoisting hook or fork lift to sling and lift engine from
installation.

(9) Remove customer ducts, plumbing, and driven equipment from engine. Plug or cap
all connections on the engine used to connect the customer-furnished and remote
installed equipment.

CAUTION: DO NOT USE TAPE TO COVER FUEL SYSTEMS PORTS OR


CONNECTIONS.

(10) Plug, cap, or seal all external pressure taps, ports, fittings, and other openings on the
engine, including the following.

(a) Fuel inlet port.

(b) Fuel bypass port.

(c) Fuel and oil drain fittings.

(d) Gearcase pressure gage connection.

(e) Fuel and oil pressure gage connections.

(11) Wash all excess fuel and oil from engine.

(12) Lockwire all controls and thermostats per AS 567.

(13) Secure a warning tag to engine to indicate that engine has been preserved.

(14) Install engine in original shipping container, in accordance with MIL-E-5595 and
MIL-E-5607.

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3. Engine Lubrication System Service

A. General Instructions

(1) Use only the Honeywell-approved oils in Table 302.

(a) Do not mix specifications or brands of oil when servicing, draining, or


changing the oil except when changing over oil fleet-wide in accordance with
Step 5.

(b) Topping-off of the oil sump (filling to full mark) with a different brand of oil
within the same specification is permitted when changing oil brands fleet-wide.
Refer to Step 7.

(c) When draining the oil, flushing (as described in Step 5. below) is only required
when there is suspected contamination of the oil.

(2) Remove the oil fill cap to fill the APU with oil unless pressure-filling is used.

(3) Fill the APU with oil when the APU is OFF to provide an accurate indication of the oil
quantity level and to prevent oil splashing if the reservoir is pressurized for any reason.

NOTE: Oil reservoir may be a gearbox sump or an oil tank.

Table 302. Approved Engine Oils

Ambient Temperature
Approved Lubricant Minimum Maximum
Brand Name C F C F

CAUTION: ANY SUBSTITUTION OR USE OF NON-APPROVED LUBRICANTS, OR MIXING OF


BRANDS OR TYPES OF LUBRICANTS MAY CAUSE CONSIDERABLE ENGINE DAMAGE.

Group I
3 Centistoke Oils
(Lubricant Specification MIL-PRF-7808)

Aeroshell Turbine Oil 390 -54 -65 54 130


Castrol 325 or 399 -54 -65 54 130
BP/Exxon Turbine Oil 2389 -54 -65 54 130

Group II
5 Centistoke Oils
(Lubricant Specification MIL-PRF-23699)

Aeroshell Turbine Oil or Royco 500 -40 -40 54 130


Aeroshell Turbine Oil or Royco 555 -40 -40 54 130
Aeroshell Turbine Oil or Royco 560 -40 -40 54 130
Castrol 5000 -40 -40 54 130

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Table 302. Approved Engine Oils (Cont)

Ambient Temperature
Approved Lubricant Minimum Maximum
Brand Name C F C F

BP/Exxon Turbo Oil 2197 -40 -40 54 130


BP/Exxon Turbo Oil 2380 -40 -40 54 130
Hatcol 3611 -40 -40 54 130
Mobil Jet Oil II -40 -40 54 130
Mobil Jet Oil 254 -40 -40 54 130
Mobil Jet Oil 291 -40 -40 54 130
Royco 899 -40 -40 54 130

Group III

7.5 Centistoke Oil

Castrol 98 -40 -40 54 130

3. B. Equipment and Materials

(1) Table 303 shows the equipment and material necessary for servicing of the APU oil
system.

Table 303. Equipment and Materials

Equipment/Material Description/Manufacturer

Container, Oil-Resistant Commercially available


(5 gallon or 20 liter minimum volume)

Lock Wire (MS20995C32) Commercially available

Oil (Refer to Table 302) Commercially available

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WARNING: BE CAREFUL WHEN YOU TOUCH THE COMPONENTS OF THE OIL SYSTEM WHEN THE
APU IS HOT. THESE COMPONENTS STAY HOTTER THAT OTHER COMPONENTS. USE
THE CORRECT PERSONAL PROTECTION. HOT PARTS CAN BURN YOU.

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

CAUTION: DO NOT LET OIL GET ON THE APU OR OTHER COMPONENTS. IMMEDIATELY CLEAN
THE OIL OFF. OIL CAN CAUSE DAMAGE TO PAINT AND RUBBER.

DO NOT MIX BRANDS OR SPECIFICATIONS OF OIL DURING ROUTINE OIL SERVICING


OF THE APU. INCORRECT OILS CAN CAUSE DAMAGE TO THE APU BECAUSE OF THE
DIFFERENT SPECIFIED TEMPERATURES RANGES AND PROPERTIES FOR EACH OIL.

4. Filling the APU with Oil

A. Gravity-Fill Procedure

CAUTION: OIL MAY BE HOT FROM APU OPERATION. MAKE SURE OIL CAP IS
ONLY REMOVED WHEN APU IS NOT OPERATING.

(1) Open oil fill cap.

(2) Slowly add oil to the opening of the oil reservoir until the oil level is at the FULL mark
on the oil sight glass or dipstick. Allow time for air to escape and oil level to recede
during filling.

(3) Close oil fill cap.

B. Pressure-Fill Pressure (Optional, if installed and used)

(1) Remove lockwire from plugs.

(2) Remove plugs and packings from the pressure fill and oil overfill ports. Remove and
discard packings from plugs.

(3) Connect the pressure fill hose of the servicing cart of the pressure fill port.

(4) Connect the overfill hose to the oil overfill port.

(5) Direct the opposite end of overfill hose into a drain container.

CAUTION: DO NOT OVERFILL APU RESERVOIR. TO REMOVE OVERFILL HOSE


BEFORE OIL HAS BECOME STABLE, OR A PRESSURE-FILL WITHOUT A
VENT FOR THE OVERFILL HOSE, CAN CAUSE APU DAMAGE.

(6) Slowly pressure-fill the oil reservoir in the gearbox assembly.

(a) Continue to add oil until oil flows from overfill hose.

(b) Stop oil fill.

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4. B. (6) (c) Wait approximately two minutes for oil in the oil reservoir to become stable
and drain and the overflow drain to cease oil flow.

(7) Remove servicing hoses.

(8) Install new packings on plugs.

(9) Install plugs with packings in the pressure fill and oil overfill ports.

(a) Lockwire plug to the gearbox/tank with lockwire (MS20995C32) per AS 567.

(b) Lockwire plug to oil filler cap with lockwire (MS20995C32) per AS 567.

5. Routine Oil Change (Same Brand and Specification)

A. Drain, Flush (as required), and Refill

WARNING: DO NOT REMOVE OIL FILLER CAP WHEN OIL IS HOT AND OIL LEVEL IS
ABOVE ADD RANGE ON SIGHT GLASS. PRECAUTIONS MUST BE
TAKEN WHEN APU OIL IS DRAINED. HOT OIL CAN CAUSE SEVER
BURNS.

USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN


ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS
AN AXPHYXIANT, IS POISONOUS, AND CAN BE ABSORBED THROUGH
THE SKIN.

NOTE: Flushing is only necessary if contamination is suspected.

(1) Drain the oil while the APU is still hot from operation.

(a) (If necessary) Start the APU.

(b) Operate the APU for 10 minutes minimum.

(c) Stop the APU.

(d) Change oil while the oil is still hot.

(2) Put an oil-resistant container below the drain port of the oil reservoir.

(3) Remove lockwire from the oil drain plug or magnetic chip detector (if installed).

(4) Loosen the oil filler cap to vent the oil reservoir to help drain the oil.

(5) Remove oil drain plug or magnetic chip detector (if installed) with packing. Remove
and discard packing.

(6) Drain the oil into the oil-resistant container.

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5. A. (6) (a) Check drained oil and metal chip detector (if installed) for metal particles that
may indicate APU internal damage. Refer to Troubleshooting procedures if
metal found.

(b) Discard the old oil.

(7) Install drain plug or magnetic chip detector (if installed) in the drain port of the oil
reservoir.

(a) Lubricate and install new packing with oil.

(b) Install drain plug or magnetic chip detector (if installed) with packing.

(c) Torque plug or detector from 60 to 70 pound-inches (6,8 to 7,9 Nm).

(d) Lockwire plug or detector to the oil reservoir with lockwire (MS20995C32) per
AS 567.

(8) Fill the oil reservoir with an Honeywell-approved brand of oil. Refer to Step 4.A. or 4.B.
and Table 302.

(9) Remove the oil resistant container.

(10) Start the APU.

(11) Operate the APU for 10 minutes minimum.

(12) Stop the APU and check for oil leaks.

(13) To flush the oil system, repeat steps (1) through (12) if the oil is being changed for
reasons of suspected oil contamination. Remove oil filter bowl, drain, and install new
oil filter.

(14) Make sure the oil quantity at the oil sight glass or dipstick is FULL.

(15) Attach a service tag to the APU to show the brand and specification of oil used
(optional).

6. Change-over of Oil From One Approved Type or Specification to a Different Approved Type or
Specification

A. Drain and Refill

(1) Refer to Step 5.

7. Changeover of Oil From One Approved Brand to Another Approved Brand of Same Type and
Specification

A. Topping-Off Method

NOTE: The topping-off method is only applicable to oil changeovers in an airline fleet with
the same oil specification/type, but a different oil brand (refer to Table 302,
"Approved Engine Oils" for approved oil brands). Oil filter elements only require
changing based on the routine intervals recommended in Table 601.
INSPECTION/CHECK Section.

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7. A. (1) Check the oil level at the oil sight glass or dipstick.

(2) If oil needs to be added, refer to Steps 4.A. or 4.B. Use approved oil of the same
specification. (Refer to Table 302)

(3) Continue to add the new approved oil to the oil reservoir as necessary at each routine
oil servicing interval to complete the changeover.

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ENGINE SECTION - REMOVAL/INSTALLATION

1. General

Table 401. Materials and compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Lubricant (OS-124 or Santovac 5) Monsanto Co, Fibers Business Unit, 800 N Lindbergh
Blvd, St. Louis, MO 63167

Lubricating compound (Liqui-Moly, Lockrey Co., Inc., Lubricants Div., 2517


Grade NV) Finlaw Ave., Pennsauken, NJ 08109

Oil (MIL-PRF-7808 Commercially available


or MIL-PRF-23699)

NOTE: Reference shall be made to the aircraft manual for procedures relative to removal and
installation of the engine from the aircraft.

A. Removal of Plumbing and Electrical Installations (Refer to Figures 401 through 407)

(1) Removal of plumbing and electrical installations components may be accomplished as


accessible and feasible during removal of accessory items. During removal, note
routing of tubing, hoses, and wiring harnesses and manner of attaching clamps for
reference at installation. Plumbing fittings and lines and wiring harness connectors
and terminals shall be tagged as removed for aid in installation.

B. Installation of Plumbing and Electrical Installation

NOTE: All packings are to be installed using a lubricant compatible with the system in
which the packing is located (i.e., packings used in lubrication system are to be
coated with oil (MIL-PRF-23699). An approved alternate method is to use lubricant
(OS-124 or Santovac 5) on all packings prior to installation. Apply lubricating
compound (Liqui-Moly, Grade NV) to all fittings, unions and tees.

(1) Installation of plumbing and electrical installations components may be accomplished


as accessible and feasible during installation of accessory items. Install new packings
and gaskets.

(2) Install swing check valve (250, Figure 402) with arrow on check valve pointing in the
direction of the oil cooler assembly and with word (hinge) stamped on hex flat in the
upward position.

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1. B. (3) Packing with retainer (20, 25, Figure 404) are procured in sets of two. Install yellow
rim packing with retainer (20) next to bolt head and knurled rim packing with retainer
(25) between elbow (30) and oil pump.

(4) Install tube assembly (480, Figure 403) so that the short leg of the tube is at the tee
(540, Figure 404).

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PLUMBING AND ELECTRICAL INSTALLATION

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Plumbing Installation (Partial Breakdown)


Figure 401

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GTCP85-98DHF/[A]

KEY TO FIGURE 401

10. HOSE ASSY (IPC FIG. 1, 49-20-01) 350. WASHER


20. TEE 360. CLAMP
30. NUT 370. BOLT
40. PACKING 380. TEE
50. BOLT 390. TUBE ASSY
60. CLAMP 400. TEE
70. NUT 410. NUT
80. WASHER 420. PACKING
90. CLAMP 430. NUT
100. CLAMP 440. ELBOW
110. BOLT 450. PACKING
120. TUBE ASSY 460. TEE
130. ELBOW 470. PACKING
140. NUT 480. NUT
150. PACKING 490. TUBE ASSY
160. TUBE ASSY 500. UNION
170. UNION 510. PACKING
180. PACKING 520. TEE
190. ELBOW 530. CAP
200. NUT 540. TUBE ASSY
210. PACKING 550. ELBOW
220. NUT 560. NUT
230. WASHER 570. PACKING
240. CLAMP 580. NUT
245. CLAMP 590. WASHER
250. BOLT 600. CLAMP
260. NUT 610. BOLT
270. WASHER 620. CLAMP
280. CLAMP 630. TUBE ASSY
290. BOLT 640. ELBOW
300. TUBE ASSY 650. NUT
310. TUBE ASSY 660. PACKING
320. UNION 670. PLUG
330. PACKING 680. PACKING
340. NUT

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Plumbing Installation (Partial Breakdown)


Figure 402

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KEY TO FIGURE 402

10. HOSE ASSY (IPC FIG. 2, 49-20-01) 170. NUT


20. UNION 180. WASHER
30. PACKING 190. BOLT
40. TEE 200. CLAMP
50. CAP 210. NUT
60. PIN 220. WASHER
70. CHAIN 230. BOLT
80. RING 240. CLAMP
90. TUBE ASSY 250. SWING CHECK VALVE
100. NUT 260. UNION
110. WASHER 270. PACKING
120. BOLT 280. TUBE ASSY
130. CLAMP 290. NUT
140. REDUCER 300. WASHER
150. PACKING 310. BOLT
160. TUBE ASSY 320. CLAMP

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Plumbing Installation (Partial Breakdown)


Figure 403

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KEY TO FIGURE 403

10. TUBE ASSY (IPC FIG. 3, 49-20-01) 390. HOSE ASSY


20. NUT 400. NUT
30. WASHER 410. WASHER
40. BOLT 420. BOLT
50. CLAMP 430. CLAMP
60. ELBOW 440. UNION
70. PACKING 450. CAP
80. NUT 460. NUT
90A. TEE 470. WASHER
100. PACKING 480. TUBE ASSY
110. NUT 490. UNION
120. CAP 500. CAP
130. TUBE ASSY 510. WASHER
140. TUBE ASSY 520. NUT
150. NUT 530. TUBE ASSY
160. WASHER 540. NUT
170. BOLT 550. WASHER
180. CLAMP 560. BOLT
190. TEE 570. CLAMP
200. CAP 580. TUBE ASSY
210. TUBE ASSY 590. NUT
220. NUT 600. WASHER
230. WASHER 610. BOLT
240. BOLT 620. CLAMP
250. CLAMP 630. UNION
260. REDUCER 640. PACKING
270. PACKING 650. HOSE ASSY
280. TUBE ASSY 660. TEE
290. TUBE ASSY 670. CAP
300. NUT 680. WASHER
310. WASHER 690. NUT
320. BOLT 700. TEE
330. CLAMP 710. CAP
340. CLAMP 720. WASHER
350. TEE 730. NUT
360. PACKING 740. ELBOW
370. CAP 750. PACKING
380. NUT 760. NUT

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(GTCP85-98DHF[A]) Plumbing Installation


(Partial Breakdown)
Figure 403A

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KEY TO FIGURE 403A

10. TUBE ASSY (IPC FIG 3A, 49-20-01) 440. TEE


20. NUT 450. PACKING
30. WASHER 460. CAP
40. BOLT 470. NUT
50. CLAMP 480. HOSE ASSY
60. ELBOW 490. NUT
70. PACKING 500. WASHER
80. NUT 510. BOLT
90. TEE 520. CLAMP
100. PACKING 530. UNION
110. NUT 540. CAP
120. CAP 550. NUT
130. TUBE ASSY 560. WASHER
140. TUBE ASSY 570. TUBE ASSY
150. NUT 580. UNION
160. WASHER 590. CAP
170. BOLT 600. WASHER
180. CLAMP 610. NUT
190. TEE 620. TUBE ASSY
200. TUBE ASSY 630. NUT
210. CAP 640. WASHER
220. TEE 650. BOLT
230. NUT 660. CLAMP
240. PACKING 670. TUBE ASSY
250. TUBE ASSY 680. NUT
260. NUT 690. WASHER
270. WASHER 700. BOLT
280. BOLT 710. CLAMP
290. CLAMP 720. UNION
300. REDUCER 730. PACKING
310. PACKING 740. HOSE ASSY
320. TUBE ASSY 750. TEE
330. TUBE ASSY 760. CAP
340. NUT 770. WASHER
350. WASHER 780. NUT
360. BOLT 790. TEE
370. SPACER 800. CAP
380. CLAMP 810. WASHER
390. NUT 820. NUT
400. WASHER 830. ELBOW
410. BOLT 840. PACKING
420. CLAMP 850. NUT
430. CLAMP

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Plumbing Installation (Partial Breakdown)


Figure 404

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GTCP85-98DHF/[A]

KEY TO FIGURE 404

10. BOLT (IPC FIG. 4, 49-20-01) 370. NUT


20. PACKING W/RTNR 380. WASHER
25. PACKING W/RTNR 390. CLAMP
30. ELBOW 400. CLAMP
40. PLUG 410. SPACER
50. PACKING 420. BOLT
60. TUBE ASSY 430. CLAMP
70. NUT 440. CLAMP
80. WASHER 450. TUBE ASSY
90. CLAMP 460. UNION
100. BOLT 470. CLAMP
110. TUBE ASSY 480. CLAMP
120. NUT 490. NUT
130. WASHER 500. ELBOW
140. CLAMP 510. PACKING
150. SPACER 520. TUBE ASSY
160. CLAMP 530. CLAMP
170. BOLT 540. TEE
180. TUBE ASSY 550. NUT
190. CLAMP 560. TEE ASSY
200. CLAMP 570. PACKING
210. TUBE ASSY 580. TUBE ASSY
220. NUT 590. NUT
230. WASHER 600. WASHER
240. CLAMP 610. CLAMP
250. SPACER 620. BOLT
260. BOLT 630. NUT
270. TEE 640. ELBOW
280. TEE 650. PACKING
290. NUT 660. HOSE ASSY
300. PACKING 670. NUT
310. TUBE ASSY 680. ELBOW
320. CLAMP 690. PACKING
330. NUT 700. PACKING
340. WASHER 710. ELBOW
350. CLAMP 720. NUT
360. BOLT

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Plumbing Installation (Partial Breakdown)


Figure 405

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GTCP85-98DHF/[A]

KEY TO FIGURE 405

10. TUBE ASSY (IPC FIG. 5, 49-20-01) 190. CLAMP


20. NUT 200. HOSE ASSY
30. WASHER 210. NUT
40. CLAMP 220. WASHER
50. BOLT 230. BOLT
60. CLAMP 240. CLAMP
70. BOLT 250. CLAMP
80. ELBOW 260. NUT
90. PACKING 270. WASHER
100. UNION 280. CLAMP
110. PACKING 290. CLAMP
120. TUBE ASSY 300. BOLT
130. NUT 310. NUT
140. TEE ASSY 320. ELBOW
150. PACKING 330. PACKING
160. NUT 340. CAP ASSY
170. WASHER 350. UNION
180. BOLT 360. PACKING

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(GTCP85-98DHF) Electrical Installation


(Partial Breakdown)
Figure 406

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KEY TO FIGURE 406

10. NUT (IPC FIG. 1, 49-20-02) 250. BOLT


20. WASHER 260. CLAMP
30. BOLT 270. CLIP
40. CLAMP 280. LEAD (IGNITER PLUG)
50. NUT 290. NUT
60. WASHER 300. WASHER
70. BOLT 310. BOLT
80. CLAMP 320. CLAMP
90. NUT 330. NUT
100. WASHER 340. WASHER
110. BOLT 350. BOLT
120. CLAMP 360. CLAMP
130. NUT 370. NUT
140. WASHER 380. WASHER
150. BOLT 390. BOLT
160. CLAMP 400. CLAMP
170. BRACKET 410. NUT
180. NUT 420. WASHER
190. WASHER 430. BOLT
200. BOLT 440. CLAMP
210. CLAMP 450. NUT
220. BRACKET 460. WASHER
225. BOLT 470. BOLT
226. WASHER 480. CLAMP
230. NUT
240. WASHER

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(GTCP85-98DHF[A]) Electrical Installation


(Partial Breakdown)
Figure 406A

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GTCP85-98DHF/[A]

KEY TO FIGURE 406A

10. NUT (IPC FIG. 1A, 49-20-02) 270. CLIP


20. WASHER 280. LEAD (IGNITER PLUG)
30. BOLT 290. NUT
40. CLAMP 300. WASHER
50. NUT 310. BOLT
60. WASHER 320. CLAMP
70. BOLT 330. NUT
80. CLAMP 340. WASHER
90. NUT 350. BOLT
100. WASHER 360. CLAMP
110. BOLT 370. NUT
120. CLAMP 380. WASHER
130. NUT 390. BOLT
140. WASHER 400. CLAMP
150. BOLT 410. NUT
160. CLAMP 420. WASHER
170. BRACKET 430. BOLT
180. NUT 440. CLAMP
190. WASHER 450. NUT
200. BOLT 460. WASHER
210. CLAMP 470. BOLT
220. BRACKET 480. CLAMP
225. BOLT 490. NUT
226. WASHER 500. WASHER
230. NUT 510. BOLT
240. WASHER 520. CLAMP
250. BOLT
260. CLAMP

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Electrical Installation (Partial Breakdown)


Figure 407

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KEY TO FIGURE 407

10. COVER ASSY (IPC FIG. 2, 49-20-02) 270. WASHER


20. SCREW 280. BOLT
30. BOLT 290. CLAMP
40. WASHER 300. BRACKET
50. RELAY 310. NUT
60. SCREW 320. WASHER
70. NUT 330. BOLT
80. WASHER 340. CLAMP
90. CIRCUIT BREAKER 345. BOLT
100. TIME TOTALIZING METER 346. WASHER
110. SCREW 350. NUT
120. WASHER 360. WASHER
130. MOUNT 370. BOLT
140. SCREW 380. CLAMP
150. WASHER 390. BOLT
160. NUT 400. LINK
170. WASHER 415. SPACER WASHER
180. BOLT 420. NUT
190. CLAMP 430. WASHER
200. CLAMP 440. BOLT
210. BOLT 450. CLAMP
220. NUT 460. BOLT
230. WASHER 480. LINK
240. BOLT 490. SPACER WASHER
250. CLAMP 500. HARNESS ASSY
260. NUT

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ENGINE - ADJUSTMENT/TEST

1. General

The test and adjustment procedures described in this section shall be performed by personnel who
operate and maintain the equipment in the field and can be accomplished with the engine removed or
installed as indicated.

