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TO: HOLDERS OF PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE, COMPONENT
MAINTENANCE MANUAL, ATA NO. 49-26-49, REVISED MARCH 30, 2001.

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

ENGINE/
COMPONENT ENGINE AIRCRAFT
PART NO. MODEL NO. APPLICATION
3800504-1 GTCP36-280[D] MD-80

REVISION NO. 5 DATED FEBRUARY 28, 2005

This is a COMPLETE revision. The pages revised are listed below together with the Highlights of the revision.
Due to the extent of the changes, this publication has been reprinted in its entirety. Please discard the entire
manual of previous issue(s) and replace with this complete manual.

This publication is distributed by:

Honeywell Engines, Systems & Services


Technical Data Distribution
M/S 64-01/2101-201
P.O. Box 52170
Phoenix, AZ 85072-2170
To order a document, please go to our web-site at www.honeywelltechpubs.com

Inquires of a technical nature regarding this publication should be directed to:

Honeywell Engines, Systems & Services


Customer Support Center
M/S 26-06/2102-323
P.O. Box 29003
Phoenix, AZ 85038-9003
Phone: (Domestic) 800-601-3099
Phone: (International) 602-365-3099
Fax: 602-365-3343

HIGHLIGHTS

Subiect/Paqe Description of Change

49-26-49 Updated specifications and vendor addresses


throughout the manual. Added WARNINGS as
required.

Title Page
Page T-1 Updated to Revision 5.

Safety/Warranty/Liability Advisory
Page SWLA-1/SWLA-2 Revised WARNING.

Record of Revisions
Page RR-1/RR-2 Added Revision 5.
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ATA NO. 49-26-49


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HIGHLIGHTS (CONT)

Subject/Pa,qe Description of Chan.qe

Temporary Revisions
Page TR-2 Added TRs 49-25 through 49-45.

Service Bulletin List


Page SB-6 Added SB 49-7587. Added SBs 49-7596
through 49-7598.

Page SB-7 Added SBs 49-7608 through 49-7734.

Pages SB-8 and SB-9 Revised SB list to incorporate Page SB-9.

List of Effective Pages


Pages LEP-1 through LEP-6 Updated to Revision 5.

Table of Contents
Page TC-1/I-C-2 Added Atlas entry.

Description and Operation


Page 3 Revised Table 3.

Page 17/18 Revised Figure 8 (Sheet I of 2) to incorporate


TR 49-43.

Testing and Faultlsolation


Pages 101 through 103 Updated Table 101.

Page 103 Added Paragraph 1.B.(6) to incorporate TR 49-25.


Revised Paragraphs 1.B.(6)(a), (b) and (c).

Page 108 Added Paragraph H. to incorporate TR 49-26.

Page 109 Revised Orifice PT Range.

Page 110 Added Fuel/Oil Pump leak limit to incorporate


TR 49-42. Revised Table 103.

Page 117 Revised Paragraph l.H(1)(g).

Page 124 Revised Paragraph 1.P. to incorporate TR 49-27.

Page 126 Revised Paragraph 1.P(3)(f)2 to incorporate


TR 49-28. Revised Paragraph 1.P.(3)(f)(2).

Page127 Revised Paragraph 1.Q. NOTE to incorporate


TR 49-29. Reversed Paragraphs 1.Q and 1.Q.(1).

Pages 129 and 130 Revised figure to incorporate TR 49-30 and


TR 49-31.

Pages 135 through 144 Revised table titles to incorporate TR 49-32 through
TR 49-41.
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ATA NO. 49-26-49


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HIGHLIGHTS (CONT)

Subiect/Pa,qe Description of Chan.qe

Disassembly
Page 301 through 303 Updated Table 301.

Pages 392 through 395 Revised Figures 317 and 317A, Key to Figure 317
and Paragraphs 4.C.(3) and 4.C.(4) to incorporate SB
49-7660.

Pages 396 thmugh 398 Revised Figure 318, Key to Figure 318 and
Paragraph 4.C.(5) to incorporate SB 49-7596.

Page 398.11 Revised Paragraph 4.C.(8) and Key to Figure 319A to


incorporate SB 49-7598.

Page 398.19 Added SB 49-7587 reference in figure title.

Page 398.20 Added SB 49-7587 reference to Paragraph 4.D.(3).

Assembly
Pages 701 through 705 Updated Table 701.

Page 732 Revised Figure 706 (Sheet 1) to incorporate SB 49-


7596.

Page 733 Revised Paragraph 4.A.(10) and Key to Figure 706


(Sheet 1) to incorporate SB 49-7596.

Page 734 Added Figure 706 (Sheet 2) to incorporate SB 49-


7596.

Page 735 Added Key to Figure 706 (Sheet 2) and revised


Paragraph 4.A.(11) to incorporate SB 49-7596.

Page 736 Added Figure 706 (Sheet 3) to incorporate SB 49-


7596.

Page 747 Revised Paragraph 4.A.(13) to incorporate SB 49-


7598.

Page 748 Added Figure 707A (Sheet 2) to incorporate SB 49-


7598.

Page 750 Added Key to Figure 707A (Sheet 2) to incorporate


SB 49-7598.

Page 752 Revised title of Figure 708 to incorporate SB 49-7660.

Page 753 Revised Paragraph 4.A.(14) to incorporate SB 49-


7660.

Page 754 Added Key to Figure 708 to incorporate SB 49-7660.


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ATA NO. 49-26-49 Page 28/05


3 of
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HIGHLIGHTS (CONT)

Subjec~Paqe Description of Chan,qe

Assembly(Cont)

Page 756 Revised title to Figure 708A to incorporate SB 49-


7660.

Page 758 Revised title to Figure 708B to incorporate SB 49-


7660.

Page 760 Revised title to Figure 708C to incorporate SB 49-


7660.

Page 761 Revised Paragraph 4.A.(15) to incorporate SB 49-


6940 and Key to Figure 708C to incorporate SB 49-
7660.

Page 762 Revised title to Figure 708D to incorporate SB 49-


7660.

Page 764 Added Figure 708D (Sheet 2) to incorporate SB 49-


7660.

Page 766 Added Figure 708D (Sheet 3) to incorporate SB 49-


7660.

Page 768 Added Figure 708E to incorporate SB 49-7660.

Page 769 Added Key to Figure 708E to incorporate SB 49-


7660.

Pages 770 and 771 Revised Paragraph 4.A.(16) to incorporate SB 49-


6805.

Page 780 Revised Paragraph 4.B.(1) and Figure 710.

Page 792 Revised Figure 714.

Page 793 Revised Paragraph 4.C.(1).

Page 796 Revised Paragraph 4.C.(2)(k).

Page 798 Revised Figure 716.

Page 798.1 Revised Paragraph 4.C.(3).

Page 798.4 Revised Figu re 718.

Page 798.5 Revised Paragraph 4.C.(5).

Page 798.6 Revised Paragraph 4.C.(5).


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ATA NO. 49-26-49


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HIGHLIGHTS (CONT)

Subiec~Paqe Description of Chan.qe

Assembly(Cont)

Page 798.9 Revised Paragraph 4.D.(1).

Pages 798.42through 798.44 Added Figure 732A and new Paragraph 4.D.(13)(h) to
incorporate TR 49-44. Revised Key to Figure 732A.
Reidentified Paragraphs 4.D.(13)(h) through
4.D.(13)(i) to be 4.D.(13)(i) through 4.D.(13)(m) to
incorporate TR 49-45.

Pages 798.56 and 798.57 Revised Figure 737. Revised Key to Figure 737.
Revised Paragraph 4.D.(18) to incorporate SB 49-
7454.

Page 798.61 and 798.62 Revised Paragraph 4.D.(20) and deleted Step (j).

Page 798.64 Deleted Figure 739A.

Page 798.65 Deleted Paragraph 4.D.(21 ) and Key to Figure 739A.

Page 798.68 Revised Figure 741.

Page 798.69 Revised Key to Figure 741.

Pages 798.70 and 798.71 Revised Paragraph 4.D.(23).

Page 798.79 Revised Paragraph 4.D.(26).

Page 798.94 Revised title to Figure 751A to incorporate SB 49-


7587.

Page 798.95 Revised Paragraph 4.D.(32) to incorporate SB 49-


7587.

Storage
Page 798.176 Revised Paragraph 5.B.(4).
UP200456

A T A NO. 49-26-49
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PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE

PART NO.

3800504-1

COMPONENT 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 is distributed by:


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

For assistance
Customer Support Center
800-601-3099
Outside North America call
602-365-3099
UP200456

Page T-1
ATA NO. 49-26-49
Revised Feb 28/05 No. 5
Copyright 1991,2005 Honeywell International Inc. All rights reserved.
RELEASED FOR THE EXCLUSIVE USE BY: ASERCA AIRLINES

Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

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.
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49-26-49
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GTCP36-280[D]

RECORD OF REVISIONS

REV ISSUE DATE REV ISSUE DATE


NO. DATE INSERTED BY NO. DATE INSERTED BY

ORIG Jul 22/91

1 Aug 31/92

2 Dec 16/94

3 Jun 30/97

4 Mar 30/01

5 Feb 28/05
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49-26-49
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GTCP36-280[D]

RECORD OF TEMPORARY REVISIONS

INCORPO-
RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.

49-1 796 Jan 10/94

49-2 797 Jan 10/97

49-3 398.25 Aug 11/95

49-4 788 Aucj 11/95

49-5 109 Jan 30/96

49-6 127 Jan 30/96

49-7 304 May 15/98

49-8 107 May 25/99

49-9 Jan 18/99 (Replaced by TR 49-10)

49-10 2 Sep 24/99

49-11 127 Feb 14/00

49-12 Feb 14/00 (Replaced by TR 49-17)

49-13 130 Feb 14/00

49-14 Feb 14/00 (Replaced by TR 49-19)

49-15 Feb 14/00 (Replaced by TR 49-20)

49-16 126 Mar 15/00

49-17 128 Mar 15/00

49-18 129 Mar 15/00

49-19 134 Mar 15/00

49-20 135 Mar 15/00

49-21 136 Mar 15/00

49-22 137 Mar 15/00

49-23 142 Mar 15/00

49-24 143 Mar 15/00


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GTCP36-280[D]

RECORD OF TEMPORARY REVISIONS (CONT)

INCORPO-
RATEDINTO
TR PAGE ISSUE DATE DATE MANUALBY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.

49-25 103 Octl~01 5

49-26 107 O~ 12/01 5

49-27 123 O~ 12~1 5

49-28 125 Oct12~1 5

49-29 126 Oct12~1 5

49-30 128 Oct12~1 5

49-31 129 O~ 12~1 5

49-32 134 Octl~01 5

49-33 135 O~ 12/01 5

49-34 136 O~ 12/01 5

49-35 137 Oct12~1 5

49-36 138 Oct12~1 5

49-37 139 Oct12~1 5

49-38 140 Octl~01 5

49-39 141 O ~ 12/01 5

49-40 142 O~ 12~1 5

49-41 143 Oct12~1 5

49-42 109 Oct 26/01 5

49-43 17/18 Dec 3/01 5

49-44 798.29 Aug 21/02 5

49-45 798.30 Aug 21~2 5


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GTCP36-280[D]

RECORD OF TEMPORARY REVISIONS (CONT)

INCORPO-
RATEDINTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
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GTCP36-280[D]

RECORD OF TEMPORARY REVISIONS (CONT)

INCORPO-
RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
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GTCP36-280[D]

SERVICE BULLETIN LIST

SB DATE
NO.__~. INCORPORATED TITLE

49-6554, Revl Refer to ATA Rework Fuel Control Unit, Part No. 3882825-5 to Part No.
No. 49-26-45 3882825-6.

49-6579 Refer to ATA Replace Electronic Control Unit, Part No. 2118814-1 and/or-2
No. 49-26-45 with Part No. 2118814-3, (Improve Surge Control Valve
Stability).

49-6593 Refer to ATA Rework Load Compressor Impeller Assembly,


No. 49-26-45 Part No. 3822270-1 to Part No. 3822270-3.

49-6594 May 31/94 Incorporate Load Compressor Impeller Assembly,


No. 49-26-45 Part No. 3822270-3 in place of Part No. 3822270-1.

49-6600 Refer to ATA Replace Electronic Control Unit, Part No. 2118814-3 with
No. 49-26-45 Part No. 2118814-4.

49-6606 Refer to ATA Secure Containment Segment Assemblies, Part No.


No. 49-26-45 3826725-1 and Part No. 3826726-1.

49-6608 Refer to ATA Replace/Rework Containment Shield Segment Assemblies,


No. 49-26-45 Part No. 3826725-1 to Part No. 3828853-1 and Part No.
3826726-1 to Part No. 3826854-1.

49-A6618, Rev 1 Refer to ATA Inspection of GTCP36-280 APUs for evidence of fuel
No. 49-26-45 manifold leakage.

49-6632, Rev 2 Refer to ATA Attach Dampers, Part No. 3810696-1 with Nycote 7- 11
No. 49-26-45 coating to the Inlet Bellmouth of Engine Compressor
Housing. (To Reduce Vibration Amplitude.)

49-6634, Rev 2 May 31/94 Replace/Rework Bleed/Surge Ducting System.

49-6648 Refer to ATA Incorporate Improved Packings on Turbine Bearing Vent


No. 49-26-45 Tube and Turbine Bearing Lubrication Tube.

49-6652, Rev 1 Refer to ATA Replace Fuel Control Unit, Part No. 3882825-5 with Part
No. 49-26-45 No. 3882825-6.

49-A6653, Rev 1 Refer to ATA Replace Rotating Group, Part No. 3822303-5 with Part
No. 49-26-45 No. 3822436-1.

49-6655, Rev 1 Refer to ATA Replace Inlet Guide Vane Actuator (IGVA), Part No.
No. 49-26-45 3883220-2 with Part No. 3883220-3.

49-6658, Rev 1 Refer to ATA Enhanced Maintainability and Product Improved


No. 49-26-45 Configuration of the GTCP36-280[D] Engine.
UP200456

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GTCP36-280[D]

SERVICE BULLETIN LIST (CONT)

SB DATE
NO.~.~. INCORPORATED TITLE

49-6659 Refer to ATA Replace Electronic Control Unit, Part No. 2118814-4 with
No. 49-26-45 Part No. 2118814-5.

49-6689 Refer to ATA Remove Lube Pump, Part No. 3880130-5 and Install Part
No. 49-26-45 No. 3880130-6.

49-6690 Refer to ATA Rework Lube Pump, Part No. 3880130-5 to Part No.
No. 49-26-45 3880130-6.

49-6699 Refer to ATA Incorporate Line Replacement Transducer Assembly


No. 49-26-45 (Flow Sensor) and Motional Transducer (Monopole).

49-6707 Refer to ATA Rework Cooling Fan Assembly, Part No. 3615133-1 to
No. 49-26-45 Part No. 3615133-3 and Part No. 3615133-2 to Part No.
3615133-4.

49-6711 Refer to ATA Remove and Replace Fan Assembly, Part No.
No. 49-26-45 3615133-1 and -2 with Part No. 3615133-3 and -4.

49-6717 Refer to ATA Replace Gearbox Housing Assembly Matched Set, Part
No. 49-26-45 No. 3862983-3 with Part No. 3862983-4.

49-6718 Refer to ATA Remove Turbine Plenum Insulation Blanket Set, Part
No. 49-26-45 No. 3846610-1 and Install Part No. 3846610-7.

49-6719 Refer to ATA Replace Combustion Chamber, Part No. 3830349-4 with
No. 49-26-45 Part No. 3830387-1.

49-6721 Refer to ATA Replace Oil Filler Cap, Part No. 194-518-9001 with Part
No. 49-26-45 No. 194-518-9004.

49-6732 Refer to ATA Replace Surge Control Valve, Part No. 3290050-2 with
No. 49-26-45 Part No. 3290050-3.

49-6736 Refer to ATA Rework/Install Improved Turbine Housing, Part No.


No. 49-26-45 3846664-1 with Part No. 3846664-2.

49-6739 Refer to ATA Replace Turbine Containment, Part No. 3846563-1 with
No. 49-26-45 Part No. 3846563-2 and Replace/Rework Turbine Nozzle
Assembly, Part No. 3846450-5 with Part No. 3846450-6.

49-6742, Rev 1 Refer to ATA Replace Gearbox Assembly, Part No. 3863019-1/-2 with
No. 49-26-45 Part No. 3863136-2.

49-6748, Rev 1 Refer to ATA Replace Carbon Seal Assembly, Part No. 3826450-5 with
No. 49-26-45 Part No. 3826880-2.

49-6755, Rev 1 Refer to ATA Rework Lube Pump Assembly, Part No. 3880130-6 to Repair
No. 49-26-45 Machining Discrepancy in the Pressure Indicator Port.
UP200456

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GTCP36-280[D]

SERVICE BULLETIN LIST (CONT)

SB DATE
NO_._~. INCORPORATED TITLE

49-6759, Rev 1 Refer to ATA Rework and/or Replacement of Surge Duct, Part No.
No. 49-26-45 3616082-1 with Part No. 3616456-1.

49-6768, Rev 2 Refer to ATA Rework the Turbine Housing Diffuser, Part No. 3846664-3
No. 49-26-45 to 3846664-4.

49-6775, Rev 1 May 31/94 Replace Surge Duct, Part No. 3616082-2 or Part No. 3616456-1
with Part No. 3616447-1 and Stiffener, Part No. 3884890-1. Also
rework or Replace Turbine (Plenum) Housing, Part No.
3846664-2 to Part No. 3846664-3.

49-6780 Refer to ATA Replace Oil Cooler Supply Line, Part No. 3881377-1 with
No. 49-26-45 Part No. 3881447-1 and Oil Cooler Return Line, Part No.
3881378-1 with Part No. 3881448-1.

49-6782 Refer to ATA Replace Load Compressor Impeller, Part No. 3822270-4
No. 49-26-45 with Part No. 3822270-5.

49-6783, Rev I Refer to ATA Replace Turbine Rotor, Part No. 3842121-2 with Turbine
No. 49-26-45 Rotor, Part No. 3842345-1.

49-6804, Rev 1 Refer to ATA Rework/Replace IGV Actuator Tube Assembly, Part No.
No. 49-26-45 3810410-1 with/to Part No. 3810410-2.

49-6805, Rev 1 Mar 30/01 APU Gearbox Gearshaft Shimming Procedure to Reduce
Rotor Seal Operating Face Load on Gearbox Assembly, Part
No. 3863136-1/-2, Part No. 3862980-1/-2 and Part No.
3863019-1/-2.

49-6814, Rev 2 Refer to ATA Rework Fuel Control Unit, Part No. 3882825-6 to Part No.
No. 49-26-45 3882825-8.

49-6816 Refer to ATA Replace Fuel Control Unit, Part No. 3882825-6 with Part No.
No. 49-26-45 3882825-8.

49-6832, Rev 2 Refer to ATA Replace Flexible Duct, Part No. 3884769-2 with Part No.
No. 49-26-45 3884930-2 and Clamps, Part No. 211-546-9010 with Part No.
211-546-9108.

49-6840 Refer to ATA Replace or Rework Turbine and Compressor Assembly, Part
No. 49-26-45 No. 3801082-3 with Part No. 3801082-4 and Replace Plumbing
and Electrical Assembly, Part No. 3616215-1 with Part No.
3616519-1 to Incorporate Oil-Cooled Vent Tube Modification.

49-6850 Refer to ATA Replace Static Pressure Sensor, Part No. 3884730-1 with Part
No. 49-26-45 No. 3884730-2.
UP200456

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GTCP36-280[D]

SERVICE BULLETIN LIST (CONT)

SB DATE
NO__.~. INCORPORATED TITLE

49-6851 Refer to ATA Replace Tube Assembly, Part No. 3881378-1 with Part No.
No. 49-26-45 3881448-1, Tube Assembly, Part No. 3881377-1 with Part No.
3881447-1, and Clamps, Part No. 211-592-9010 with Part No.
211-592-9014.

49-6856, Rev 3 No Effect Rework of Containment Ring, Part No. 3846563-2.

49-6862 Refer to ATA Add Sealant Between the Driven Compressor Shroud, Part
No. 49-26-45 No. 3826589-2 or 3826754-2 and the IGV Cover, Part No.
3810324-1.

49-6883 Jun 30/97 Replace Omni "C" Seal, Part No. 3846520-1 and Bearing
Spacer, Part No. 3846523-1 with Turbine Bearing Spacer, Part
No. 3846640-1.

49-6886 Refer to ATA Rework/Replace Inlet Guide Vane Housing Assembly (IGV),
No. 49-26-45 Part No. 3810316-2 to/with Part No. 3810316-4.

49-6887, Rev 2 Refer to ATA Rework Fan Rotor, Part No. 3884664-1 to Part No. 3884664-3,
No. 49-26-45 Containment Ring, Part No. 3615122-1 to Part No. 3615122-2,
Fan Assembly, Part No. 3614663-3 to Part No. 3614663-5 and
Seal Housing, Part No. 3614670-2 to Part No. 3614670-3.

49-6888 Refer to ATA Replace Cooling Fan Assembly, Part No. 3615133-3 to Part
No. 49-26-45 No. 3615133-5 and Part No. 3615133-4 to Part No. 3615133-6.

49-6905, Rev 1 Refer to ATA Replace/Rework Engine Compressor Housing Assembly,


No. 49-26-45 Part No. 3826823-1/-2/-3 to Part No. 3826823-4.

49-6920 Refer to ATA Replace Electronic Control Unit (ECU), Part No. 2118814-5
No. 49-26-45 with Part No. 2118814-6.

49-6939 Refer to ATA Rework the Oil-Fill Housing Assembly, Part No. 3863058-2/-3
No. 49-26-45 to Part No. 3863058-4.

49-6940, Rev 2 Jun 30/97 Rework to Clamp Gear Seal Rotor and Change Gearbox
Assemblies, Part No. 3862980-3 to -4, or 3863019-2 to -3, or
3863136-2 to -4, or 3863136-3 to -5.

49-6952 Refer to ATA Replace Shutoff Butterfly Valve, Part No. 109382-34 with
No. 49-26-45 Part No. 109382-36.

49-6962, Rev I Refer to ATA Rework Fuel Control Assembly, Part No. 3882825-8 to Part No.
No. 49-26-45 3882825-9.

49-6967, Rev 1 Refer to ATA Replace/Rework Turbine Bearing Carrier Assembly, Part No.
No. 49-26-45 3846612-1 with/to Part No. 3846612-2 or Part No. 3846521-4
with/to Part No. 3846521-5.
UP200456

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GTCP36-280[D]

SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-7051 Refer to ATA Replace Surge Control Valve, Part No. 3920050-3 with Part
No. 49-26-45 No. 3290050-4.

49-7054 Refer to ATA Replace Fuel Control Assembly, Part No. 3882825-8 with
No. 49-26-45 Part No. 3882825-9.

49-7095, Rev 2 Refer to ATA Replace Load Compressor Bellows Seal Assembly, Part No.
No. 49-26-45 3826880-2 with Part No. 3826880-3.

49-7104 Refer to ATA Rework Turbine Housing, Part No. 3846664-3/-4 to Part No.
No. 49-26-45 3846664-5 and Replace Union, Part No. MS24392J8 with Part
No. 3616822-1.

49-7117 Refer to ATA Replace Combustion Chamber, Part No. 3830387-1 with Part
No. 49-26-45 No. 3830387-3

49-7152, Rev 1 Refer to ATA Replace Turbine Rotor, Part No. 3842121-2 or 3842345-1 with
No. 49-26-45 Dual Alloy Turbine Rotor, Part No. 3842146-1.