It is particularly important and recommended that the engine test and adjustment checks be performed
before the engine is installed. Should any of the heavy maintenance practices be accomplished, refer
to TROUBLE SHOOTING for aid in correcting malfunctions encountered during test.

2. Special Tools, Fixtures and Equipment

Refer to Table 501 for listing of applicable Special Tools, Fixtures and Equipment.

Table 501. Special Tools, Fixtures and Equipment

Item Source/
No. Nomenclature Use Part No.

NOTE: Equivalent substitutes may be used for listed items.

1. Gas Turbine Engine To checkout Gas Turbine 290122-400


Tester (use with Engine during maintenance. or
engines utilizing Provides control to start, 290122-500
mechanical speed stop and load engine.
switch) Provides instrumentation
for monitoring exhaust gas
temperature, engine rpm,
oil pressure, switch
actuations and dc voltage.

1A. Gas Turbine Engine 290270-1-1


Tester (alternate
engine tester; use
with engines util-
izing mechanical
speed switch

2. Electrical Cable As- Interconnects engine 290214-2-1


sembly (use with tester with engine
Tester PN 290122-400 electrical system.
or 290122-500)

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Table 501. Special Tools, Fixtures and Equipment (Cont)

Item Source/
No. Nomenclature Use Part No.

2A. Adapter Kit (use 290310-1-1


with alternate
Tester PN 290270-1-1

3. Portable Engine Secures and holds engine 281270-0-3


Stand (replaced in various positions during
by P/N 833063-1) assembly, disassembly,
testing and transport .

3A. Portable Engine Secures and holds engine 833063-1


Stand (replaces in various positions during
PN 281270-0-3) assembly, disassembly,
testing and transport .

4. Engine Mount Supports engine on stand 284126-1-1


PN 281270-0-3 or 833063-1.

5. Engine Mount Supports engine on stand 284125-1-1


PN 281270-0-3 or 833063-1.

6. Engine Adapter Adapts and supports accessory 281893-1-1


drive gearcase housing assem-
bly to stand PN 281270-0-3 or
833063-1.

7. Pressure Gage and To check acceleration limiter 282645


Case Set Assembly valve cracking pressure.

8. Screwdriver and Holds and prevents rotation 280353


Wrench Assembly of nut while adjusting screw
on fuel control governor.

9. Thermostat Calibra- Provides a means of measuring 290417-2-1


tion Test Set exhaust gas temperature and
(replaced by loading engine while cali-
833657-1) brating pneumatic thermostats.

9A. Thermostat Calibra- Provides a means of measuring 833657-1


tion Test Set exhaust gas temperature and
loading engine while cali-
brating pneumatic thermostats.

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Table 501. Special Tools, Fixtures and Equipment (Cont)

Item Source/
No. Nomenclature Use Part No.

10. Cable Assy (component Connects thermocouple assem- 290424-1


of 290417-3-1 or bly to receptacle of thermostat
833657-1) calibration test set.

11. Thermocouple Assy Connects thermocouple assem- 290416-2


(component of bly to receptacle of thermostat
290417-2-1 or calibration test set.
833657-1)

12. 100% Governor Adjustor To adjust fuel control 833274-1


Wrench governor.

13. 100% Governor Jamnut Holds nut while adjusting 833275-1


Wrench fuel control governor.

14. Digital Multimeter Measures resistance of Model 8050A


thermocouple circuit. Keithley Mfg.
Corp.

3. Equipment Connections

A. Prepare Engine for Test (Installed in Installation) (Refer to Figure 501)

(1) Disconnect engine wiring harness connector from remote bulkhead receptacle.

NOTE: Connectors of cable assembly are identified by aluminum marker bands.

(2) Connect cable assembly (2, Table 501) as follows:

(a) Connect CABLE ASSY TO TESTER connector to tester receptacle.

(b) Connect ENGINE CONN connector to engine wiring harness connector and
connect CUSTOMER CABLE connector to remote bulkhead receptacle.

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3. A. (3) Remove cap from output fuel pressure connection port. Install fuel pressure hose
assembly on output fuel pressure connection port. Install other end of fuel pressure
hose assembly on fuel pressure coupling.

(4) Remove cap from control air pressure connection port. Install control air pressure
hose assembly on control air pressure connection port. Install other end of control
pressure hose assembly on control air pressure coupling.

(5) Remove cap from oil pressure connection port. Install oil presssure hose assembly on
oil pressure connection port. Install other end of oil pressure hose assembly on oil
pressure coupling.

(6) At initial use of tester (1, Table 501), check the exhaust temperature loop resistance.

(a) Remove tester panel attaching screws and lift panel to obtain access to
temperature indicating circuit components.

(b) Disconnect wire leads from exhaust temperature indicator terminals on rear of
indicator case to remove indicator from thermocouple circuit.

NOTE: Make sure that white Chromel wire lead is connected to the CR
terminal and that the green Alumel wire lead is connected to AL
terminal.

(c) Connect (Model 4289-2) Wheatstone bridge to disconnect wire leads to


measure resistance of thermocouple circuit. Measure thermocouple circuit.
Resistance shall be 8.000 0.035 ohms. If resistance is not within specified
limit, adjust slide of variable resistor in tester to obtain specified resistance.

(d) Disconnect Wheatstone bridge and reconnect wire leads to temperature


indicator terminals. Replace panel of tester and secure with attaching screws.

(e) Engine is now ready for test.

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THIS PAGE INTENTIONALLY LEFT BLANK

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Connection of Tester to Engine


Figure 501

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KEY TO FIGURE 501

1. ENGINE WIRING HARNESS 11. OUTPUT FUEL PRESSURE


CONNECTOR CONNECTION PORT
2. ELECTRICAL CABLE ASSY 12. INLET FUEL PRESSURE
(2, TABLE 501) CONNECTION PORT
3. REMOTE BULKHEAD RECEPTACLE 13. CONTROL AIR PRESSURE
4. OVERSPEED TEST STOP SWITCH CONNECTION PORT
5. TESTER (1, TABLE 501) 14. OIL PRESSURE COUPLING
6. CONTROL AIR PRESSURE 15. FUEL PRESSURE COUPLING
HOSE ASSY 16. CONTROL AIR PRESSURE
7. FUEL PRESSURE HOSE ASSY COUPLING
8. OIL PRESSURE HOSE ASSY 17. RECEPTACLE
10. OIL PRESSURE CONNECTION
PORT

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3. B. Prepare Engine for Test (Engine not installed in aircraft)

(1) Install engine in 281270-0-3 or 833063-1 stand. Use mount 284126-1-1 to support
one side of engine, 284125-1-1 mount to support other side of engine, and 281893-1-1
adapter to support accessory end of engine.

(2) Install mounted engine in test setup facility so that all sides, top, and bottom of engine
are readily accessible. Compressor air inlet and cooling fan air inlet shall be clear.

(3) Provide a source of clean fuel as specified in DESCRIPTION AND OPERATION,


Table 1, at 30 1 psig. Connect source of fuel to fuel inlet (11, Figure 502) and fuel
pressure connection (16) on fuel control unit (10). Connect a control air pressure gage
to the control air pressure connection port on the test panel assembly. Install a fuel
drain line on the plenum drain connection.

KEY TO FIGURE 502

1. LOAD CONTROL THERMOSTAT 15. GOVERNOR SPEED ADJUSTMENT


2. LOAD CONTROL VALVE TEE FITTING SCREW
3. LOAD CONTROL VALVE 15A. GOVERNOR ADJUSTMENT NUT
4. FUEL ATOMIZER 16. FUEL PRESSURE CONNECTION
5. FUEL SUPPLY LINE 17. COOLING FAN AIR INLET
6. PLENUM DRAIN CONNECTION 18. COMPRESSOR AIR INLET
7. AIR PRESSURE REGULATOR 19. MANUAL SHUTOFF VALVE
8. TEST PANEL ASSY 20. INLET FILTER
9. CONTROL AIR PRESSURE 21. MANUAL SPEED CONTROL
CONNECTION PORT NEEDLE VALVE
10. FUEL CONTROL UNIT 22. FUEL PRESSURE GAGE
11. FUEL INLET 23. NEEDLE VALVE
12. FUEL FILTER 24. CONTROL AIR PRESSURE GAGE
13. FUEL OUTLET (TO ATOMIZER) 25. CONTROL AIR PRESSURE GAGE
14. ACCELERATION LIMITER VALVE 26. GOVERNOR ADJUSTMENT JAM
ADJUSTMENT SCREW NUT

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Fuel and Air System Test Setup


Figure 502

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CAUTION: ANY SUBSTITUTION OR USE OF NON-APPROVED LUBRICANTS, OR


MIXING OF BRANDS OR TYPES OF LUBRICANTS MAY CAUSE
CONSIDERABLE ENGINE DAMAGE.

3. B. (4) Provide lubricating oil as specified in Table 302. Fill oil tank to FULL mark on sight
gage. Connect an oil pressure gage (Figure 503) to the oil pressure connection port
on the test panel assembly.

(5) Install an electrical system with necessary wiring, switches, and controls.

(a) Provide a source of 26 2 volts DC electrical power.

(b) Provide a control panel with a stop switch, a start switch, a bleed-air switch, a
green ready-to-load light, a starter relay, and an ammeter and shunt.

(c) Provide a harness assembly to connect the control panel to the engine wiring
harness receptacle. Provide a lead to connect the starter relay to the starter
positive terminal.

(d) Provide jumper wires for the non-ram door interlock receptacle and the ram
door actuator receptacle.

(e) Connect a tachometer indicator to measure engine turbine wheel speed.

KEY TO FIGURE 503

1. SEQUENCING OIL PRESSURE 7. OIL TEMPERATURE BULB


2. OIL TANK 8. OIL PRESSURE ADJUSTMENT
3. TEST PANEL ASSY 9. COMPOUND PRESSURE GAGE
4. OIL PRESSURE CONNECTION PORT 10. OIL PRESSURE GAGE
5. OIL PUMP ASSY 12. ACCESSORY GEARCASE NEGATIVE
6. TACHOMETER-GENERATOR PRESSURE CONNECTION
PAD 13. ORIFICED CAP

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Lubrication System Test Setup


Figure 503

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Table 502. Operating Limits

Observation Condition Limit Requirements

Accessory Gearcase At rated speed with 0 to -10 in.


Assembly Cavity gearcase assembly Hg ga
Pressure vented to atmosphere
through a 0.035 to
0.949 in. diameter
orifice

Turbine Bearing At rated speed with +4 psig to -25 in.


Cavity Pressure cavity port capped Hg ga

Leakage
Fuel From fuel control unit One drop per min.
drain max

NOTE: Fuel leakage from turbine plenum assembly is permitted only after a false start or blowout.

Oil (from output - None


shaft seals
during operation)

Oil (from compres - None-


sor inlet seal
during operation)

Oil pressure Except below 30,000 rpm 95 5 psig


Measure at oil pump
pressure tap
Measure at test 70 10 psig
panel

Oil Pressure Fluctua- Measure at oil pump 3 psig


tion (steady-state pressure tap
Condition)

Oil Consumption At rated speed 0.25 lb/hr max

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Table 502. Operating Limits (Cont)

Observation Condition Limit Requirements

Starter Motor Duty


Cycle Refer to Table 504.

NOTE: A cooling period of 30 minutes is required after four starter duty cycles.

Temperature

Inlet air - 54C (130F) max

Oil Shall not exceed 70C 124C (255F) max


or 125F above ambient
air temperature

CAUTION: TURBINE DISCHARGE TEMPERATURE DURING NORMAL ENGINE OPERATION


SHOULD NOT EXCEED CONTINUOUS OPERATION LIMIT. ENGINE OPERATION AT
TURBINE DISCHARGE TEMPERATURES ABOVE CONTINUOUS OPERATION LIMIT IS
EVIDENCE OF ENGINE DISTRESS, AND APPROPRIATE CORRECTIVE ACTION SHOULD
BE TAKEN TO RESTORE NORMAL OPERATION

NOTE: Maximum turbine discharge temperatures may be exceeded during engine start and acceleration,
provided that start time does not exceed normal limits.

Turbine discharge Continuous operation 630C (1166F) max

Recommended operation 574C (1066F) max

Never exceed governed 662C (1225F) max


speed condition

Turbine Wheel Speed

Continuous operation No load governed 42,500 100


speed

Turbine wheel speed Full load 400 rpm min


droop 1,000 rpm max

Absolute maximum - 46,000 rpm

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Table 502. Operating Limits (Cont)

Observation Condition Limit Requirements

Turbine Wheel Speed (Cont)

10-second operation Do not exceed a speed 43,900 rpm


in excess of 43,900 rpm
for longer than 10 sec

CAUTION: MAXIMUM PEAK VIBRATIONS GREATER THAN THE LIMITS SHOWN MAY OCCUR AT
CERTAIN CRITICAL TURBINE WHEEL SPEED FROM 17,000 TO 23,000 RPM. DO NOT
OPERATE THE UNIT CONTINUOUSLY AT ANY SPEED WHERE VIBRATION EXCEEDS
THESE LIMITS OR UNDER CONDITIONS THAT CREATE SPEED DWELLINGS BETWEEN
17,000 AND 23,000 RPM.

NOTE: Momentary vibration amplitudes in excess of specified limits are acceptable during start and
acceleration cycles, however, the magnitude of the observed amplitude excursions should not
exceed twice the specified limits, i.e. 1.2 mil at gearcase end or 0.8 mil at turbine end.

Gearcase end Any operating condition 0.6 mil max

Turbine end Any operating condition 0.4 mil max

Table 503. Engine exhaust Gas Temperature (EGT) Settings

EGT Measurement Pneumatic (Load


Mode) Thermostat

Max *Recommended

630C 574 + 0 -10C


Test Set (1166F) (1066 + 0 -20F)
Thermocouple

* The manufacturer recommends these lowered temperature settings to increase the service life of the engine
"hot"section. These temperatures may be adjusted as necessary to meet each individual operators
requirements. Operators are advised that a reduction of EGT will reduce bleed airflow and can affect cabin
temperatures under warmer ambient conditions.

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Table 504. Starter Motor Duty Cycle

Starts or Attempted
Starts During One Normal Cycle
Hour Time Span Operation Cool Down

NOTE: Starter shall be inspected after last start cycle abort.

First Start 0-90 Sec. Max. 0 Minutes Min.

Second Start 0-90 Sec. Max. 5 Minutes Min.

Third Start 0-90 Sec. Max. 60 Minutes Min.

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4. Precautionary Requirements

WARNING: DURING ENGINE OPERATION, PERSONNEL SHALL STAND CLEAR OF THE


COMPRESSOR AND TURBINE PLANES OF ROTATION.

A. Follow Precautionary Requirements

(1) If operation limits tabulated in Table 502 are exceeded, or if seizing, unusual noise,
smoke, fuel or oil leakage, or other obvious malfunction is observed, shut down the
engine immediately and correct the cause of trouble.

NOTE: The use of the hot section components will be extended by operating the
engine at no-load governed speed for at least one minute prior to
application of a bleed-air load.

(2) Allow the engine to operate at no-load governed speed for one minute (minimum) prior
to application of a bleed-air load.

NOTE: The use of the hot section components will be extended by operating the
engine at or below the recommended pneumatic thermostat setting.

(3) Allow the engine to operate at zero-bleed-air load for three minutes (minimum) prior to
shutdown.

5 Check and Adjustment

A. Check and Adjust Fuel Control Unit Acceleration Limiter Valve Cracking Pressure as Follows:

NOTE: Connection of tester (1, Table 501) is not required for this check.

(1) Remove cap at control air pressure connection port (Figure 501) and remove electrical
connector at sequencing oil pressure switch (Figure 503).

(2) Remove plug from fuel control unit fuel pressure connection (Figure 502) and install
suitable fitting.

(3) Connect 282645 pressure gage and case set assembly to fitting installed in step (2).

CAUTION: DO NOT EXCEED STARTER DUTY CYCLE LIMITS SPECIFIED IN TABLE


504.

(4) Energize start switch to rotate engine by starter action.

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5. A. (5) Check and record acceleration limiter valve cracking pressure at approximately 20
percent (7500 to 9000 rpm) engine speed. Cracking pressure must be 60 3 psig.

(6) If cracking pressure is not within limits, loosen locknut and adjust acceleration limiter
valve adjustment screw (Figure 505) using screwdriver and wrench. Clockwise
adjustment increases pressure.

(7) When cracking pressure is satisfactory, tighten locknut, and repeat cracking pressure
check in accordance with steps (4) and (5). Lock wire locknut per AS 567.

(8) Disconnect 282645 pressure gage and case set assembly from fuel control unit.
Remove fitting and install plug.

(9) Install cap on control air pressure connection port (13, Figure 501) and connect
electrical connector at sequencing oil pressure switch (1, Figure 503).

Acceleration Limiter and Fuel Governor


Adjustment Screws
Figure 505

NOTE: Figure 504 intentionally omitted.

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5. B. Check Engine Start, Acceleration, Operation, and Actuation of Automatic Controls as Follows:

NOTE: If the engine does not operate satisfactorily as indicated in the following steps, stop
the engine and correct malfunction before proceeding.

(1) Place the bleed air switch in the OFF position.

(2) Momentarily place start switch in START position.

(3) Observe the following sequence of events.

(a) Low oil pressure light (red) and 35-percent light shall go on immediately.

(b) The engine shall start and accelerate smoothly, indicated by evidence of oil
pressure at oil gage, engine speed at tachometer indicator, compressor air
pressure at control air pressure gage, fuel pressure at fuel pressure gage, and
exhaust gas temperature at gas temperature indicator. If APU does not reach
governed speed within time limit shown in Figure 506, terminate start.