49-7166, Rev I No Effect Provides Instructions to Perform a Buffer Air Blockage Test to
Check for a Blocked Buffer Supply Port Internal to the Load
Compressor Bearing Carrier.

49-7201 Refer to ATA Replace Turbine Backshroud Shims, Part No. 3846480-1/-2/-3/
No. 49-26-45 -4/-5 with Part No. 3846670-1/-2/-3/-4/-5.

49-7258, Rev 1 Refer to ATA Replace Bolt, Part No. MS9565-09 with Part No. MS9565-08.
No. 49-26-45

49-7270, Rev 3 Refer to ATA Replace Clutch, Part No. 3610945-1 with Part No. 3617044-1.
No. 49-26-45

49-7307, Revl Refer to ATA Incorporate Curvic Seal Gasket, Part No. 3617088-1.
No. 49-26-45

49-7309 Refer to ATA Rework Lube Clutch Restrictor, Part No. 3611869-9 to Part No.
No. 49-26-45 3611869-8 and Part No. 3862961-2 to Part No. 3862961-1.

49-7390, Rev 1 Refer to ATA Rework Compressor Housing, Part No. 3826823-4 to Part No.
No. 49-26-45 3826823-3.

49-7398, Rev I No Effect Provides Instructions for a One-Time Inspection of the Total
Pressure Transducer, Part No. 3876084-1/-2, Differential
Pressure Transducer, Part No. 3876085-4 and Inlet Pressure
Transducer, Part No. 3876035-4.
UP200456

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GTCP36-280[D]

SERVICE BULLETIN LIST (CONT)

SB DATE
NO.__~. INCORPORATED TITLE

49-7445 Refer to ATA Replace Turbine Backshroud, Part No. 3613968-2 with Part No.
No. 49-26-45 3846688-1.

49-7454 Refer to ATA Replace IGV Assembly, Part No. 3810316-1/-2/-3/-4 with Part
No. 49-26-45 No. 3810910-1 and Incorporate IGV Cavity Seal, Part No.
3810916-1 and Support Ring, Part No. 3617448-1.

49-7462 Refer to ATA Rework Bridge Hoist Assembly, Part No. 3616174-1 to Part No.
No. 49-26-45 3616174-2.

49-7473 Refer to ATA Incorporate Load Compressor Containment Shield Kit, Part No.
No. 49-26-45 3617748-2.

49-7493, Rev 1 No Effect Provides Instructions for a One-Time Inspection of Turbine


Wheel, Part No. 3842146-1.

49-7565 Refer to ATA Replace Electronic Control Unit, Part No. 2118814-6 with Part
No. 49-26-45 No. 2118814-7.

49-7574 Refer to ATA Rework Transducer Assembly, Part No. 3884833-1 to Part No.
No. 49-26-45 3884833-2.

49-7578 Refer to ATA Replace Elbow, Part No. MS24394J4 and Nut, Part No.
No. 49-26-45 AN924-4J with Union, Part No. AN815-4J, Packing, Part No.
M83248-1-904 with CRES Seal, Part No. 362-015-9111 and
Incorporate Swivel Fitting, Part No. MS51521B4S.

49-7581 Refer to ATA Replace Differential Pressure Transducer, Part No. 3876085-4
No. 49-26-45 with Part No. 3876085-5.

49-7587 Refer to ATA Replace Load Compressor Impeller, Part No. 3822270-4/5
No. 49-26-45 with Part No. 3822587-1.

49-7596, Rev 1 Feb 28/05 Provides the instructions and authorization for incorporating an
improved Gearshaft Assembly, Part No. 3860769-2, Carbon
Face Seal, Part No. 3863007-1 and associated hardware in
place of Gearshaft Assembly, Part No. 3860769-1 and Lip Seal,
Part No. 3862734-1

49-7598 Feb 28/05 Rework the Gearbox Housing Assembly, Part No. 3863135-1/-2
by adding material to oil jet bosses and machining to new
dimensional requirements to accept an Oil Jet, Part No.
3863543-1. Add O-rings, Part Nos. M83248-1-012 and
M83248-1-014 to the jet. Secure the jets using a Retainer, Part
No. M27426-4104D.

49-7603 No Effect Provides the procedure for reworking Flow Divider Assembly,
Part No. 3883687-1 to Part No. 3883687-2.
UP200456

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GTCP36-280[D]

SERVICE BULLETIN LIST (CONT)

SB DATE
NO~ INCORPORATED TITLE

49-7608 No Effect Provides the procedure for reworking Wire Harness Part No.
3888259-1 to Part No. 3888259-2 by pulling a single wire from
the P1 connector and tying it back to the wire bundle. Replaced
by Service Bulletin 49-7682

49-7610 No Effect Provides the procedure for reworking Wire Harness, Part No.
3888259-2 to Part No. 3888259-1 by re-inserting the DMM
power wire into the P1 connector. Replaced by Service Bulletin
49-7682

49-7628 No Effect Provides the procedure for reworking Oil Fill Housing/Scupper
Assembly, Part No. 3863058-1 or 3863658-4 to Oil Fill Housing
Assembly, Part No. 3863058-6 or 3863058-5.

49-7646, Rev I No Effect Provides the procedure to remove and replace Packing, Part
No. 3615648-1 with Seal Part No. 3617970-1.

49-7660 Feb 28/05 Provides authorization and instructions to replace Spacer, Part
No. 3616659-1/-2 and Rotor, Part No. 3616658-1 with Drive
Ring, Part No. 3861113-1, Rotor, Part No. 3861114-1 and
Packing, Part No. $3225-032. Replace Retaining Nut, Part No.
3616663-1 with Part No. 3861111-1. Replace Seal, Part No.
3614502-1 or Part No. 3863029-1 with Seal, Part No. 3863545-
1 or Part No. 3863544-1, respectively.

49-7669 No Effect Provides authorization and instructions to Replace Seal


Assembly, Part No. 3826450-5 or 3826880-3 and Seal Rotor,
Part No. 3822169-1 with Seal Assembly, Part No. 3827514-4
and Hydropad Rotor, Part No. 3822549-1.

49-7682 No Effect Provides authorization and instructions to disconnect the P11


connector install Cap, Part No. M83723/59-114RN on the P11
connector, install Cap, Part No. M83723/60-114RN on the DMM
connector, and secure the P11 connector using Clamp, Part No.
211-592-9216, Bracket, Part No. MS9592-054, Bolt, Part No.
MS9556-05 and Nut, Part No. MS21043-3. Replaces Service
Bulletins 49-7608 and 49-7610.

49-7692 No Effect Incorporate Starter Clutch Assembly, Part No. 3860813-4 in


place of Part No. 3860813-3 on Gearbox, Part No. 3863136-2/-
4 or Part No. 3860798-6 in place of Part No. 3860798-5 on
Gearbox, Part No. 3863019-3.

49-7734 No Effect Provided instructions for removing and replacing DART Rotor,
Part No. 3842146-1 with Part No. 3842146-2.
UP200456

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GTCP36-280[D]

SERVICE BULLETIN LIST (CONT)

SB DATE
NO~ INCORPORATED TITLE

GTE0741 Refer to ATA To update packings to new specifications.


No. 49-26-45

GTE0807 Refer to ATA To provide authority for the use of Packing, Part No.
No. 49-26-45 MS9386-177 in place of Part No. MS9386-171.

GTE0808, Rev 1 Refer to ATA To authorize use of Motional Transducer, Part No.
No. 49-26-45 3878058-2 as an alternate part in place of Part
No. 3878058-3. (CANCELED)

GTE0826 Refer to ATA To provide authority to use Bolt, Part No.


No. 49-26-45 MS9557-22 in place of MS9557-14.

GTE0860 Refer to ATA To eliminate possibility of bolt interference, and


No. 49-26-45 install correct size packing.

GTE0861 Refer to ATA To replace Oil Packing, Part No. 3615769-12 with
No. 49-26-45 Part No. 561-515-0018.

GTE0888 Refer to ATA To provide authority to use Gasket, Part No. 3830351-1
No. 49-26-45 in place of Preformed Packing, Part No. 3830189-1.

GTE0899 Refer to ATA To provide authority to use Clamp, Part No.


No. 49-26-45 211-502-9030 in place of 211-592-9010.

GTE0933 Refer to ATA To provide authority to use Insert, Part No.


No. 49-26-45 423-603-9032 in place of 423-603-9012.

GTE0937, Rev 1 Refer to ATA To provide authority to use Load Compressor


No. 49-26-45 Impeller, Part No. 3822270-4 in place of Part No.
3822270-5 for Rotating Group, Part No. 3822436-3.

GTE0951 Refer to ATA To provide authority to use Low Oil Pressure Switch,
No. 49-26-45 Part No. 3876186-3 as an alternate part for Part No.
3876186-4 on existing applications.

GTE0957 Refer to ATA To provide authority to use Insert, Part No.


No. 49-26-45 MS21209C0815L in place of MS21209C0815.

GTE0959 Refer to ATA To provide authority to use Packing, Part No.


No. 49-26-45 M83248-1-151 in place of M83248-1-150.

GTE0963 Refer to ATA To provide authority to replace Packing, Part No.


No. 49-26-45 NAS1532C3E and Part No. $8990-008 with Part No.
3615648-1.

GTE0967 Refer to ATA To provide authority to use Packing, Part No. 3615648-1
No. 49-26-45 in place of Part No. NAS1523C3E.
UP200456

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GTCP36-280[D]

SERVICE BULLETIN LIST (CONT)

SPB DATE
NO...~ INCORPORATED TITLE

GTE0970 Refer to ATA To provide authority to use Flow Divider Valve Assembly,
No. 49-26-45 Part No. 3882835-4 as an alternate for Part No. 3882835-3.

GTE0979 Refer to ATA To authorize use of Ignition Exciter, Part No. 3888000-3
No. 49-26-45 as an alternate part for Part No. 3888000-2.

GTE0983 Refer to ATA To provide authority to use Labyrinth Seal Housing


No. 49-26-45 Assembly, Part No. 3827040-1 in place of Part No.
3826776-1.

GTE0998 Refer to ATA To authorize the use of Data Memory Module, Part No.
No. 49-26-45 304643-2 in place of Data Memory Module, Part No.
304643-1.

GTE1029 Refer to ATA To authorize use of Starter Clutch Assembly, Part No.
No. 49-26-45 3860798-4.

GTE 1094 Refer to ATA To provide authority to use Starter Motor, Part No. 2000866-2,
No. 49-26-45 Series 4MR1 in place of Part No. 2000866-2, Series 4.
UP200456

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GTCP36-280[D]

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page T-1 Feb 28/05 INTRO-11 Feb 28/05


INTRO-12 Feb 28/05
Safety/ INTRO-13 Feb 28/05
Warranty/ INTRO-14 Blank
Liability
Advisory SWLA-1 Feb 28/05 Description
SWLA-2 Blank and Operation 1 Feb 28/05
2 Feb 28/05
Record of 3 Feb 28/05
Revisions RR-1 Feb 28/05 4 Feb 28/05
RR-2 Blank 5 Feb 28/05
6 Feb 28/05
Record of 7 Feb 28/05
Temporary 8 Feb 28/05
Revisions TR-1 Feb 28/05 9 Feb 28/05
TR-2 Feb 28/05 10 Feb 28/05
TR-3 Feb 28/05 11FO Feb 28/05
TR-4 Feb 28/05 12 Blank
13 FO Feb 28/05
Service 14 Blank
Bulletin List SB-1 Feb 28/05 15 FO Feb 28/05
SB-2 Feb 28/05 16 Blank
SB-3 Feb 28/05 17 FO Feb 28/05
SB-4 Feb 28/05 18 Blank
SB-5 Feb 28/05 19 FO Feb 28/05
SB-6 Feb 28/05 2O Blank
SB-7 Feb 28/05 21 Feb 28/05
SB-8 Feb 28/05 22 Blank
SB-9 Feb 28/05
SB-10 Blank Testing and
Fault Isolation 101 Feb 28/05
List of Effective 102 Feb 28/05
Pages LEP-1 Feb 28/05 103 Feb 28/05
LEP-2 Feb 28/05 104 Feb 28/05
LEP-3 Feb 28/05 105 Feb 28/05
LEP-4 Feb 28/05 106 Feb 28/05
LEP-5 Feb 28/05 107 Feb 28/05
LEP-6 Feb 28/05 108 Feb 28/05
109 Feb 28/05
Table of 110 Feb 28/05
Contents TC-1 Feb 28/05 111 Feb 28/05
TC-2 Blank 112 Feb 28/05
113 Feb 28/05
Introduction INTRO-1 Feb 28/05 114 Feb 28/05
INTRO-2 Feb 28/05 115 Feb 28/05
INTRO-3 Feb 28/05 116 Feb 28/05
INTRO-4 Feb 28/05 117 Feb 28/05
INTRO-5 Feb 28/05 118 Feb 28/05
INTRO-6 Feb 28/05 119 Feb 28/05
INTRO-7 Feb 28/05 120 Feb 28/05
INTRO-8 Feb 28/05 121 Feb 28/05
INTRO-9 Feb 28/05 122 Feb 28/05
INTRO-10 Feb 28/05 123 Feb 28/05
UP200456

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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

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354 Feb 28/05
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AIRLINES

LIST OF EFFECTIVE PAGES

SU BJ ECT PAGE DATE SUBJECT PAGE DATE

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369 Feb 28/05 398.24 Feb 28/05
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388 Feb 28/05
389 Feb 28/05 Cleaning 401 Feb 28/05
390 Feb 28/05 402 Feb 28/05
391 Feb 28/05 403 Feb 28/05
392 Feb 28/05 404 Feb 28/05
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398.3 Feb 28/05
398.4 Feb 28/05 Check 501 Feb 28/05
398.5 Feb 28/05 502 Blank
398.6 Feb 28/05
398.7 Feb 28/05 Repair 601 Feb 28/05
398.8 Feb 28/05 602 Blank
398.9 Feb 28/05
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398.11 Feb 28/05 (With Storage) 701 Feb 28/05
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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

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798.67 Feb 28/05 798.120 Feb 28/05
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798.70 Feb 28/05 798.123 Feb 28/05
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798.74 Feb 28/05 798.127 Feb 28/05
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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

798.128 Feb 28/05 803 Feb 28/05


798.129 Feb 28/05 804 Feb 28/05
798.130 Feb 28/05 805 Feb 28/05
798.131 Feb 28/05 806 Blank
798.132 Feb 28/05
798.133 Feb 28/05 Special Tools,
798.134 Feb 28/05 Fixtures and
798.135 Feb 28/05 Equipment 901 Feb 28/05
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Fits and
Clearances 801 Feb 28/05
802 Feb 28/05
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T A B L E OF C O N T E N T S

SECTION PAGE

Introduction ..................................................................................................................................... INTRO-1

Description and Operation ........................................................................................................................... 1

Testing and Fault Isolation ...................................................................................................................... 101

Automatic Test Requirements (ATLAS) (Not Applicable)

Disassembly ............................................................................................................................................ 301

Cleaning ................................................................................................................................................... 401

Check ...................................................................................................................................................... 501

Repair ...................................................................................................................................................... 601

Assembly (With Storage) ......................................................................................................................... 701

Fits and Clearances ................................................................................................................................. 801

Special Tools, Fixtures and Equipment ................................................................................................... 901


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INTRODUCTION

. General

This publication gives maintenance instructions for the equipment shown in Table 1 which is made by:

Honeywell Engines, Systems, and Services, Phoenix, AZ.

This publication is written to the Air Transport Association Specification 100.

The same exploded view illustrations are shown in DISASSEMBLY, CHECK, REPAIR, and
ILLUSTRATED PARTS CATALOG (IPC), ATA No. 49-26-49. These illustrations are numbered in the
same sequence in each section. For example, Figure 301 in DISASSEMBLY is the same as Figure 1
in the IPC. A note is used to keep the figure number sequence if any illustration is not used in a
section.

. Equipment Identification

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

Special procedures or illustrations necessary for each configuration will be identified by a part number,
a service bulletin number (Pre SB-, Post SB-) or a code symbol. Procedures and illustrations not
identified apply to all configurations of the equipment.

. Measurement Conversion

If measurements, weights, dimensions, pressure or torque values are changed to metric equivalents,
they are shown in parentheses after the United States measurements.

. Temperature

Temperatures shown in degrees Fahrenheit use the symbol F. Celsius (centigrade) is shown with the
symbol (C).

. Applicable Publications

The nomenclature, part number, and publication number of any component publication applicable to
the unit is shown in Table 2.
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. Codin.q System

The purpose of the effectivity system is to identify non-interchangeable changes.

These changes are caused by modifications to the basic unit. This makes it necessary to reidentify the
end unit. For example, Part No. 123456-1 becomes Part No. 123456-2.

A single code is given to each different part number and dash number.

If no codes are shown in the text, the procedures apply to all the units.

If one or more codes are shown for a part number, the procedure in the text will apply only to the coded
parts.

The Equipment Identification List, Table 1, shows the part number and code for each unit part number.

. Performance Check of Technical Data

When possible, and to make sure the procedures in the sections of the technical manuals are correct a
performance check is done of the procedures in the manual.

The sections shown below have been performance checked at the manufacturer's overhaul facility.

Section Date
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Table 1. Equipment Identification List


For Part No. 3800504-1

Code Series Change Service


Symbol No. No. Description Bulletin

1 1 Original Configuration

2 1 and 3

3 Incorporate Improved Flow Divider


Valve Assembly

3 1,3 and 4, 7

4 Provide Longer Hose Assembly

7 Provide New Rotating Group 49-6594


Assembly

4 1,3,4,7,
and 11

11 Incorporate New Primary and 49-A6618


Secondary Fuel Manifolds

1,3,4,7,11,
and 10, 12, 13

10 Incorporate New Surge Ducts For 49-6634


Better Fit

12 Incorporate Improved Blanket To 49-6718


Correct Potential Interference

13 Incorporate Improved Lube Pump 49-6689

6 1,3,4,7,10,
11,12,13, and
17,20,23
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Table 1. Equipment Identification List


For Part No. 3800504-1 (Cont)

Code Series Change Service


Symbol No. No. Description Bulletin

17 Incorporate -2 Engine Assembly at 49-6658


Customer Request

20 Incorporate Improved Fan Assembly 49-6711


to Preclude Possible Interference

23 Incorporate Power Section with 49-6632


Bellmouth Housing

7 1;3,4,7,10,
11, 12, 13, 17,
20, 23 and 29

29 Incorporate Shimadzu Gearbox 49-6742

8 1,3,4,7,10,11,
12, 13, 17, 20,
23, 29 and 16

16 Incorporate Turbine & Compressor 49-6719,


Assembly with Improved Face & Rotor 49-6739,
Seals and Stub Shaft Containment 49-A6653,
49-6782

9 1,3,4,7,10,11,
12,13,16,17,20,
23,29 and 21,
25,26,27,30

21 Incorporate New Engine Bridge Hoist

25 Provide Improved Rotating Group and


Impeller
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Table 1. Equipment Identification List


For Part No. 3800504-1 (Cont)

Code Series Change Service


Symbol No. No. Description Bulletin

26 Authorizes use of 561-515-0022 49-6648


Packing in Place of M83248-1-112
Packing for Improved Packing Life

27 Incorporate Fuel Control for 49-6652


Improved Reliability

30 Incorporate Improved Surge 49-6732


Control Valve

10 1,3,4,7,10,11,
12,13,16,17,20,
21,23,25,26,27
30 and 33

33 Provide an Improved Surge Exhaust 49-6759


Duct

11 1,3,4,7,10,11,
12, 13, 16, 17, 20,
21,23, 25, 26, 27,
30, 33 and 34

34 Incorporate Improved Turbine Wheel 49-6783

12 1,3,4,7,10,11,
12,13,16,17,20,
21,23,25,26,27,
30,33,34 and 24

24 Incorporate Improved Turbine 49-6736


Housing
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Table 1. Equipment Identification List


For Part No. 3800504-1 (Cont)

Code Series Change Service


Symbol No. No. Description Bulletin

13 1,3,4,7,10,11,
12, 13, 16, 17, 20,
21, 23, 24, 25, 26,
27, 30, 33, 34 and
35

35 Incorporate Improved Plenum

14 1,3,4,7,10,11,
12, 13, 16, 17, 20,
21,23, 24, 25, 26,
27, 30, 33, 34, 35
and 36

36 Provide Flex Lines for Easier 49-6780


Maintainability

15 1,3,4,7,10,11,
12,13,16,17,20,
21,23,24,25,26,
27,30,33,34,35,
36 and 37,39

37 Provide Improved Surge Duct 49-6775

39 Provide Static Pressure Sensor 49-6850


Adjustment Range

16 1,3,4,7,10,11,
12,13,16,17,20,
21,23,24,25,26,
27,30,33,34,35,
36,37,39 and 41

41 Provide Reduced Seal Friction 49-6748


and Carbon Face Wear
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Table 1. Equipment Identification List


For Part No. 3800504-1 (Cont)

Code Series Change Service


Symbol No. No. Description Bulletin

17 1,3,4,7,10,11,
12, 13, 16, 17, 20,
21, 23, 24, 25, 26,
27, 30, 33, 34, 35,
36, 37, 39, 41 and
42

42 Provide Reinforced Exhaust Diffuser 49-6768

18 1,3,4,7,10,11,
12, 13, 16, 17, 20, 21,
23, 24, 25, 26, 27,
30, 33, 34, 35, 36,
37, 39, 41,42 and
45, 46

45 Provide Oil Cooled Vent Tube 49-6840

46 Provide Improved Fuel Control 49-6816

19 1,3,4,7,10,11,
12,13,16,17,20,
21,23,24,25,26,
27,30,33,34,35,
36,37,39,41,42,45,
46 and47, 48,49

47 Provide Gearbox Shimming 49-6805


to Relieve Carbon Seal Load

48 Provide Improved Fan Rotor 49-6888

49 Provide Improved Bonding of 49-6632


Damper Strip
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Table 1. Equipment Identification List


For Part No. 3800504-1 (Cont)

Code Series Change Service


Symbol No. No. Description Bulletin

20 1,3,4,7,10,11,
12, 13, 16, 17, 20,
21,23, 24, 25, 26,
27, 30, 33, 34, 35,
36, 37, 39, 41,42,
45, 46, 47, 48, 49 and
51,53

51 Provide Improved IGV Bushing 49-6804

53 Provide Improved Linkage 49-6862

21 1,3,4,7,10,11,
12, 13, 16, 17, 20,
21,23, 24, 25, 26,
27, 30, 33, 34, 35,
36, 37, 39, 41,42, 45,
46,47,48,49,51,53
and 52,54,56,57,58,
59,60,62,63,64,65,
66,67,69

52 Provide Improved Turbine Bearing 49-6883


Spacer

54 Provide Improved Surge Bleed Duct 49-6832

56 Provide Improved Compressor Housing 49-6905


Assembly

57 Provide Improved Oil Scupper 49-6904

58 Provide Improved IGV Housing


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Table 1. Equipment Identification List


For Part No. 3800504-1 (Cont)

Code Series Change Service


Symbol No. No. Description Bulletin

59 Provide Improved Isolation Valve 49-6930

60/61 Provide Improved Gearbox Assembly 49-6940

62 Provide Improved Turbine Bearing 49-6967


Carrier

63 Provide Improved FCU 49-6962

64 Provide Improved SCV 49-7051

65 Provide Improved Turbine Housing 49-7104


to Provide Gearbox Pressure
Reduction

66 Provide Improved Stationary Oil 49-7095


Seal Assembly

67 Provide Improved Combustion Chamber 49-7117

69 Provide Improved Dual Alloy Turbine 49-7152


Wheel

No Series 5 Incorporate Improved Surge Valve 49-6579


Kicker Hardware

8 Incorporate Improved ECU 49-6660

19 Provide Improved IGV Actuator 49-6655

22 Provide Improved Start Motor

32 Provide Improved Transfer Tube in


Gearbox

38 Provide Improved Surge Exhaust Duct

40 Provide Improved LOP Switch


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Table 1. Equipment Identification List