(c) Throughout start, acceleration, and operation, exhaust gas temperature,


indicated on exhaust gas temperature indicator, shall not exceed limits of
Table 502.

CAUTION: SHUT DOWN ENGINE AT ONCE AND CORRECT TROUBLE IF


EXHAUST GAS TEMPERATURE PERSISTS AT OR EXCEEDS
LIMITS SPECIFIED IN TABLE 502 DURING RUN PERIOD.

(d) When oil pressure reaches 2.5 to 3.5 psig, indicated at oil pressure gage, fuel
solenoid circuit shall close allowing fuel flow indicated on fuel pressure gage.

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Starting Time Vs. APU Oil Temperature


Figure 506

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5. B. (3) (e) When engine speed reaches approximately 35-percent, indicated on the
tachometer indicator, the 35-percent switch shall actuate to break the starter
circuit indicated by the 35-percent light going off.

(f) When engine oil pressure reached 65 psig maximum, indicated on the oil
pressure gage (at oil pump discharge port connected in step 3.A.(5)), the low
pressure light shall go out indicating satisfactory operation of the low oil
pressure switch.

(g) When engine speed reaches approximately 75-percent, indicated on the tester
tachometer indicator, engine oil pressure shall be 90 to 110 psig indicated on
the oil pressure gage and shall remain at this pressure for all operation above
75-percent speed. Oil pressure shall not fluctuate more than 3 psi during
steady state operation.

(h) When engine speed reaches 95-percent, indicated on the tester tachometer
indicator, the 95-percent switch shall actuate to break ignition circuit and close
the hourmeter circuit indicated by 95-percent light going on and engine
hourmeter starting to record time.

NOTE: Indication of 100 percent engine speed on the tester tachometer


indicator is equivalent to 42,000 rpm engine speed.

(i) The engine shall continue to accelerate and the fuel control unit governor shall
operate to control engine speed at no-load governed speed, 101.4 percent
(42,600 rpm) maximum, indicated on the tester tachometer.

(j) Energize pneumatic solenoid valve (NC) to shut down the engine. The valve
shall open to pressurize the centrifugal switch assembly and actuate the
overspeed switch.

C. Check and Adjust Fuel Control Governor Speed Setting

(1) Place bleed air switch in OFF position.

(2) Momentarily place start switch in START position and allow engine to accelerate to no-
load governed speed.

(3) With no-load applied, engine speed shall stabilize at 102 percent maximum indicated
on the tester tachometer indicator.

NOTE: Indication of 100 percent engine speed on the tester tachometer indicator is
equivalent to 41,185 rpm engine speed.

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5. C. (4) (Pre SB 49-5196) If the steady speed no-load governed speed is not within limits of
101.0 to 101.4 percent (42,400 to 42,600 rpm) indicated on the tester tachometer
indicator, adjust using screwdriver and wrench on the governor speed adjustment
screw (Figure 505). Clockwise adjustment increases speed, counterclockwise
adjustment decreased speed.

(Post SB 49-5196) With no-load applied, check the steady-state no-load governed
speed indicated on tester tachometer indicator. Steady-state no-load governed speed
shall be within limits of 101.0 to 101.4 percent (42,400 to 42,600 rpm) indicated on the
tester tachometer indicator. Use 833275-1 jamnut wrench and 833274-1 adjustor
wrench to adjust governor adjustment nut (15A, Figure 502) to obtain limits.

(5) When adjustment is satisfactory, tighten locknut and lockwire per AS 567.

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5. D. Check Oil Pressure Relief Valve Setting

(1) Place the tester load switch in the OFF position.

(2) Momentarily place start switch in start position and allow engine to accelerate to no-
load governed speed. Run the engine approximately two minutes to stabilize
operation.

(3) Observe oil pressure indicated on oil pressure gage located on the tester control
panel. If oil pressure is not within 90 to 110 psig during steady state operation, adjust
oil pressure relief valve cracking pressure as follows:

(a) Loosen locknut and turn valve metering screw clockwise to increase cracking
pressure. (Refer to Figure 507).

(b) Turn valve metering screw counterclockwise to decrease cracking pressure.

(c) When adjustment is satisfactory, tighten locknut and lockwire per AS 567.

Oil Pressure Relief Valve Metering Screw


Figure 507

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5. E. Check and Adjust Air Pressure Regulator Output Pressure

(1) Remove cap from tee fitting located in the outlet air pressure regulator and the load
control valve. (Refer to Figure 508).

(2) Connect one end of the control air pressure hose assembly to the tee fitting and the
other end to the control air pressure coupling on the tester.

(3) Start the engine and allow it to accelerate to the no-load governed speed. Observe
the pressure indicated on the control air pressure gage. The pressure shall be 37.6 to
39.7 inched Hg gage (18.5 to 19.5 psig).

(4) If the regulated outlet pressure is not within specified limits, shut down the engine,
loosen the locknut on opposite ends of the air pressure regulator and turn the
adjustment screw clockwise to increase outlet pressure, counterclockwise to decrease
outlet pressure. Tighten locknut and repeat the check procedure.

Air Pressure Regulator Adjustment Screw


Figure 508

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5. F. (98DHF Post SB 49-5233 and 98DHF[A]) Check and Adjust Economy System as follows:

NOTE: Make sure that the fuel economy solenoid is closed (de-energized) except during
systems operational checks.

(1) Start the engine and allow it to accelerate to full-load (no shaft load) governed speed.

(2) Cycle the fuel economy solenoid two times to assure system operability and that the
fuel conservation EGT control point is 90.55 to 96.11C (195 to 205F).

(3) If the EGT is not within limits, loosen the locknut on the adjustable orifice, then turn the
adjusting screw until the desired EGT control point is reached. Tighten locknut.

(4) Repeat the procedures outlined in steps (1) through (3) until the desired EGT control
point is reached.

Fuel Economy System Adjustment


Figure 508A

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5. G. Check and Calibrate Pneumatic Thermostat

(1) Remove installed engine thermocouple (12, Figure 504) and replace with 290416-2
test thermocouple. Refer to Section 49-70-01, Removal/Installation for thermocouple
removal instructions.

(2) Connect 290424-1 cable assembly to 290416-2 thermocouple assembly and


receptacle on 290417-2-1 or 833657-1 test set.

(3) Check the thermostat temperature control point as follows:

(a) Start engine in accordance with applicable instructions.

NOTE: If the APU is not fully loaded, it is not possible to determine the
setpoint of an installed thermostat. To properly load the APU, it is
necessary to impose a potential overload on the APU to make sure
that the thermostat is fully open and at its control temperature
setpoint.

(b) Open the engine load control valve and turn on both airconditioning packs (do
not select "the AIR-CONDITIONING COLDER" position). Allow the EGT to
stabilize, not to exceed 630C (1166F) for more than one minute and never to
exceed 662C (1224F).

CAUTION: DO NOT ALLOW TURBINE DISCHARGE TEMPERATURE TO


EXCEED LIMITS SPECIFIED IN TABLE 502.

(c) Record the EGT. If exhaust gas temperature is not within the limits specified
in Table 503, recalibrate the thermostat in accordance with step (4).

NOTE: To avoid hot shutdown, remove load and operate for one minute at
no-load condition prior to shutting down the engine.

(d) Remove the pneumatic load and allow the temperature to stabilize, then shut
down the engine.

(4) Calibrate the pneumatic thermostat, if required, as follows:

(a) Determine thermostat control cracking temperature in accordance with step


(3).

NOTE: There are two self-locking helicoil inserts located in the adjustable
collar to prevent the collar from rotating and changing calibration in
service. To ensure integrity of this locking device, the torque on
the adjustment collar should be observed during adjustment. If the
running torque on the adjustment collar is less than 20 pound-
inches, the thermostat must be removed from service for repair.

(b) Calibrate the adjustable thermostat to the required setting as follows:

1 Observing that each index mark on the adjustment head equals 2C


(4F), rotate the adjustable collar in a clockwise direction (viewed from
the fitting end) to increase the temperature setting.

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5. G. (4) (b) 2 Rotate the adjustment collar in a counterclockwise direction to


decrease the temperature setting.

(c) Recheck the temperature control point after adjusting the thermostat in
accordance with step (3). Controlling the temperature shall repeat within 3C
(5F) for two successive checks.

(d) Remove the 290416-2 from the engine. Install the engine thermocouple.
Refer to Section 49-70-01, Removal/Installation for thermocouple installation
instructions.

H. Check and Adjust the Load Control valve Opening Rate (Refer to Figure 509)

(1) Start the engine and allow it accelerate to the no-load governed speed.

(2) Apply bleed load and record the time for the load control valve to control from no-load
to full bleed load.

(3) The full bleed load shall be reached within nine to ten seconds.

CAUTION: THE RATE ADJUSTMENT SCREW SHALL NOT BE BOTTOMED IN THE


LOAD CONTROL VALVE. DAMAGE TO THE LOAD CONTROL VALVE MAY
RESULT.

(4) If opening time is not within limits, hold the load control valve rate adjustment screw
(refer to applicable publication list) and loosen the locknut. Turn the adjustment screw
clockwise to increase opening time, counterclockwise to decrease opening time. Hold
adjustment screw and tighten the locknut.

(5) Repeat procedures outlined in steps (1) through (4) until opening time is within limits.

Load Control Valve Rate Adjustment Screw


Figure 509

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5. I. Check Accessory Gearcase Assembly Negative Pressure

NOTE: This check shall only be accomplished during trouble shooting to determine the
cause of high oil consumption or noticeable oil smoke from the exhaust.
Connection of the tester is not required for this check.

(1) Remove the vent plug from the port on the front of the accessory gearcase.

(2) Install a suitable tee fitting (11, Figure 502) with 0.035 to 0.040 inch orificed cap (13)
installed into the accessory gearcase assembly.

(3) Connect a suitable flexible hose to the tee fitting and connect the other end of the hose
to a compound pressure gage.

(4) Start the engine and allow it accelerate to a no-load governed speed.

(5) Note the pressure reading on the compound pressure gage; the pressure shall be 0 to
-10 inches mercury on the gage.

(6) Shut down the engine and remove the flexible hose, compound pressure gage, and
the tee fitting from the accessory gearcase vent port. Install the vent plug. Make sure
the vent hole in plug is not obstructed.

J. (Post SB 49-5233) Check and Adjust Fuel Economy System

NOTE: Make sure that the fuel economy solenoid is closed (de-energized) expect during
systems operational checks.

(1) Start the engine and allow it to accelerate to full-load (no shaft load) governed speed.

(2) Cycle the fuel economy solenoid two times to assure system operability and that the
fuel conservation EGT control point is 91 to 96C (195 to 200F).

(3) If the EGT is not within limits, loosen the locking nut on the adjustable orifice; then turn
the adjusting screw until the desired EGT control point is reached. Tighten the locking
nut.

(4) Repeat the procedures outlines in steps (1) through (3) until the desired EGT control
point is reached.

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ENGINE - INSPECTION/CHECK

1. General

A general inspection for leakage at fittings, security of component part attachment, chafing of wiring
harness and obstructions at inlet and exhaust areas shall be accomplished at each inspection interval.
Inspect all tubing for chafing, cracks, signs of corrosion, or other damage.

2. On-Condition Maintenance Concept

The manufacturer recommends the On-Condition maintenance concept for all GTCP85 series APU's
in lieu of a firm overhaul time period. The International Air Transport Association (IATA) definition of
"ON-CONDITION" is: "A primary maintenance process having repetitive inspections or test to
determine the condition of units, systems, or portions of structure with regard to continued
serviceability (corrective action is taken when required by item condition)".

The objective of On-Condition maintenance is to establish a scheduled maintenance program which


has the potential effectiveness for improving system and component reliability. Recommended initial
maintenance intervals described below are provided to guide operators in establishing an effective On-
Condition maintenance program. Incremental increases in scheduled maintenance intervals are to be
substantiated by each individual operator based on the condition of component inspected relative to
continued service. This procedure must be followed to insure that incremental increases will not
adversely affect APU system serviceability and reliability.

3. Periodic Inspection

A. Accomplish Inspections on Installed Engine (APU)

(1) Components listed in Table 601 shall be checked periodically at specified intervals.
Intervals are in hours or cycles. Hours are equal to actual hours of APU operation;
cycles are equal to number of APU starts. Inspections shall be accomplished at
whichever comes first. The periodic inspection of interval should not be increased
unless a program consisting of an incremental increase (100 to 150 APU hour/cycle
increments) on a sampling basis is undertaken by the individual operator to
substantiate that an increase in time between inspection intervals would not adversely
affect the APU.

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Table 601. Periodic Inspection Requirements

Interval
(hours/
Section/Component cycles) Nature of Inspection

Engine (Hot) Section

NOTE: Manufacturer recommends that the combustor unit consisting of a combustor cap, fuel atomizer
assembly, and igniter plug be removed and replaced as a unit.

Combustor Unit

P/N 899244-1 250 Remove, inspect and repair or replace as


(Combustor) necessary (Refer to Section 49-20-04.)

P/N 899981-2
(Atomizer)

P/N 369162
(Ignitor)

P/N 3605384-3 500 Remove, inspect and repair or replace as


(Combustor) necessary (Refer to Section 49-20-04.)

P/N 3601193-2/-5
(Atomizer)

P/N 369162
(Ignitor)

P/N 3605384-8 1000 Remove, inspect and repair or replace as


(Combustor) necessary (Refer to Section 49-20-04.)

P/N 3601193-5
(Atomizer)

P/N 3888210-1
(Ignitor)

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Table 601. Periodic Inspection Requirements (Cont)

Interval
(hours/
Section/Component cycles) Nature of Inspection

Engine (Hot) Section (Cont)

Containment Ring 250 (Pre SB 49-3914) Check containment ring


through liner opening in plenum assembly
exerting pressure on the ring and assuring
that it cannot be moved to a "cocked"
position; freedom of the ring to "float" is
normal, however axial movement shall not
exceed 1/8-inch. If the ring position is sus-
pect, use inspection mirror and flashlight to
assure that the two washers that may be
viewed are in place and that no evidence of
washer fretting beyond 50 percent of the
original thickness is indicated. (Refer to
Section 49-20-04.)

500 (Post SB 49-3914) Check containment ring


through liner opening in plenum assembly
exerting finger pressure on the ring and
assuring that it cannot be moved with
brackets installed. (Refer to Section 49-20-
04.)

Oil Tank Vent Hose 250 Check that the hose assembly ID and
Assembly and Flange opening in flange are not obstructed.
(Refer to Section 49-20-04.)

Turbine Plenum Assembly 250 Check for cracks. (Refer to Section 49-20-
04.)

Turbine Plenum Gasket 250 Check for evidence of deterioration or


leakage. (Refer to Section 49-20-04.)

Turbine Nozzle, Turbine 250 Check these components for obvious dis-
Torus Assembly, and tress by observation through the liner
Turbine/Exducer Wheel opening in plenum assembly. (Refer to
Section 49-20-04.)

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Table 601. Periodic Inspection Requirements (Cont)

Interval
(hours/
Section/Component cycles) Nature of Inspection

Engine Fuel and Control Section

Fuel Control Unit 800 Check cracking pressure. (Refer to


ADJUSTMENT/TEST.)

800 Check no-load governed speed. (Refer


to ADJUSTMENT/TEST.)

2500 Lubricate drive shaft. (Refer to Section


49-30-01.)

Fuel Filter Element 250 Remove and replace. (Refer to Section


49-30-01.)

Turbine Plenum Drain 250 Remove, clean, and inspect. (Refer to


Section 49-30-10.)

Ignition/Starter Section

Electrical Engine 1000- Remove starter. Inspect starter brushes


Starter 1250 and perform clutch check in accordance
with Section 49-40-01.

Air Section

Pneumatic 250 Check calibration (Refer to ADJUSTMENT/


Thermostat TEST).

Air Pressure Regulator 250 Remove, clean, and check regulator output
Filter pressure. (Refer to Section 49-50-07.)

Orifice Tee Assembly 1000- Clean (Refer to CLEANING/PAINTING).

Engine Controls Section

Centrifugal Switch 1000- Lubricate gearshaft. (Refer to Section 49-


Assembly 1250 60-01.)

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Table 601. Periodic Inspection Requirements (Cont)

Interval
(hours/
Section/Component cycles) Nature of Inspection

Oil Section

Check valve 750 Remove, clean, and examine. (Refer to


Section 49-90-01.) To coincide with the
third oil filter element change.

Oil system Deleted.

Oil Filter Element 250 Remove, examine, and replace. (Refer to


Section 49-90-02.)

Gearbox Vent Plug 750 Ensure orifice is not obstructed.

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3. B. Inspection of Removed Engine (APU)

(1) Manufacturer recommends a detailed inspection of the hot section components (Table
601) be accomplished during a convenience removal of the APU at a time not
exceeding 2500 APU hours/cycles or 3500 hours/cycles (Post SB 49-
5834/5913/5941/5196/5699/6534). If a 2500 APU hour/cycle schedule has been
established and SB's 49-5834, 5913, 5941, 5196, 5699 and 6534 have been
accomplished add 1000 hour/cycles to the schedule. The inspection time
recommendation should not be increased unless a program consisting of an
incremental increase (500 to 750 hour/cycle increments) on a sampling basis is
undertaken by the individual operator to substantiate that an increase in time/cycles
would not adversely affect the APU.

NOTE: The recommended sampling program is shown in the following table of


total APU inventory (regardless of model) versus the sample quantity. This
table recognizes that the sampling of a small fleet can be of proportionately
smaller quantity than in the case of a larger fleet, since the risk involved is
significantly less. This sampling basis is considered applicable when an
increase in periodic intervals is undertaken, such as periodic inspections
and hot section inspections.

SAMPLE
QUANTITY APU INVENTORY

1-3 1-10
3-4 11-30
4-5 31-75
5-8 76-100
8-10 100 or more

(2) During this inspection, the removal (except turbine wheel assembly) and detailed
inspection of hot section components (Table 601) is recommended. Refer to Heavy
Maintenance Section of Engine Overhaul Manual, ATA 49-21-83, for detailed
inspection of hot section components.

(3) Hot section components not meeting inspection requirements shall be repaired or
replaced prior to reuse.

4. Hot Start and Overtemperature Inspection

A. Perform Hot Start Inspection

(1) Remove Combustor Unit. (Refer to Section 49-20-04.)

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4. A. (2) Visually check the following hot section components to the extent that the components
are visible through the combustor unit opening in the turbine plenum assembly. Use
normally available equipment, i.e., light, mirror, fiber optics, etc. for the inspection.
Inspect for evidence of distress per Engine Overhaul Manual ATA No. 49-21-83 as
specified in the Heavy Maintenance Section. If no distress is indicated, the APU may
continue in service; if distress is indicated, the APU should be removed for overhaul.

(a) Turbine Wheel blade tips for erosion/burning.

(b) Turbine Wheel blades for erosion/rubbing.

(c) Turbine nozzle guide vanes for erosion.

(d) Turbine torus assembly for erosion.

(3) Install replacement combustor unit. (Refer to Section 49-20-04.)

(4) Replace fuel control unit. (Refer to Section 49-30-01.)

(5) Check calibration of pneumatic thermostat. (Refer to ADJUSTMENT/


TEST.)

(6) Check turbine plenum drain for obstructions. (Refer to Section 49-30-
10.)

(7) Check aircraft battery voltage (22 volts dc minimum, 26 volts dc minimum with charger
connected).

5. Oil Condition Monitoring Program

A. Monitor Condition of Engine Oil

(1) Determine condition of engine oil observing the following recommendation:

A recommended monitoring technique is a spectrographic oil analysis program


(SOAP) for the determination of the metallic content of oil in part-per-million where the
metal is either chemically bounded to the oil, or is in a colloidal form. Since this
method of analysis is unaffected by metal chips, the total quantity of oil in the
lubrication system will contain the same proportional metal content as does the
sample.

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5. A. (2) Engine oil condition shall meet the following requirements. Change oil if requirements
are not met.