For Part No. 3800504-1 (Cont)

Code Series Change Service


Symbol No. No. Description Bulletin

43 Provide Improved Rotating Group

44 Provide Improved IGV Actuator Rod

55 Provide Improved Rotating Group Assy

68 Provide Improved Rotating Group

70 Remove/Replace Turbine Backshroud 49-7201


Shims, Part No. 3646480-1/-2/-3/-4/-5
with Part No. 3846670-1/-2/-3/-4/-5

71 Provide Improved Differential


Pressure Transducer 49-7235

72 Provide Improved Delta P Transducer 49-7235

74 Incorporate Specific Bolt for Blind Hole 49-7258

77 Provide Improved Packing 49-7296


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Table 1. Equipment Identification List


For Part No. 3800504-1 (Cont)

Code Series Change Service


Symbol No. No. Description Bulletin

78 Rework/Replace Lube Clutch Restrictor, 49-7309


Part No. 3611869-9 to/with Lube Clutch
Restrictor, Part No. 3611869-8 and Lube
Clutch Restrictor, Part No. 3862361-2 to/with
Lube Clutch Restrictor, Part No. 3862961-1

79 Incorporation of L/C Impeller Curvic Seal 49-7307


Gasket, Part No. 3617088-1

80 Replace/Rework Engine Compressor 49-7390


Housing Assembly, Part No. 3826823-4
to 3826823-3

81 Installation of Inlet Guide Vane (IGV) 49-7454


Assembly, Part No. 3810910-1, IGV
Cavity Seal, Part No. 3810916-1, and
Support Ring, Part No. 3617448-1

83 Replace Turbine Backshroud, Part No. 49-7445


3613968-2 with Turbine Backshroud,
Part No. 3846688-1

84 Provide for Load Compressor Containment 49-7473


Ring

85 Eliminate Oil Leakage from Oil Vent 49-7578


Fitting

86 Provide identity for units incorporating 49-7587


Rotating Group Assembly, Part No.
3822436-2 (Improved Load Compressor
Impeller)

87 Replace Transducer Assembly, Part 49-7574


No. 3884833-1 with Part No. 3884833-2
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Table 2. Applicable Publications List

Nomenclature Part No. Publication Type

Gas Turbine Engine Assembly 3800504-1 49-26-45 IPC


49-26-47 MM
49-26-51 IRM

Data Memory Module 304643-1 49-60-61 CMM/IPL


304643-2

De-Oil Valve 3876166-1 49-91-47 CMM/IPL

Electronic Control Unit 2118814-1 49-61-50 CMM/IPL


2118814-3
2118814-4
2118814-5
2118814-6
2118814-7

Fan Assembly 3615133-2 49-51-75 CMM/IPL


3615133-4
3615133-6

Fuel Flow Divider 3882835-1 49-32-07 CMM/IPL


3882835-3
3882835-4

Fuel Control Assembly 3882825-5 49-30-97 CMM/IPL


3882825-6
3882825-8
3882825-9

Ignition Exciter 3888000-1 49-40-39 CMM/IPL


3888000-2
3888000-3

Inlet Guide Vane Actuator 3883220-2 49-50-02 CMM/IPL


3883220-3
3886182-1 49-50-06 CMM/IPL

Load Control Valve 109382-34-1 49-50-40 CMM/IPL


109382-36-1

Lube Pump Assembly 3880130-5 49-91-53 CMM/IPL


3880130-6

Oil Temperature Regulator 160466-1 49-94-18 CMM/IPL


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Table 2. Applicable Publications List (Cont)

Nomenclature Part No. Publication Type

Pressure Relief Valve 968214-17 49-31-09 CMM/IPL

Remote BITE Display 2118820-1 49-61-52 CM M/IPL

Starter Motor 2000866-2 49-41-08 CMM/IPL

Surge Control Valve 3290050-2 49-50-87 CMM/IPL


3290050-3
3290050-4

Transducer 3884714-1 49-51-83 CMM/IPL


3884833-1 49-51-91 CMM/IPL
3884833-2
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DESCRIPTION AND OPERATION

. General

The gas turbine auxiliary power unit (APU) is a self-contained power unit. The APU is controlled by a
system of automatic, pneumatic and electromechanical controls. The APU is designed to function as a
combination shaft and pneumatic power source. Power output is ready for use while the aircraft is on
the ground or in-flight.

The physical operationai characteristics of the engine are listed in Table 1. Approved engine oils are
listed in Table 2.

Table 1. Leading Particulars

NOTE: This APU is designed for operation with a customer-furnished air-cooled generator.

Rated Output Shaft Power ......................................................................................................60 HP (continuous)


90 HP (max. generator continuous)
120 HP (five minutes)
145 HP (five seconds)

Rated Output Shaft Speed ..................................................................................................................6,000 RPM

Maximum Turbine Exhaust Gas


Temperature at Rated Output ................................................................................1216F (103F at sea level)

Maximum Allowable Speed ...............................................................................................................69,204 RPM

Maximum Oil Consumption Rate ...................................................................................10 cc/hour (0.0106 qt/hr)

Oil Pressure Limits for Manual and Idle Operation ...............................................................65 ___5psig (nominal)
28 +_2 psig (automatic LOP shutdown)

Usable Oil Capacity .............................................................................................Total sump capacity 6.1 quarts.


Approximately 3.4 quarts
depletion to automatic shutdown.

Frequency of Oil Change .........................................................................................Every 800 hours of operation

Frequency of Oil Filter Change .........................................................................On condition. A Delta P indicator


is provided to indicate when filter change
is required. (500 hour minimum interval)

Oil ......................................................................................................Synthetic-base. Lubricating Oil Type I per


MIL-PRF-7808 and Type II per
MIL-PRF-23699. (Refer to Table 2)
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Table 1. Leading Particulars (Cont)

Fuel ...................................................................................................... Refer to Table 3 for list of approved fuels.

Minimum Fuel Inlet Pressure .................................................................... 10 to 55 psi for starting and operation.

Fuel Filter ....................................................................................................................................... 10 micron filter

Power Supply ............................................................................................................................................ 28 VDC

Table 2. Approved Engine Oils

Ambient Temperature
Minimum Maximum
Approved Lubricant Brand Name F (C) F (C)

CAUTION: ANY SUBSTITUTION OR USE OF NON-APPROVED LUBRICANTS, OR MIXING OF


BRANDS OR TYPES OF LUBRICANTS MAY CAUSE CONSIDERABLE ENGINE
DAMAGE.

3 Centistoke Oils
Type I
(Lubricant Specification MIL-PRF-7808)

Aeroshell Turbine Oil 390 -65 (-54) 130 (54)


Brayco 880 -65 (-54) 130 (54)
Castrol 325 or 399 -65 (-54) 130 (54)
BP/Exxon Turbo oil 2389 -65 (-54) 130 (54)

5 Centistoke Oils
Type II
(Lubricant Specification MIL-PRF-23699)

Aeroshell Turbine Oil or Royco 500 -40 (-40) 130 (54)


Aeroshell Turbine Oil or Royco 555 -40 (-40) 130 (54)
Aeroshell Turbine Oil or Royco 560 -40 (-40) 130 (54)
Castro15000 -40 (-40) 130 (54)
Exxon Turbo Oil 2197 -40 (-40) 130 (54)
BP/Exxon Turbo Oil 2380 -40 (-40) 130 (54)
Hatcol 3611 -40 (-40) 130 (54)
Mobil Jet Oil II -40 (-40) 130 (54)
Mobil Jet Oil 254 -40 (-40) 130 (54)
Mobil Jet Oil 291 -40 (-40) 130 (54)
Royco 899 -40 (-40) 130 (54)

7.5 Centistoke Oil

Castrol 98 -40 (-40) 130 (54)


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Table 3. Approved Fuels

Fuel Inlet Temperatures for


Starting and Operation
Minimum Maximum
Fuel F (C) F (C)

.NOTE: This APU is designed for operation with a customer-furnished air-cooled generator.

American Fuels
MIL-DTL-5624
JP-4 -40 (-40) 135 (57)
JP-5 -30 (-34) 135 (57)

MIL- DTL-83133
JP-8 -30 (-34) 135 (57)

ASTMD-1655
Jet A -30 (-34) 135 (57)
Jet A-1 -30 (-34) 135 (57)
Jet B -40 (-40) 135 (57)

British Fuels
DERD 2486 -40 (-40) 135 (57)
DERD 2494 -30 (-34) 135 (57)
DERD 2498 -30 (-34) 135 (57)

Canadian Fuels
CAN 2-3.22-77 -40 (-40) 135 (57)
CAN 2-3.23-77 -30 (-34) 135 (57)
3-GP-24g -30 (-34) 135 (57)

IATA Fuels
1978 (Kerosene Type) -30 (-34) 135 (57)
1978 (JP-4 Type) -40 (-40) 135 (57)

French Fuels
Air 3405/C -30 (-34) 135 (57)
Air 3407/B -40 (-40) 135 (57)

. Description

The APU will supply the aircraft with:

Pneumatic power for aircraft main engine starting (MES)


Pneumatic power for cabin air conditioning
Shaft power to drive an electrical generator
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Cooling air for the generator/APU lubrication oil

The APU has two modules.

The power section/load compressor


A gearbox with accessories.

The APU uses a single-shaft gas turbine power section directly driving the load compressor and
gearbox. The power section and load compressor are mounted together on a single shaft supported
by two bearings as shown in Figure 1.

Figure 2 shows the four major parts that make up the entire hot end of the APU. Only two of the four
parts, the turbine nozzle and rotor, are exposed to full turbine temperature.

A3800504MM21

APU Incorporates a Simple Single-Shaft Design (Typical)


Figure 1
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GTCP36-280[D]

TURBINE PLENUM
WITH INTEGRAL
EXHAUSTDUCT

COMBOSl
./
\
\
\
/
\ /"
f

\ /- /
'\//

NOZZLEASSY

TURBINE
ROTOR
X3800504DO169

APU Has Only Four Major Hot End Parts


Figure 2
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The APU gearbox is a wet sump modular assembly design interfaced with the load compressor and
incorporates the following accessory drive pads:

Generator assembly
Oil pump/fuel control
Starter motor assembly
Cooling fan assembly.

The accessory gearbox is designed as a module and is removable from the APU with all gears,
bearings and seals in place.

The Electronic Control Unit (ECU) provides a full-authority, microprocessor-based electronic control
system, contained in a single box, remotely mounted from the APU in an environment compatible with
electronic equipment.

The four major parts of the APU hot end are:

Turbine rotor
Nozzle assembly
Combustor
Turbine plenum with integral exhaust duct.

Figure 3 shows detailed items and their locations on the APU, to maximize accessibility and
maintainability to the APU.

Power Section

The APU power section is shown in Figure 4.

The power section is a single-shaft design employing a single stage centrifugal compressor and radial
inflow turbine.

The single main shaft that ties the power section compressor and turbine to the load compressor is
supported by two bearings:

A roller bearing aft of the gearbox


- A ball bearing between the power section compressor and turbine.

Carbon seals are used in the front and rear bearing cavities.

The load compressor bearing incorporates a buffered carbon face seal while the turbine bearing uses
a pair of carbon ring seals.

The carbon seals provide more positive sealing than labyrinth seals, which results in lower oil
consumption and improved heat rejection.
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GTCP36-280[D]

Refer to Figure 5 for lubricating system schematic, Figure 6 for fuel system schematic, Figure 7 for the
pneumatic system schematic and Figure 8 (Sheets 1 and 2) for the wiring diagram.

3. Operation

The APU START is initiated from the APU master control panel located in the aircraft cockpit. The
APU master switch is placed to START momentarily and spring loads to RUN. Electrical power is
supplied to the Electronic Control Unit (ECU) and energizes the aircraft boost pump, fuel solenoid, and
the APU inlet door actuator. Starter motor engagement is delayed until the APU inlet door has opened
and a door position signal is received by the ECU. A drop in DC volts is seen when the starter
engages.

The ECU accomplishes a pre-start bit check to verify operational readiness. The de-oil solenoid is
allowed to open if oil temperature is low enough to require de-oiling.

At 7% speed, the ECU:

Energizes the ignition system


Opens the fuel valve on the fuel control assembly
Establishes the correct metered fuel level for APU lightoff

When combustion occurs, the operator will notice a rise in EGT. Based on a speed rate increase, the
ECU is programmed to schedule starting fuel flow to effect smooth, efficient APU starts and maximize
turbine life. If EGT exceeds the programmed schedule, fuel flow is reduced to prevent
overtemperature shutdowns.

As the APU reaches 40% speed, the ECU commands the inlet guide vanes to open to a 22 degree
angle, which allows sufficient airflow to cool the load compressor components.

At 50% speed the starter is de-energized and voltage should return to normal.

At 60% speed the de-oil solenoid is de-energized and closes and oil pressure should build to normal
limits.

When the APU is at 95% of governed speed, ignition is terminated and some protection circuits are
armed. The generator and pneumatic bleed system are now ready to load and EGT will begin to
stabilize.
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GTCP36-280[D]

'o~#' I,~ (~
0 '..~

SURGECONTROL
VALVE FRONTVIEW

FUELCONTROL FAN DE-OIL INLET GUIDE TRANSDUCER LOAD CONTROL


ELEMENT OIL PUMP ASSEMBLY SOLENOID VANEACTUATOR ASSEMBLY VALVE

LI

COOLER
/
OIL FILTER/ OIL SUMP LOW OIL
EXCITER
ELEMENT TEMPERATURE PRESSURE
SENSOR SWITCH LEFT SIDE VIEW
X3800504MM186

APU External Features (Code A)


Figure 3
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GTCP36-280[D]

OILFILL I ~%
PORT

OIL LEVEL ~ ~)
SIGHTGLASS

STARTERMOTOR

"SURGECONTROL
VALVE FRONT VIEW SENSOR
FUELCONTROL FAN DE-OIL INLETGUIDE
ASSEMBLY OILPUMP ASSEMBLY SOLENOID VANEACTUATOR

/ LOADCONTROL
VALVE

)---

\
NSDUCER PRESSURE
OILFILTER TEMPERATURE ASSEMBLY ASSEMBLY ASSEMBLY EXCITER
ELEMENT SENSOR LEFT SIDE VIEW X3800504MM187

APU External Features (Code B)


Figure 3A
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GTCP36-280[D]

I
| ....

EXHAUST

DIFFUSER ~ "
o .@
I

COMP.JJ.STCJR

ATOMIZER

_[11 TURBINEHUB

TURBINE
"~
__i_
qJ
J CONTAINMENT

!
! STATOR

COMPRESSORHUB
CONTAINMENT

POWERSECTION / I
COMPRESSOR

w
I! I

i' I
'
|


I
\I
lii#?

i"
,I
,, .j'

IPl,ll
F A3801082MM2

APU Power Section Employs a Single Stage Compressor and Turbine (Typical)
Figure 4
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TO TAILPIPE VENT

LOWOIL
PRESSUR
SWITCH

FUEL
AIR / OIL POWERED
SEPARATOR ACTUATOR

OIL TEMPERATUREREGULATOR
AIRCOOLED --[11
li ~1~ FANAIR
FLOW
GENERATOR

NC SOLENOID
VALVE (DE-OIL)
,THERMALBYPASS
VALVE
~HOWN HO~
I IQJ

PRESSURE SCAVENGE

E
\
--1
FUEL

LEGEND:
OILPRESSURE GRAVITYFILL
RELIEFVALVE WITHSCUPPER
GEARBOX ) ) [~ GEARCASEAIR
REGULATING ~ o LUBEPUMPREGULATEDPRESSURE
VALVE
FILTERBYPASS LUBEPUMPINLET
VALVE
DIFFERENT~L SCAVENGEPUMPDISCHARGE
PRESSURE SIGHT
FILTER GLASS SENSOR
INDICATOR SCAVENGEPUMPINLET

GEARCASEVENTAIR
LUBEPUMP PUMPINLET | MAGNETIC PLUG
ASSEMBLY (SCAVENGE) REGULATED (SEALING)
(SCREENED) PRESSURE AND DRAINPLUG A3800504MM125
TESTPORT

Lubrication System Schematic (Typical)


Figure 5
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GTCP36-280[D]

VANEACTUATOR

DRAIN PORT
(-6PORT)

VA~ES OPEN
VANESCLOSE
(-6PORT)

ACTUATOR
ACTUATOR PRESSURE
RETURN -e-- ,REOULATOI
COMBUSTOR
ACTUATOR
TORQUEMOTOR SUPPLY
METERINGVALVE, , ~
PRESSURIZING
VALVE
FUEL
SHUTOFF
SOLENOID
N~]~~ 1 .'-I TESTPORT
/(-3 PORT)
HIGH PRESSURE
', /"FUEL. FILTER DRIVEN POWER
N.O.~
COMPRESSOR

- m
~m

OIL PUMP
AND VALVE
ASSEMBLY
FILTER GEARBOX NOZZLE
BYPASS
SEAL DRAIN
(-6 PORT)
-IIGH~RESSURE SCREEN ,,/t4 PORT)
FUELPUMP (-~PORT)N .__________d_(SELFBYPASSI"C) . m

/ L / db RELIEFVALVE "(-4PORT)
DIFFERENTIAL FUEL /
PRESSURE CONTROL FUEL
REGULATOR DIFFERENTIAL
INLET STARTSEQUENCE
(-BPORT) PRESSURE
INDICATOR

ll-maL'--mJ I "~'~"INLET FILTER

DRAINVALVE DRAINPORT
FLOW DIVIDER SECONDARY (-6 PORT)
AND DRAINVALVES
A3000505MM56

Fuel System Schematic (Typical)


Figure 6
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GTCP36-280[D]

O 41, 8 0 8 8 0

f <3===

I
~LA
RI yBUI
~ FFENREED
1 L i]~l
.o,,T,MPE~,URE
REOULATOR i~ I
rt~ 0'so"A"GE
L~ " = ~ "
CARBONFACE I rllll \ AIROUT I
'r-'--r

NfCSOLENOID
VALVE(DEOIL). GENERATOR
COOLINGAIR
DISCHARGE
~N~oTAi~PIPE) A
[]

4
TOTAILPIPE
DETAILA VENT
LUBE
PUMP
!

SOLENOID AIRINLET I
VALVE. VARIABLEVOLUME STATICPRESSURE DUCT q
LOAD
CONTROL~..~.
F~_ CHAMBER "~ PROBE(AELIUSTABI

VALVE ,I TOTAL
VENT-~, PRESSURE
TESTPORT "'"~, ~_~ DIFFERENTIAL
PRESSURE
ij ,--a TOTALPRESSURE
PROBEWITH
L VDIRECTIONAL
i ~ I. "
I ~ACTU~TOR
= ./
~ / D U M P
~.
QUICK -- -- I
~1
ACTUATOR
TRANSDUCER
_ ~ / 1 cONTROLVALVE I II " II/ II~-----[l--~r~ VALVEr~ ~h !
I
VENT-7~1711'
AIRCRAFT ~]
I
q J
SYSTEM ~ ~ ~ SURGE ~
LEGEND: BLEEDAIR BLEEDAIR J
" 1~" ~ ~ t"t" "el"
I i'
- /=I ...... ~------------I
~ f f ~ n i--~--i~.1 RES SURE
I) '
~ ~t SURGE I CLO~ED~/ ~ , r ~ -L~-I
/x z~
()

v VENT
INLETAIR I SERVO
i INDICATOR ~1--
BLEEDAIR = ELECTRONICI . . . . . . I _ _~[-'" ~' -- _ _ _ VALVE _ _ _t, . . . . .

<3===
CONTROL ~ ~ 1 TORQUE
COOLINGAIR BOX I = = = = = = e = = = = = MOTOR A3800504MM126

Pneumatic System Schematic (Typical)


Figure 7
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GTCP36-280[D]

P/O JtB EDU

t
ECU I P!OJ1C / tj PIOJIA . . . . '~

NC NC

II I NON-~L II I I I I I I II I I I II I I I I / I I
III JUMPER " '' I IIIIIIIII' I"l'lll
'I' ~~~ ~~" o ::)
z ~F- = I,~_,~,~
.~ i ~_''
~ ~__._-- I o:_
~.~
E -- -- ~UJ O -Jj N ~ ~ . 0 I I _~ ~ _ ~ ' _ ~
I ' E:I
~ _IJLI~~)_"~,
~ o5 oU.I flU --i
~(D(D In u~ ~ r < ~ E I U ~ O O O o E E P~ : 2 I-- oZl - , XX IZ:I]E O
~ O ~ U ~ ~

0 ~ 0 0 O

t:t"t:In

NC A/C

APU APU

P,o~ /
(P1-2269)
!! P/O P1
(P1-2268)

U
APUDOORACTUATOR P5
(m-tss)
RAM O P E N ~ . ~ .
P~16) I OPEN

NOTOPEN
OPEN v v . NON RAM OPEN
DOORI I~ II LOWOIL FUEL LOAD
NOT I J I DOOR BRAKE PRESSURE SOLENOID CONTROL
CLOSE[:~- - ~ - - J CLOSED SWITCH(LOP) VALVE
J
RAM DOOR i DE-OILING
INTERLOCK ,o o- I SOLENOID
CLOSED ~ NON RAMOPEN l

IGNITION
i
! UNIT
i
i
GENERATOR
CURRENT
-o o TRANSFORMERS
ALL CLOSED i
! T1.27 T1-28 T1-29 / P / O P3

, X 2 X2~ 1/ X2 1 ~1 (P1-1108)

,, /
APU
I L._~7f
r V ~.NU D.GGH._BG_~S A T K C E_M.P C B A D I APU

NC

CUSTOMER
SUPPLIED
WIRING

<>
IL O-(
~L o(
u- I-- :~ i
To
~ 88 X3800504DO213

Wiring Diagram (Schematic) (Typical)


Figure 8 (Sheet 1 of 2)
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MANUAL

ECU ~ ~ ~ .....

. . -: ~ M J t- ~ -:~ ' (-: J ,'--: J (-: J LL : ) ( - : ~ (-~--: J ,

FI_~ q ' ':- r :'l r' 'l r':- r'l-:'-:' r r~ NC_

P/O P2
L L ?]
"-]
--[-- 0-- -] "
~-:,---[;; -q~-- - - P/O P1
(P1-2269) / -- (P1-2268)

-. ! ~

) i i P18 15 17 P12 3 14 9
,~ ~: =_~s_~.j 11_!_ ~ - - I 4__~ ~._.~_1 6 ~ 74
{.) {-14 (-) I * - N(-) (4 (-)1 ...... -) ) (

- _ I TM
EGT EGT LCIT OIL SUMP
THERMOCOUPLE THERMOCOUPLE SENSOR TEMPERATURE LC & P SURGEVALVE FUEL CONTROL SPEED SENSOR
ASSY NO. 1 ASSY NO. 2 SENSOR DATA MEMORY MODULE LC PT SENSOR P2 SENSOR SENSOR TORQUE MOTOR TORQUE MOTOR I_VOT J

IGV ACTUATOR
X3800504MM46

Wiring Diagram (Schematic) (Typical)


F i g u r e 8 (Sheet 2)
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4 ~ K E Y TO FIGURE 8 (SHEETS 1 AND 2)

ABBREVIATIONS CONNECTORS

A/C AIRCRAFT P1 APU TO ECU INTERFACE CONNECTOR


AL ALUMEL WIRE 223-685-9001
ARINC AERONAUTICAL RADIO P2 APU TO ECU INTERFACE CONNECTOR
INCORPORATED 223-685-9002
APU AUXILIARY POWER UNIT P3 APU TO A/C INTERFACE CONNECTOR
CH CHROMEL WIRE MS3459KT28-21 P
P2 COMPRESSOR INLET P4 RAM DOOR INTERLOCK SWITCH
PRESSURE CONNECTOR MS3476L12-3S
ECU ELECTRONIC CONTROL UNIT P5 DOOR ACTUATOR CONNECTOR
EGT EXHAUST GAS MS3476L12-10S
TEMPERATURE P6 IGNITION UNIT CONNECTOR
IGV INLET GUIDE VANE MS3459L10SL-3S
LCIT LOAD COMPRESSOR INLET P8 LOP SWITCH CONNECTOR
TEMPERATURE M83723/95R803N
LC LOAD COMPRESSOR P9 FUEL SOLENOID VALVE CONNECTOR
PT TOTAL PRESSURE M83723/95R8036
LMES LEFT MAIN ENGINE START P10 DE-OIL SOLENOID VALVE CONNECTOR
LOP LOW OIL PRESSURE M83723/95R1203N
P/O PART OF P11 DATA MEMORY MODULE CONNECTOR
RMES RIGHT MAIN ENGINE START M83723/95R1415N
S/D SHUTDOWN P12 SURGE VALVE TM CONNECTOR
BATT BATTERY M83723/95R1005N
XMIT TRANSMIT P13 FUEL CONTROL TM CONNECTOR
REC RECEIVE M83723/95R1203N
PWR POW ER P14 IGV ACTUATOR CONNECTOR
TM TORQUE MOTOR M83723/95R1407N
SIG SIGNAL P15 P2 SENSOR CONNECTOR
AP DIFFERENTIAL PRESSURE M83723/95R 1407N
P16 LC PT SENSOR CONNECTOR
M83723/95 R14076
P17 LC AP SENSOR CONNECTOR
M83723/95R1407N
P18 OIL TEMPERATURE SENSOR
CONNECTOR MS3459L12S-3S
P19 SPEED SENSOR NO. 1 CONNECTOR
M83723/95R1005N
P20 SPEED SENSOR NO. 2 CONNECTOR
M83723/95R1005N
P21 LOAD CONTROL VALVE CONNECTOR
MS3459L10SL-3S
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TESTING AND FAULT ISOLATION

. Testing

A. Equipment and Materials

Table 101 shows the equipment and materials necessary to do the tests.

Table 101. Equipment and Materials

Equipment/Material Description/Manufacturer

NOTE: Equivalentequipment/material can be used.


Instrumented bleed duct Required for bleed air flow Honeywell Engines, Systems &
(834662-1) measurement. Services, Ground Support
Equipment
717 N. Bendix Drive
South Bend, IN 46628-1000
(574) 231-3987
Airflow measuring section Required for bleed air flow Daniels Flow Products, 9753
(MF05DS) measurement. Pinelake Dr, Houston, TX 77055
Electrical power DC External 28 vdc independent Sorensen, 767 Island Pond Road,
(DCR40-25B) of the APU electrical system. Manchester, NH 03103
Required to operate the starter
motor relays and igniter circuit.

Electronic control unit (ECU) Controls the functions of the Honeywell Engines, Systems &
(2118814-5) APU starter motor, ignition Services, Ground Support
Equipment
unit, fuel flow divider 717 N. Bendix Drive
and fuel control during starts. South Bend, IN 46628-1000
Controls speed, EGT, and (574) 231-3987
overtemperature protection.
Engine stand mounts (834389-1, Used to adapt the APU to the Honeywell Engines, Systems &
834390-1,834119-2) portable stand assembly. Services, Ground Support
Equipment
717 N. Bendix Drive
South Bend, IN 46628-1000
(574) 231-3987
Bleed duct elbow Setup with thermocouples. Honeywell Engines, Systems &
(834131-1) Services, Ground Support
Equipment
717 N. Bendix Drive
South Bend, IN 46628-1000
(574) 231-3987
Exhaust gas temperature meter Required for APU EGT Analogic Corp, 8 Centennial Drive,
(AN25MO2-TP-I-K-F-A) thermocouple check Peabody, MA 01961
and engine performance
verification.
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GTCP36-280[D]

Table 101. Equipment and Materials (Cont)

Equipment/Material Description/Manufacturer

Fuel MIL-T-6524, Grade JP-4 or


JP-5 or ASTM D-1655-75T,
Jet A or Jet B. Filtered and
supplied at 110F (43C) (max)
and 10 to 55 psi (20,36 to 112 Hg)

Shaft loading device or Required to apply shaft load Supplied by customer.


waterbrake of 100 shp/5 or more. Generator Part No. 9765252-6
Waterbrake Part No. WA200

Inlet duct assembly Refer to Figure 102. Required to Honeywell Engines, Systems &
(834400-1) measure inlet air temperature. Services, Ground Support
Equipment
717 N. Bendix Drive
South Bend, IN 46628-1000
(574) 231-3987

Lubrication Synthetic-base lubricating oil,


Type 11 (5 centistokes).

Portable stand assembly Used to support the APU during Honeywell Engines, Systems &
(833565-2) test and removal or installation Services, Ground Support
Equipment
of components. 717 N. Bendix Drive
South Bend, IN 46628-1000
(574) 231-3987

Vibration pickups (3) Required for gearbox, load Bruel and Kjaer Inst Co., 2117 S.
(6222S-50A) compressor, and turbine 48th St., Suite 107, Tempe, AZ
section. 85282

Exhaust tailpipe Required for exhaust gas Honeywell Engines, Systems &
(834611-1 ) temperature. Services, Ground Support
Equipment
717 N. Bendix Drive
South Bend, IN 46628-1000
(574) 231-3987
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Table 101. Equipment and Materials (Cont)

Equipment/Material Description/Manufacturer

Vibration accelerometer Required for measuring exhaust Honeywell Engines, Systems &
mounts (834134-1/-2/-3) gas temperature. Services, Ground Support
Equipment
717 N. Bendix Drive
South Bend, IN 46628-1000
(574) 231-3987

Surge valve positioning Required for surge valve Honeywell Engines, Systems &
sensor (2024323-1) position indication. Services, Ground Support
Equipment
717 N. Bendix Drive
South Bend, IN 46628-1000
(574) 231-3987

1. g. General instructions.
(1) Approved engine oils are given in DESCRIPTION AND OPERATION, Table 2.
(2) Engine test requirements and operating limits are given in Table 102.
(3) Complete and accurate record of all test information must be kept on a test record and
performance data sheet. A separate set of records and data sheets must be used for
each engine and kept as a permanent record on the engine. A sample test record
sheet and performance data sheet are supplied.
(4) Calculation may be necessary to change certain values to standard values. When
such calculations are necessary, the instructions, charts, curves, tables or other data
are given in the text.
NOTE: All instrumentation and gages used in the test and fault isolation, must be
calibrated and accurate.

(5) All instrumentation must be carefully calibrated against recognized standards.


Manometer must be zeroed or set to barometer reading as applicable, at least once a
day. Any error more than accuracy limits given in Table 102 must be corrected before
testing.

(6) Test release criteria are provided for three APU test categories. The depth of repair
identifies the categories as follows:

(a) Light repair. Continue-time (WPG) inspection criteria apply.

1 External work only (electrical harness, LRUs, plumbing)

2 Partial gearbox disassembly

3 Any combination of the above

(b) Medium repair. Continue-time (WPG) inspection criteria apply.

1 Complete gearbox disassembly

2 Partial or complete load compressor disassembly only


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1. B. (6) (b) 3 partial or complete power section disassembly only

4 Complete disassembly of any or all sections (gearbox, compressor,


and turbine) to repair a specific discrepancy affecting APU operation
with all other parts reused as removed

5 Any combination of the above

(c) Heavy repair - IRM inspection criteria applies.

1 Complete load compressor and power section disassembly, where


exposed detail parts are inspected per IRM requirements. This has
previously been called an "overhaul" unit or "heavy repair" or "zero-
time" unit
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PRESSURE
TRANSDUCERS
*USEOFFLOWCONTROLORIFICE
ORVENTURIOPTIONAL.

LABBLEEDDUCT
[]

T
.-,=1

FUEL
C~NTF

X~O~O~TI~

GTCP36-280[D] General Test Setup Schematic (Typical)


Figure 101
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~ l n KEY TO FIGURE 101

I-I TEST PARAMETERS

1 BLEEDAIR ORIFICE AP 10 UNIT VIBRATION (3)


2 BLEEDAIR ORIFICE INLET 11 UNIT SPEED
PRESSURE 12 OIL DISCHARGE PRESSURE
3 BLEEDAIR TOTAL PRESSURE 13 OIL DISCHARGE TEMPERATURE
4 BLEEDAIR ORIFICE INLET 14 FUEL INLET PRESSURE
TEMPERATURE 15 GENERATOR LOAD OR DYNO
5 COMPRESSOR INLET TORQUE
TEMPERATURE 16 FUEL FLOW
6 BLEEDAIR TEMPERATURE 17 FUEL PUMP DISCHARGE
7 FUEL INLET TEMPERATURE PRESSURE
8 CELL EXHAUST GASAVERAGE 18 EXHAUST STATIC PRESSURE
TEMPERATURE (12) 19 OILSUMP PRESSURE
9 UNIT EXHAUST GAS 20 OIL SUMP TEMPERATURE
TEMPERATURE (4)

O EQUIPMENT IDENTIFICATION

1 TEST CELL MANUAL FLOW 11 OIL GRAVITY FILL PORT


CONTROL VALVE 12 FUEL FILTER
2 ORIFICE MEASURING SECTION 13 LAB BLEED AIR DUCT
3 LAB EXHAUST DUCT 14 ELECTRONIC CONTROL UNIT
4 BLEEDAIR VALVE (NOT SHOWN) 15 LAB LOAD CELL
5 ELECTRIC START MOTOR 16 24 VDC ELECTRICAL SUPPLY
6 FUEL ROTAMETER TERMINALS (NOT SHOWN)
7 VIBRATION PICKUP (3) 17 FUEL SUPPLY
8 SPEED PICKUP (2) 18 OIL FILTER
19 MAGNETIC DRAIN PLUG -
20 ELECTRICAL HARNESS
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GTCP36-280[D]

/1

10.39
(263,~06MM)

ii
= |
,q f

10THERMOCOUPLES
10 PRESSURES
15.00IN.
(381,000MM)

TOPVIEW

0.125IN.

I
t t
2.500 IN.

I
I ~ D D D 1~ 0.125IN.

!
J SIDEVIEW
~, 6.I IN.
A3800504TT129

Part No. 834400-1 Inlet Duct Assembly


Figu re 102
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. C. Test conditions.

Conduct all tests at existing laboratory conditions of temperature, pressure and humidity, using
the test equipment and instrumentation listed in steps (D) and (E) below.

D. Test equipment.

Provide the laboratory test equipment listed in Table 101. Figure 101 shows a schematic
diagram of the test setup, and Figure 102 shows the Inlet Duct Assembly Part No. 834400-1.

E. Instrumentation.

Provide standard instrumentation to measure the parameters shown in Table 102. All
instrumentation must be calibrated. Disconnect any malfunctioning thermocouples. Only one
failed probe for each of the measured parameters is permissible during performance data
acquisition.

F. Operating limits.

During all operating conditions, observe the limits of Table 103. EGT trim and shutdown
schedules are referenced in Figures 103, 104, 105, and 106 for starting, ECS, and MES
operating conditions. Monitor APU parameters continuously during operation and review test
data carefully for any of the following conditions:

(1) Unit EGT spread greater than 80F (44C).

(2) Oil sump pressure greater than 25 in. H20 for overhauled units and 33 in. H20 for
repaired or continued time units. (Except when cell valve is closed).

NOTE: If any vibration exceeds 0.65 in./sec at any time during the testing, reject
the APU and call Engineering disposition.

G. APU History Data.

Before starting the APU, record the Data Memory Module (DMM) APU history data, (SN, HR,
CY, and BDCY) under the HST DATA menu on the ECU display. Disconnect the DMM
connector (P11, APU wiring harness) for acceptance testing.

H. Limited Test Requirements.

Test Section Check Light Medium Heavy


#, J
1.H. (2) (b) Motoring, positive oil pressure
1.H. (2) (c) Leaks, vibration ,/ ,/ ,/
1.1.(1) Run-in ,/ ,,/ ,/
l.J. Oil filter and magnetic plug ,z J ,/
I.N. ,/ ,/ ,/
LRU BITE test
1.O. ,/ ,z ,/
Surge control system ,/
I.P. Performance check ,z
I.Q. IGV adjustment ,/
* Optional, based on experience and judgment of the repair facility. Use Medium Repair release limits.

** Optional unless complete load compressor or complete power section disassembly required
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GTCP36-280[D]

Table 102. Equipment and Instrumentation Check List for


GTCP36-280[D] Mechanical and Performance Checkout

Parameter Range Console Digital


Barometric pressure 13 to 15 psia xl x
Cell pressure 12 to 17 psia x x
Cell temperature -65 to 130F x x
Engine Speed 0 to 100,000 rpm x x
Waterbrake torque (if applicable) 0 to 1000 in. Ibs shp xl x
Generator current (if applicable) 0 to 1500 amps x
Generator voltage (if applicable) 0 to 300 vac x
Generator electrical power (if applicable) 0 to 100 kW x x
Oil pressure 0 to 100 psig x x
Oil sump pressure 0 to 100 in. H20 x x
Oil sump temperature 0 to 500F x x
Fuel inlet temperature, 1 probe at TFM 0 to 150F x
Fuel flow, 2 TFM 0 to 2.5 gpm x1
APU inlet air temperature, 10 probes -65 to 130F x
Orifice PT 0 to 20 psia z x x
Orifice AP 0 to 5 psid x x
Orifice TT 0 to 500F x x
Flow sensor PT 0 to 75 psia x x
Flow sensor AP 0 to 5 psid x x
Bleed temperature, 4 probes (minimum) 0 to 500F x1 x
Bleed PT, 5 probes (minimum) 0 to 100 psia x1 x
EGT - l a b rake, 12 probes 0 to 1500F x x
EGT - high response (optional) 0 to 2000F x
EGT - Unit
1 0 to 1500F x1 x
2 0 to 1500F x1 x
Exhaust static pressure, 4 probes +_2.5 psig x
Vibration
Gearbox, load compressor, and
turbine areas displacement 0 to 1 in./sec x
Cell valve position 0 to 100% open x
32F reference 31.6 to 32.4F x
Bleed orifice diameter Thumbwheel x x
Bleed duct diameter Thumbwheel x x
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GTCP36-280[D]

Table 102. Equipment and Instrumentation Check List for


GTCP36-280[D] Mechanical and Performance Checkout (Cont)

Parameter Range Console Digital


Fuel specific gravity Thumbwheel x x
Fuel lower heating value Thumbwheel x x
Test condition Thumbwheel x x
Surge valve position 0 to 100% closed x x
IGV position 0 to 100 degrees x x
Unit LCIT -65 to 130F x x
1 Only if manual data is recorded.
2 Only if cell bleed control valve is upstream of measuring orifice. If valve is downstream,
range becomes 0 to 60 psig (0 to 414 kPa).

Table 103. Operating Limits

Type Limit Tolerance Remarks

(1) Leakaqe

(a) Fuel 1 drop per minute Maximum

1. Plenum drain -- See Fuel leakage from the


Remarks plenum drain is permitted
only after a false start or
blowout.

2. Fuel/oil pump 1 drop per 10 minutes Maximum

3. Fuel 1 drop per minute Maximum Measured after 5 minutes


flow divider operation when residual fuel
from previous fuel manifold
purge on shutdown has
drained. Fuel from manifold
purging during APU
shutdown normally drains
through this port into ecology
tank.

4. IGV actuator 1 drop per minute Maximum

(b) Oil

1. Fuel/oil pump Zero Maximum At the seal drain port.

2. Generator seal 2 cc/hr (0.002 qt/hr) Maximum Measured at the bottom of


the gearbox generator mount
flange.
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GTCP36-280[D]

Table 103. Operating Limits (Cont)

Type Limit Tolerance Remarks

(2) Light-off time 17 sec after Maximum Any condition.


7% speed

(3) Oil pressure (normal) 65 psig _+5 psig Measured at oil pump
(448,5 kPa) (_+34,5 kPa) discharge port.

Oil pressure 30-35 psig Maximum Measured at oil pump


(shutdown) (207,0-241,50 discharge.
kPa)

(4) Oil pressure fluctu- _3 psi Maximum Measured at oil pump


ation (under steady- (+_20,7 kPa) discharge.
state operating con-
ditions)

(5) Starter-motor duty 3 consecutive Maximum 3 starts per hour maximum


cycle starts or attempts with 1 minute minimum
between attempts.

(6) Lube-oil consumption 10 cc/hr Maximum Verified by gearbox


(.0106 qt/hr) pressure less than 25 in.
H20 and visual.

(7) Temperatures

(a) Inlet air 130F (54C) Maximum


(b) Oil (shutdown) 325F (163C) _+7F Measured at oil temp sensor
(c) Exhaust gas tem- Refer to Figures -+25F Shutdown limit and T5 trim
perature (MES/ 103,104 limits shown.
ECS operation)
(d) Exhaust gas tem- Refer to Figures +_25F Shutdown limit and T5 trim
perature during 105,106 limits shown.
acceleration
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GTCP36-280[D]

Table 103. Operating Limits (Cont)

Type Limit Tolerance Remarks

(8) Rotor Speeds

(a) Continuous 62,553 rpm +_0.25%


recommended
operation
(NORMAL)

(b) In-flight (HI-SPEED) 63,830 rpm +_0.25%


(c) Absolute maximum 65,625 rpm +_0.25% Overspeed shutdown.
68,890 rpm +_0.25% Backup overspeed
shutdown.
(d) Speed Variation +_200 rpm No instantaneous speed
Steady State deviation will exceed the
limit.
+_200 rpm No amplitude modulation
rate in a one second time
period will exceed the
limit. Repetition rate must
be lower than 2 Hz.

(9) Vibration

Gearbox, load 0.65 in./sec


compressor, and
turbine pickups
110 to 2000 Hz
"z" direction

(10) EGT Spread

Temperature spread 60F (15.5C) Maximum


between #1 and #2 Overhaul
Thermocouple rakes 80F (26.6C) Maximum
On condition
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GTCP36-280[D]

ECS2-PACKMODE
1280
I 1 I I
NOTES:
1. PERFORMANCEMODELMV280D3NTACOM.
2. SEA LEVELINSTALLEDSTATICCONDITIONS.
,, 1240 - 3. EGT IS UPSTREAMOF LOADCOMPRESSOR
(9
uJ SURG" BLEED.

r~

2 1220
J
J
J
J
' " ~ 1200
n--
I
o

1180
Z
rr~
tY

1160

1140
-50 -30 -10 10 30 50 70 90 110 130
T2, COMPRESSORINLETTEMPERATURE,DEGF

MESMODE
1320
I I I I
NOTES:
1. PERFORMANCEMODELMV280D3NTACOM.
2. SEA LEVELINSTALLEDSTATICCONDITIONS.
1300 - 3. EGT IS UPSTREAMOF LOADCOMPRESSOR
0
LLI
SURGli BLEED.
,.-.,

LU-

~1280
U.I
J
~._-w J
0 ~
,,, ~ 1260 J
Y
J
J
" 1240
IJJ

',n
Y

1220

1200
-50 -30 -10 10 30 50 70 90 110 130
T2, COMPRESSORINLETTEMPERATURE,DEG F
A3800504TT3

Governed Speed EGT Trim Schedules


Figure 103
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GTCP36-280[D]

1380

1360
LL
(.9
ILl

UU-
n,,
~340
tY
f
LLI
13_
~_-LU
J
(D~--
'" ~320
rv-

-1-

r~
uu
N300
m

1280

1260
-50 -30 -10 10 30 50 70 90 110 130
T2, COMPRESSORII~_ETTEMPERATURE,DEC F

NOTES:
1. PERFORMANCE MODEL MV280D3N'rACOM.
2. SEA LEVEL INSTALLED STATIC CONDITIONS.
3. EGT IS UPSTREAM OF LOAD COMPRESSOR
SURGE BLEED.
4. APU SHUTDOWN OCCURS IF EGT EXCEEDS
THIS SCHEDULE.
A3B00504TT4

Governed Speed EGT Overtemperature Shutdown Schedule


Figure 104
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1800 --

17oo ( B

1600--

1540

1500

I.L 1420
(.9 1400

1360

1280

1240
1200
1200
1160 1160

1000 I I I I 1 I I I I I
20 50 60 70 75 80 85 90 95 98

N, PERCENT
A3800516TT2

E G T Trim Schedule During Timed Acceleration


Figure 105
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'GTCP36-280[D]

2000

1900 1900

1800 1784

LL

LM

1668

1600
1552

1460 0

1400 I I I I I I I
50 60 70 8O 88 100 120

N, PERCENT
A3800516TTI

EGT Overtemperature Shutdown Schedule During Timed Acceleration


Figu re 106
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. H. Test setup.

(1) Make APU ready for test as follows. Refer to Figure 101.

(a) Use 834389-1,834390-1, and 834119-2 engine stand mounts to attach APU
to 833565-2 portable stand assembly.

(b) Install engine in test facility so that all sides, top and bottom of APU are easy
to get to for installation and connection of test equipment compressor. Air
inlet and turbine exhaust must be free of blockage.

(c) Remove surge exhaust duct, surge bleed duct, coupling clamp, clamps,
support strut, bolts and nuts.

(d) Install the exhaust tailpipe (834611-1 ), inlet duct, (834400-1), instrumented
bleed duct (834662-1), surge bleed and oil cooler exhaust ducts, surge valve
positioning sensor (2024323-1) and required instrumentation. Clamp surge
valve position sensor to housing with a "C" clamp and attach the helicoil to the
rotating shaft flex coupling.

(e) Connect the APU to the test cell digital acquisition system, if applicable.
Check all instrumentation and plumbing for proper location and connection.
Service and prime the APU with oil. Duct the oil cooler discharge air out of the
test cell.

(f) Disconnect the ecology tank for the test.

(g) Supply one of the fuels listed below to the APU inlet at a pressure of 10 to 55
psig.

MIL-DTL-5624, Grade JP-4 or JP-5


ASTM D-1655-75T, Jet A or Jet B

(h) Use an approved type MIL-PRF-23699 lubrication oil. A synthetic-base


lubricating oil Type II (5 centistokes) to service the APU. 6 quart capacity.

(i) Provide a 28 vdc electrical power supply to the APU.

U) Select Speed Set display on ECU front panel and confirm that ECU is set on
NORMAL speed. If it is set on HI speed, reprogram to NORMAL speed.

(2) BITE Interrogation.

(a) If the customer ECU was returned with the APU, record the BITE information
(CUR RCD and all five HISTORY records, including numeric error codes )
must be recorded in the test log.
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GTCP36-280[D]

WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS


AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE
AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-
ENERGIZED AND GROUNDED BEFORE THE INPUT AND
OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE
CENTER CONTACT OF OUTPUT TERMINAL.

CAUTION: DO NOT EXCEED OPERATING LIMITS SPECIFIED IN TABLE 103.


MAKE SURE THAT VIBRATION MEASURED AT GEARBOX AND
POWER SECTIONS DOES NOT EXCEED .65 INCH PER SECOND
DURING ACCELERATION AND STEADY STATE.

1. H. (2) (b) Disconnect the igniter lead (Figure 313, item 120), de-oil solenoid (Figure 306,
item 90) and the fuel supply to the unit.

NOTE: The electronic control unit will delay starter engagement for
approximately two to four seconds.