Group I Group II

Type 1 (MIL-PRF-7808) Type 2 (MIL-PRF-23699)


Viscosity Limits Viscosity Limits
38C (100F)-11 centistokes 38C (100F)-25.0 centistokes
per min per min
99C (210F)-3 centistokes 99C (210F)-5.0 centistokes
per min per min
Flash point - 204C (400F) Flash point - 232C (450F)
min min
Acid number-2.0 max Acid number - 2.0 max

Group III

Viscosity Limits
38C (100F)-35 centistokes
per min
99C (210F)-3 centistokes
per min
Flash point - 232C (450F)
min
Acid number-2.0 max

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ENGINE - CLEANING/PAINTING

1. General

Table 701. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Acetone (ASTM D239) Commercially available

Aluminum deoxidizer Henkel Surface Technologies, 32100 Stephenson


(DW-2487) Hwy, Madison Heights, MI 48071

Corrosion-preventive compound Commercially available


(MIL-C-6529, Type III)

Glass Beads, Class III, Ballotini Division, Potter Brothers Inc.,


Size AF or AG, Class MS-M Carlstadt, JN; Microbeads Division,
Cotophoto Corporation, Jackson, MS
39205

Methyl-ethyl-ketone (MEK) Commercially available


(ASTM D740)

Sand (120 grit) (MIL-A-22262) Commercially available

Solvent (Federal Specification Commercially available


P-D-680, Type I)

A. Follow general Cleaning Instructions

(1) Clean components in a clean, well-ventilated area, adequately lighted. Fire


extinguishers, rubber gloves, and other protective devices and equipment required by
cleaning methods and materials used be readily available.

WARNING: ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND FLAMMABLE.


USE IN WELL-VENTILATED AREA. AVOID BREATHING FUMES OR LONG
CONTACT WITH SKIN TO PREVENT DAMAGE TO PHYSICAL HEALTH.
KEEP AWAY FROM FLAME TO AVOID FIRE HAZARD.

(2) Remove adherent gasket or sealing compound residues using acetone (ASTM D239)
or methyl-ethyl-ketone (MEK) (ASTM D740) and a fiber bristled brush.

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1. A. (3) Clean painted parts but do not remove old paint if paint is still serviceable.

(4) Heat discoloration of metal surface is not objectionable, however, scale which may
come loose and damage the unit shall be removed.

(5) Corrosion products wherever they appear shall be removed and the base metal
treated to prevent further corrosion before assembly into a unit.

(6) Place parts in clean plastic bags or equivalent containers after cleaning for protection
from contaminants. Ports and orifices shall be capped, plugged, or sealed.

(7) Steel and 400 series stainless steel parts require the application of corrosion-
preventive compound (MIL-C-6529, Type III) after cleaning to prevent rust and
corrosion.

2. Cleaning

A. Degrease Parts Using Petroleum Solvent Cleaning Method

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH
CHEMICAL.

CLEAN PARTS IN AN AREA OPEN TO THE AIR AND THAT HAS GOOD
LIGHT AND SUFFICIENT SAFETY AND FIRE PREVENTION EQUIPMENT.

(1) Place solvent (Federal Specification P-D-680, Type I) in dip tank or use as a spray in a
positive outside-ventilated spray booth.

WARNING: SPRAY VAPORS ARE TOXIC AND SHALL NOT BE INHALED. OBSERVE
ALL FIRE PRECAUTIONS.

(2) Dip, soak, agitate, or spray parts to be cleaned until oil and grease have been
removed.

WARNING: USE THE CORRECT PERSONAL PROTECTION. ABRASIVE BLAST


PROCEDURES WILL CAUSE LOOSE PARTICLES THAT CAN GET IN
YOUR EYES.

(3) Remove caked grease or soft carbon deposits using a fiber-bristled brush. Hand
carbon deposits that remain after brushing may be removed by glass bead peening,
sandblasting, or soaking in a decarbonizing solution.

NOTE: Sandblasting or glass bead peening shall not be used if the part is to be
subjected to magnetic particle inspection.

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ENGINE - APPROVED REPAIRS

1. General

Table 801. Materials and Compounds

Material or Compound Manfacturer

NOTE: Equivalent substitutes may be used for listed items.

Abrasive Cloth, Grit 400 to 600 Commercially available


(A-A-1048 or A-A-1200)

Chromic acid (A-A-55827) Commercially available

Crocus Cloth (A-A-1206) Commercially available

Nitric Acid (A-A-59105) Commercially available

Powder (Iridite No. 14-2) MacDermid Inc, 526 Huntington Ave,


Waterbury, CT 06702

A. Repairs to the engine and engine components consists of a minor cleanup of small surface
scratches and dents. All other repair procedures shall be accomplished by removing a
defective or damaged subassembly or component, replacing it with a satisfactory component,
then sending the defective component to the indicated repair or overhaul depot.

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2. Approved Repairs

A. Repair Engine Minor Surface Damage

CAUTION: DO NOT USE CROCUS CLOTH ON ALUMINUM PARTS. CROCUS CLOTH


CONTAINS AN OXIDE OF IRON THAT CAUSES RAPID CORROSION OF
ALUMINUM.

(1) Remove minor nicks, burrs, scratches, and adherent corrosion from aluminum parts
using abrasive cloth (A-A-1048 or A-A-1200). Treat affected areas, if removal of
surface defect from part exposes base metal, in accordance with step (3).

(2) Remove minor nicks, burrs, and scratches from steel parts using crocus cloth
(A-A-1206).

(3) To repair minor damage to anodized surfaces, swab affected area with touch-up
solution. Prepare solution by mixing four ounces of powder (Iridiate No. 14-2) per
gallon distilled water. Adjust pH of 0.9 to 1.0 by adding chromic acid (A-A-55827) or
nitric acid (A-A-59105) to solution. Use solution at room temperature. Allow affected
areas to remain wetted for one minute, then rinse in tap water and dry in an air blast.

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EXTERNAL PARTS INSTALLATION - MAINTENANCE PRACTICES

TABLE OF CONTENTS

SUBJECT PAGE

Removal/Inspection 202
Inspection/Check 212
Cleaning/Painting 212

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EXTERNAL PARTS INSTALLATION - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Fuel (MIL-DTL-5624, Grade JP4 Commercially available


or JP5)

Lubricant (OS-124 or Santovac 5) Monsanto Co, Fibers Business Unit, 800 N Lindbergh
Blvd, St. Louis, MO 63167

Lubricating compound Lockrey Co., Inc., Lubricants Div., 2517


(Liqui-Moly, Grade NV) Finlaw Ave., Pennsauken, NJ 08109

Oil (MIL-PRF-7808 Commercially available


or MIL-PRF-23699)

A. Remove External Parts Installation

NOTE: Replace all packings and gaskets.

(1) Disassembly of details of external parts installation may be accomplished as


accessible and feasible during removal of accessory items from engine as defined in
various sections. Note orientation of components and manner of attachment. Refer to
Section 49-20-00, REMOVAL/INSTALLATION for disassembly of plumbing and
electrical installation components when required. (Refer to Figures 401 through 407.)

B. Install External Parts Installation

NOTE: All packings are to be installed using a lubricant compatible with the system in
which the packing is located; i.e., packings used in the lubricating system shall be
coated with oil (MIL-PRF-7808 or MIL-PRF-23699). An approved alternate method
is to use lubricant (OS-124 or Santovac 5) on all packings prior to installation.

(1) Coat threads of tube (CRES) (110, Figure 201) with lubricating compound (Liqui-Moly,
Grade NV) and install with new gasket (120). Tighten tube assembly to torque value
of 1385 to 1440 inch-pounds.

(2) Install tube assembly (90) with new front and rear packings (80, 100). Install fitting
(40) with spring (50) and new center packings (60, 70). Install bolts (10, 20) and
washers (30). Tighten bolts to torque value to 50 to 70 inch-pounds.

(3) Install nut (30) and new packing (20) on tee assembly (10). Install and position tee
assembly so that the arrow on the tee body is pointing aft of the APU. Tighten the nut
to torque value of 30 to 40 inch-pounds.

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External Parts Removal/Installation


Figure 201

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KEY TO FIGURE 201

* 10. FITTING (ATA NO. 49-23-04, 180. NUT (IPC FIG. 4, 49-20-00)
IPC FIG. 12) 190. WASHER
* 20. BOLT 200. BRACKET ASSY.
* 25. BOLT 210. SPACER WASHER
* 30. WASHER 220. BOLT
* 40. SPRING 240. SPACER (IPC FIG.6, 49-20-00)
* 50. PACKING 260. BOLT
* 60. PACKING 270. BOLT
* 70. PACKING 280. BRACKET (200, IPC FIG. 6,
* 80. TUBE ASSY. 49-20-00)
* 90. PACKING 290. NUT (210, IPC FIG. 6, 49-20-00)
*100. TUBE 300. WASHER (220, IPC FIG. 6, 49-20-00)
*110. GASKET

*COMPONENT OF COMPRESSOR AND TURBINE ASSEMBLY

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External Parts Removal/Installation


Figure 202

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KEY TO FIGURE 202

10. IDENTIFICATION PLATE 120. WARNING TAG


(IPC FIG. 2, 49-20-00) 180. SCREW
20. SCREW (IPC FIG. 6, 49-20-00)
110. WARNING TAG 190. IDENTIFICATION PLATE
(IPC FIG.1, 49-20-04)

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External Part Removal/Installation


Figure 203

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KEY TO FIGURE 203

10. SCREW (210, IPC FIG. 2, 49-20-00) 150. WASHER


10A. SCREW (210A, IPC FIG. 2, 49-20-00) 160. BOLT
20. WASHER (220, IPC FIG. 2, 49-20-00) 170. WASHER (150, IPC FIG. 6,
30. BRACKET (200, IPC FIG. 2, 49-20-00) 49-20-00)
30A. BRACKET (200A, IPC FIG. 2, 49-20-00) 180. WASHER (50, IPC FIG. 7,
40. NUT (60, IPC FIG. 4, 49-20-00) FIG. 6, 49-20-00)
50. WASHER (70, IPC FIG. 4, 49-20-00) 190. PANEL ASSY. (170, IPC
60. SPACER WASHER (80, IPC FIG. 4, FIG. 6, 49-20-00)
49-20-00) 200. SCREW (40, IPC FIG. 6,
70. BOLT (90, IPC FIG. 4, 49-20-00) 49-20-00)
80. BRACKET (50, IPC FIG. 4, 49-20-00) 210. WASHER (50, IPC FIG. 6,
90. SCREW (IPC FIG. 5, 49-20-00) 49-20-00)
100. WASHER 220. MOUNT ASSY. (60, IPC
110. PACKING W/RTNR FIG. 6, 49-20-00)
120. CLAMP (70, IPC FIG. 5, 49-20-00) 230. GROMMET (60, IPC FIG. 7,
130. BRACKET (80, IPC FIG. 5, 49-20-00) 49-20-00)
140. BOLT (IPC FIG. 6, 49-20-00)

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External Parts Removal/Installation


Figure 204

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KEY TO FIGURE 204

130. NUT 560. TEE ASSY


140. TEE ASSY 570. PACKING
150. PACKING 670. PLUG (IPC FIG. 1, 49-20-01)
550. NUT (IPC FIG. 4, 49-20-01) 680. PACKING

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2. Inspection/Check

A. Check External Parts

(1) Visually check fitting (10, Figure 201), tube (100), and tube assembly (80) for cracks,
crossed threads, or other physical damages.

(2) Check tee assemblies (140 and 560, Figure 204) in accordance with Figure 205.

3. Cleaning/Painting

A. Clean External Parts

(1) Use solvent (Section 49-20-00, Table 701) in a dip tank or spray. Observe cleaning
instructions outlined in Section 49-20-00, CLEANING/PAINTING.

CAUTION: CHECK THAT ALL OPENINGS ARE FREE OF OBSTRUCTION.

(2) Ports and orifices shall be capped, plugged or sealed until assembly.

DIA A 0.30 to 0.34 in. (PN 692755-90/-100)


0.138 to 0.142 in. (PN 3604865-3)
DIA B 0.017 to 0.022 in. (PN 692755-100)

Inspection of Orifice Tee Assembly


Figure 205

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COMBUSTION AND EXHAUST SECTION - MAINTENANCE PRACTICE

TABLE OF CONTENTS

SUBJECT PAGE

Removal/Inspection 202
Inspection/Check 205

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COMBUSTION AND EXHAUST SECTION - MAINTENANCE PRACTICES

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1. Removal/Installation

A. Remove Combustor Unit (Refer to Figure 201)

NOTE: The combustor unit consists of a liner assembly, combustor cap, igniter plug, and
fuel atomizer assembly.

(1) Disconnect igniter plug lead from igniter plug and fuel supply line from fuel atomizer
assembly.

(2) Loosen coupling (10) then remove combustor unit (30) from engine. Remove and
discard packing (20).

NOTE: Check hot section components (Figure 202) prior to installing combustor
unit. The hot section components may be checked by observation through
the combustor unit opening in the turbine plenum assembly to the extent
that the components are visible.

The removed combustor unit (combustion liner assembly portion) should be checked
for cracks, erosion, buckling, and hot sports in accordance with step 2.B.(6). If liner
assembly damage is indicated, a closer examination of the engine hot section
components should be undertaken to make sure that the damage is limited to the liner
assembly.

B. Install Combustor Unit (Refer to Figure 201)

(1) Install existing combustor unit.

(a) Apply a thin film of lubricant (OS-124 or Santovac 5) to the new packing (20).
Install the combustor unit (30) with new packing into the engine.

CAUTION: MAKE SURE THE TEE-BOLT AND NUT THREADS OF COUPLING


(10) ARE NOT WORN, GALLED, STRIPPED OR HAVE OTHER
DAMAGE AND THAT THE NUT IS NOT CROSS-THREADED
BEFORE TIGHTENING.

(b) Position coupling (10) around flanges of combustor unit and plenum assembly
flanges with nut on coupling pointing downward. Tighten nut on coupling to
torque value of 50 to 70 inch-pounds and lockwire per AS 567.

(2) Install serviceable or replacement combustor unit.

NOTE: Make sure that fuel atomizer assembly and ignitor plug bolts are
loose enough to allow self-aligning of liner assembly and torus
opening.

(a) Install engine identification plate, if applicable, on replacement combustor unit


with attaching screws. If new identification plate is used, make sure that all
data stamped on the old identification plate is transferred to the new
identification plate.

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10. COUPLING (IPC FIG. 1) 30. COMBUSTOR UNIT


20. PACKING

Combustor Unit Removal/Installation


Figure 201

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1. B. (2) (b) Apply a thin film of lubricant (OS-124 or Santovac 5) to new packing (20).
Install new packing, coupling (10), and combustor unit (30) on the turbine
plenum assembly.

(c) Install coupling with nut on coupling pointing downward. Tighten coupling nut
on coupling to torque value of 50 to 70 inch-pounds and lockwire per AS 567.

(d) Tighten igniter plug bolts to a torque value of 50 to 70 inch-pounds plus


fractional torque and lockwire per AS 567.

(e) Tighten atomizer bolts to a torque value of 20 inch-pounds and lockwire per
AS 567.

2. Inspection/Check

A. General

The following methods and procedures can be accomplished by personnel who maintain the
equipment in the field. A careful visual inspection shall precede any detail checks to eliminate
unnecessary inspection procedures and to determine the extent of further checking. Long life
and continued efficient operation of the engine depend upon the care and accuracy with which
inspections are conducted.

B. Inspect Hot Section Components (Refer to Figure 202)

(1) (Pre SB 49-3914) Check containment ring for security of mounting. Check
containment ring through liner opening in plenum assembly by exerting finger pressure
on the ring and assuring that it cannot be moved to a "cocked" position; freedom of the
ring to "float" is normal, however, axial movement shall not exceed 1/8-inch. If the ring
position is suspect, use inspection mirror and flashlight to assure that the two washers
that may be viewed are in place and no evidence of washer fretting beyond 50 percent
of original thickness is indicated. If axial movement exceeds 1/8-inch or washer
fretting beyond 50 percent of the original thickness is indicated, remove the engine
from the installation and perform a detailed inspection of the engine hot section in
accordance with instructions outlined in the Heavy Maintenance Section of Engine
Overhaul Manual ATA No. 49-21-83.

(Post SB 49-3914) Check containment ring through liner opening in plenum assembly
exerting finger pressure n the ring and assuring that it cannot be moved with brackets
installed.

(2) Check turbine plenum gasket for evidence of deterioration or leakage. If deterioration
or leakage is indicated, remove the engine from the installation and perform a detailed
inspection of the engine hot section in accordance with instructions outlined in the
Heavy Maintenance Section of Engine Overhaul Manual ATA No. 49-21-83.

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Inspection of Hot Section Components


Figure 202

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2. B. (3) Check that oil tank vent tube assembly ID and opening in flange are not obstructed. If
obstructions are indicated, remove and clean in accordance with Section 49-20-00,
CLEANING/PAINTING. Install oil tank vent tube assembly and flange in accordance
with Section 49-20-00, REMOVAL/INSTALLATION.

(4) Visually check turbine plenum assembly for cracks in welds and adjoining material. If
cracks are indicated, remove the engine from the installation and perform a detailed
inspection of the engine hot section in accordance with instructions outlined in the
Heavy Maintenance Section of Engine Overhaul Manual ATA No. 49-21-83.

(5) Visually check the turbine nozzle, turbine torus assembly (Refer to Figure 202A), and
turbine wheel by observing through the liner opening in the plenum assembly. The
purpose of this limited inspection is to check for obvious distress to the extent possible
through the opening available, using inspection mirror and flashlight or equivalent. If
severe distress is observed, remove the engine from the installation and perform a
detailed inspection of the engine hot section in accordance with instructions outlines in
the Heavy Maintenance Section of Engine Overhaul Manual ATA No. 49-21-83.

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1. CHECK INLET FLANGE (INCLUDING THROAT AREA) OF THE TORUS FOR DEFORMATION.
DEFORMATION LESS THAN 1/4-INCH IN DEPTH IS PERMISSIBLE.

2. CHECK THE FLANGE TO MAKE SURE THAT SPRAY COATING WEAR IS NOT THROUGH TO
BASE METAL.

3. CHECK ACCESSIBLE AREA OF THE TORUS FOR CLOSED CRACKS. CRACKS LESS THAN 1-1/2
INCHES ARE PERMISSIBLE PROVIDED NO INTERSECTING CRACKS EXIST WHICH COULD
CAUSE MATERIAL TO BREAK AWAY.

4. CHECK VISIBLE DRILLED HOLES IN THE TORUS FOR CLOSED CRACKS NOT EXCEEDING 1-1/2
INCHES. THESE CRACKS ARE PERMISSIBLE PROVIDED IT IS NOT POSSIBLE FOR MATERIAL
TO BREAK AWAY DUE TO INTERSECTING CRACKS.

Limited Visual Check of Turbine


Torus Assembly (Typical)
Figure 202A

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2. B. (6) Check combustor unit (combustion liner assembly portion) as follows. (Refer to Figure
203)

(a) Check for cracks connecting holes (item 1). No cracks permitted.

(b) Check tube for cracks (item 2). Cracks one-fourth inch or less are
acceptable. Cracks greater than one-fourth inch shall be repaired.

(c) Check distance between cracks (item 3). Cracks separated by less than
0.030 inch due to corrosion or erosion shall be repaired.

(d) Check tube for buckling (item 6). Buckling with greater than one-eighth inch
deformation shall be repaired.

(e) Check tube for cracks which could cause material to break away (item 7).
Cracks which could cause material to break away shall be repaired.

(f) Check spacers for wear (item 5). Replace spacers or entire discharge end of
combustion liner assembly if spacer thickness is less than 0.020 inch.

(g) Check swirl for cracks (item 8). Cracks shall not exceed the limits of
Dimensions AM and cannot be intersecting.

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NOTE: 1. Swirl inspection for Combustion Liner Assembly looking through the
opening in the liner.

DIM. AM 0.250 IN. MAX.

Inspection of Combustion Liner Assembly


Figure 203

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ACCESSORY GEARCASE SEALS - MAINTENANCE PRACTICES

TABLE OF CONTENTS

SUBJECT PAGE

Removal/Inspection 202

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ACCESSORY GEARCASE SEALS - MAINTENANCE PRACTICES

Page 201
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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Adhesive Glyptal, Inc.


(Glyptal 1276) 305 Eastern Ave.
Chelsea, MA 02150

Compound Loctite Corp., 1001 Trout Brook Crossing


(Loctite Grade AV) Rocky Hill, CT 06067-3582

Lubrication (OS-124 or Santovac 5) Monsanto Co, Fibers Business Unit, 800 N Lindbergh
Blvd, St. Louis, MO 63167

Table 202. Special Tool, Fixtures and Equipment

Item Source/
No. Nomenclature Use Part No.

NOTE: Equivalent substitutes may be used for listed items.

1. Spanner Wrench To loosen or tighten output 253562-1


shaft nut.

2. Seal Driver To guide and press carbon 259560


seal into seal retainer
without damaging face of
seal.

3. Wrench Adapter Adapts to standard torque 285418-1-1


(Use with Wrench wrench and holds output
PN 253562-1) shaft when loosening or
tightening output shaft nut.

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1. A. Removal

(1) Remove output shaft bearing seal as follows. (Refer to Figure 201.)

NOTE: Record the number and thickness of shim washers (70) removed as an aid
at assembly.

(a) Remove screws (10) and washers (20), then remove retainer (30 with packing
(40) and seal stator (60). Remove shim washers (70).

(b) Press seal stator (60) from retainer (30). Remove packing (40) from retainer.
Discard packing and seal stator.

NOTE: Record the number and thickness of washers (120) removed as an


aid at assembly.

(c) Straighten tab of key (80). Hold output shaft using 285418-1 wrench adapter,
then remove nut (90) using 253562-1 spanner wrench. Remove spacer (100),
key (80), seal rotor (110), and washers (120). Discard the key and seal rotor.

10.SCREW (IPC FIG. 1, 49-26-02) 70. SHIM WASHER


20.WASHER 80. KEY
30.RETAINER 90. NUT
40.PACKING 100. SPACER
60.SEAL STATOR 110. SEAL ROTOR
120. WASHER

Removal of
Output Shaft Bearing Seal Assembly
Figure 201

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1. A. (2) Remove fuel control seal as follows. (Refer to Figure 202.)

(a) Remove fuel control unit in accordance with Section 49-30-01.

(b) Remove seal retainer (150) with ring (160), fuel control seal (170) and packing
(40) from gearcase assembly.

(c) Remove ring (160), fuel control seal (170), and packing (180) from retainer
(150). Discard seal and packing.

150. SEAL RETAINER (IPC FIG. 1, 49-26-02) 170. FUEL CONTROL SEAL
160. RING 180. PACKING

Removal of Fuel Control Seal


Figure 202

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Installation of Output Shaft Bearing Seal


(Determining Thickness of Shim Washers)
Figure 203 (Sheet 1 of 2)

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1. B. Installation

(1) Install output shaft bearing seal as follows.

NOTE: The following shimming procedure provides a 0.002 to 0.005 inch pinch
between retainer and outer race of bearing.

(a) Determine thickness required for shim washers (70, Figure 201) as follows.
(Refer to Figure 203, Sheet 1.)

1 Measure Dimension A and B. Subtract Dimension B from Dimension


A and record result as Dimension C.

2 Add required pinch on outer race of bearing (0.000 to 0.003 inch) to


Dimension C and record result as Dimension D.

3 Dimension D equals thickness of shim washers (70, Figure 201)


required to provide 0.002 to 0.005 inch pinch on outer race of bearing.

(b) Determine thickness required for washers (120, Figure 201 ) as follows.
(Refer to Figure 203, Sheet 1).

NOTE: The following shimming procedure provides a 0.734 to 0.739 inch


seal assembly operating length.

1 Measure Dimension E. Add Dimension D recorded in step (a) to


Dimension E and record result as Dimension F.

2 Subtract required seal assembly operating length (0.734 to 0.739


inch) from Dimension F and record result as Dimension G.

3 Dimension G equals thickness of washers (120, Figure 201) required


to provide 0.734 to 0.739 inch seal assembly operating length.

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Installation of
Output Shaft Bearing Seal Assembly
Figure 203 (Sheet 2)

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1. B. (1) (c) Install thickness of washers (120, Figure 203 (Sheet 2)) determined in step
(b).

(d) Carefully clean faces of seal rotor (110) using lint-free cloth, then install seal
rotor (110) with flat face facing outward. Install spacer (100).

(e) Install key (80) in slot of output shaft. Apply compound (Loctite Grade AV) to
threads of nut (90), then install nut. Using 253562-1 wrench, 285418-1-1
wrench adapter, and a torque wrench, apply 145 to 155 inch-pounds torque to
nut. Bend key up into slot of nut.

CAUTION: IF SLOT IN NUT FOR KEY DOES NOT ALIGN, REPLACE NUT. DO
NOT ADD SHIMS.

(f) Coat mating surfaces of new seal stator (60) and retainer (30) with adhesive
(Glyptal No. 1276). Press seal stator (60) in retainer (30) using 259560 driver.

(g) Install required thickness of shim washers (70) determined in step (a) against
bearing outer race. Install retainer (30) with assembled seal stator on output
shaft over nut and seal rotor. Secure with washer (20) and screws (10).
Tighten screws to a torque value of 15 to 20 inch-pounds.

KEY TO FIGURE 203 (SHEET 2)

10. SCREW (IPC FIG. 1, 49-26-02) 80. KEY


20. WASHER 90. NUT
30. RETAINER 100. SPACER
40. PACKING 110. SEAL ROTOR
60. SEAL STATOR 120. WASHER
70. SHIM WASHER

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150. SEAL RETAINER (IPC FIG. 1, 49-26-02) 170. FUEL CONTROL SEAL
160. RING 180. PACKING

Installation of Fuel Control Seal


Figure 204

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1. B. (2) Install fuel control seal as follows: (Refer to Figure 204.)

(a) Install new fuel control seal (170), in seal retainer (150) with seal lip oriented
as shown in Figure 204. Secure seal in place with ring (160).

(b) Install new packing (180) dry if possible. When dry installation is difficult to
accomplish or physical damage could occur, apply lubricant (OS-124 or
Santovac 5) to packing. Install seal retainer (150) with packing in gearcase
assembly.

(c) Install fuel control unit in accordance with Section 49-30-01.

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ENGINE FUEL AND CONTROL SECTION

TABLE OF CONTENTS

SECTION
SUBJECT SUBJECT PAGE

DESCRIPTION AND OPERATION 49-30-00


Description and Operation 1
Trouble Shooting 101
FUEL CONTROL UNIT 49-30-01
Maintenance Practices 201
REDUCER ORIFICE (TURBINE PLENUM DRAIN) 49-30-10
Maintenance Practices 201

Page TC-1/TC-2
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ENGINE FUEL AND CONTROL SECTION - DESCRIPTION AND OPERATION

1. Description

The engine fuel and control system is fully automatic in operation and does not require external
controls. A customer-furnished source of specified fuel and electrical power is required. The system
consists of a fuel control unit and an integral fuel filter mounted on the front of the accessory assembly,
a fuel solenoid valve mounted on the fuel control unit, a fuel atomizer assembly mounted on the turbine
section combustor cap, and adjustable pneumatic thermostat mounted in the turbine exhaust flange, a
reducer orifice (turbine plenum drain) fitting mounted on the combustor cap, and the necessary
plumbing and fittings.

2. Operation

When clean pressurized fuel is delivered to the fuel control unit fuel inlet and the engine started, fuel is
pumped by the fuel control unit gears through a fuel filter to the fuel solenoid valve. The fuel solenoid
valve is automatically opened as engine oil pressure builds up and permits fuel to flow to the fuel
atomizer assembly. Low pressure fuel passes through the primary orifices in the fuel atomizer
assembly and is sprayed into the combustion chamber. As fuel pressure increases, fuel passes
through both primary and secondary orifices in the fuel atomizer assembly to provide adequate fuel
spray. (Refer to Figure 2.)

Fuel flow during acceleration is metered by the acceleration limiter valve in the fuel control unit to
provide smooth acceleration; fuel flow during normal speed operation is metered by the fuel governor
in the fuel control unit to maintain constant speed. Fuel flow at overtemperature conditions is
modulated by action of the pneumatic thermostat operating in the acceleration mode in conjunction
with a three-way solenoid shutoff valve to bleed control air from the acceleration limiter valve in the fuel
control unit.

Small quantities of fuel which may collect in the bottom of the turbine plenum are drained through the
turbine plenum drain. Other fuel drain connections a relocated at the fuel control unit acceleration
limiter valve and drive shaft seal.

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1. FUEL CONTROL UNIT (REFER TO SECTION 49-30-01)


2. TURBINE PLENUM DRAIN (REFER TO SECTION 49-30-01)
3. FUEL ATOMIZER ASSY (REFER TO SECTION 49-30-10)
4. FUEL ECONOMY SOLENOID VALVE POST SB 49-5233,
DHF[A] (REFER TO SECTION 49-60-61)

Engine Fuel and Control Section


Figure 1

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Fuel Control System and


Bleed-Air Control System
Figure 2

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ENGINE FUEL AND CONTROL SECTION - TROUBLE SHOOTING

1. General

Trouble shooting procedures for the engine fuel and control system are outlined in Section 49-20-00,
TROUBLE SHOOTING.

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FUEL CONTROL UNIT - MAINTENANCE PRACTICES

Page 201
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1. Removal/Installation

Table 201. Materials and compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Fuel (MIL-DTL-5624, Grade JP4 or JP5) Commercially available

Grease (MIL-G-21164) Commercially available

Grease (Mobil 29) (MIL-G-81827) Mobil Oil Corp., P.O. Box 3311, Beaumont,
(Molybdenum-Disulphide) TX 77704

(Royco 13D) Royal Lubricants Co., Inc., 215 Merry Ln


East Hanover, NJ 07936-0518

1. A. Remove Fuel Control Unit (Refer to Figure 201)

(1) Disconnect low pressure fuel inlet.

(2) Remove all tube assemblies. Disconnect electrical connector. (Refer to Section
49-20-00, REMOVAL/INSTALLATION.)

NOTE: Avoid loss of drive shaft.

(3) Remove attaching nuts (180) and carefully withdraw fuel control units in a straight line
to avoid damage to shaft splines and mounting studs.

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1. B. Install Fuel Control Unit (Refer to Figure 201)

(1) Clean and visually check the gearcase assembly mating splines for signs of wear or
damage. No wear or damage is permitted.

(2) Apply a light coat of grease (MIL-G-21164, Mobil 29, or Royco 13D) to square drive
flats and splined teeth of fuel control unit drive shaft.

(3) Carefully install fuel control unit (170) on studs on accessory gearcase, exercising care
as drive shaft splines mesh with accessory gearcase splines.

(4) Install attaching nuts (180) and tighten to torque value of 70 to 90 inch-pounds.

(5) Connect harness assembly to fuel solenoid valve and connect all tube assemblies to
applicable ports. (Refer to Section 49-20-00, REMOVAL/INSTALLATION.)

170. FUEL CONTROL UNIT (IPC FIG. 5, 49-20-00)


180. NUT

Fuel Control Unit Removal/Installation (Typical)


Figure 201

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1. C. Remove Fuel Solenoid Valve (Refer to Figure 202)

(1) Shut off fuel supply to fuel control unit.

(2) Remove nut (10) and washer (20), then remove assembled fuel solenoid valve (40)
and fitting (50). Remove washer (30), fitting (50), and packings (60, 70). Discard
packings.

D. Install Fuel Solenoid Valve (Refer to Figure 202)

(1) Apply thin film of fuel (MIL-DTL-5624, Grade JP4 or JP5) to packings, then install
fitting with new packing (60) on fuel solenoid valve. Install new packings (70) on fitting
(50).

(2) Install assembled fitting (50) and washer (30) in fuel control unit, orienting fuel solenoid
valve (40) as shown in Figure 202.

(3) Install washer (20) and nut (10) and tighten to a torque of 100 to 110 inch-pounds.

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*10. NUT (IPC FIG. 11, 49-20-00) *50. FITTING


*20. WASHER *60. PACKING
*30. WASHER *70. PACKING
*40. FUEL SOLENOID VALVE

*Component of Fuel Control Unit

Fuel Solenoid Valve Removal/Installation


Figure 202

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1. E. Remove Fuel Filter Element (Refer to Figure 203)

(1) Shut off fuel supply to fuel control unit.

(2) Remove filter cap (10) from fuel control unit.

(3) Remove packings (20, 40) and fuel filter element (30) and discard.

F. Install fuel Filter Element

(1) Apply thin film of fuel (MIL-DTL-5624, Grade JP4 or JP5) to packings (20, 40).

(2) Install new packing (40 in fuel filter element (30) and position filter element over spigot
in fuel control unit.

(3) Screw filter cap (10) with packing (20) in fuel control unit until filter cap bottoms out,
then tighten to a torque value of 100 to 120 inch-pounds.

*10. FILTER CAP (IPC FIG. 12, 49-20-00) *30. FUEL FILTER ELEMENT
*20. PACKING *40. PACKING

*Component of Fuel Control Unit

Fuel Filter Element Removal/Installation


Figure 203

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2. Inspection/Check

A. Inspect Fuel Solenoid Valve

(1) Check case for cracks or other damage.

(2) Check that fuel passages are clear and free from foreign material.

(3) Check for continuity between pins A and B. Continuity shall be indicated.

(4) Apply 11 to 30 volts dc to pins A and B. Solenoid valve shall open.

3. Adjustment/Test

A. Perform the Following Checks and Adjustments

(1) Check acceleration limiter cracking pressure and adjust. (Refer to Section 49-20-00,
ADJUSTMENTS/TEST.)

(2) Check governor setting and adjust. (Refer to Section 49-20-00,


ADJUSTMENT/TEST.)

4. Cleaning/Painting

Clean components, as necessary, in accordance with Section 49-20-00, CLEANING/PAINTING.

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REDUCER ORIFICE (TURBINE PLENUM DRAIN) - MAINTENANCE PRACTICES

Page 201
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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Fuel (MIL-DTL-5624, Grade JP4 or JP5) Commercially available

Lubricant (OS-124 or Santovac 5) Monsanto Co, Fibers Business Unit, 800 N Lindbergh
Blvd, St. Louis, MO 63167

A. Remove Turbine Plenum Drain (Refer to Figure 201)

(1) Disconnect turbine plenum drain line (customer furnished).

(2) Unscrew turbine plenum drain (90) from cap assembly and remove packing (100).
Discard packing.

B. Install Turbine Plenum Drain (Refer to Figure 201)

(1) Apply a thin film of fuel (MIL-DTL-5624, Grade JP4 or JP5) or lubricant (OS-124 or
Santovac 5) to packing (100), then install turbine plenum drain (90) with new packing
onto cap assembly.

(2) Connect turbine plenum drain line (customer furnished).

2. Inspection/Check

Check turbine plenum drain for cracks, corrosion, and damage to threads.
Check that the opening is free of obstruction.

3. Cleaning/Painting

WARNING: ALL CLEANING SHALL BE PERFORMED IN A CLEAN, WELL VENTILATED AND WELL
LIGHTED ROOM. RUBBER GLOVES AND PROTECTIVE MASKS AND CLOTHING SHALL
BE WORN. VATS AND TANKS SHALL HAVE METAL COVERS AND SPRAY BOOTHS
SHALL HAVE POSITIVE VENTILATION TO THE OUTSIDE OF THE BUILDING. FIRE
EXTINGUISHERS SHALL BE READILY AVAILABLE.

The turbine plenum drain may be cleaned by soaking it in solvent (Section 49-20-00,
CLEANING/PAINTING, Table 701.) Check that the opening is free of obstruction.

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90. REDUCER ORIFICE 100. PACKING


(IPC FIG. 1, 49-20-04)

Reducer Orifice (Turbine Plenum Drain)


Removal/Installation
Figure 201

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IGNITION/STARTER SECTION

TABLE OF CONTENTS

SECTION
SUBJECT SUBJECT PAGE

DESCRIPTION AND OPERATION 49-40-00


Description and Operation 1
Trouble Shooting 101
ELECTRICAL STARTER ASSY 49-40-01
Maintenance Practices 201
IGNITER PLUG 49-40-02
Maintenance Practices 201
IGNITION UNIT 49-40-05
Maintenance Practices 201

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IGNITION/STARTING SECTION - DESCRIPTION AND OPERATION

1. Description

The ignition/starting system is fully automatic in operation; however, customer-furnished start switch,
start relay, and 26 volt dc power source are required for starting. The system consists of an electrical
engine starter, an ignition unit, an igniter plug, a high temperature ignition lead assembly, and the
necessary wiring. (Refer to Figure 1.)

2. Operation

When the customer start switch is actuated and the customer relay closes, the starter begins rotating
and drives the accessory gear train. The oil pump gears build up oil pressure; rising oil pressure
actuates the sequencing oil pressure switch, which completes a circuit to the fuel solenoid valve and to
the ignition unit. The energized ignition unit delivers power through the ignition lead assembly to the
igniter plug for firing and the fuel solenoid valve opens to allow fuel flow to the atomizer assembly for
combustion.

As the engine speed increases, the 35-percent switch in the centrifugal switch assembly is opened,
which breaks the circuit to the starter. When engine speed reaches 95 percent, the 95-percent switch
in the centrifugal switch assembly closes which opens the circuit to the ignition unit. If a flameout
occurs, the ignition circuit is re-energized when the engine speed drops below 95 percent.

Page 1
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GTCP85-98DHF/[A]

1. IGNITER PLUG (REFER TO SECTION 49-40-02)


2. ELECTRICAL STARTER ASSY (REFER TO SECTION 49-40-01)
3. IGNITION UNIT (REFER TO SECTION 49-40-05)

Ignition/Starting Section
Figure 1

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MAINTENANCE MANUAL
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IGNITION/STARTING SECTION - TROUBLE SHOOTING

1. General

Trouble shooting procedures for the engine controls system are outlined in Section 49-20-00,
TROUBLE SHOOTING.

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ELECTRICAL STARTER ASSEMBLY - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Oil (MIL-PRF-7808 Commercially available


or (MIL-PRF-23699)

Table 202. Special Tools, Fixtures and Equipment

Source/
Nomenclature Use Part No.

NOTE: Equivalent substitutes may be used for listed items.

Clutch Torquing Holder Holds starter motor housing 285541-1-1


during assembly.

Torque Wrench Adapter Engages clutch pawls when 286782-1


checking slip torque.

Torque Wrench Adapter Engages clutch pawls when 280368


(Alternate) checking slip torque.

Torque Wrench (0 to 300 Check slip torque Commercially


inch-pound dial indicator, available
5 inch-pound increments)

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THIS PAGE INTENTIONALLY LEFT BLANK

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310. ELECTRICAL STARTER ASSY 320. NUT


(IPC FIG. 6, 49-20-00) 330. PACKING

Electrical Starter Assembly


Removal/Installation
Figure 201

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1. A. Removal of the Electrical Starter Assembly (Refer to Figure 201)

(1) Disconnect positive electrical lead and negative electrical lead from terminal posts on
electrical starter assembly.

CAUTION: IF STARTER ASSEMBLY IS BEING REPLACED DUE TO A CLUTCH


FAILURE, CHECK THE CLUTCH PORTION OF THE STARTER ASSEMBLY
FOR MISSING PARTS. IF MISSING CLUTCH PARTS ARE INDICATED, (1)
REMOVE OIL PUMP ASSEMBLY FOR OVERHAUL, (2) DISASSEMBLE THE
ACCESSORY DRIVE GEARCASE ASSEMBLY TO THE EXTENT
REQUIRED TO MAKE SURE THAT ALL DEBRIS FROM THE FAILURE IS
REMOVED AND MOVING PARTS ARE DAMAGE FREE (REFER TO
ENGINE OVERHAUL MANUAL ATA NO. 49-21-83), AND (3) FLUSH
ENGINE LUBRICATING SYSTEM PRIOR TO INSTALLING REPLACEMENT
OIL PUMP AND ASSEMBLIES.

(2) Remove attaching nuts (320), then carefully withdraw the electrical assembly (310) in
a straight line. Remove and discard packing (330).

B. Install Electrical Starter Assembly (Refer to Figure 201)

(1) Install new packing (330), then carefully install electrical starter assembly (310) on
studs on accessory assembly mounting pad, exercising care as the electrical starter
assembly clutch enters the gearcase.

(2) Install attaching nuts (320) and tighten to a torque value of 70 inch-pounds.

(3) Connect the positive electrical lead and negative electrical lead to the electrical starter
assembly terminal posts.