CAUTION: DO NOT EXCEED STARTER MOTOR DUTY CYCLE.


REFER TO TABLE 103.

1 Set START switch to ON. Allow engine to motor, check oil pressure
for positive pressure indication on oil pressure gage.

NOTE: The engine will shut down automatically at approximately


17 seconds.

2 If no oil pressure indication appears, stop engine and trouble shoot.


Repeat step 1.

3 During engine roll down, listen for any unusual noises (evidence of
rubbing or grinding). If excessive or unusual noises are evident,
terminate test and trouble shoot to determine cause. Repeat test as
necessary.

4 Connect igniter, de-oil solenoid valve, and the fuel supply to the unit.

NOTE: Make sure the ECU fault memory is clear.

(c) Start the APU, check for stable combustion, leaks and vibration.

NOTE: Leak from fuel plenum drain is acceptable during engine start.
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1. I. Run-In procedure.

(1) Disconnect the fuel solenoid connector plug (P9).

NOTE: The APU should be in NONESSENTIAL and GROUND modes throughout


testing.

(a) Motor the APU with the start motor until automatic shutdown occurs. Confirm
normal rolldown after motoring, free of unusual noises or other indications of
APU distress.

(b) Connect the fuel solenoid connector plug (P9).

NOTE: Do not exceed the start motor duty cycle. (Refer to Table 103.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(c) With the oil fill cap removed, check the oil level. Top off the oil sump to the full
mark on the sight glass.

NOTE: If the oil fill cap is not removed, the oil level in the sight glass may
not be correct.

(d) Clear the ECU BITE memory and attempt an APU start. If the APU fails to
start, interrogate the ECU CUR SDN and CUR FLTS records before turning
the MASTER SWITCH OFF. Make sure NO FLAME and DMM are the only
fault indication. If any other faults are indicated, record the fault numbers in
the test log and determine their cause.

(e) Repeat step (d) until the APU successfully starts and accelerates to governed
speed. Apply bleed and shaft loads to verify correct function of APU and lab
equipment. Monitor ECU APU DATA parameters to verify correct indications.
Verify correct function of all lab instrumentation. After a minimum of 15
minutes run time, (overhaul only), shut down the APU.

NOTE: When operating the APU previous to the surge control check,
make sure the cell valve is sufficiently open to prevent load
compressor surge.

J. Oil filter and magnetic chip detector.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN


ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS
AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH
THE SKIN.

(1) Check the oil filter elements and magnetic chip detector. If the filter and/or detector is
contaminated, change the filter and recheck after approximately 15 minutes of
operation. If further contamination is observed, refer to appropriate engineering for
disposition.
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. K. Automatic start test.

CAUTION: ALLOW THE STARTER TO COOL FOR A MINIMUM OF ONE HOUR AFTER THREE
CONSECUTIVE START ATTEMPTS.

During at least one start, make sure that no abrupt increase in starter voltage occurs prior to
reaching cutout speed.

L. Acceleration time.

During three automatic starts, make sure the APU starts and accelerates to governed speed
within 60 seconds. Record the time required to attain governed speed on data sheet.

M. Surge Control System.

(1) Calibrate the APU surge control system as follows:

(a) Install a block-off plate at the surge bleed duct/surge control valve interface.
Disconnect the load control valve (LCV) connector plug (P21). Connect the
LCV to a control panel dc switch and activate the switch.

NOTE: Power the LCV open whenever the block-off plate is installed.
Starting the APU with the LCV closed will cause load compressor
surge.

(b) With the cell valve sufficiently open to prevent load compressor surge, start
the APU and apply bleed load in MES mode.

(c) Close the cell valve to attain 60 (+0.5, -0.0) Ib/min discharge bleed corrected
airflow. Allow the APU to stabilize at this point.

(d) Calculate AP/PT = DP + PT, using DP and PT from the ECU display.

(e) If AP/PT is greater than 0.0574, rotate the static pressure probe
counterclockwise according to the following equation, where N is the number
of notches on the static pressure probe:

N(notches) = (AP/PT - 0.0535) + 0.0025

(f) If AP/PT is less than 0.0505, rotate the static pressure probe clockwise
according to the following equation where N is the number of notches on the
static pressure probe:

N(notches) = (0.0535 - AP/PT) + 0.0025


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1. M. (1) (g) Repeat steps (d) through (f) until AP/PT is between 0.0505 and 0.0574.
Record the final discharge bleed corrected airflow and AP/PT in the test log.

(h) Lockwire the static pressure probe locking bolt in accordance AS567.

(i) Remove the block-off plate and reconnect the LCV connector plug (P21).

N. LRU BITE test.

(1) After completing the surge control system calibration, clear the ECU BITE memory
and make sure that DMM is the only fault displayed. If any other faults occur during
acceptance testing, interrogate the ECU, record the fault number(s) in the test log, and
determine their cause(s). To prevent loss of BITE memory, always interrogate the
BITE memory before turning the MASTER SWITCH OFF.

NOTE: If the ECU BITE flags any fault other than DMM during acceptance test,
record the fault number in the acceptance test log and determine the
cause.

O. Surge control system verification.

(1) Verify the correct function of the load compressor surge control system, as follows:

(a) Start the APU and allow it to accelerate to governed speed.

(b) With the cell valve sufficiently open to prevent load compressor surge, apply a
bleed load in MES mode.

(c) Connect the LCIT thermocouple simulator lead to the breakout box LCIT
connector. Set T2 on the ECU display equal to the lab average inlet
temperature (T2 +_2F).

(d) Close the cell valve to the point at which the surge valve just begins to open
(97.0 to 99.9 percent closed -- if the SCV opens beyond this range, reopen the
cell valve and perform this step again). Allow the APU to stabilize for 30
seconds at this point.

(e) Record the discharge corrected bleed airflow (WBCDNA) on test data sheet.
Discharge corrected bleed airflow at the surge valve crack point must be
within the tolerances indicated in Figure 107.
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1. O. (1) (f) Use the surge valve positioning sensor (2024323-1) to adjust the cell valve to
attain 63 +_2 Ib/min discharge corrected bleed airflow (WBCDNA). Close the
cell valve as rapidly as possible with normal lab position control. Make sure
the SCV opens to successfully prevent load compressor surge.
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61

60

o9
0ILl: : < 5 0
~8
o~
I--

57

56

55
30 40 50 60 70 80 90 100 110

APULABAVERAGEINLETTEMPERATURE(I"2),F

NOTES:
1. PHOENIXAMBIENTCONDITIONS,UNINSTALLED.
2. NOMINALMESSURGEVALVESCHEDULE.
3. CRACKPOINTTOLERANCEIS 22 LB/MIN.
4. MODELMV280D3CUSTOMERDECKNTACOM. A3800504TT5

Surge Valve Crack Point


Figure 107
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1. O. (1) (g) Repeat step (f) from a discharge bleed airflow of 30 to 35 Ib/min.

(h) Remove the block-off plate and reconnect the LCV connector plug (P21).

P. Performance test procedure (Optional for light Repairs).

NOTE: All performance tests are performed at NORMAL speed.

(1) No Load Performance.

(a) Start the APU and allow it to accelerate to governed speed.

(b) Allow all monitored APU parameters to stabilize with APU AIR OFF and no
shaft load.

(c) Record digital performance data or complete the test data sheet.

(2) Environmental Control System (ECS) two-pack standard mode performance. Refer to
Table 104.

(a) Apply a shaft load of 60 (+3.0, -0.0) shp/8, as follows:

For electrical loading,

KWe = 40 (+2.0, -0.0) (PCELL/14.7)

Where:

KWe = Generator load, KW


P Cell = Absolute cell pressure, psia
Power factor = 1.0
Generator efficiency = 0.85

For waterbrake loading,

T = 630 (+32, -0) (PCELL/14.7)

Where:

T = Waterbrake torque, in.-Ibs.

NOTE: Load changes must be applied instantaneously. All data must be


recorded with the digital acquisition system, or manually recorded if
the digital system is not available.
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GTCP36-280[D]

1. P. (2) (b) Activate the APU AIR, RIGHT PACK and LEFT PACK switches. (The
RECIRCULATING FAN switch must be OFF.) Make sure the APU is in the
STANDARD mode. (The asterisk must be next to STANDRD under APU
MODE on the ECU display: *STANDRD.)

(c) Connect the LCIT thermocouple simulator lead to the breakout box LCIT
connector. Set T2 on the ECU display equal to the lab average inlet
temperature (T2 +_2F).

(d) Adjust the cell valve to attain 56.2 (+_0.5), Ib/min discharge corrected bleed
airflow.

(e) Allow all APU measured parameters to stabilize.

(f) Record digital performance data or complete the test data sheet and make
sure:

The setpoint parameters (T2 on the ECU display, WBCDNA, and


SHPSL) are within the required tolerances.

The sea level, 103F, installation corrected data (PBCOR, WBCOR,


EGTCOR, and WFCOR) meets or exceeds the ECS 2-pack standard
requirements. Refer to Table 105 (overhaul) or Table 107 (continued
time).

(3) Main Engine Start (MES) performance. Refer to Table 104.

(a) Apply a shaft load of (60 +3.0, -0.0) shp (as in step 1.Q.(1)(a)).

(b) Activate the APU AIR switch and the RIGHT M r s and/or LEFT MES
switch(es).

(c) Connect the LCIT thermocouple simulator lead to the breakout box LCIT
connector. Set T2 on the ECU display equal to the lab average inlet
temperature (T2 +_2F).

(d) Adjust the cell valve to attain 39.7 (+_0.5), Ib/min discharge corrected bleed
airflow.

(e) Allow all APU measured parameters to stabilize.


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GTCP36-280[D]

1. P. (3) (f) Record digital performance data or complete the test data sheet and make
sure:

1 The setpoint parameters (T2 on the ECU display, WBCDNA, and


SHPSL) are within the required tolerances.

2 The sea level, 103F, installation corrected data (PBCOR, EGTCOR,


and WFCOR) meets or exceeds requirements. (Refer to Table 106
(Heavy Repair) or Table 108 (Medium Repair).
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GTCP36-280[D]

Table 104. Performance Load Specifications

Disch Corr Airflow


Test Condition Mode Shaft Load, shp/6 Ib/min

0001 Ready to Load 0


Two-Pack Standard
0002 ECS 60 + 3/-0 56.2 _+0.5

0003 MES 60 + 3/-0 39.7 _+0.5

NOTE: If digital data is not available, refer to paragraph 1. R. (2) for performance load specification
calculations.

1. e. IGV adjustment. (Heavy Repair units only).

NOTE: The corrected bleed pressure (PBCOR) must be within the minimum and maximum
tolerances of Table 105 for Heavy Repairs and Table 107 for Medium Repairs.
The IGVs may be adjusted according to the following paragraphs to meet these
requirements. IGV may not be adjusted on continued-time units. After IGV
adjustment, acceptance tests must be reaccomplished.

(1) Adjustment of IGV position (allowed on Heavy Repair only).

(a) Remove the IGV actuator assembly and associated tubing.

(b) If corrected bleed pressure (PBCOR) is below the minimum requirement,


open IGVs by adjusting the IGV actuator nut counterclockwise a maximum of
one full turn. (The bleed pressure will increase approximately 0.25 psi per IGV
degree, 1/4 turn.)

NOTE: After IGV adjustment, paragraph I.P. must be repeated in its


entirety.

(c) If the corrected bleed pressure (PBCOR) is above the maximum requirement,
close the IGVs by adjusting the IGV actuator nut clockwise as necessary to
reduce corrected bleed pressure to below the maximum requirement. (The
bleed pressure will decrease approximately 0.25 psi per IGV degree, 1/4 turn.)

(d) Install the IGV actuator assembly and tubing.


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GTCP36-280[D]

1. a. Performance Data Correction.

(1) Digital Data Acquisition System Performance Data Correction.

(a) If the digital acquisition system is available, instruct the digital operator to
reduce the data and provide FULL LOGS and QUICK LOOKS. Carefully
review the FULL .LOGS and QUICK LOOKS to make sure the measured
parameters are within the limits of paragraph 1.F.

(b) Once the data has been verified to be accurate and acceptable, use the
applicable data sheets (Figure 108) to record performance data.

(2) Manual Performance Data Correction.

(a) To manually record and correct performance data, use the applicable data
sheet equations (Figure 108) to record performance data. Use Data sheet 1
for overhaul or Data sheet 2 for continued-time units. Use Data sheets 3 and
4 for units with QEC or sheets 5 and 6 for units without QEC.

NOTE: The calculations on Test Data Sheet correct the bleed pressure
(PB), bleed airflow (WB), delta pressure across the APU (APU AP),
and fuel flow (WF) for ambient pressure (delta(8) correction) to
simulate sea level conditions. In addition, PB, WB, bleed
temperature (TB), EGT and WF are corrected for temperature
(lapse rate correction) to simulate 103F ambient temperature.
(The lapse rate corrections account for IGV scheduling as well as
ambient temperature effects.) EGT and WF are also corrected for
APU AP to remove effects of the lab inlet and exhaust ducting. PB,
WB, TB, EGT and WF are then corrected for aircraft installation
effects. Finally if the corrected bleed pressure (PBCOR) is above
the minimum requirement, EGT and WF are corrected to simulate
power section performance with a minimum specification load
compressor.
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GTCP36-280[D]

HEAVY REPAIR
ACCEPTANCETEST DATA SHEET
GTCP36-280(D) APU
Date PIN 3800504-1
Unit SIN
APU Outline No.
ECU PIN S/N** .Slave**

OHDS Parameter 2-Pack Std. ECS Mode* MES Mode*


Description
Line Name Required Corrected Required Corrected

"14" PBCOR Bleed Pressure, psia 47.0 (min) 50.2 (min)

"18" WBCOR Bleed Airflow, Ib/min 139.0(min) NIR


Exhaust Gas Temperature, F
*26* EGTCOR (Adjustedto min. bleed pres.) 1170 (max) 1200 (max)

Fuel Flow, Ibthr


*34* WFCOR (Adjustedto min. bleed pres.) 252 (max) 260 (max)

* Performance data have been adjusted to S.L., 103 F, installed conditions


** Indicate "lab slave" and ECU SIN when applicable
"XX" Data from OHDS-
Automatic starts check: #1 ~ see: #2 ~ s e c : #-3 ~ s e c
Surge control valve crack point: Ib/min
Total number of starts (during T.I.):
Total operating time (during T.I.): hrs:min

UNIT STATUS: ACCEPT [ ] REJECT [ ]

We certify the above data are ~'ue and correct, and in addition, the unit has successfully met all other test requirements
specified in the latest revision of the applicable test specification indicated above.
Signature Date
Technician
Supervisor
Checked By

X3800504TT214

Sample Test Data Sheet


Figure 108 (Sheet 1 of 6)
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GTCP36-280[D]

MEDIUM REPAIR
ACCEPTANCETEST DATA SHEET
GTCP36-280(D) APU
Date P/N 3800504-1
Unit S/N
APU Outline No.
ECU PIN S/N** Slave**

OHDS Parameter 2-Pack Std. ECS Mode* MES Mode*


DessdpUon
Line Name Required Corrected Required Corrected

"14" PBCOR Bleed Pressure, psia 47.0 (min) 50.2 (min)

"18" WBCOR Bleed Airflow, Iblmin 139.0 (min) N/R


Exhaust Gas Temperature, F
*26* EGTCOR (Adjustedto rain. bleed pres.) 1180 (max) 1210 (max)

Fuel Flow, Ib/hr


*34* WFCOR (Adjustedto min. bleed pres.) 254.0 (max) 261.0 (max)

* Performance data have been adjusted to S.L., 103 F, installed conditions


** Indicate "lab slave" and ECU SIN when applicable
"XX" Data from OHOS-
~,.utomaticstarts check: #1 sec: #2 sec: #-3 sec
Surge cenb'ol valve crack point: Ib/min
total number of starts (during T.I.):
I'otal operaling time (during T.I.): hrs:min

LINITSTATUS: ACCEPT [ ] REJECT [ ]

,We certify the above data are lrue and correct, and in addition, the unit has successfully met all other test requiremerJts
specified in the latest revision of the applicable test specification indicated above.
Signature Date
Technician
Supervisor
Checked By

X3800504TT215

Sample Test Data Sheet


Figure 108 (Sheet 2)
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GTCP36-280[D]

ACCEPTANCETESTDATASHEET
GTCP36-280(D)APU
P/N3800504-1
WITHQEC

DATE: TESTCELL
UNITP/N UNITS/N TECHNICIAN

READY 2-PACKSTD MES


OPERATIONALDATA: TOLOAD ECS MODE MC)FII=
TIME DIGITALTIMEOF FIRSTSCAN HRS/MIN
GEARBOX/LOADCOMPRESSORKURBINEVIBRATION IN/SEC II I I II
OILSUPPLYTEMPERATURE SUMPTEMP,ORLUBEPUMPINLETTEMP. F
OILSUPPLYPRESSURE LUBEPUMPDISCHARGEPRESSURE PSIG
GEARBOXPRESSURE INH20
PERFORMANCEDATA:
* 1* PCEL CELLPRESSURE PSlA
* 2" PS58 EXHAUSTSTATICPRESSURE(AVG) PSIA
T2 T2 - APU INLET TEMP. (AVG) F
-.-,,,%,,,.,,,,

"3" WBDNA BLEEDAIRFLOW LB/MIN :.;.:.-...:..-...:


;.;.;.....1.:..'.
' 4" PB BLEEDPRESSURE(AVG) PSL~ .......-.-,.-.::-...:
* 5" TB BLEEDTEMPERATURE(AVG) F
PIGV INLETGUIDEVANEPOSITION SCHEDULEDUSINGT2 DEGREES :!:i:~i:i:i:i:
WBCDNA CORRECTEDDISCHARGEAIRFLOW 56.2 PPM(ECS):39.7PPM(MES):-0.0/+0.5 LB/MIN
:::::.::.:-_::..::
TBORFA BLEEDAIR ORIFICETEMP.(AVG) F ;:::::.'-.':::.'...'::
., . . . . ,,.

PBORFA BLEEDAIR ORIFICEPRESSURE PSlA :'.:::.::':':':-:


,,,.,.-,,,,.,,%,

PDBORA BLEEDAIR ORIFICEAEP PSlD i:i:i:i:i:i:i:i:i


"8" TD50 LABEGT(AVG) F
TTDEA UNITEGT#1 F
TTDEB UNITEGT#2 F
" 7" WFPPH FUELFLOW(AVG) LB/HR
"8" SHPGEN SHAFTLOAD 60/DELTA(RTL= 0): -0.0I+3.0 SHP
XNL SHAFTSPEED GOVERNEDSPEEDOF 63.830RPM RPM
X3800504TT180

Sample Test Data Sheet


F i g u r e 108 ( S h e e t 3)
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GTCP36-280[D]
MANUAL

ACCEPTANCETEST DATASLEET
GTCP~2S00:)] A~U
P/N 3800504-1
WITH QEC
DATE: TEST CELL
UNIT P~N UNITS/N TECHNICIAN

READY 2-PACKSTD MES


CALCULATIONS:
TO LOAD ECS MODE MODE
"9" DELTA "1" 114.696
SHAFT LOAD- SEA LEVEL "8" ('9" SHP ~{~!~t~!
*I(Y' APU DELTAP/DELTA ('1"-'2.) 1"9* PSIA iii!!!iiiiiiiiii!
:::::::::::::::=:

*il* SEA LEVELBLEEDPRESSURE *4* t*J* PSIA iiiiiiiiiiiiiiiii


*12" BLEEDPRESS. LAPSERATECORR. USE T2 IN TABLE109 (ECS)AND 110 (MES)
PSIA ~iiiiiiiHiiiii!i
"13" INSTALLATIONEFFECTON PB FROMTESTED BARETO INSTALLED PSIA
!CORRECTS 0.0 0.O
.,,,,.=..,.,..,,

"14= PBCOR SEA LEVEL103FBLEEDPRESSURE =11"+'12.+'13" PS~A ~i~i~i~iil


"15" SEA LEVELBLEEDAIRFLOW *3*/'9" LB~IIN iiii~iiiiiiiiiil
*16" BLEEDFLOW LAPSERATECORR. USE T2 IN TABLE 109 (ECS)AND 110 (MES) LB/MIN
*t7" INSTALLATIONEFFECTON WB CORRECTS
FROMTESTED BARETO INSTALLED LB~N ;iiiiii~E{~E~Eiii
:::::::::::=::;;
0.0 0.0
"18" WBOOR WB- S.L. INSTALLED103F *15" '16"+*17" I_B/MIH !~!!!ii!!!!!!!!!i
"ll)' BLEEDTEMP.LAPSERATECORR_ USE T2 IN TABLE 109 (ECS)AND 110 (MES) ,,,.,,=,,,,=,,,,

"20* TBCOR. TB- S.L. INSTALLED103F "5" +'19" F ~i!iiii"ii"iii


|l|||lllllllllll;
"21" EGTLAPSERATECORRECTION USE T? IN TABLE109 (EOS)AND 110 (MES) F iiiii!iiii!!~!~!i
"22* APU/EPCORRECTIONONEGT USE "10" IN TABLE 1l i (ECS)AND 112 ~ES) F |i|iiii!iiiii|iil
*23* INSTALLATIONEFFECTON EGT CORRECTS FROMTESTED BARETO INSTALLED F "~iiiii!!!ii'~i!i 9 12
*24* EGT- S.L INST.103F "6" +'21" +'22.* "23"
*25* EXCESSBLEEDPRESS.CORR.ON EGT USE *14" IN TABLE113 OECS)AND 114 (MES) F ~i~iiii~iii~i~ii
::::::::ll]llllll
llll'~lllllllllll
*'26" EGTCOR EGT- S.L INST.103F(~ MIN PB 24=.,25.
::=:::::==::=::::
"27" SEA LEVELFUELFLOW "7"/'9" LB/HR i~iiiiiiiiiiiii!
"28" FUEL FLOW LAPSERATECORR. USE T? IN TABLE 109 (EP~)AND 110 (MES} LB/HR ii~ii~i~i~ili~ii
*29* APU IEP CORRECTIONON WF USE *10" INTABLE 111 (ECS)AND 112 (MES) LB~HR ~!!!iiiiiiiiiiiii
*3O* INSTALLATIONEFFECTON WF CORRECTS FROMTESTED BARETO INSTALLED LB,,I-IR !!i!!!i!!!!!!!!!! 1.7 2.3
"31" WF - S.L. INST. I03F "2? -* "28~ + "29= * '30= LB R iiiiiiiiiiiiiiiil
*32" EXCESSBLEEDPRESS.CORR.ON WF USE"14"INTABLE113(ECS)AND114(IVIES) LB/HR iiiiiiiiiiiiiiiii
*33* FUEL LOWERHEATINGVALUE RATIO LATESTLABFLI-IVDIVIDEDBYIB,400BTU/LB NONE ~iiiii~iiii~iil]
*34* WFCOR WF-S.L. INST.103F@ MIN P3 ('31" + "32") x "33" La~R iiiiiiiiiiii~iii

* - DATATRANSFERREDTO TESTSHEET ~ DATANOT I~EEDED

CA APPROVAl
X3800504TT188

Sample Test Data Sheet


F i g u r e 1 0 8 ( S h e e t 4)
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GTCP36-280[D]

ACCEPTANCETESTDATASHEET
GTCP36-280(D)APU
P/N3800504-1
WITHOUTQEC
DATE: TESTCELL
UNITPiN UNITS/N TFCHNICIAN

READY 2-PACKSTD MES


OPERATIONALDATA: TO LOAD ECS MODE MODE
TIME DIGITALTIMEOF FIRSTSCAN HRS/MIN
GEARBOX/LOADCOMPRESSOR/TURBINEVIBRATION IN/SEC / I 1 1 I 1
OILSUPPLYTEMPERATURE SUMPTEMP.ORLUBEPUMPINLETTEMP. F
OILSUPPLYPRESSURE LUBEPUMPDISCHARGEPRESSURE PSIG
GEARBOXPRESSURE INH20

PERFORMANCEDATA:
* 1* PGEL CELLPRESSURE PSIA
"2" PS58 EXHAUSTSTATICPRESSURE(AVG) PSIA
T2 T2 - APU INLETTEMP.(AVG) F
'3" WBDNA BLEEDAIRFLOW LB~IN iiiiiiiiiiiiii~ii
,%,.,%,%,
' 4" PB BLEEDPRESSURE(AVG) PSIA :-:.:-:.:-:-:-:.:
=5" TB BLEEDTEMPERATURE(AVG) F :::::::::::::::::
%%.%%%....
PIGV INLETGUIDEVANEPOSITION SCHEDULEDUSINGT2 DEGREES::::::~::::::::
WBCDNA CORRECTEDDISCHARGEAIRFLOW 56.2PPM (ECS):39.7PPM (MES):-0.0/+0.5 LB/MIN
,.%%,%=='=%,
.,%%,,%%.=,.
TBORFA BLEEDAIR ORIFICETEMP.(AVG) F ;:;:;:;:;:;:;:;:;
PBORFA BLEEDAIR ORIFICEPRESSURE PSIA :::::::::::::::::
%%=~'.%%"~%'

PDBORA BLEEDAIR ORIFICE/EP PSID :::::::::::::::::


* 6" "rD50 LABEGT (AVG) F
TTDF__A UNITEGT#1
TTDEB UNITEGT#2
"7" WFPPH FUELFLOW(AVG) LB/HR
"8" SHPGEN SHAFTLOAD 60/DELTA(RTL= 0): -0.0/+3.0 SHP
XNL SHAFTSPEED GOVERNEDSPEEDOF 63.830RPM RPM
X3800504TT41

Sample Test Data Sheet


Figure 108 ( S h e e t 5)
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Hone) well COMPONENT MAINTENANCE


GTCP36-280[D]
MANUAL

ACCEPTANCETEST DATASHEET
GTCP36-280(D)APU
P/N 3800504-1
WITHOUT QEC
DATE: TEST CELL
UNIT PiN UNIT S/N TECHNICIAN

CALCULATIONS: READY 2-PACKSTD MES


TO LOAD ECS MODE MODE
*0- DELTA "1"I 14.696
:::||."~=i::=:::
SHAFTLOAD - SEA LEVEL "8* 1"9" SHP li:lli~i',li'.lll
==....;...,,,,,,,,,
"19. ~,PU/EP/DELTA ('1"- *2*)I "9" PSIA iiiiiiiii~iiiiii
|=|====;=;==|===

"11" -~EALEVELBLEEDPRESSURE *4* /*9* PSlA iiiiiiiiii!i!iii


====:=:====::===
"12" BLEEDPRESS. LAPSERATE CORR. USET?INTABLE109(ECS)ANDi iO(IVIES) PSIA "..T":'".-";';
Z~: ;:: ~_-_-_=_-_._-_-__

'13" NSTALLATIONEFFECTON PB CORRECTSFROMTESTEDBARETOINSTALLED PSIA iiiiiiiiiiiiiiii - 1.96 - 1.98


"14" PBCOR ,;EA LEVEL103F BLEEDPRESSURE "11" +'12" +'13" PSIA *
'15" ;EA LEVELBLEEDAIRFLOW .3"1"9" LB/MIN .:_:'iiiiiiiiiiiiii
j :....:;;: .=:.=:.=.=.=

"16" BLEEDFLOW LAPSERATE CORR. USE T? IN TABLE 109 (ECS)AND 110 (IVIES) LB/MIN ii!i!iiiiiiiii!i
"17" NSTALLATION EFFECTON WB 3ORRECTS FROMTESTED BARETO INSTALLED LB/MIN - 6.2 - 4.4
||=|:|:|===|=."=|

"16. WBCOR NB-S.L. INSTALLED103F *15" '16"+'17"

"19" 3LEEDTEMP.LAPSERATECORR. USE T2 IN TABLE 109 (ECS} AI~) 110 (MES) F i!!!.a.!!i!i!i!!i
*20* TBCOR I'B-S.L. INST. 103F "5"+'19" F iiiiiiiiiiii!iii
.21" -GT LAPSE RATECORRECTION USE T2 IN TABLE 109 (ECS)AND 110 (MES) F ":-=':.~i.=P"L=!"="="~"="=
IIIIIIIIII:IIIII
"22* ~PU/EP CORRECTIONON EGT USE*10* IN TABLE 111 (ECS)AND 112 (MES) F ,:IT"I|.'|:'I|"
!!!!!!iiiiiiiiii
"23* !INSTALLATION EFFECTON EGT CORRECTS FROMTESTED BARETO INSTALLED F ii!iiiiii!i!!ili
;.;= .;9" r.=; ;~ r. =.; r. r,
44 48
*24* EGT- S.L INST.103F "6"+'21"+'22"+'23" F iiiiiiiliiiiiiii
III:IIIIIIIIIIII
*25* EXCESSBLEEDPRESS.CORR.ON EGT USE "14" IN TABLE 113 (ECS)AND 114 (MES) F i!ii!!iiiiii'-'ii
....... ,..,....=

*'26* EGTCOR EGT - S.L. INST. 1OGF@ MIN. PB *24* + "25" F iiiiiiiiiiiiiliii * *
llllll:ll~lillll
*27* SEA LEVELFUEL FLOW "7"I'9" LBtr-iR !!!!!!i!!iiiiiiii
ll:ll=:l='~==:".".==l
*28* FUEL FLOW LAPSE RATECORR. USE T2 IN TABLE 109 (ECS) AND110(MES) LB,I-IR !!iiiiiii~iiiii!
llll;l:lllil:ll;l
*29* APU/EP CORRECTIONON WF USE*I0* INTABLEI I I (ECS)AND112(MES) LB/HR ""'~Y~"E~'
i::llllli:iilll:

INSTALLATION EFFECTON WF CORRECTSFROMTESTEDBARETOINSTALLED LBt,-tR iiiiii;.=.iiiiiiii -8.2 -7.7


lllll:llillll:l

"31" WF- S.L. INST. 103F *27*+*28*+*29*+*30* LB~R iiiiiiiiiiiiiiii


..............
*32* EXCESS BLEEDPRESS.CORR.ON WF USE *14* IN TABLE 113 (ECS)AND 114 (MES) LB,HR iii~iiiiiiiiiii
III~IIIIIIIIIII
FUEL LOWER HEATINGVALUE RATIO LATEST LABFLHVDIVIDED BY 1B,400BTU/LB NONE ii!iiii!i!i!!!i
:..:..::l=.:::==".:l:

*34* WFCOR WF - S.L INST. 103F @ MIN. PB ('31" '32") x'33" LB/HR iiiiiiiiii!iiiiii *

* - DATA TRANSFERREDTO TEST SHEET ~ DATANOT NEEDED

QAAPPROVAL

X3800504TT40

Sample Test Data Sheet


Figure 108 (Sheet 6)
UP200456

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Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

Heavy Repairs Only

Table 105. Two-pack Standard Mode ECS Performance Load Requirements

Symbol Parameter Requirement Units


Minimum Bleed
W BCOR ('18*) Airflow 139.0 Ib/min
Minimum Bleed
PBCOR ('14") Pressure 47.0 psia
Maximum Bleed
PBCOR ('14") Pressure 48.5 psia

EGTcoR (*26*) Maximum EGT 1170 F

WFCOR (*34*) Maximum Fuel Flow 252.0 Ib/hr

Heavy Repairs Only

Table 106. MES Performance Load Requirements

Symbol Parameter Requirement Units


Minimum Bleed
PBcoR ('14*) Pressure 50.2 psia

EGTcoR (*26*) Maximum EGT 1200 F

WFCOR (*34*) Maximum Fuel Flow 260.0 Ib/hr


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GTCP36-280[D]

Medium Repairs Only

Table 107. Two-pack Standard Mode ECS Performance Load Requirements

Symbol Parameter Requirement Units


Minimum Bleed
WBCOR ('18") Airflow 139.0 Ib/min
Minimum Bleed
PBCOR ('14") Pressure 47.0 psia

EGTcoR (*26*) Maximum EGT 1180 F

WFcoR (*34*) Maximum Fuel Flow 254.0 Ib/hr

Medium Repairs Only

Table 108. MES Performance Load Requirements

Symbol Parameter Requirement Units


Maximum Bleed
PBcoR ('14*) Pressure 50.2 psia

EGTcoR (*26*) Maximum EGT 1210.0 F

WFCOR (*34*) Maximum Fuel Flow 261.0 Ib/hr


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GTCP36-280[D]

Table 109. Two-pack ECS Standard Mode Lapse Rate Corrections, (Heavy and Medium Repairs)

Delta Delta Delta Delta Delta Delta Delta Delta Delta Delta
TAMB Press Flow Temp Fuel Wf EGT TAMB Press Flow Temp Fuel Wf EGT
(F) (psia) (Ib/min) (F) (Ib/hr) (F) (F) (psia) (Ib/min) (F) (Ib/hr) (F)
30 5.1 7.7 93 5.9 223 76 1.5 1.5 35 6.0 108
31 5.1 7.7 92 6.1 221 77 1.4 1.5 34 5.8 104
32 5.0 7.7 91 6.3 219 78 1.4 1.5 32 5.6 101
33 5.0 7.7 90 6.5 217 79 1.3 1.4 31 5.4 97
34 4.9 7.7 89 6.7 216 80 1.3 1.4 30 5.1 93
35 4.9 7.6 87 6.9 214 81 1.3 1.6 29 5.3 91
36 4.9 7.6 86 7.1 212 82 1.4 1.8 28 5.4 88
37 4.8 7.6 85 7.3 210 83 1.4 1.9 27 5.5 86
38 4.8 7.5 84 7.5 208 84 1.4 2.1 26 5.6 83
39 4.8 7.5 83 7.7 206 85 1.5 2.3 25 5.7 80
40 4.7 7.5 82 7.9 205 86 1.5 2.4 24 5.8 78
41 4.7 7.5 81 8.0 203 87 1.5 2.6 23 6.0 75
42 4.6 7.4 79 8.2 201 88 1.5 2.8 22 6.0 72
43 4.6 7.4 78 8.4 199 89 1.6 3.0 21 6.1 69
44 4.5 7.3 77 8.5 197 90 1.6 3.1 20 6.2 66
45 4.5 7,3 76 8.7 195 91 1.4 2.8 18 5.7 61
46 4.4 7.3 75 8.8 193 92 1.3 2.5 17 5.2 56
47 4.4 7.2 74 9.0 191 93 1.2 2.3 15 4.7 51
48 4.4 7.2 72 9.1 189 94 1.1 2.0 14 4.2 46
49 4.3 7.2 71 9.3 187 95 0.9 1.8 12 3.7 41
50 4.3 7.1 70 9.4 185 96 0.8 1.5 11 3.2 36
51 4.2 7.1 69 9.5 183 97 0.7 1.3 9 2.8 31
52 4.2 7.0 68 9.7 181 98 0.6 1.0 8 2.3 26
53 4.1 7.0 66 9.8 179 99 0.4 0.8 6 1.8 21
54 4.1 6.9 65 9.9 177 100 0.3 0.6 5 1.4 16
55 4.0 6.8 64 10.0 175 101 0.2 0.4 3 0.9 10
56 4.0 6.8 63 10.1 172 102 0.1 0.2 2 0.4 5
57 3.9 6.7 62 10.3 170 103 0.0 0.0 0 0.0 0
58 3.9 6.7 60 10.4 168 104 0.1 0.2 -1 0.2 -3
59 3.8 6.6 59 10.5 166 105 0.1 0.5 -2 0.4 -6
60 3.6 6.2 57 10.1 163 106 0.2 0.7 -3 0.6 -9
61 3.4 5.7 56 9.8 159 107 0.2 1.0 -4 0.8 -11
62 3.3 5.3 54 9.5 156 108 0.3 1.2 -5 1.1 -14
63 3.1 4.9 53 9.2 153 109 0.3 1.4 -6 1.3 -16
64 2.9 4.5 51 8.9 149 110 0.4 1.7 -7 1.5 -19
65 2.7 4.1 50 8.7 146 111 0.4 1.9 -8 1.8 -21
66 2.6 3.7 48 8.4 142 112 0.5 2.2 -9 2.0 -24
67 2.4 3.3 47 8.1 139 113 0.5 2.4 -10 2.2 -26
68 2.2 2.9 45 7.8 135 114 0.6 2.7 -11 2.5 -28
69 2.1 2.5 44 7.5 132 115 0.7 2.9 -12 2.7 -31
70 1.9 2.1 42 7.2 128 116 0.7 3.2 -13 2.9 -33
71 1.7 1.8 41 7.0 124 117 0.8 3.4 -14 3.2 -36
72 1.6 1.5 39 6.7 121 118 0.8 3.6 -15 3.4 -38
73 1.6 1.5 38 6.5 118 119 0.9 3.9 -16 3.6 -41
74 1.5 1.5 37 6.4 114 120 0.9 4.1 -17 3.8 -43
75 1.5 1.5 36 6.2 111
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Table 110. MES Mode Lapse Rate Corrections (Heavy and Medium Repairs)

Delta Delta Delta Delta Delta Delta Delta Delta Delta Delta
TAMB Press Flow Temp Fuel Wf EGT TAMB Press Flow Temp Fuel Wf EGT
(F) (psia) (Ib/min) (F) (Ib/hr) (F) (F) (psia) (lb/min) (F) (Ib/hr) (F)
30 -5.3 -14.8 51 -51.9 63 76 -2.0 -5.9 26 -10.1 55
31 -5.3 -14.6 51 -51.2 63 77 -1.9 -5.7 25 -9.7 53
32 -5.2 -14.4 50 -50.5 62 78 -1.9 -5.5 24 -9.3 51
33 -5.2 -14.3 49 -49.8 61 79 -1.8 -5.3 23 -8.9 5O
34 -5.1 -14.1 48 -49.1 61 80 -1.7 -5.1 22 -8.5 48
35 -5.1 -13.9 48 -48.5 60 81 -1.7 -4.8 22 -8.1 46
36 -5.0 -13.7 47 -47.8 59 82 i -1.6 -4.6 21 -7.7 44
37 -4.9 -13.5 46 -47.2 59 831-1.5 -4.4 20 -7.3 42
38 -4.9 -13.4 45 -46.5 58 84 I -1.4
P
-4.2 19 -6.9 41
39 -4.8 -13.2 44 -45.9 57 85 -1.4 -4.0 18 -6.5 39
40 -4.3 -12.7 52 -35.8 80 86 -1.3 -3.8 17 -6.1 37
41 -3.9 -12.1 59 -26.5 100 87 -1.2 -3.6 16 -5.7 35
42 -3.8 -12.0 58 -25.9 99 88 -1.1
i
-3.3 15 -5.3 33
43 -3.8 -11.8 57 -25.4 97 89 -1.1 -3.1 14 -4.9 31
44 -3.7 -11.6 56 -24.8 96 90 [ -1.0 -2.9 13 -4.5 29
45 -3.7 -11.5 55 -24.3 95 91 -0.9 -2.7 12 -4.1 27
46 -3.6 -11.3 55 -23.7 94 92 -0.8 -2.5 11 -3.8 25
47 -3.6 -11.1 54 -23.2 93 93 -0.8 -2.2 10 -3.4 23
48 -3.5 -11.0 53 -22.7 92 94 -0.7 -2.0 9 -3.1 21
49 -3.5 -10.8 52 -22.2 91 95 -0.6 -1.8 8 -2.7 19
50 -3.4 -10.6 51 -21.7 90 96 -0.5 -1.6 7 -2.4 16
51 -3.3 -10.4 50 -21.2 88 97 -0.5 -1.4 6 -2.0 14
52 -3.3 -10.3 50 -20.7 87 98 -0.4 -1.1 5 -1.7 12
53 -3.2 -10.1 49 -20.2 86 99 -0.3 -0.9 4. -1.3 10
54 -3.2 -9.9 48 -19.7 85 100 , -0.2 -0.7 3 -1.0 7
55 -3.1 -9.7 47 -19.2 84 101 L -0.2 -0.5 2 -0.7 5
56 -3.1 -9.5 46 -18.7 83 102 ! -0.1 -0.2 1 -O.3 2
57 -3.0 -9.3 45 -18.2 82 103 0.0 0.0 0 0.0 0
58 -2.9 -9.1 44 -17.7 80 104 0.1 0.2 -1 0.3 -3
59 -2.9 -8.9 43 - 17.2 79 105 0.1 0.4 -2 0.6 -5
60 -2.8 -8.7 42 -16.8 78 106 0.2 0.6 -3 0.9 -8
61 -2.8 -8.6 41 -16.4 77 107 0.3 0.8 -4 1.2 -10
62 -2.7 -8.4 40 -15.9 75 108 1
i 0.4 1.1 -5 1.6 -12
63 -2.7 -8.2 39 -15.5 74 109 0.4 1.3 -6 1.9 -14
64 -2.6 -8.1 38 -15.1 72 110 0.5 1.5 -7 2.2 -16
65 -2.6 -7.9 37 -14.7 71 111 0.6 1.7 -8 2.6 -19
66 -2.5 -7.7 36 -14.2 70 112 0.7 1.9 -9 2.9 -21
67 -2.5 -7.5 35 -13.8 68 113 0.7 2.1 -10 3.2 -23
68 -2.4 -7.4 34 -13.4 67 114 0.8 2.3 -11 3.6 -25
69 -2.4 -7.2 33 -13.0 65 115 0.9 2.5 -12 3.9 -27
70 -2.3 -7.0 32 -12.6 64 116 0.9 2.7 -13 4.2 -29
71 -2.3 -6.8 31 -12.1 62 117 1.0 2.9 -14 4.5 -32
72 -2.2 -6.6 30 -11.7 61 118 1.1 3.2 -15 4.9 -34
73 -2.2 -6.4 29 -11.3 59 119 1.2 3.4 -16 5.2 -36
74 -2.1 -6.2 28 -10.9 58 120 1.2 3.6 -17 5.5 -38
75 -2.0 -6.1 27 -10.5 56
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Table 111. Two-pack ECS Standard Mode APU Delta P EGT and Fuel Flow Corrections.
(Heavy and Medium Repairs)

Without QEC With QEC


APU Delta P Delta EGT Delta Fuel Wf APU Delta P Delta EGT Delta Fuel Wf
(psia) (F) (Ib/hr) (psia) (F) (Ib/hr)
-0.15 -5.4 -1.10 -0.15 -6.0 -1.00
-0.14 -5.0 -1.02 -0.14 -5.6 -0.94
-0.13 -4.6 -0.94 -0.13 -5.2 -0.88
-0.12 -4.3 -0.86 -0.12 -4.8 -0.82
-0.11 -3.9 -0.78 -0.11 -4.4 -0.76
-0.10 -3.5 -0.70 -0.10 -4.0 -0.70
-0.09 -3.2 -0.62 -0.09 -3.6 -0.64
-0.08 -2.8 -0.54 -0.08 -3.2 -0.58
-0.07 -2.5 -0.46 -0.07 -2.8 -0.52
-0.06 -2.1 -0.38 -O.O6 -2.4 -0.46
-0.05 -1.8 -0.30 -0.05 -2.0 -0.40
-0.04 -1.4 -0.24 -0.04 -1.6 -O.32
-0.03 -1.1 -0.18 -0.03 -1.2 -0.24
-0.02 -0.7 -0.12 -0.02 -0.8 -0.16
-0.01 -0.4 -0.06 -0.01 -0.4 -0.08
0.00 0.0 0.00 0.00 0.0 0.00
0.01 0.4 0.08 0.01 0.4 0.08
0.02 0.7 0.16 0.02 0.8 0.16
0.03 1.1 0.24 0.03 1.2 0.24
0.04 1.4 0.32 0.04 1.6 0.32
0.05 1.8 0.40 0.05 2.0 0.40
0.06 2.1 0.46 0.06 2.4 0.46
0.07 2.5 0.52 0.07 2.8 0.52
0.08 2.8 0.58 0.08 3.3 0.58
0.09 3.2 0.64 0.09 3.7 0.64
0.10 3.5 0.70 0.10 4.1 0.70
0.11 3.9 O.76 0.11 4.6 0.80
0.12 4.2 0.82 0.12 5.1 0.90
0.13 4.6 0.88 0.13 5.5 1.00
0.14 4.9 0.94 0.14 6.0 1.10
0.15 5.3 1.00 0.15 6.5 1.20
0.16 5.6 1.08 0.16 6.9 1.28
0.17 6.0 1.16 0.17 7.3 1.36
0.18 6.3 1.24 0.18 7.7 1.44
0.19 6.7 1.32 0.19 8.1 1.52
0.20 7.0 1.40 0.20 8.5 1.60
0.21 7.4 1.48 0.21 8.9 1.68
0.22 7.8 1.56 0.22 9.3 1.76
0.23 8.2 1.64 0.23 9.7 1.84
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Table 111. Two-pack ECS Standard Mode APU Delta P EGT and Fuel
Flow Corrections, (Heavy and Medium Repairs) (Cont)

Without QEC With QEC


APU Delta P Delta EGT Delta Fuel Wf APU Delta P Delta EGT Delta Fuel Wf
(psia) (F) (Ib/hr) (psia) (F) (Ib/hr)
0.24 8.6 1.72 0.24 10.1 1.92
0.25 9.0 1.80 0.25 10.5 2.00
0.26 9.3 1.88 0.26 10.9 2.08
O.27 9.7 1.96 0.27 11.3 2.16
0.28 10.1 2.04 0.28 11.7 2.24
0.29 10.4 2.12 0.29 12.1 2.32
0.30 10.8 2.20 0.30 12.5 2.40
0.31 11.1 2.26 0.31 13.0 2.48
0.32 11.4 2.32 0.32 13.4 2.56
0.33 118 238 0.33 13.9 2.64
0.34 121 244 0.34 14.3 2.72
0.35 12.4 2.50 0.35 14.8 2.80
0.36 12.7 2.56 0.36 15.2 2.88
0.37 13.0 2.62 0.37 15.6 2.96
0.38 13.4 2.68 0.38 16.0 3.04
0.39 13.7 2.74 0.39 16.4 3.12
0.40 14.0 2.80 0.40 16.8 3.20
0.41 14.3 2.86 0.41 17.2 3.30
0.42 14.7 2.92 0.42 17.6 3.40
0.43 15.0 2.98 0.43 18.0 3.50
0.44 15.4 3.04
0.45 15.7 3.10
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Table 112. MES Mode APU Delta P EGT and Fuel Flow Corrections.
(Heavy and Medium Repairs)