2. Adjustment/Test

A. Check and Adjust Electric Starter Clutch Slip Torque

(1) Place the electrical starter assembly (310, Figure 201) in a 285541-1-1 holder that will
prevent rotation of the motor armature.

(2) Remove retaining ring (90, Figure 202A) from the spider (70) and lift keyed washer
(100A) out of the slots on the retaining ring (110).

(3) Spray a light film of oil (MIL-PRF-7808 or MIL-PRF-23699) on the clutch parts.

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*60. PAWL (IPC FIG. 1, *150. RETAINER


ATA NO. 49-40-01) *190. STARTER MOTOR

*COMPONENT OF STARTER ASSEMBLY

Adjusting the Clutch Slip Torque


Figure 202

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*60. PAWL (IPC FIG. 1, *100A. WASHER


ATA NO. 49-40-01) *110. RING
*70. SPIDER *150. RETAINER

*COMPONENT OF THE STARTER ASSEMBLY

Starter Clutch Adjustment


Figure 202A

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2. A. (4) (Preferred Method) Insert 296782-1 adapter over retainer (150, Figure 202) engaging
pawls (60).

(Alternate Method) Insert 280368 adapter into retainer (150), engaging pawls (60).

NOTE: Slip torque is the torque reading obtained during a slow steady clutch slip
as noted by rotation of the retainer. It is the slip torque that is to be set at
values listed below. Breakaway torque is to be set at values listed below.
Breakaway torque is defined as the initial torque applied prior to clutch slip.

(5) Attach suitable torque wrench (dial indicator type, 0 to 300 inch-pounds, 5 inch-pounds
increments or equivalent) and turn adapter clockwise to check torque required to slip
the clutch.

(Part No. 372697-21) Slip torque shall be 135 to 145 inch-pounds.

(Part No. 3605812-10) Slip torque shall be 130 to 170 inch-pounds.

(Part No. 3605912-14/-17) Slip torque shall be 130 to 150 inch-pounds.

(6) Adjust slip torque if required by tightening or loosening the retaining ring (110, Figure
202A). Slip clutch 10 revolutions and recheck slip torque in accordance with step (5).
Install keyed washer (110A) and retaining ring (90).

NOTE: No tests of electrical starter assembly are required at field level.

(7) Check for free movement of drive pawls (60). Drive pawls shall pivot freely and not
stick or bind.

3. Inspection/Check

A. Check Starter Brush Assembly Wear (Refer to Figure 203)

(1) Remove attaching nuts and clamp from starter. Remove any accumulation of brush
residue with clean, dry low pressure air.

(2) Visually check brush assembly leads for discoloration. If leads are discolored, remove
starter and send to an authorized overhaul facility for a brush assembly change and
run-in.

NOTE: A 0.340 inch distance from the top of the brush holder cap to the top of
each brush assembly equates to approximately 400 APU operating hours
remaining; a 0.290 inch distance equates to approximately 800 APU
operating hours remaining.

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3. A. (3) Measure the distance from the top of the brush holder cap to the top of each brush
assembly. If the brush assembly wear exceeds the limit specified in Figure 203,
remove the starter and send it to an authorized overhaul facility for brush change and
run-in.

(4) Install the clamp and secure it with attaching nuts.

Starter Brush Assembly Inspection/Check


Figure 203

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IGNITER PLUG - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

High temperature compound Fel-Pro Inc., Div. of Felt Products Mfg. Co.,
(Fel-Pro C5-A) 7450 N. McCormick Blvd., Skokie, IL
60076

A. Remove Igniter Plug (Refer to Figure 201)

WARNING: THE IGNITION SYSTEM HIGH CURRENT AND VOLTAGE CAN BE FATAL.
MAKE CERTAIN THAT ELECTRICAL POWER IS REMOVED FROM THE
IGNITION SYSTEM FOR A MINIMUM OF 5 MINUTES BEFORE ANY
DISCONNECTIONS ARE MADE. AFTER DISCONNECTING THE IGNITER
LEAD(S), MAKE SURE OF COMPLETE DISCHARGE OF CAPACITORS IN
THE IGNITION UNIT BY IMMEDIATELY SHORTING THE IGNITER LEAD(S)
TO GROUND: TO AVOID EXPLOSION, MAKE CERTAIN THAT NO
VOLATILE FLUIDS OR GASES ARE PRESENT.

(1) Disconnect the igniter plug lead from the igniter plug.

(2) Remove attaching bolts (50), washer (60), and retainer (70), then remove the igniter
plug (40) and gasket (80) from the combustor cap assembly. Discard the gasket.

B. Install the Igniter Plug (Refer to Figure 201)

(1) Install the igniter plug (40) with retainer (70) and new gasket (80) into the combustor
cap assembly and through the combustion chamber liner assembly. Coat the threads
of the bolts (50) with high temperature compound (Fel-Pro C5-A). Install bolts (50)
with washers (60). Tighten bolts to a torque value of 50 to 70 inch-pounds.

(2) Connect the igniter plug lead to the igniter plug.

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40. IGNITER PLUG 60. WASHER


(IPC FIG.1, 49-20-04) 70. RETAINER
50. BOLT 80. GASKET

Igniter Plug Removal/Installation


Figure 201

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IGNITION UNIT - MAINTENANCE PRACTICES

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Ignition Unit Removal/Installation (Typical)


Figure 201

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1. Removal/Installation

A. Remove Ignition Unit (Refer to Figure 201)

WARNING: THE IGNITION SYSTEM HIGH CURRENT AND VOLTAGE CAN BE FATAL.
MAKE CERTAIN THAT ELECTRICAL POWER IS REMOVED FROM THE
IGNITION SYSTEM FOR A MINIMUM OF 5 MINUTES BEFORE ANY
DISCONNECTIONS ARE MADE. AFTER DISCONNECTING THE IGNITER
LEAD, MAKE SURE OF COMPLETE DISCHARGE OF THE CAPACITORS
IN THE IGNITION UNIT BY IMMEDIATELY SHORTING THE IGNITER LEAD
TO GROUND: TO AVOID EXPLOSION, MAKE CERTAIN THAT NO
VOLATILE FLUIDS OR GASES ARE PRESENT.

(1) Remove the harness assembly and ignition lead from the ignition unit (160).

(2) (Pre SB 49-5744, Post SB 49-6774) Remove the attaching nuts (170), washers (180),
clip (270), and screws (190) which secure the ignition unit (160) to the bracket
assembly (200).

(3) (Pre SB 49-6774, Post SB 49-5744) Remove nuts (230) and ignition unit (160).

B. Install the Ignition Unit (Refer to Figure 201)

(1) (Pre SB 49-6774, Post SB 49-5744) Install the ignition unit (160) on bracket assembly
(200) and secure with screws (190), clip (270), washers (180), and nuts (170).
Tighten screws to a torque value of 20 to 25 inch-pounds.

(2) (Pre SB 49-6774, Post SB 49-5744) Install ignition unit (160) on bracket assembly
(200A) and secure with nuts (230).

(3) Connect the harness assembly and ignition lead to the ignition unit (160).

KEY TO FIGURE 201

160. IGNITION UNIT 200. BRACKET ASSY


(IPC FIG. 2, 49-20-00) 200A. BRACKET ASSY
170. NUT 230. NUT
180. WASHER 270. CLIP (IPC FIG. 1, 49-20-02)
190. SCREW

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2. Cleaning/Painting

A. Clean Ignition Unit

WARNING: ALL CLEANING SHALL BE PERFORMED IN A CLEAN, WELL LIGHTED


ROOM. RUBBER GLOVES AND PROTECTIVE MASKS AND CLOTHING
SHALL BE WORN. VATS AND TANKS SHALL HAVE METAL COVERS AND
SPRAY BOOTHS SHALL HAVE POSITIVE VENTILATION TO THE
OUTSIDE OF THE BUILDING. FIRE EXTINGUISHERS SHALL BE READILY
AVAILABLE.

The ignition unit may be wiped clean with solvent (Section 49-20-00, CLEANING/PAINTING,
Table 701.)

3. Inspection/Check

Visually check the ignition unit for dents, cracks, bent receptacle pins, and damaged threads.

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AIR SECTION

TABLE OF CONTENTS

SECTION
SUBJECT SUBJECT PAGE

DESCRIPTION AND OPERATION 49-50-00


Description and Operation 1
Trouble Shooting 101
ACCESSORY COOLING FAN ASSY 49-50-01
Maintenance Practices 201
PNEUMATIC THERMOSTAT 49-50-04
Maintenance Practices 201
LOAD CONTROL VALVE 49-50-06
Maintenance Practices 201
AIR PRESSURE REGULATOR 49-50-07
Maintenance Practices 201
THREE WAY PNEUMATIC SOLENOID VALVE 49-50-28
Maintenance Practices 201

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1. General

The engine air section includes two separate systems. The bleed-air system concerns the control and
delivery of bleed-air from the engine compressor section for pneumatic uses. The cooling air system
concerns the development and delivery of air for cooling lubricating oil, for cooling customer-furnished
driven equipment such as a generator, and for cooling the engine installation compartment. (Refer to
Figure 1.)

2. Description

The bleed-air system is fully automatic in operation. A single bimetallic bleed-off pneumatic thermostat
provides overtemperature protection during engine acceleration and operation and upon application of
pneumatic load.

The bleed-air system consists of a single dual purpose thermostat to perform the function of both an
acceleration and load control thermostat. A three-way solenoid shutoff valve is added in the pneumatic
line between the thermostat and the fuel control unit acceleration limiter valve. When actuated, the
three-way solenoid shutoff valve interconnects the thermostat and load control valve. (Refer to Figure
2.)

The cooling air system is fully automatic in operation and requires only customer-furnished ducting to
direct generator and compartment cooling air to their destinations. The cooling air system consists of
an engine driven cooling air fan mounted on the front of the accessory section and a duct to connect
the fan discharge to the oil cooler assembly and to the customer-furnished ducting.

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1. ACCESSORY COOLING FAN ASSY (REFER TO SECTION 49-50-01)


2. LOAD CONTROL VALVE (REFER TO SECTION 49-50-06)
3. PNEUMATIC THERMOSTAT (REFER TO SECTION 49-50-04)
4. THREE-WAY PNEUMATIC SOLENOID VALVE (MS2)
(REFER TO SECTION 49-50-28)
5. AIR PRESSURE REGULATOR (REFER TO SECTION 49-50-07)

Air Section
Figure 1

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Fuel Control System and Bleed-Air Control System


Figure 2

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3. Operation

During the starting sequence, the single dual purpose pneumatic thermostat is in the acceleration
mode. The thermostat opens to decrease control-air pressure to the acceleration limiter valve
whenever a predetermined engine exhaust gas temperature (EGT) is reached. This, in turn,
decreases fuel to the combustor to limit the EGT and prevent engine overtemperature. Actuating the
load switch operates the three-way solenoid shutoff valve. This shuts of compressor discharge air to
the acceleration limiter valve, switching the pneumatic thermostat to the load control mode. The
thermostat opens to bleed air from the pneumatic actuator of the load control valve whenever a
predetermined engine exhaust gas temperature (EGT) is reached. This, in turn, decreases bleed-air
flow from the engine by modulating (closing) the load control valve to limit EGT and prevent engine
overtemperature. (Refer to Figure 2.)

When the engine is operating at governed speed, the air pressure regulator receives air pressure from
the engine compressor section. This pressure is referenced across the air pressure regulator and
constant pressure control air is discharged from the air pressure regulator through a switcher valve in
the load control valve to the lower chamber in the load control valve actuator. Air pressure in this
chamber acts on a diaphragm and linkage mechanism to hold the load control valve butterfly closed.

When the customer-furnished bleed-air switch is actuated, the load control valve operates the switcher
valve to divert regulator control to the upper chamber in the load control valve actuator. Air pressure in
this chamber acts on the diaphragm and linkage mechanism to move the load control valve butterfly to
the open position. The air in the lower chamber is now vented to atmosphere.

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AIR SECTION - TROUBLE SHOOTING

1. General

Trouble shooting procedures for the engine controls system are outlined in Section 49-20-00,
TROUBLE SHOOTING.

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ACCESSORY COOLING FAN ASSEMBLY - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Oil (MIL-PRF-7808 or MIL-PRF-23699) Commercially available

Lubricant (OS-124 or Santovac 5) Monsanto Co, Fibers Business Unit, 800 N Lindbergh
Blvd, St. Louis, MO 63167

A. Remove Accessory Cooling Fan Assembly (Refer to Figure 201)

CAUTION: BACK ACCESSORY COOLING FAN ASSEMBLY SLOWLY OUT OF


GEARCASE ASSEMBLY IN A STRAIGHT LINE SO AS TO NOT DAMAGE
EXTERNAL FAN ASSEMBLY SPLINES OR INTERNAL GEARCASE
SPLINES.

(1) Remove bolts (110), washers (120) and carefully back accessory cooling fan
assembly (100) out of accessory drive gearcase assembly. Remove and discard
packing (130).

B. Install Accessory Cooling Fan Assembly (Refer to Figure 201)

(1) Apply a thin film of oil (MIL-PRF-7808 or MIL-PRF-23699) or lubricant (OS-124 or


Santovac 5) to packings. Install new packings (130) on accessory cooling fan
assembly (100), then install accessory cooling fan assembly (100) by inserting into
gearcase assembly in a straight line so that internal and external splines mesh
properly and are not damaged.

CAUTION: IF ACCESSORY COOLING FAN ASSEMBLY IS BEING REPLACED DUE TO


INTERNAL FAILURE, (1) DISASSEMBLE ACCESSORY GEARCASE
ASSEMBLY TO THE EXTENT REQUIRED TO MAKE SURE THAT ALL
DEBRIS FROM THE FAILURE IS REMOVED AND MOVING PARTS ARE
DAMAGE FREE. (REFER TO ENGINE OVERHAUL MANUAL ATA NO. 49-
21-83.) (2) INSPECT OIL FILTER ELEMENT FOR EVIDENCE OF METAL
PARTICLES. IF METAL PARTICLES ARE PRESENT, FLUSH ENGINE
LUBRICATING SYSTEM.

(2) Coat threads of bolts (110) with oil (MIL-PRF-7808 or MIL-PRF-23699). Install
washers (120) and bolts (110) to secure accessory cooling fan assembly to gearcase
assembly. Tighten bolts to a torque value of 50 to 70 inch-pounds.

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100. ACCESSORY COOLING FAN 120. WASHER


ASSY (IPC FIG. 4, 49-20-00) 130. PACKING
110. BOLT

Accessory Cooling Fan Assembly


Removal/Installation
Figure 201

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PNEUMATIC THERMOSTAT - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be use for listed items.

High temperature compound Fel-Pro Inc., Div. of Felt Products Mfg. Co.,
(Fel-Pro C5-A) 7450 N. McCormick Blvd., Skokie, IL 60076

A. Remove Pneumatic Thermostat (Refer to Figure 201)

CAUTION: HOLD PNEUMATIC THERMOSTAT HEX FITTING FIRMLY AND DO NOT


ALLOW PNEUMATIC THERMOSTAT COLLAR TO ROTATE WHEN
REMOVING TUBE ASSEMBLY AS PNEUMATIC THERMOSTAT SETTING
WILL CHANGE AND POSSIBLY CREATE AN OVERTEMPERATURE
CONDITION WITHIN THE APU.

(1) Disconnect tube assembly from pneumatic thermostat.

NOTE: Record amount and thickness of shim washers as an aid at installation.

(2) Remove bolt (40), Washers (50). Then remove thermostat (30) with shim washers
(60).

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30. THERMOSTAT 50. WASHER


(IPC FIG. 2, 49-20-00) 60. SHIM WASHER
40. BOLT

Pneumatic Thermostat Removal/Installation


Figure 201

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1. B. Install Pneumatic Thermostat (Refer to Figure 201)

(1) Install thermostat (30) with shim washers (60) as required, to obtain a pinch on
thermostat of 0.010 to 0.020 inch into exhaust flange. Apply high temperature
compound (Fel-Pro C5-A) to threads of bolts (40). Install washer (50) and bolt (40).
Tighten bolts to a torque value of 70 inch-pounds.

CAUTION: WHEN INSTALLING TUBING ON PNEUMATIC THERMOSTAT, USE BACK-


UP WRENCH ON HEX FLATS OF THERMOSTAT FITTING TO PREVENT
CHANGE OF SETTING AND DAMAGE TO THERMOSTAT.

(2) Connect tube assembly to pneumatic thermostat.

2. Adjustment/Test

After removal and installation of a pneumatic thermostat, check operation and adjust if necessary.
(Refer to Section 49-20-00, ADJUSTMENT/TEST.)

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PNEUMATIC SHUTOFF VALVE - MAINTENANCE PRACTICES

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1. Removal/Installation

A. Remove Load Control Valve (Refer to Figure 201)

(1) Disconnect customer-furnished bleed air outlet duct and clamp from load control valve
(40).

(2) Disconnect harness and tube assemblies from load control valve. (Refer to Section
49-20-00, REMOVAL/INSTALLATION.)

NOTE: Note orientation of load control valve for aid at assembly.

(3) Remove coupling (50), then remove load control valve (40) and gasket (60) from
turbine plenum.

B. Install Load Control Valve (Refer to Figure 201)

(1) Position load control valve (40) on turbine plenum as noted at removal.

(2) Install gasket (60) and coupling (50), position clamp with screw head at the six o'clock
position, viewed from side of engine, with screw head toward rear of engine, then
tighten.

(3) Connect harness and tube assemblies to load control valve (40). (Refer to Section
49-20-00, REMOVAL/INSTALLATION.)

(4) Connect customer-furnished bleed air outlet duct and clamp to load control valve (40).

2. Adjustment/Test

After removal and installation of valve, check preparation of valve and setting of pneumatic (load
control) thermostat. (Refer to Section 49-20-00, ADJUSTMENT/TEST.)

No testing of load control valve is permitted at field level.

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40. LOAD CONTROL VALVE 50. COUPLING


(IPC FIG. 3, 49-20-00) 60. GASKET

Load Control Valve Removal/Installation


Figure 201

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AIR PRESSURE REGULATOR - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Compound (Sealube) Fleet Suppliers, Inc, 869 East 140th


St, Cleveland, OH 44110

Methyl-ethyl-ketone (MEK) Commercially available


(ASTM D740)

Paint and carbon remover Purex Corp., Turco Products Div.,


24600 S. Main Street, P.O. Box
6200, Carson, CA 90749

A. Remove Air Pressure Regulator (Refer to Figure 201)

(1) Disconnect air inlet line and regulated air line at air pressure regulator. (Refer to
Section 49-20-00, REMOVAL/INSTALLATION.)

(2) Remove clamp (80) and remove air pressure regulator (70) from mounting bracket.

B. Install Air Pressure Regulator

(1) Disconnect air inlet line and regulated air line at air pressure regulator. (Refer to
Section 49-20-00, REMOVAL/INSTALLATION.)

CAUTION: DO NOT TIGHTEN TUBING NUT ON AIR INLET LINE TO TORQUE


GREATER THAN 65 INCH-POUNDS, TO PREVENT SHEARING FITTING
FROM FILTER COVER.

(2) Connect air inlet line and regulated air line to air pressure regulator. (Refer to Section
49-20-00, REMOVAL/INSTALLATION.)

2. Adjustment/Test

After removal and installation of the air pressure regulator, the output regulated air pressure shall be
checked and adjusted if required. (Refer to Section 49-20-00, ADJUSTMENT/TEST.)

3. Cleaning/Painting

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70. AIR PRESSURE REGULATOR 80. CLAMP


(IPC FIG. 3, 49-20-00)

Air Pressure Regulator Removal/Installation


Figure 201

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3. A. Remove and Clean Air Pressure Regulator Filter Element (Refer to Figure 202)

(1) Remove regulator from mounting bracket.

(2) Unscrew and remove filter cover (10) from regulator (50), then remove filter element
(30), packing (40), and seal (20). Discard packing and seal.

WARNING: METHYL-ETHYL-KETONE IS TOXIC AND FLAMMABLE, USE IN WELL


VENTILATED AREAS. AVOID BREATHING FUMES OR LONG CONTACT
WITH SKIN TO PREVENT DAMAGE TO PHYSICAL HEALTH. KEEP AWAY
FROM FLAME TO AVOID FIRE HAZARD.

USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE
AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

(3) Clean filter element in paint and carbon remover (Turco Transp). Wash filter element
in methyl-ethyl-ketone (ASTM D740) and blow dry with clean, dry, filtered compressed
air.

(4) Install cleaned filter element (30) with packing (40). Coat external threads of air
pressure regulator housing with compound (sealube), then install filter cover (10) with
new seal (20).

CAUTION: DO NOT TIGHTEN TUBING NUT ON AIR INLET LINE TO A TORQUE


GREATER THAN 65 INCH-POUNDS, TO PREVENT SHEARING FITTING
FROM FILTER COVER.

(5) Connect air inlet line.

(6) Check regulated air pressure and adjust if required. (Refer to Section 49-20-00,
ADJUSTMENT/TEST.)

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*10. COVER (IPC FIG.8, 49-20-00) *40. PACKING


*20. SEAL *50. REGULATOR
*30. FILTER ELEMENT

*Components of the Air Pressure Regulator

Air Pressure Regulator Filter


Disassembly/Assembly
Figure 202

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THREE-WAY (MS2) PNEUMATIC SOLENOID VALVE - MAINTENANCE PRACTICES

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1. Removal/Installation

A. Remove Pneumatic (Three-Way) Solenoid Shutoff Valve (Refer to Figure 201)

(1) Disconnect harness assembly and tube assemblies from pneumatic (three-way)
solenoid shutoff valve. (Refer to Section 49-20-00, REMOVAL/INSTALLATION.)

(2) (Pre SB 49-5233) Remove attaching bolt (150), washer (160), shield (170), special
washer (180, 190) and pneumatic (three-way) solenoid shutoff valve (140).

(98DHF Post SB 49-5233 and 98DHF[A]) (Refer to Figure 201A) Remove adjustable
orifice (180) with packing (190) from solenoid valve (140). Remove bolts (150,
washers (160), solenoid valve (140), and washers (170) from bracket assembly (230).
Remove bolts (210), washers (220), bracket assembly (230), washers (240),
pneumatic solenoid valve (200), and washers (250).

B. Install Pneumatic (Three-Way) solenoid Shutoff Valve (Refer to Figure 201)

(1) (Pre SB 49-5233) Install pneumatic (three-way) solenoid shutoff valve (140) on
mounting bracket and secure with special washer (180, 190), shield (170), washer
(160), and bolt (150). Tighten bolt to a torque value of 20 to 25 inch-pounds.

(98DHF Post SB 49-5233 and 98DHF[A]) Install packing (190) and adjustable orifice
(180) to solenoid valve (140). Install solenoid valve (140), washers (160, 170) with
bolts (150) to bracket assembly (230).

(2) Connect harness assembly and tube assemblies to solenoid valve. (Refer to Section
49-20-00, REMOVAL/INSTALLATION.)

2. Inspection/Check

A. Check

(1) Check case for cracks or other damage.

(2) Check that air passages are clear and free from foreign material.

(3) Check for insulation breakdown between case and coil using an ohmmeter. Replace
pneumatic (three-way) solenoid shutoff valve if insulation breakdown is indicated.

(4) Apply 28 to 30 volts dc to pins A and B. Pneumatic (three-way) solenoid shutoff valve
shall close.

(5) Check residual magnetism by applying a minimum of 26.5 volts to energize solenoid
for a period of 15 seconds, then de-energize solenoid. The unit shall return to its
normal position within 0.10 second.

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140. PNEUMATIC (THREE-WAY) (MS2) SOLENOID 170. SHIELD


VALVE (IPC FIG. 3, 49-20-00) 180. SPECIAL WASHER
150. BOLT 190. SPECIAL WASHER
160. WASHER

Pneumatic (Three-Way) Solenoid Shutoff Valve


(98DHF Pre SB 49-5233)
Removal/Installation
Figure 201

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Pneumatic Solenoid Valve


(98DHF Post SB 49-5233 and 98DHF[A])
Removal/Installation
Figure 201A

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KEY TO FIGURE 201A

140. SOLENOID VALVE (IPC FIG. 3A, 200. SOLENOID VALVE


49-20-00) 210. BOLT
150. BOLT 220. WASHER
160. WASHER 230. BRACKET ASSEMBLY
170. WASHER 240. WASHER
180. ORIFICE 250. WASHER
190. PACKING

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ENGINE CONTROLS SECTION

TABLE OF CONTENTS

SECTION/
SUBJECT SUBJECT PAGE

DESCRIPTION AND OPERATION 49-60-00


Description and Operation 1
Trouble Shooting 101
CENTRIFUGAL SWITCH ASSY 49-60-01
Maintenance Practices 201
SEQUENCING OIL PRESSURE SWITCH 49-60-03
Maintenance Practices 201
PNEUMATIC SOLENOID VALVE (NC) 49-60-04
Maintenance Practices 201
ARMATURE RELAY 49-60-05
Maintenance Practices 201

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ENGINE CONTROLS SECTION - DESCRIPTION AND OPERATION

1. Description

The engine controls system is fully automatic in operation; however, customer-furnished holding relays
and switches are required for operation. The system consists of a sequencing oil pressure switch on
the oil pump assembly flange, a centrifugal switch assembly on the front of the accessory gearcase, a
pneumatic shutdown solenoid valve (NC) mounted on top of the compressor plenum, an armature
relay mounted on the electrical panel assembly on the right front of the engine, and the necessary
plumbing and wiring. (Refer to Figure 1.)

2. Operation

After the engine has started, rising oil pressure actuates the sequencing oil pressure switch, which
completes a circuit to the fuel solenoid valve and to the ignition unit.

As engine speed increases, the normally closed 35-percent switch in the centrifugal switch assembly
opens, opening the circuit to the starter. As engine speed increases further, the 95-percent switch in
the centrifugal switch assembly actuates, opening a circuit to the ignition unit and closing the circuit to
the hourmeter and customer-furnished bleed-air switch. If the engine overspeeds, the normally closed
overspeed switch in the centrifugal switch assembly opens, opening the circuit to the fuel solenoid
valve. When the fuel solenoid is de-energized, it closes and shuts off fuel flow to the combustion
chamber, thus stopping the engine.

When the engine is to be stopped, actuation of the customer-furnished stop switch energizes the
normally closed pneumatic shutdown solenoid valve, mounted on top of the compressor inlet plenum.
This valve is connected on the inlet port side to a compressor air discharge port, and on the outlet port
side to a port on the centrifugal switch assembly.

When the solenoid is energized, the valve opens allowing flow of compressed air into the centrifugal
switch assembly. As the air pressure in the switch assembly builds up, the switch actuating lever is
forced into contact with the overspeed switch. When the overspeed switch is actuated it opens a
circuit to the fuel solenoid valve and so shuts off fuel to the combustion chamber, thus stopping the
engine.

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1. ARMATURE RELAY (REFER TO SECTION 49-60-05)


2. CENTRIFUGAL SWITCH ASSY (REFER TO SECTION 49-60-01)
3. SEQUENCING OIL PRESSURE SWITCH (REFER TO SECTION 49-60-03)
4. PNEUMATIC SOLENOID VALVE (NC) (REFER TO SECTION 49-60-04)

Engine Controls Section


Figure 1

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ENGINE CONTROLS SECTION - TROUBLE SHOOTING

1. General

Trouble shooting procedures for the engine controls system are outlined in Section 49-20-00,
TROUBLE SHOOTING.

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CENTRIFUGAL SWITCH ASSEMBLY - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Grease (MIL-G-21164) Commercially available

(Mobil 29) Mobil Chemical Co., Chemical


Coating Div., 150 E. 42nd St.,
New York, NY 10017

(Royco 13D) Royal Lubricants Co.,


215 Merry Ln., P.O. Box 518
East Hanover, NJ 07936-0518

Oil (MIL-PRF-7808 or Commercially available


MIL-PRF-23699)

A. Remove Centrifugal Switch Assembly (Refer to Figure 201)

(1) Disconnect harness assembly and tube assembly from centrifugal switch assembly.
(Refer to Section 49-20-00, REMOVAL/INSTALLATION.)

(2) Remove attaching nuts (290), and carefully withdraw centrifugal switch assembly (280)
in a straight line. Remove and discard packing (300).

B. Install Centrifugal Switch Assembly (Refer to Figure 201)

(1) Apply a light film of oil (MIL-PRF-7808 or MIL-PRF-23699) to packing (300).

(2) Apply light coat of grease (MIL-G-211264, Mobil 29, or Royco 13D) to female splined
areas of gearshaft.

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280. CENTRIFUGAL SWITCH ASSY 290. NUT


(IPC FIG. 6, 49-20-00) 300. PACKING

Centrifugal Switch Assembly


Removal/Installation
Figure 201

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1. B. (3) Carefully install centrifugal switch assembly (280) and new packing (300) on studs on
accessory gearcase mounting pad, exercising care as centrifugal switch drive shaft
enters gearcase.

(4) Install attaching nuts (290) and tighten to a torque value of 70 to 90 inch-pounds.

(5) Check condition of electrical connector; particular attention must be made to detent
holes. Replace connector if worn.

(6) Reconnect electrical connector and tube assembly to centrifugal switch assembly.
(Refer to Section 49-20-00, REMOVAL/INSTALLATION).

2. Adjustment/Test

No adjustment of the centrifugal switch is permitted at field level.

After removal and installation of centrifugal switch assembly, an operational check of all switch
actuations shall be performed. (Refer to Section 49-20-00, ADJUSTMENT/TEST.)

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SEQUENCING OIL PRESSURE SWITCH - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Oil (MIL-PRF-7808 or MIL-PRF-23699) Commercially available

A. Remove Sequencing Oil Pressure Switch (Refer to Figure 201)

(1) Disconnect harness assembly from sequencing oil pressure switch. (Refer to Section
49-20-00, REMOVAL/INSTALLATION.)

(2) Disconnect tube assembly. Remove tee, gasket, and nut. (Refer to Section 49-20-00,
REMOVAL/INSTALLATION.)

(3) Remove attaching clamp (70) and remove sequencing oil pressure switch (60) from
bracket mounted on oil pump assembly flange.

B. Install Sequencing Oil Pressure Switch (Refer to Figure 201)

NOTE: Be sure clamp is not placed over oil pressure switch vent holes.

(1) Install sequencing oil pressure switch (60) in place on bracket and secure with clamp
(70).

(2) Install gasket, nut, and tee on sequencing oil pressure switch. Connect tube assembly,
and electrical connector. (Refer to Section 40-20-00 REMOVAL/INSTALLATION.)

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60. SEQUENCING OIL PRESSURE SWITCH 70. CLAMP


(IPC FIG. 5, 49-20-00)

Sequencing Oil Pressure Switch


Removal/Installation
Figure 201

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2. Inspection/Check

A. Check Sequencing Oil Pressure Switch for Satisfactory Operation

(1) Check continuity of sequencing oil pressure switch with multimeter. Circuits across
pins A and B and C and E shall be open; circuit across pins C and D shall be closed.

(2) Apply oil (MIL-PRF-7808 or MIL-PRF-23699) to sequencing oil pressure switch inlet
port.

NOTE: Actuation of circuits across pins A and B and across pins C and E may be
non-simultaneous providing A-B precedes C-E and both close within
actuating pressure limits.

(3) Sequencing oil pressure switch shall actuate at five to seven inches mercury inlet
pressure to close circuits across pins A and B, C and E, and a open circuit across pins
C and D.

(4) Slowly decrease inlet pressure. Sequencing oil pressure switch shall deactuate at
three inches mercury minimum inlet pressure to reset circuits across pins A and B, C
and E to open position and circuit across pins C and D to closed position.

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PNEUMATIC SHUTDOWN SOLENOID VALVE (NORMALLY CLOSED)


MAINTENANCE PRACTICES

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1. Removal/Installation

A. Remove Pneumatic Shutdown Solenoid Valve (Refer to Figure 201)

(1) Disconnect harness assembly and tube assemblies from pneumatic shutdown
solenoid valve (10). (Refer to Section 49-20-00, REMOVAL/INSTALLATION.)

(2) Remove attaching washers (30) and bolts (20) and remove pneumatic shutdown
solenoid valve (10) from mounting bracket on compressor plenum.

B. Install Pneumatic Shutdown Solenoid Valve (Refer to Figure 201)

(1) Place pneumatic shutdown solenoid valve (10) on mounting bracket on compressor
plenum and secure with washers (30) and bolts (20). Tighten bolts to a torque of 20 to
25 inch-pounds.

(2) Connect electrical connector and tube assemblies to pneumatic shutdown solenoid
valve. (Refer to Section 49-20-00, REMOVAL/INSTALLATION.)

2. Inspection/Check

A. Check Pneumatic Shutdown Solenoid Valve

(1) Check case for cracks or other damage.

(2) Check that air passages are clear and free from foreign material.

(3) Check for continuity between pins A and B.

(4) Apply 18 to 30 volts dc to pin A and B. Pneumatic shutdown solenoid valve shall open.

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10. PNEUMATIC SHUTDOWN SOLENOID VALVE 20. BOLT


(IPC FIG. 3, 49-20-00) 30. WASHER

Pneumatic Shutdown
Solenoid Valve Removal/Installation
Figure 201

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ARMATURE RELAY - MAINTENANCE PRACTICE

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1. Removal/Installation

Removal procedures consists only of disconnecting armature relay (70, Figure 201) from the electrical
receptacle on the electrical panel assembly and removing the armature relay.

Installation procedures consists of placing armature relay (7) on the electrical panel assembly and
connecting the electrical receptacle.

2. Inspection/Check

A. Check Armature Relay (Refer to Figure 201)

(1) Apply 10 volts dc power across armature relay pins A and B. Armature relay shall
operate. Circuits through pins C and D, and pins F and G shall open. Circuits through
pins D and E, and pins G and H shall close.

(2) Reduce applied voltage. Armature relay shall drop out at 3.5 volts dc maximum.

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70. ARMATURE RELAY (IPC FIG. 6, 49-20-00)

Armature Relay Removal/Installation


Figure 201

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INDICATING SECTION

TABLE OF CONTENTS

SECTION/
SUBJECT SUBJECT PAGE

DESCRIPTION 49-70-00
Description and Operation 1
Troubleshooting 101
EXHAUST GAS TEMPERATURE THERMOCOUPLE 49-70-01
Maintenance Practices 201
TIME TOTALIZING METER 49-70-03
Maintenance Practices 201
CIRCUIT BREAKER 49-70-05
Maintenance Practices 201
LOW OIL PRESSURE SWITCH 49-70-06
Maintenance Practices 201
GENERATOR TACHOMETER 49-70-07
Maintenance Practices 201
OIL TEMPERATURE SWITCH 49-70-08 201

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INDICATING SECTION - DESCRIPTION AND OPERATION

1. Description

The engine indicating components provide a signal to customer-furnished meters for read-out, except
the hourmeter which is read directly. Indicating components include an exhaust gas temperature
thermocouple mounted in the turbine exhaust flange, a low oil pressure switch mounted on the oil tank
assembly, a tachometer-generator mounted on the oil pump assembly, a high oil temperature
thermostatic switch mounted in a port on the oil pump assembly, a hourmeter and circuit breaker
mounted on an electrical panel assembly on the accessory gearcase, and the necessary wiring and
plumbing. (Refer to Figure 1.)

2. Operation

The exhaust gas temperature thermocouple is located in the turbine exhaust flange in position to be
completely immersed in turbine exhaust gas. The exhaust gas temperature thermocouple creates a
small electrical current which is proportioned to the temperature of the exhaust gas during operation.
A Chromel wire (white) and an Alumel wire (green) carry the signal to the engine wiring harness
receptacle for pickup and connection to customer-furnished equipment.

The low oil pressure switch, actuated by engine oil pressure is normally closed and provides a signal
through the engine wiring harness receptacle for connection to customer equipment. At engine oil
pressure above 55 psig, the low oil pressure switch is actuated to open position. The low oil pressure
switch circuit to the engine wiring harness receptacle is broken at engine shutdown by the engine relay.

The tachometer-generator is driven by the oil pump drive gearshaft. The tachometer-generator
generates an electrical voltage and frequency which is proportional to the drive speed. This signal is
carried through the engine wiring harness receptacle for customer connection.

The high oil temperature thermostatic switch extends into the oil pump assembly where it is immersed
in oil. The normally open switch is actuated to close if oil temperature reaches 121 5C (250 10F).
The signal is carried through the engine wiring harness receptacle for customer connection.

The hourmeter is a shockproof electric clock enclosed in a water-tight case. The hourmeter circuit is
energized at 95-percent engine speed and records engine operating time above this speed in hours
and tenths of hours. The hourmeter circuit is protected by a circuit breaker against sudden inrushes of
current. The circuit breaker reset is a button type which requires only pushing in to reset.

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1. HOURMETER (REFER TO SECTION 49-70-03) 4. OIL TEMPERATURE SWITCH


2. EXHAUST GAS TEMPERATURE (REFER TO SECTION 49-70-08)
THERMOCOUPLE 5. TACHOMETER-GENERATOR
(REFER TO SECTION 49-70-01) (REFER TO SECTION 49-70-07)
3. LOW OIL PRESSURE SWITCH 6. HOURMETER CIRCUIT BREAKER
(REFER TO SECTION 49-70-06) (REFER TO SECTION 49-70-05)

Indicating Section
Figure 1

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INDICATING SECTION - TROUBLE SHOOTING

1. General

Trouble shooting procedures for the engine controls system are outlined in Section 49-20-00,
TROUBLE SHOOTING.

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EXHAUST GAS TEMPERATURE THERMOCOUPLE - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

High temperature compound Fel-Pro Inc., Division of Felt Products Mfg.,


(Fel-Pro C5-A) Co., 7450 N. McCormick Blvd., Skokie, IL
60076

A. Remove Exhaust Gas temperature Thermocouple (Refer to Figure 201)

CAUTION: EXERCISE CARE WHEN REMOVING LOCKNUTS TO PREVENT DAMAGE


TO THERMOCOUPLE.

(1) Remove locknuts (140, 150) and harness assembly leads from terminal of exhaust
gas temperature thermocouple (120). (Refer to Section 49-20-00,
REMOVAL/INSTALLATION.)

(2) Remove attaching bolts (130).

(3) Carefully withdraw exhaust gas temperature thermocouple (120) from exhaust duct
flange.

B. Install Exhaust Gas Temperature Thermocouple (Refer to Figure 201).

(1) Install exhaust gas temperature thermocouple (120) in exhaust duct flange.

(2) Coat threads of attaching bolts (130) with high temperature compound (Fel-Pro C5-A).

(3) Secure exhaust gas temperature thermocouple (120) with bolts (130).

(4) Tighten bolts to torque value of 70 inch-pounds.

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120. EXHAUST GAS TEMPERATURE *140. LOCKNUT


THERMOCOUPLE (IPC FIG. 2, 49-20-00) *150. LOCKNUT
130. BOLT

*COMPONENT OF THERMOCOUPLE

Exhaust Gas Temperature Thermocouple


Removal/Installation
Figure 201

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CAUTION: DO NOT EXCEED 25 INCH-POUNDS TIGHTENING TORQUE AT AL


TERMINAL AND 15 INCH-POUNDS TIGHTENING TORQUE AT CR
TERMINAL WHEN CONNECTING HARNESS ASSEMBLY LEADS.

1. B. (5) Connect harness assembly leads to exhaust gas temperature thermocouple terminals
with lock nuts (140, 150) matching chromel leads to CR and alumel lead to AL marked
terminals. (Refer to Section 49-20-00, REMOVAL/INSTALLATION.)

2. Inspection/Check

A. Inspect Thermocouples

(1) Check exhaust gas temperature thermocouple if facilities are available.

NOTE: Test fixture temperature indicator should be checked against a calibrated


temperature indicator to make sure that correct temperature is applied to
thermocouple.

(2) If special facilities are available, immerse EGT thermocouple in 677C (1250F)
surroundings. EGT thermocouple shall register 28.00 to 28.30 millivolts at 0C (32F)
reference junction or 27.05 to 27.35 millivolts at 24C (75F) reference junction.

(3) If special facilities are not available, place thermocouple in a holder.

(4) Connect a millivoltmeter (register to 1.6 volts dc full scale deflection) to terminal
connections on thermocouple.

(5) Apply heat to thermocouple in area of sensing holes. As heat is applied, millivoltmeter
shall register increase. If increase is noted, thermocouple is acceptable. If not
increase is noted, thermocouple is defective and shall be replaced.

(6) Using a multimeter, measure resistance from each stud to body. Resistance shall be
20,000 ohms minimum at 20C (68F) or 10,000 ohms minimum at 650C (1200F).

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HOURMETER - MAINTENANCE PRACTICES

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10. TOTALIZING METER (HOURMETER) 40. SCREW


(IPC FIG. 6, 49-20-00) 50. WASHER
20. SCREW 60. MOUNT ASSY
30. WASHER

Hourmeter Removal/Installation
Figure 201

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MAINTENANCE MANUAL
GTCP85-98DHF/[A]

1. Removal/Installation

A. Remove Hourmeter and Mount Assembly (Refer to Figure 201)

NOTE: Total engine operating time indicated on hourmeter shall be recorded on engine log
sheet.

(1) Remove screws, washers, and remove harness assembly leads from hourmeter (10).

(2) Remove attaching screws (20), washers (30), then remove hourmeter (10).

(3) Remove screws (40), washers (50), then remove mount assembly (60) from bracket.

B. Install Hourmeter and Mount Assembly

(1) Position mount assembly (60) onto bracket and secure with washers (50) and screws
(40). Tighten screws to a torque value of 25 inch-pounds.

(2) Place hourmeter (10) in position on mount assembly (60) and secure with attaching
washer (30) and screws (20). Tighten screws to a torque value of 25 inch-pounds.

(3) Install harness assembly leads and secure with washers and screws.

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CIRCUIT BREAKER - MAINTENANCE PRACTICES

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1. Removal/Installation

A. Remove Circuit Breaker (Refer to Figure 201)

(1) Disconnect harness assembly leads from circuit breaker (100).

(2) Remove circuit breaker (100). (Refer to Section 49-20-00,


REMOVAL/INSTALLATION.)

B. Install Circuit Breaker (Refer to Figure 201)

(1) Place circuit breaker (100) in position and secure with attaching parts. (Refer to
Section 49-20-00 REMOVAL/INSTALLATION.)

NOTE: After installation of circuit breaker, set circuit breaker by pushing in on reset
button.

(2) Connect harness assembly leads.

100. CIRCUIT BREAKER (IPC FIG. 6, 49-20-00)

Circuit Breaker Removal/Installation


Figure 201

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LOW OIL PRESSURE SWITCH - MAINTENANCE PRACTICE

Page 201
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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Oil (MIL-PRF-7808 or MIL-PRF 23699) Commercially available

A. Check Low Oil Pressure Switch (Refer to Figure 201)

(1) Disconnect harness and tube assemblies from low oil pressure switch (140). (Refer to
Section 49-20-00, REMOVAL/INSPECTION.

(2) Remove screws (150) and washers (160), then remove low oil pressure switch (140)
from mounting bracket on oil tank.

B. Install Low Oil Pressure Switch (Refer to Figure 201)

(1) Check continuity of low oil pressure switch with multimeter. Circuit across pins B and
E, C and D shall be open, and circuit across pins A and B shall be open.

(2) Apply oil (MIL-PRF-7808 or MIL-PRF-23699) to low oil pressure switch inlet port.

(3) Low oil pressure switch shall actuate at 55 psig maximum inlet pressure to open circuit
across pins B and E, C and D, and close circuit across pins A and B.

(4) Slowly decrease inlet pressure. Low oil pressure switch shall deactuate at 45 +3/-3
psig to reset circuit across pins B and E, C and D to close position and circuit across
pins A and B to open position.

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140. LOW OIL PRESSURE SWITCH 150. SCREW


(IPC FIG. 4, 49-20-00) 160. WASHER

Low Oil Pressure Switch Removal/Installation


Figure 201

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TACHOMETER-GENERATOR - MAINTENANCE PRACTICES

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1. Removal/Installation

A. Remove Tachometer-Generator (Refer to Figure 201)

(1) Remove harness assembly from tachometer-generator (10). (Refer to Section


49-20-00, REMOVAL/INSTALLATION.)

(2) Remove nuts (20), then carefully remove tachometer-generator (10) and oil pump
housing in a straight line. Remove and discard gasket (30).

B. Install Tachometer-Generator

(1) Carefully install tachometer-generator (10) and new gasket (30) on studs on oil pump
housing mounting pad, exercising care as tachometer-generator splined drive shaft
enters oil pump housing.

(2) Install nuts (20) and tighten to a torque value of 20 to 25 inch-pounds.

(3) Connect harness assembly to tachometer-generator (10). (Refer to Section 49-20-00,


REMOVAL/INSTALLATION.)

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10. TACHOMETER-GENERATOR 20. NUT


(IPC FIG. 5, 49-20-00) 30. GASKET

Tachometer-Generator Removal/Installation
Figure 201

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OIL TEMPERATURE SWITCH - MAINTENANCE PRACTICES

Page 201
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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Oil (MIL-PRF-7808 Commercially available


or MIL-PRF-23699)

Removal procedure consists of disconnecting harness assembly and removing oil temperature switch
(40, Figure 201) with packing with retainer (50) from oil pump. (Refer to Section 49-20-00,
REMOVAL/INSTALLATION.)

Installation procedure consists of installing oil temperature switch (40, Figure 201) with packing with
retainer (50) in oil pump port and connecting harness assembly. (Refer to Section 49-20-00,
REMOVAL/INSTALLATION.)

2. Inspection/Check

A. (Pre SB 49-6508) Check Oil Temperature Switch

(1) Immerse oil temperature switch sensing probe in oil (MIL-PRF-7808 or


MIL-PRF-23699) at 121 5C (250 10F).

(2) Reduce oil temperature below 115C (240F). Circuit across receptacle pins shall open.

(Post SB 49-6508) Check Oil Temperature Switch

(1) Immerse oil temperature switch sensing probe in oil (MIL-PRF-7808 or


MIL-PRF-23699) at 140 6C (285 10F).

(2) Reduce oil temperature below 134C (275F). Circuit across receptacle pins shall open.

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40. OIL TEMPERATURE SWITCH 50. PACKING W/RTNR


(IPC FIG. 5, 49-20-00)

Oil Temperature Switch Removal/Installation


Figure 201

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OIL SECTION

TABLE OF CONTENTS

SECTION/
SUBJECT SUBJECT PAGE

DESCRIPTION 49-90-00
Description and Operation 1
Trouble Shooting 101
OIL COOLER ASSY 49-90-01
Maintenance 201
OIL PUMP ASSY 49-90-02
Maintenance Practices 201
OIL PUMP DRIVE SHAFT SEAL 49-90-04
Maintenance Practices 201
OIL TANK ASSY 49-90-06
Maintenance Practices 201

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OIL SECTION - DESCRIPTION AND OPERATION

1. Description

The engine oil (lubrication ) system is fully automatic in operation and completely self-contained. The
system consists of an oil tank assembly mounted on the lower left side of the compressor plenum, and
oil pump assembly mounted on the front of the accessory gearcase, a check valve, an oil cooler
assembly mounted on the upper left side of the compressor plenum, and the necessary plumbing.
(Refer to Figure 1.)

1. OIL COOLER ASSY 3. OIL PUMP ASSY


(REFER TO SECTION 49-90-01) (REFER TO SECTION 49-90-02)
2. OIL TANK -4. OIL PUMP DRIVE SHAFT SEAL
(REFER TO SECTION 49-90-06) (REFER TO SECTION 49-90-04)

- ITEM NOT ILLUSTRATED

Oil Section
Figure 1

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2. Operation

When the engine is started, supply oil is pumped from the oil tank assembly by oil pressure pump
gears in the oil pump assembly through the oil pump assembly oil filter. If the oil filter is clogged, the
filter bypass valve will open to permit continuing oil flow. From the oil pump assembly, the oil is routed
to fittings on the gearcase assembly and turbine and compressor assembly to provide jet and splash
lubrication for the engine gears and bearings. An oil pressure regulating valve in the oil pump
assembly operates to maintain output oil pressure of 100 10 psig at governed speed. The oil
pressure measured at the tester panel is approximately 30 psi lower than the oil pressure measured at
the oil pump discharge port. (Refer to Figure 2.)

Lubrication oil in the engine drops into sumps in the gearcase assembly and turbine and compressor
assembly and is pumped from these sumps by the scavenge oil pump gears in the oil pump assembly.
Scavenge oil is directed to the tube type oil cooler assembly for cooling, and then to the oil tank
assembly. Any air trapped in the lubricating system is released through an oil tank vent line to the
turbine exhaust.

KEY TO FIGURE 2

1. LOW OIL PRESSURE SWITCH 9. OIL PRESSURE PUMP


2. SEQUENCING OIL PRESSURE SWITCH VALVE
3. CHECK VALVE 10. OIL PRESSURE PUMP
4. OIL COOLER ASSY 11. OIL FILTER BY-PASS VALVE
*5. OIL PRESSURE CONNECTION *12. OIL PRESSURE TAP
6. OIL TANK ASSY 13. OIL TEMPERATURE SWITCH
7. PLUG AND BLEEDER 14. OIL FILTER
8. OIL SCAVENGE PUMP 15. OIL PUMP ASSY

*CUSTOMER CONNECTION

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Lubrication System Schematic


Figure 2

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OIL SECTION - TROUBLE SHOOTING

1. General

Trouble shooting procedures for the engine controls system are outlined in Section 49-20-00,
TROUBLE SHOOTING.

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OIL COOLER ASSEMBLY - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Adhesive (RTV721) Dow Corning Corp., 3901 S. Saginaw Rd.,


Midland, MI 48641

Alkaline cleaner Henkel Surface Technologies,


(Ridolene 909) 32100 Stephenson Hwy.,
Madison Heights, MI 48071

Solvent (Federal Commercially available


Specification P-D-680, Type I)

A. Remove Oil Cooler Assembly (Refer to Figure 201)

NOTE: Remove check valve.

(1) Disconnect oil inlet and outlet lines for oil cooler assembly. (Refer to Section 49-20-
00, REMOVAL/INSTALLATION.)

(2) Remove attaching clamps (20, 30), then remove oil cooler assembly (10) and air duct
hose (40).

B. Install Oil Cooler Assembly (Refer to Figure 201)

(1) Place air duct hose (40) and oil cooler assembly (10) in position abutting fan duct and
secure with clamps (20, 30).

NOTE: Install check valve with arrow on check valve pointing in the direction of the
oil cooler assembly and with the word "HINGE" stamped on hex flat in the
upward position.

(2) Connect inlet and outlet lines to oil cooler assembly (10) ports. (Refer to Section
49-20-00, REMOVAL/INSTALLATION.)

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10. OIL COOLER ASSY 30. CLAMP


(IPC FIG. 4, 49-20-00) 40. AIR DUCT HOSE
20. CLAMP

Oil Cooler Assembly Removal/Installation


Figure 201

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2. Inspection/Check

A. Inspect Hose (Refer to Figure 201)

Inspect hose for small breaks, holes, and large tears. None are permissible.

B. Inspect Check Valve Assembly

Inspect cap and body for damaged threads. Refer to ATA No. 49-90-41 for functional test or
overhaul of check valve assembly.

C. Check Operation of Check Valve Assembly

(1) Internal air leakage of check valve assembly in the checked flow position is not
permitted at pressure above three inches water.

(2) External air leakage is not permitted at pressures from 0 to 500 psig.

(3) Check valve assembly shall open at 0.5 to 2.0 psig air pressure with check valve
assembly oriented in any position.

3. Approved Repairs

A. Repair Air Duct Hose

(1) Repair small breaks or holes with adhesive (RTV721).

(2) Repair large tears by vulcanizing a patch of similar material.

4. Cleaning/Painting

A. Clean Check Valve Assembly

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS CHEMICAL/SOLUTION


CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S
INSTRUCTIONS FOR EACH CHEMICAL.

USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN
CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

Clean check valve assembly with solvent (Federal Specification P-D-680, Type I) or soap
cleaning solution depending upon degree of contamination. (If soap cleaning solution is
preferred, mix five ounces Alkaline cleaner (Ridolene 909) per gallon of water. Use solution at
54 to 82C (130 to 180F) with air agitation. Dry with clean compressed air.

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OIL PUMP ASSEMBLY - MAINTENANCE PRACTICES

Page 201
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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Oil (MIL-PRF-7808 Commercially available


or MIL-PRF-23699)

Lubricant (OS-124 or Santovac 5) Monsanto Co, Fibers Business Unit, 800 N Lindbergh
Blvd, St. Louis, MO 63167

A. Remove Oil Pump Assembly (Refer to Figure 201)

(1) Disconnect tube assemblies, fittings and gasket from oil pump assembly (120). (Refer
to Section 49-20-00, REMOVAL/INSTALLATION.)

(2) Remove attaching bolts (130, 150) and washers (140), and remove oil pump assembly
(120) from accessory drive gearcase assembly.

(3) Remove and discard packings (160).

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120. OIL PUMP ASSY 140. WASHER


(IPC FIG. 5, 49-20-00) 150. BOLT
130. BOLT 160. PACKING

Oil Pump Assembly Removal/Installation


Figure 201

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1. B. Install Oil Pump Assembly (Refer to Figure 201)

CAUTION: IF OIL PUMP ASSEMBLY IS BEING REPLACED DUE TO INTERNAL


FAILURE, (1) DISASSEMBLE ACCESSORY DRIVE GEARCASE ASSEMBLY
TO THE EXTENT REQUIRED TO MAKE SURE THAT ALL DEBRIS FROM
THE FAILURE IS REMOVED AND MOVING PARTS ARE DAMAGE FREE.
(REFER TO ENGINE OVERHAUL MANUAL ATA NO. 49-21-83.) (2)
INSPECT OIL FILTER ELEMENT FOR EVIDENCE OF METAL PARTICLES.
IF METAL PARTICLES ARE PRESENT, FLUSH ENGINE LUBRICATION
SYSTEM.

(1) Coat new packings (160) with lubricant (OS-124 or Santovac 5). Install packings.

NOTE: (Pre SB 49-5205) The oil pump assembly prior to installation on the
engine is held together by four (4) screws and one 1/4 inch bolt. The pump
is secured to the gearcase with three (3) 3/8 inch bolts. It is recommended
that the technician, when installing the oil pressure switch, loosen only the
two (2) screws necessary to retain the oil pressure switch bracket. If this
procedure is followed, there should be no relative movement that would
result in misalignment.

(2) Install oil pump assembly (120) to accessory drive gearcase assembly and secure with
washers (140) and bolts (130, 150). Tighten bolts to a torque value to 50 to 70 inch-
pounds.

(3) Install fitting switch packings and tube assemblies. (Refer to Section 49-20-00,
REMOVAL/INSTALLATION.)

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1. C. Remove Oil Filter Element (Refer to Figure 202)

(1) Remove oil filter element (40) and oil filter case assembly (10) by unscrewing the oil
filter case assembly from the pump body, then removing the oil filter element and
packings (20, 50).

(2) Discard the oil filter element (40) and packings (20, 50).

D. Install Oil Filter Element

(1) Coat new packing (20, 50) with oil (MIL-PRF-7808 or MIL-PRF-23699).

(2) Install new packing (50) on oil filter element (40) and install oil filter element in oil filter
case assembly (10).

CAUTION: DO NOT EXCEED A TORQUE VALUE OF 25 INCH-POUNDS WHEN


TIGHTENING OIL FILTER CASE ASSEMBLY.

NOTE: After installation of oil filter element, engine oil supply shall be checked and
replenished if required.

(3) Install oil filter case assembly (10) and packing (20) in oil pump assembly and
lockwire per AS 567.

*10. OIL FILTER CASE ASSY *40. OIL FILTER ELEMENT


(IPC FIG. 9, 49-20-00) *50. PACKING
*20. PACKING

*Component of Oil Pump Assembly.

Oil Filter Element Removal/Installation


Figure 202

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1. E. Remove Pressure Relief Valve Assembly (Refer to Figure 203)

(1) Remove pressure relief valve assembly (10) by unscrewing it from the pump body.

(2) Remove packings (20, 30) from pressure relief valve assembly (10). Discard
packings.

F. Install Pressure Relief Valve Assembly (Refer to Figure 203)

(1) Coat new packings (20, 30) with oil (MIL-PRF-7808 or MIL-PRF-23699) and assemble
packings on pressure relief valve assembly (10).

(2) Install pressure relief valve assembly (10) with packings (20, 30) in oil pump body and
tighten.

*10. PRESSURE RELIEF VALVE ASSY *20. PACKING


(IPC FIG. 9, 49-20-00) *30. PACKING

*Component of Oil Pump Assembly

Pressure Relief Valve Assembly


Removal/Installation
Figure 203

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2. Cleaning/Painting

A. Clean Oil Pump Assembly

(1) Clean oil pump assembly in accordance with Section 49-20-00,


CLEANING/PAINTING.

3. Inspection/Check

A. Visually check Oil Filter Element

Check filter element for metal particles and other foreign material which may indicate internal
engine damage. If metal particles are indicated, change oil and oil filter element; then operate
the APU for a minimum of fifteen (15) minutes. If no further accumulation after 15 minutes,
APU is acceptable for continues service. Further accumulation during the 15 minute run is
unacceptable.

4. Adjustment/Test

After removal and installation of oil pump assembly, check oil pressure relief valve setting and adjust if
required. (Refer to Section 49-20-00, ADJUSTMENT/TEST.)

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OIL PUMP DRIVE SHAFT SEAL - MAINTENANCE PRACTICES

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1. Removal/Installation

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Oil (MIL-PRF-7808 Commercially available


or MIL-PRF-23699)

Lubricant (OS-124 or Santovac 5) Monsanto Co, Fibers Business Unit, 800 N Lindbergh
Blvd, St. Louis, MO 63167

Table 202. Special Tools, Fixtures and Equipment

Source;
Nomenclature Use Part No.

NOTE: Equivalent substitutes may be used for listed items.

Seal Puller Remove Seal. 280209

A. Remove Oil Pump Drive Shaft Seal (Refer to Figure 201)

(1) Remove tachometer-generator in accordance with Section 49-70-07.

(2) Remove ring (10). Use 280209 seal puller to remove seal (20). Remove packing (30).

B. Install Oil Pump Drive Shaft Seal (Refer to Figure 201)

(1) Coat new packing (30) and new seal (20) with oil (MIL-PRF-7808 or MIL-PRF-23699)
or lubricant (OS-124 or Santovac 5).

(2) Install new packing (30) and new seal (20) with lip facing outward.

(3) Install ring (10).

(4) Install tachometer-generator in accordance with Section 49-70-07.

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*10. RING (IPC FIG. 10, 49-20-00) *30. PACKING


*20. SEAL

*Components of Oil Pump Assembly.

Oil Pump Drive Shaft Seal Removal/Installation


Figure 201

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OIL TANK ASSEMBLY - MAINTENANCE PRACTICES

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1. Removal/Installation

A. Remove Oil Tank Assembly (Refer to Figure 201)

(1) Drain all oil from oil tank assembly (170). (Refer to Section 49-20-00), SERVICING.)

(2) Disconnect tube and hose assemblies from oil tank assembly (170). (Refer to Section
49-20-00, REMOVAL/INSTALLATION.)

(3) Remove low oil pressure switch. (Refer to Section 49-70-06.)

(4) Remove bolts (180, 200) and washers (190, 210) from left side mounting bracket and
oil tank assembly (170). Remove oil tank assembly.

B. Install Oil Tank Assembly (Refer to Figure 201)

(1) Position oil tank assembly (170) to side of engine intake plenum and left side mounting
bracket. Secure with bolts (180, 200) and washers (190, 210). Tighten bolts to a
torque value of 20 to 25 inch-pounds.

(2) Install low oil pressure switch. (Refer to Section 49-70-06.)

(3) Connect tube and hose assemblies to oil tank assembly (170).

(4) Fill oil tank assembly (170) with oil of same specification used in engine lubricating
system. (Refer to Section 49-20-00, Table 302.)

2. Cleaning/Painting

A. Clean Oil Tank Assembly

Clean oil tank assembly in accordance with Section 49-20-00, CLEANING/PAINTING.

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GTCP85-98DHF/[A]

170. OIL TANK ASSEMBLY 190. WASHER


(IPC FIG. 4, 49-20-00) 200. BOLT
180. BOLT 210. WASHER

Oil Tank Assembly Removal/Installation


Figure 201

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49-90-06 Feb 14/03
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