Without QEC With QEC


APU Delta P Delta EGT Delta Fuel Wf APU Delta P Delta EGT Delta Fuel Wf
(psia) (F) (Ib/hr) (psia) (F) (Ib/hr)
-0.15 -5.3 -1.10 -0.15 -6.0 -1.00
-0.14 -4.9 -1.02 -0.14 -5.6 -0.96
-0.13 -4.6 -0.94 -0.13 -5.2 -0.92
-0.12 -4.2 -0.86 -0.12 -4.8 -0.88
-0.11 -3.9 -0.78 -0.11 -4.4 -0.84
-0.10 -3.5 -0.70 -0.10 -4.0 -0.80
-0.09 -3.2 -0.64 -0.09 -3.6 -0.72
-0.08 -2.8 -0.58 -0.08 -3.2 -0.64
-0.07 -2.5 -0.52 -0.07 -2.8 -0.56
-0.06 -2.1 -0.46 -0.06 -2.4 -0.48
-0.05 -1.8 -0.40 -0.05 -2.0 -0.40
-0.04 -1.4 -0.32 -0.04 -1.6 -0.32
-0.03 -1.1 -0.24 -0.03 -1.2 -0.24
-0.02 -0.7 -0.16 -0.02 -0.8 -0.16
-0.01 -0.4 -0.08 -0.01 -0.4 -0.08
0.00 0.0 0.00 0.00 0.0 0.00
0.01 0.4 0.08 0.01 0.4 0.08
0.02 0.7 0.16 0.02 0.8 0.16
0.03 1.1 0.24 0.03 1.2 0.24
0.04 1.4 0.32 0.04 1.6 0.32
0.05 1.8 0.40 0.05 2.0 0.40
0.06 2.2 0.46 0.06 2.4 0.48
0.07 2.6 0.52 0.07 2.8 0.56
0.08 2.9 0.58 0.08 3.3 0.64
0.09 3.3 0.64 0.09 3.7 0.72
0.10 3.7 0.70 0.10 4.1 0.80
0.11 4.1 0.78 0.11 4.5 0.88
0.12 4.4 0.36 0.12 4.9 0.96
0.13 4.8 0.94 0.13 5.4 1.04
0.14 5.1 1.02 0.14 5.8 1.12
0.15 5.5 1.10 0.15 6.2 1.20
0.16 5.8 1.18 0.16 6.7 1.28
0.17 6.1 1.26 0.17 7.2 1.36
0.18 6.4 1.34 0.18 7.6 1.44
0.19 6.7 1.42 0.19 8.1 1.52
0.20 7.0 1.50 0.20 8.6 1.60
0.21 7.4 1.56 0.21 9.1 1.68
0.22 7.7 1.62 0.22 9.5 1.76
0.23 8.1 1.68 0.23 10.0 1.84
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GTCP36-280[D]

Table 112. MES Mode APU Delta P EGT and Fuel Flow Corrections. (Cont)
(Heavy and Medium Repairs)

Without QEC With QEC


APU Delta P Delta EGT Delta Fuel Wf APU Delta P Delta EGT Delta Fuel Wf
(psia) (F) (lb/hr) (psia) (F) (Ib/hr)
0.24 8.4 1.74 0.24 10.4 1.92
0.25 8.8 1.80 0.25 10.9 2.00
0.26 9.1 1.88 0.26 11.3 2.08
0.27 9.5 1.96 0.27 11.7 2.16
0.28 9.8 2.04 0.28 12.2 2.24
0.29 10.2 2.12 0.29 12.6 2.32
0.30 10.5 2.20 0.30 13.0 2.40
0.31 10.9 2.26 0.31 13.4 2.50
0.32 11.3 2.32 0.32 13.8 2.60
0.33 11.7 2.38 0.33 14.2 2.70
0.34 12.1 2.44 0.34 14.6 2.80
0.35 12.5 2.50 0.35 15.0 2.90
0.36 12.9 2.56 0.36 15.4 2.98
0.37 13.3 2.62 0.37 15.8 3.06
0.38 13.6 2.68 0.38 16.2 3.14
0.39 14.0 2.74 0.39 16.6 3.22
0.40 14.4 2.80 0.40 17.0 3.30
0.41 14.8 2.90 0.41 17.4 3.37
0.42 15.2 3.00 0.42 17.8 3.43
0.43 15.5 3.10 0.43 18.2 3.50
0.44 15.9 3.20
0.45 16.3 3.30
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Table 113. Two-pack ECS Standard Mode EGT and Fuel Flow
Corrections for Excess Corrected Bleed Pressure.
(Heavy and Medium Repairs)

APU PBCOR Delta Wf Delta EGT APU PBCOR Delta Wf Delta EGT
(psia) (Ib/hr) (F) (psia) (Ib/hr) (F)
47.0 0.0 49.0 -8.0 -28
47.1 -0.4 -2 49.1 -8.4 -29
47.2 -0.8 -3 49.2 -8.7 -30
47.3 -1.2 -5 49.3 -9.0 -31
47.4 -1.6 -7 49.4 -9.4 -32
47.5 -2.0 -8 49.5 -9.7 -33
47.6 -2.3 -9 49.6 -10.0 -34
47.7 -2.8 -11 49.7 -10.4 -35
47.8 -3.3 -12 49.8 -10.7 -36
47.9 -3.7 -14 49.9 -10.4 -37
48.0 -4.0 -15 50.0 -10.1 -38
48.1 -4.4 -16 50.1 -10.5 -39
48.2 -4.8 -18 50.2 -10.8 -40
48.3 -5.2 -19 50.3 -11.1 -41
48.4 -5.6 -20 50.4 -11.4 -41
48.5 -6.0 -22 50.5 -11.7 -42
48.6 -6.4 -23 50.6 -12.0 -42
48.7 -6.8 -24 50.7 -12.3 -43
48.8 -7.2 -25 50.8 -12.2 -44
48.9 -7.6 -27 50.9 -12.5 -45
51.0 -12.8 -46
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GTCP36-280[D]

Table 114. MES Mode EGT and Fuel Flow Corrections for Excess Corrected Bleed
Pressure. (Heavy and Medium Repairs)

APU PBCOR Delta Wf Delta EGT APU PBCOR Delta Wf Delta EGT
(psia) (Ib/hr) (F) (psia) (Ib/hr) (F)
50.2 0.0 52.2 -6.2 -23
50.3 -0.3 -1 52.3 -6.5 -24
50.4 -0.6 -2 52.4 -6.8 -25
50.5 -0.9 -3 52.5 -7.1 -26
50.6 -1.2 -5 52.6 -7.4 -27
50.7 -1.6 -6 52.7 -7.6 -29
50.8 -1.9 -7 52.8 -7.9 -30
50.9 -2.2 -8 52.9 -8.2 -31
51.0 -2.6 -10 53.0 -8.5 -32
51.1 -2.9 -11 53.1 -8.8 -33
51.2 -3.2 -12 53.2 -9.2 -34
51.3 -3.5 -13 53.3 -9.5 -35
51.4 -3.8 -14 53.4 -9.8 -36
51.5 -4.1 -15 53.5 -10.1 -37
51.6 -4.3 -16 53.6 -10.4 -38
51.7 -4.6 -17 53.7 -10.6 -39
51.8 -4.9 -18 53.8 -10.9 -40
51.9 -5.2 -19 53.9 -11.2 -41
52.0 -5.5 -20 54.0 -11.4 -42
52.1 -5.9 -22 54.1 -11.6 -43
54.2 -11.8 -44
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1. S. Preservation.

After completion of testing, complete the following:

(1) Prepare the APU for final leak check by removing unnecessary laboratory
instrumentation and equipment.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN


ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS
AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH
THE SKIN.

(2) Replace the oil filter with a new element dipped in an approved oil.

(3) Do a final five minute leak check.

(4) Preserve the APU fuel system with M IL-L-6081, Grade 1010 or 1005 oil.

T. Miscellaneous requirements.

(1) Replacement of parts.

Do not replace or adjust detail parts or assemblies once the APU has successfully
completed the acceptance test.

(2) Operating time and starts.

Make sure that the total operating time and number of starts for all tests, including the
preliminary APU runs or run-in, does not exceed 100 starts, or 25 hours of running at
or above 50 percent of the normal-rated output.

(3) After completion of testing, reconnect the DMM connector (P11). Cycle the MASTER
switch and make sure the APU history data (SN, HR, CY, and BDCY) are the same as
previously recorded. (Refer to paragraph 1.H.).

(4) Make sure that the ECU display does not flash and that no faults exist at completion of
testing. (Refer to paragraph I.R.).
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. Fault Isolation

NOTE: Tests are to make sure the unit operates correctly when it is in for service. These tests will
show if the unit is serviceable and/or if any maintenance is necessary. If the unit operates
satisfactorily, the unit can be put in use again.

These tests make sure the unit operates correctly after a repair or an overhaul has been
completed, or after a long time in storage.

All shutoff valves must be closed, air pressure set at zero, and the electrical power shutoff
at the start of each test.

A. Engine

Engine (APU) fault isolation is shown in six tables:

- Table 115 lists all conditions for all shutdowns.

- Table 116 identifies automatic shutdowns and component isolation.

- Table 117 lists the actual BITE display mnemonics for automatic shutdowns.

- Table 118 lists the BITE display mnemonics for the LRU faults.

- Table 119 lists Power-up Test BITE Display Mnemonics.

- Table 120 lists Fault Display Definitions.

B. Pneumatic system.

(1) Always look at the BITE display readout before fault isolation.

(2) If the ECS valves are not manually closed before a main engine start is tried, the APU
could have low bleed pressure.

(3) Low bleed pressure associated with high EGT is an indication the APU is low in power.
The inlet guide vanes (IGV) will decrease bleed pressure and prioritize electrical
power. Remove the APU.

(4) Visually examine the surge control valve indicators during APU operation to make sure
the valve butterfly plates are in their correct positions.
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Table 115. Shutdown Indicators and Existing Conditions

Shutdown Indicator Existing Condition

OVERSPEED N>107% SEC (ANALOG) (PRIMARY)


N>109% SEC (DIGITAL) (BACKUP)

OVERTEMP f(N) = T5>LIMIT + 1 SEC 7%<N<95%


f(N, P2, T2) = T5>LIMIT + 5 SEC N>95%

LO OIL PRESS P OIL <33 PSI + N>95% + 15.5 SEC

HI OIL TEMP T OIL >LIMIT + 95% + 20 SEC

NO ACCEL N < 7 % FOR 15 SECONDS, OR N < 0.5%


%/SEC AND N 95 % AND T5 > 400F + 12.55 SEC. FOR OIL TEMP <
5F AND N < 7 % AND N< 0 %/SEC FOR 6 SECONDS, OR N < 7 %
FOR 25 SECONDS

AIRCRAFT SHUTDOWN AIRCRAFT COMMANDED NORMAL SHUTDOWN

NO FLAME N>7% + 17 SEC + T5<400F + ECU RUN VALID

REVERSE FLOW N>50% + LCIT>350F + 5.0 SEC

SHUTDOWN FAIL APU COMMANDED OFF > 90 SECS + N> 95%

DC LOSS OF POWER SPEED DROOP < 4% DURING POWER LOSS

LOSS OF EGT SENSORS BOTH EGT SENSOR OPEN + 0.5 SEC

LOSS OF SPEED
DETECTION EITHER MONOPOLE ELEMENT + OTHER CONDITIONER FAIL OR
BOTH MONOPOLE ELEMENTS FAIL OR TWO CONDITIONERS
FAIL

ECU ECU INTERNAL SYSTEM FAILURE

APU FIRE APU FIRE INPUT IS ACTIVE

DOOR SHUTDOWN APU FAILURE TO HOLD APU DOOR OPEN


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Table 116. Automatic Shutdown Component Isolation

Automatic Shutdown Probable Corrective


Indication Cause Action

APU FIRE Aircraft Command Check A/C MM.

DC LOSS Aircraft System ECU Check APU power system.


Failure Replace ECU.

DISABLED ECU Disabled Replace ECU.

DOOR SDN APU Door Failure Replace door actuator.

EGTLOSS Loss of EGT Signal Replace both EGT Sensors.


from EGT 1 and EGT 2

ECU ECU Replace ECU.

HIGH OIL HOT Sensor Replace HOT Sensor.


TEMPERATURE
Incorrect Servicing Fill oil system. Check overfill.

External Leakage Repair any leaks.

Oil Cooler Ducts Examine ducts for damage and


attachment. Repair all damage.

Oil Cooler Assembly Replace oil cooler.

Cooling Fan ~Replace cooling fan.

HW OVERSPEED Fuel Control Unit (FCU) Replace FCU.

ECU Replace ECU.

Generator Shaft Shear Replace generator.

ECU Circuit failure Replace ECU.


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Table 116. Automatic Shutdown Component Isolation (Cont)

Automatic Shutdown Probable Corrective


Indication Cause Action

IGV SHUTDOWN Fuel Supply Repair fuel supply.

Inlet Guide Vane (IGV) Replace IGV actuator.


Actuator

IGV Rod is Binding Make sure the vanes can be moved


freely.

Electronic Control Unit Replace ECU.


(ECU)

LOW OIL PRESSURE Incorrect Servicing Check overfill condition. Fill oil system.

Oil Pressure Switch Replace oil pressure switch.

Lube Pump Replace lube pump.

Lube Pump Filter Replace filter.

External Leakage Repair any leaks.

De-oil Solenoid If cold day condition exists,


20F (-6.67C) or Pd 4, replace the
solenoid.

Plumbing Make sure plumbing is free of


obstructions.

Internal APU Failure Check APU.

NO ACCELERATION Internal APU Engine Damage The APU engine must rotate freely. If
resistance is felt or rubbing is heard,
replace APU.

De-Oil Solenoid If cold day condition exists, 20F (-6.67C)


or Pd 4, replace solenoid.
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Table 116. Automatic Shutdown Component Isolation (Cont)

Automatic Shutdown Probable Corrective


Indication Cause Action

NO ACCELERATION Starter Motor Replace starter motor.


(CONT)
Starter Clutch Replace starter clutch.

Fuel Supply to Fuel Control Check fuel supply and lines.


Inlet Guide Vane (IGV) Adjust IGV. (Refer to Figure 104)
Adjustment

Inlet Guide Vane Actuator Replace IGV actuator.

Fuel Control Unit (FCU) Replace FCU.

Flow Divider Will not accelerate if secondary


nozzles do not get fuel.

ECU Faulty fuel schedule. Replace


ECU.

NO FLAME Ignition System Replace Ignition Box.

A/C Fuel System Check A/C Fuel System.


Blockage

FCU Replace FCU.

ECU Replace ECU.

OVERSPEED Software Backup for Replace ECU.


Overspeed

OVERTEMPERATURE Internal APU Engine Damage The APU engine must rotate freely. If
resistance is felt or rubbing is heard,
replace APU.

Overload while on ground Reduce APU load.


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Table 116. Automatic Shutdown Component Isolation (Cont)

Automatic Shutdown Probable Corrective


Indication Cause Action

OVERTEMPERATURE Inlet Guide Vane (IGV) Replace IGV actuator.


(CONT) Actuator

Fuel Control Unit (FCU) Replace FCU.

Flow Divider Replace flow divider.

ECU Replace ECU.

Fuel Nozzles Replace fuel nozzles.

OVERTEMPERATURE Fuel Control Unit (FCU) Replace FCU.


DURING START
Inlet Guide Vane (IGV) Replace IGV actuator.
Actuator

Starter Motor Replace starter motor.

REVERSE FLOW Load Compressor Inlet If fault persists, examine wiring


Temperature Connection harness and repair as necessary.

Surge Control Valve (SCV) Replace SCV.

ECU Failure Replace ECU.

SPD LOSS Loss of speed signal. Replace monopoles.


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Table 117. Actual BITE Display Message'For Automatic Shutdowns

Mnemonic Definition of Shutdown

APU FIRE APU compartment fire

DC LOSS DC power loss

DISABLED ECU disabled (ECU operating mode)

DOOR SDN APU door driver failure

ECU SDN ECU internal system failure

EGT LOSS Both EGT thermocouples failed

HOT SDN Hot oil temperature

HW OVSPD Overspeed (hardware circuit detected)

IGV SDN IGV shutdown

LOP SDN Low oil pressure

NO ACCEL No acceleration

NO FLAME No flame

OVER SPD Software backup overspeed

OVR TEMP Overtemperature

RVR FLOW Reverse flow

SHUTFAIL Shutdown relay failure

SPD LOSS Loss of both speed signals


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Table 118. BITE LRU Fault Display Mnemonics

Mnemonic LRU

APU DOOR APU door driver

APU IGN Ignition circuit

DOlL SOL De-Oil solenoid

DMM Data memory module

DP SNSR Delta P sensor

ECU ECU

EGTMETER EGT meter

EGT 1 EGT thermocouple rake 1

EGT 2 EGT thermocouple rake 2

EGT 1 & 2 Both thermocouples failed

FC UNIT Fuel control unit (fuel torque motor)

FIRESENS APU engine compartment fire

FLT IND Fault indicator

FUEL SOL Fuel solenoid

HOLD RLY 95% Hold relay

IGV TM Inlet guide vane (IGV) torque motor

LCV Load control valve

LOP SW Low oil pressure switch


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Table 118. BITE LRU Fault Display Mnemonics (Cont)

Mnemonic LRU

LOP IND LOP indicator failed

LVDT IGV LVDT

MONO 1 Speed monopole 1 circuit

MONO 2 Speed monopole 2 circuit

MONO 1&2 Failed both speed signals

OIL TEMP Oil temperature sensor

P2 SENSR P2 (ambient pressure) sensor

PT SENSR Total Pressure sensor

REM DISP Remote BITE display

RPMMETER % rpm meter

SCV TM Surge control valve torque motor

STARTER Starter motor

STRT RLY Starter relay

T2 SNSR T2 (ambient temperature) sensor


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Table 119. Power-up Test BITE Display Mnemonics

Mnemonic Test Failure

PROM FLT PROM failure

RAM FLT RAM failure

TIME FLT Real-time overun

CPU FLT CPU failed


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Table 120. Fault Display Definitions

Error Code Definition

1 Divide by 0
2 Bad interrupt
3 Background EEPROM RAM image Test Failed
4 EEPROM write did not take
5 Fuel solenoid stuck open
6 Loss of DC power
7 A/D conversion not complete
8 DMM download verify failed
9 Spare
10 Spare
11 Keep-alive counter
12 Keep-alive prestart
13 Keep-alive didn't clamp off fuel
14 Keep-alive powerdown
15 A card overspeed reference
16 C card overspeed reference
17 TEST A card freq
18 TEST C card freq
19 A card overspeed reference
2O C card overspeed reference
21 TEST A card freq
22 TEST C card freq
23 A card overspeed
24 C card overspeed
25 Overspeed didn't clamp fuel flow
26 H/W O/S
27 S/W O/S
28 Speed A F/D interrupt not received
29 Speed A F/D interrupt not received
3O Speed C F/D interrupt not received
31 Speed C F/D interrupt not received
32 TEST A F/D interrupt not received
33 TEST C F/D interrupt not received
34 OSREF A F/D interrupt not received
35 OSREF C F/D interrupt not received
36 Spare
37 Spare
38 Speed 1A low
39 Speed 2A low
4O Speed 1C low
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Table 120. Fault Display Definitions (Cont)

Error Code Definition

41 Speed 2C low
42 Monopole A low
43 Monopole C low
44 One conditioner from each, no shutdown
45 One or more conditioners from each, shutdown
46 Monopole A V bit high
47 Monopole A V bit high
48 EGT 1 high
49 EGT 1 low
50 EGT 1 high
51 EGT 1 low
52 EGT 1 open
53 EGT 2 high
54 EGT 2 low
55 EGT 2 high
56 EGT 2 low
57 EGT 2 open
58 Both EGT 1 and EGT 2 failed
59 Both EGT 1 and EGT 2 failed
60 Ref 28 less than 7V or Ref 28 more than 48V
61 High oil temperature
64 OILT high
65 OILT low
68 T-2 high
69 T-2 low
72 Cold junction compensation high
73 Cold junction compensation low
76 Pressure sensor reference bit high
77 Pressure sensor reference bit low
78 Delta pressure high
79 Delta pressure low
80 Delta pressure high (only if BLEEDON = 0)
81 Delta pressure low (only if BLEEDON = 1)
82 Total pressure high
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Table 120. Fault Display Definitions (Cont)

Error Code Definition

83 Total pressure low


84 Total pressure high
85 Total pressure low
86 Ambient pressure high
87 Ambient pressure low
88 Ambient pressure high
89 Ambient pressure low
90 LVDT primary voltage high
91 LVDT primary voltage low
93 Refc ground voltage high
95 Refc bias voltage low
97 A/D 10 volt reference low
99 A/D 10 volt card A reference low
101 A/D 10 volt card A reference low
103 A/D 10 volt card A reference low
105 A/D 10 volt card A reference low
107 A/D 10 volt card A reference low
109 A/D 0 volt reference high
112 5 volt reference high
113 5 volt reference low
114 Monopole C V bit high
115 Monopole C V bit high
116 Fuel torc ue motor on current high
117 Fuel torc ue motor on current low
118 Fuel torc ue motor on voltage high
119 Fuel torc ue motor on voltage low
120 Fuel torc ue motor off current high
121 Fuel torc ue motor shorted
122 Fuel tore ue motor off voltage high
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Table 120. Fault Display Definitions (Cont)

Error Code Definition

124 Fuel torque motor over current


125 Fuel torque motor failed to turn off
126 Surge valve torc ue motor on current high
127 Surge valve torc ue motor on current low
128 Surge valve torc ue motor on voltage high
129 Surge valve torc ue motor on voltage low
130 Surge valve torc ue motor off current high
131 Surge valve torc ue motor shorted
132 Surge valve torc ue motor off voltage high
134 Surge valve torc ue motor over current
135 Surge valve torc ue motor failed to turn off
136 Inlet guide vane torque motor on current high
137 Inlet guide vane torque motor on current low
138 Inlet guide vane torque motor on voltage high
139 Inlet guide vane torque motor on voltage low
140 Inlet guide vane torque motor off current high
141 Inlet guide vane torque motor shorted
142 Inlet guide vane torque motor off voltage high
144 Inlet guide vane torque motor over current
145 Inlet guide vane torque motor failed to turn off
146 Both P2 and PT sensors failed
148 EGT meter over current
149 EGT meter failed to turn off
150 One conditioner from each, no shutdown
151 One conditioner from each, no shutdown
152 RPM meter over current
153 RPM meter failed to turn off
154 Low oil pressure switch fail
155 Low oil pressure occurred
156 LVDT secondary coil bit
157 APU fire
158 APU fire
159 Only have mono 2 hi conditioner, shutdown
161 Continuous RAM test failed
163 DMM off voltage high
164 DMM on voltage low
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Table 120. Fault Display Definitions (Cont)

Error Code Definition

165 DMM on overcurrent


166 DMM off overcurrent
169 DEOIL solenoid on voltage low
170 DEOIL solenoid off voltage high
171 DEOIL on overcurrent
172 DEOIL off overcurrent
175 DOOR solenoid on voltage low
176 DOOR solenoid off voltage low
177 DOOR on overcurrent
178 DOOR off overcurrent
181 FUELSOL solenoid on voltage low
182 FUELSOL solenoid off voltage high
183 FUELSOL on over current
184 FUELSOL off over current
187 IGN unit on voltage low
188 IGN unit off voltage high
189 IGN unit on over current
190 IGN unit off over current
191 No accel shutdown
192 No accel shutdown
193 No accel shutdown
194 No accel shutdown
195 No accel shutdown
196 No accel shutdown
197 No flame shutdown
198 No flame shutdown
199 No flame shutdown
200 No flame shutdown
201 Fuel torque motor on voltage low
202 IGV torque motor on voltage low
203 Fuel torque motor on voltage high
204 Spare
205 LOPIND on overcurrent
206 LOPIND off overcurrent
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Table 120. Fault Display Definitions (Cent)

Error Code Definition

207 Spare
208 Spare
209 Spare
210 Spare
211 Fault indicator on overcurrent
212 Fault indicator off overcurrent
213 Spare
214 Spare
215 Start relay on voltage low
216 Start relay on overcurrent
217 Start relay off overcurrent
218 Starter motor on voltage low
219 Starter motor off voltage high
221 HOLD relay on voltage low
222 HOLD relay off voltage high
223 HOLD relay on over current
224 HOLD relay off over current
226 LCV on voltage low
227 LCV off voltage high
228 LCV on overcurrent
229 LCV off overcurrent
230 IGV shutdown
231 IGV shutdown
232 IGV shutdown
233 RBD terminal parity error
234 Overtemp shutdown 1
235 Overtemp shutdown 2
236 Overtemp shutdown 3
237 Overtemp shutdown 4
238 Overtemp shutdown 5
239 Spare
240 No accel
241 No accel
242 No accel
243 No accel
244 No accel
246 No accel
248 Error to log starter LRU
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Table 120. Fault Display Definitions (Cont)

Error Code Definition

249 Spare
250 Loss of DC power
251 Reverse flow shutdown
252 RBD Ioopback failed
253 ECB is disabled
254 Shutdown failure
255 ARINC Ioopback failed
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DISASSEMBLY

. Equipment and Materials

A. Table 301 shows the equipment and materials necessary for disassembly.

Table 301. Equipment and Materials

Equipment/Material Description/Manufacturer

NOTE: Equivalent equipment/material can be used.

Bearing and puller plate set (Part No. 833123-1) *

Bearing and puller plate set (Part No. 833980-9) *

Bearing carrier puller (Part No. 2024292-1) *

Bearing puller (Part No. 2024020-1) *

Bearing removal adapter (Part No. 2024015-1) *

Bearing removal adapter (Part No. 2024016-1 ) *

Bearing removal adapter (Part No. 2024254-1 ) *

Bearing puller plate set (Part No. 833123-102) *

Bearing puller plate set (Part No. 833123-105) *

Bearing removal adapter set (Part No. 833130-1) *

Bearing removal adapter (Part No. 833130-200) *

Bearing removal adapter (Part No. 833135-203) *

Bearing removal adapter set (Part No. 833978-2) *

Bearing removal adapter set (Part No. 833984-1) *

Bearing removal adapter (Part No. 833974-1 ) *

Bearing removal adapter (Part No. 833978-1) *

Bearing removal adapter (Part No. 833999-1) *

Bearing removal adapter (Part No. 834622-9) *

Bearing removal adapter (Part No. 834826-1) *

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment 717 N. Bendix
Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987
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Table 301. Equipment and Materials (Cont)

Equipment/Material Description/Manufacturer

Bearing removal fixture (Part No. 2024014-4)

Bearing removal and installation fixture


(Part No. 2024019-1 )

Bearing removal and installation fixture


(Part No. 833986-1)

Bearing removal fixture (Part No. 833440-1)

Bearing removal plate (Part No. 833985-2)

Bearing removal tool (Part No. 833092-3)

Bearing removal tool (Part No. 835550-1)

Bearing support fixture (Part No. 833987-1)

Coupling puller (Part No. 833429-1)

Engine cart (Part No. 835332-1 )

Gearbox housing adapter (Part No. 2024003-1)

Generator adapter puller (Part No. 2024293-1)

Generator drive gear seal puller


(Part No. 2024287-1)

Idler shaft puller (Part No. 2024080-1)

Labrinth seal removal Fixture


(Part No. 835587-1)

Lip seal puller (Part No. 2024285-1)

Lip seal puller (Part No. 2024297-1)

Load compressor diffuser puller


(Part No. 2024230-1 )

Lube pump puller (Part No. 2024308-1) *

Maintenance stand (Part No. 287750-1) *

Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment 717 N. Bendix
Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987
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Table 301. Equipment and Materials (Cont)

Equipment/Material Description/Manufacturer

Medium duty proto puller (Model No. 4020C)

Oil pickup tube puller (Part No. 2024084-1 )

Plenum puller (Part No. 833186-1)

Portable gas turbine engine stand


(Part No. 833565-3)

Power section fixture assy (Part No. 2024008-1 )

Power section lift fixture (Part No. 833431-1 )

Seal removal fixture (Part No. 2024018-1 )

Seal removal fixture (Part No. 835607-1)

Shaft stretching fixture (Part No. 833094-1)

Spanner wrench (Part No. 2024465-1 )

Stand assembly support adapter


(Part No. 833426-1)

Stand assembly support adapter-


(Part No. 834119-2)

Stand assembly support adapter


(Part No. 834389-1)

Stand assembly support adapter


(Part No. 834390-1)

Starter clutch puller (Part No. 834397-1 )

Starter cover puller (Part No. 2024291-1 )

Transfer tube puller (Part No. 833434-1)

Tube puller (Part No. 2024084-1)

Tube puller (Part No. 2024228-1)

Tube installation adapter (Part No. 833184-1)

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment 717 N. Bendix
Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987
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GTCP36-280[D]

. Initial Disassembly Procedures

A. Before the engine can be disassembled, the procedures that follow must be done.

(1) Remove all hardware that holds the engine to the shipping container, crate, skid or
other support.

WARNING: MAKE SURE HOIST BAR AND RING ARE CORRECTLY ATTACHED AND
OPERATE SAFELY PRIOR TO APU INSTALLATION OR REMOVAL. DO
NOT STAND DIRECTLY BELOW APU DURING INSTALLATION OR
REMOVAL AS THE HOIST BAR OR RING COULD BREAK, RESULTING IN
SERIOUS BODILY INJURY OR DEATH.

(2) Remove the engine from the shipping container with the use of 833431-1 -lift fixture
and a hoist attached to the hoisting point.

(3) Install 834119-2, 834389-1 and 834390-1 stand assembly support adapters on the
gearbox mount points and the mount bracket.

(4) Lower the engine into a 833565-3 portable gas turbine engine stand and attach it to
the stand.

(5) Remove the hoist from the hoisting point.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN


ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS
AN ASPHYXIANT, IT IS POISONOUS AND CAN BE ABSORBED THROUGH
THE SKIN.

(6) Use a container to catch the oil and remove the magnetic drain plug from the gearbox.
Discard the packing. Install the magnetic drain plug with a new packing.

NOTE: When using the 835332-1 vertical maintenance stand, be sure to install the
2024008-1 fixture assembly to secure the power section to the stand.

. General Disassembly Procedures

WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS AND


COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND CAN
KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENERGIZED AND
GROUNDED BEFORE THE INPUT AND OUTPUT LEADS ARE
DISCONNECTED. DO NOT TOUCH THE CENTER CONTACT OF OUTPUT
TERMINAL.

NOTE: Do not disassemble tube assemblies, hose assemblies, wiring harness as-
semblies, riveted assemblies, staked or press-fit parts (except seals and
bearings) or remove nameplates, modification plates, lubrication plates,
decals, studs, or their Iockrings, or thread inserts, unless specifically
required in the text or necessary for replacement of a part. If disassembly
or removal is necessary, proceed in a manner consistent with good shop
practice.

A. Disassemble in a dry, well lighted, dust free room.

B. Be careful to prevent damage to parts that can be used again.


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WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE
CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT, IT
IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN.

. C. Apply lubricating oil to parts and put them in a protective container to prevent corrosion until
the parts can be cleaned and examined.

D. Do not disassemble any staked, welded, riveted, soldered, swaged, or press fit assemblies or
remove plates, passage hole plugs, or threaded inserts unless replacement is necessary.

E. Examine all bearings for roughness, brinelling, and damaged races or retainers. These
conditions can be an indication of possible damage.

F. Remove all protective caps, plugs, and closures before disassembly of the unit.

G. Make a record of the quantities and thickness of the shims and washers. This will help when
you assemble the part.

H. Removal of electrical connectors.

NOTE: Disassembly of details of the plumbing and electrical installation shall be


accomplished as accessible and "feasible" during removal of engine section
components from the engine. Note routing of tubing electrical wiring harness and
location and manner of attaching clamps. Tag tubing and electrical gaskets.
(Refer to Figures 302 through 308B.)

(1) Remove threaded connectors.

CAUTION: TO PREVENT DAMAGE TO CONNECTORS, DO NOT USE TOO


MUCH FORCE. DO NOT PULL ON THE ATTACHED WIRES.

(a) Use connector pliers to loosen the coupling rings.

(b) Pull on the plug body and turn the coupling ring until the connector is apart.

(c) Use caps or plastic bags to keep dirt and unwanted material out of the
receptacles.

(2) Remove the bayonet connector.

(a) Turn the coupling ring in a counterclockwise direction to remove the bayonet
connector.

Honeywell recommends that the parts found in Table 302 be replaced at each disassembly.
However, actual replacement of parts may be done on in-service experience.
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GTCP36-280[D]

Table 302. Parts to be Replaced at Each Disassembly

Figure Item
No. No. Nomenclature Quantity

302 120, 280, 310, 330, 340, Packing 13


360, 380, 390, 430

302A 130, 160, 180, 220, 260, Packing 7


280

302B 130, 160, 180, 220, 260, Packing 7


28O

303 8O Packing 1

303A 30, 40, 150, 170 Packing 6

303B 30, 40, 150, 170 Packing 6

304 90, 100, 150, 260, 290 Packing 7

304A 100, 160, 240,290, 310 Packing 10

304B 100, 160, 240, 290, 310 Packing 10

305 160, 200 Packing 3

305A 50, 150 Packing 4

305B 50, 150, 210, 210A Packing 5

306 110, 170, 230, 240 Packing 7

306A 40, 150, 180, 270, 350, Packing 9


38O

306B 40, 150, 180, 270, 350, Packing 9


38O

307A 90 Packing 1

307B 9O Packing 1

308A 120, 210 Packing 3


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GTCP36-280[D]

Table 302. Parts to be Replaced at Each Disassembly (Cont)

Figure Item
No. No. Nomenclature Quantity

308B 120, 210 Packing 3

3O9 100, 110, 180 Packing 3

309A 100, 110, 180 Packing 3

310 100 Packing 1

310A 100, 310 Packing 3

311 80, 180, 220 Packing 3

311A 80, 180, 220 Packing 3

312 30, 50, 90, 130, 190, 210, Packing 9


220

313 40, 80, 90 Packing 3

314 130 Packing 1

314A 130 Packing 1

315 10, 20, 50, 70 Packing 4

316 50, 80, 120, 130, 165, 180, Packing 11


220, 260, 290, 310

316A 50, 80, 150, 160, 200, 220, Packing 8


250,290

317 70, 90 Packing 2

317A 40, 70 Packing 2

318 40, 240, 360 Packing 3

318A 40, 240, 290, 330 Packing 4

319 90, 140, 160, 180, 245, Packing 7


270, 310
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GTCP36-280[D]

Table 302. Parts to be Replaced at Each Disassembly (Cont)

Figure Item
No. No. Nomenclatu re Quantity

319A 50, 90, 110, 200, 220, Packing 7


37O

321 105 Packing 1

322 30, 40, 90, 150, 160 Packing 10

323 40, 41,42, 110 Packing 5

325 130, 140, 150, 330, 340, Packing 6


350

326 20, 150, 160 Packing 3


280 Gasket, Seal Curvic 1

327 120 Packing 19

327A 150 Packing 19


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GTCP36-280[D]

. Disassembly Procedures

NOTE: Refer to TESTING AND FAULT ISOLATION to find the condition of the unit and the level of
disassembly necessary to repair the unit.

Obvious steps or procedures necessary to disassemble the engine, such as removal of


Iockwire, attaching parts, or simple components are omitted from the text. Removal of
plumbing, electrical and external parts installation may be accomplished whenever parts are
accessible. In general, disassembly must be accomplished in sequence of index numbers
assigned to individual exploded views. Variations from this sequence and special
processes or methods are specifically mentioned in the text. The following general
procedures should be observed throughout the disassembly operations.

A. Disassemble the plumbing and electrical installation.

(1) Remove components of plumbing and electrical installation (Refer to Figures 302
through 308B) and replace as required in accordance with good shop practice. During
removal, note must be made of the routing of wiring, tubing and hoses, and manner of
attaching clamps for reference at assembly. Plumbing fittings, lines, and wiring
harness connectors and terminals, must be tagged as removed to help in assembly.
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GTCP36-280[D]

10 10
250 20 20
430 110 110
410 350 ~10
. . . .

43O
220
24O
430
(BEHINDFILTER) A
10 20
70 80 90 20 100
140 140
330 340
120
400
110 370 o o ~//"':::B
450 380
B130

60

40
390
280 ' ~
320 ~ .
460 ~ ,

25O
310 " - ~ '

1() / 10 270 ~ 10 10
10 20 170 20 280 160 20 20 10
10 20 20
150 150 290 150 150
50 180 150
10 300 210 420 420 420
190 420 410
20
200
180
420
X3800504PL140

Disassemble the Plumbing and Electrical Installation (Part No. 3615682)


(Code A) (Partial Breakdown)
Figure 302

NOTE: Figure 301 intentionally omitted.


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GTCP36-280[D]

~KEY TO FIGURE 302

10. NUT (IPC FIG. 2) 240. REDUCER


20. BOLT 250. NUT
30. ELBOW 260. UNION
40. TUBE ASSY 270. ELBOW REDUCER
50. BOLT 280. PACKING
60. TUBE ASSY 290. NUT
70. TUBE ASSY 300. TUBE ASSY
80. TUBE ASSY 310. PACKING
90. TUBE ASSY 320. UNION
100. TUBE ASSY 330. PACKING
110. CLAMP 340. PACKING
120. PACKING 350. UNION
130. TUBEASSY 360. PACKING
140. BOLT 370. RETAINER
150. CLAMP 380. PACKING
160. TUBEASSY 390. PACKING
170. TUBE ASSY 400. BOLT
180. CLAMP 410. CLAMP
190. CLAMP 42O. CLAMP
200. SPACER 430. PACKING
210. CLAMP 440. REDUCER
220. TEE 45O. CLAMP
230. UNION 460. TUBE ASSY
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GTCP36-280[D]

10
100
110
250 270 270 310
230 240 260 280 ~ 0 280 300

210
220
200

170
180
190

20
150
160

140
20 10 10 60 50 10 30
120 90 20 330
130 100 70
110 80

A
A3800504PL187

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 302A
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GTCP36-280[D]

~lm KEY TO FIGURE 302A

10. NUT (IPC FIG. 2A) 180. PACKING


20. BOLT 190. NUT
30. TUBE ASSY 200. TUBE ASSY
40. CLAMP 210. UNION
50. WIRE HARNESS 220. PACKING
60. REDUCER 230. TUBE ASSY
70. CLAMP 240. TUBE ASSY
80. CLAMP 250. TUBE ASSY
90. CLAMP 260. PACKING
100. SPACER 270. REDUCER
110. BOLT 280. PACKING
120. TUBE ASSY 290. DE-OIL SOLENOID VALVE
130. PACKING 300. TUBE ASSY
140. TUBE ASSY 310. CLAMP
150. TUBE ASSY 320. CLAMP
160. PACKING 330. CLAMP
170. ELBOW
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GTCP36-280[D]

10
100
110
2~ 270 270 310
~0 2~ 2~ 280 290 280 300

Y
J

210 ~"~----~

170 -

150 - ~/ /

,./ /
120 10 10 60 50 10 30 10
130
340
90
100
110
20
70
80
20
40
--I---~.--~ ;~\-, [k
~-"

A
A3800504PL196

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 302B
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GTCP36-280[D]

~KEY TO FIGURE 302B

10. NUT (IPC FIG. 2B) 180. PACKING


20. BOLT 190. NUT
30. TUBE ASSY 200. TUBE ASSY
4O. CLAMP 210. UNION
50. WIRE HARNESS 220. PACKING
60. REDUCER 230. TUBE ASSY
70. CLAMP 240. TUBE ASSY
80. CLAMP 250. TUBE ASSY
90. CLAMP 260. PACKING
100. SPACER 270. REDUCER
110. BOLT 280. PACKING
120. TUBE ASSY 290. DE-OIL SOLENOID VALVE
130. PACKING 300. TUBE ASSY
140. TUBEASSY 310. CLAMP
150. TUBEASSY 320. CLAMP
160. PACKING 330. CLAMP
170. ELBOW 340. BOLT
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GTCP36-280[D]

10
10 20
20 30
40 50
130 I

/ ~ ~- - - - ;

', \ ',, \

\,
"ai I
' ,'"t )l
l'\
\
9O \
100
\
\
X" ..... " '"/!'
/ / / I
/ i, ~'
,., o ,,// , /,' ~!li..,..~,

@
10
20
30 10 t
J
120 20
30
L___ .__j
120
~ L. /

10 1t0
20
7O
110
X3800504PL141

Disassemble the Plumbing and Electrical Installation (Part No. 3615682)


(Code A) (Partial Breakdown)
Figure 303
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GTCP36-280[D]

4~KEY TO FIGURE 303

10. NUT (IPC FIG. 3) 80. PACKING


20. BOLT 90. ELBOW
30. CLAMP 100. NUT
40. CLAMP 110. CLAMP
50. CLAMP 120. CLAMP
7O. BRACKET 130. BRACKET
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GTCP36-280[D]

10 10
20 20
20 40 30 50 110
60 70 80 110 120

180 130 130 10


160 140 2O
170 150 110
120
A3800504PL188

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 303A
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GTCP36-280[D]

~lm KEY TO FIGURE 303A

10. NUT (IPC FIG. 3A) 100. UNION


20. BOLT 110. CLAMP
30. PACKING 120. BRACKET
40. PACKING 130. SCREW
5O. CLAMP 140. TUBE RETAINER
6O. TUBE ASSY 150. PACKING
70. TUBE ASSY 160. TUBE RETAINER
80. TUBE ASSY" 170. PACKING
90. TUBE ASSY 180. TUBEASSY
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GTCP36-280[D]

10 10
20 20
20 40 30 5O 110
70 8O 9O 100 1:,10 1;~)
/ / /

180 200 190 130 210 130 10


160 140 20
170 150 110
120 A3800504PL197

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 303B
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GTCP36-280[D]

~1~ KEY TO FIGURE 303B

10. NUT (IPC FIG. 3B) 120. BRACKET


20. BOLT 130. SCREW
3O. PACKING 140. TUBE RETAINER
40. PACKING 150. PACKING
50. CLAMP 160. TUBE RETAINER
60. TUBE ASSY 170. PACKING
70. TUBE ASSY 180. TUBEASSY
80. TUBE ASSY" 190. TEE
90. TUBE ASSY 200. TUBE ASSY
100. UNION 210. TUBEASSY
110. CLAMP
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GTCP36-280[D]

~oo~.~ i----'

150 J : !

30 . / ~
/ t

;I F E T ' ~ , ~'~"1o
,o
--, .Y" U ii -;,, 27o
- - ,, ,- ,,o A B
10
30 100 170 170 10
330 130 180 200 20 210
340 310, 190 290 40
- \./ ~~ ~-'~

,7O
i-so
c~
.~-- 10
20
25O
! 280

\. /
260 lo 1o / I
300 40 20 60
w

330 40 110
34O 25O 120
X3800504PL142

Disassemble the Plumbing and Electrical Installation (Part No. 3615682)


(Code A) (Partial Breakdown)
Figure 304
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GTCP36-280[D]

41~ KEY TO FIGURE 304

10. NUT (IPC FIG. 4) 180. RETAINER


20. BOLT 190. PACKING
30. CLAMP 200. RETAINER
40. CLAMP 210. TUBEASSY
50. HOSEASSY 220. TUBEASSY
60. TUBEASSY 230. UNION
70. NUT 240. TUBE ASSY
80. ELBOW 250. CLAMP
90. PACKING 260. PACKING
100. PACKING 270. CLAMP
110. PRESSURE RELIEFVALVE 280. BRACKET
120. TEE TUBE 290. PACKING
130. NUT 300. REDUCER
140. NUT 310. ELBOW
150. PACKING 320. CLAMP
160. ELBOW 330. SPACER
170. SCREW 340. BOLT
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GTCP36-280[D]

THIS PAGE INTENTIONALLY LEFT BLANK


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Honeywell GTCP36-280[D]

10
2o
3O
C

~~
--.~ ,

B-,~

r ' . , ~: . - -~

10 10 10 10
30
40 30 30 10
50 80 60 170
70 -- 180
[ ~ 190......~

t lS0~~~ ~,.l_A / 1 0
160 -,.~ ~ S / / ~ " ~ \ / 20

/ lo . . ~ - / - 7 ~ - - L ~ " ~ / ~'/Z - lOO


/~o -~' -7-~ ,~.~-~ 11o
L" ' '%~! A
X3800504PL143

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 304A (Sheet 1 of 2)
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GTCP36-280[D]

170
250

260

360

270
310
280
290 350

300
310 310
340
330
310
320
B
10 10 10
20 20 20
70 30 30
1_40 ~ ~ 70 140

i "i ;,---'"-'--'. '

C
A3800504PL190

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 304A (Sheet 2)
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GTCP36-280[D]

41~ KEY TO FIGURE 304A

10. NUT (IPC FIG. 4A) 190. BRACKET


20. BOLT 200. BRACKET
30. CLAMP 210. CLAMP
40. SPACER 220. TUBE ASSY
50. BOLT 230. REDUCER
60. CLAMP 240. PACKING
70. CLAMP 250. RETAINER
80. BRACKET 260. BOLT
90. NUT 270. NUT
100. PACKING 280. ELBOW
110. ELBOW 290. PACKING
120. BRACKET 300. UNION
130. CLAMP 310. PACKING
140. CLAMP 320. REDUCER
150. REDUCER 330. TEE
160. PACKING 340. UNION
170. BOLT 350. NUT
180. CLAMP 360. REDUCER
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Honeywell GTCP36-280[D]

10
2o C
" 30

'1 \
" ~ c: )

~ r,---
r_~___,, I 1.

B ~I~~ ~
AI I
' ';~/i.

L ~ 10101010
30 20 2O 20
40 70 30 30 10
50 80 60 170
70 1M
,=,... 190.....,.._
_ if/i/ --i
"~ . L~t~
~~ ~ .

110
2O 1-
"-~ ~~,~- ' ~ ./~ -

130 i / ~ A
X3800504PL143

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 304B (Sheet 1 of 2)
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GTCP36-280[D]

170
2,50

260

360

270
310
280
290 350

300
310

33O
310
320

10 10 10
20 20 2O
70 3O 3O
:0 140

A3800504PL190

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 304B (Sheet 2)
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GTCP36-280[D]

~KEY TO FIGURE 304B

10. NUT (IPC FIG. 4B) 190. BRACKET


20. BOLT 200. BRACKET
30. CLAMP 210. CLAMP
40. SPACER 220. TUBE ASSY
50. BOLT 230. REDUCER
60. CLAMP 240. PACKING
70. CLAMP 250. RETAINER
80. BRACKET 260. BOLT
90. NUT 270. NUT
100. PACKING 28O. ELBOW
110. ELBOW 290. PACKING
120. BRACKET 300. NIPPLE
130. CLAMP 310. PACKING
140. CLAMP 320. REDUCER
150. REDUCER 330. TEE
160. PACKING 340. UNION
170. BOLT 350. NUT
180. CLAMP 360. REDUCER
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Honeywell GTCP36-280[D]

10 10 10
10
20 40 20 10 ] 70 20
40 180 30
20\ ~ ""~..'~ 180
220 40
60
40 ~ / / , " ~ "~ ~ 19o
170 t'~ ~--~'~ ~

, 30
~'% 180
220
230
=o ='i i:,.; .~'4 /io
40
2O 2O .: .' "!
It.. " ~" '
". ' '
: f',.20
40 4O 180 ~~"~ 170
100 190 A 180
BI
10

90 D
B 110
120
%.,
2OO

Iq~l~-/-1;
I.IIU ;

)t

210
10-
20
170
180

/
,-+'~
140
A 80

X3800504PL145

Disassemble the Plumbing and Electrical Installation (Part No. 3615682)


(Code A) (Partial Breakdown)
Figure 305
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GTCP36-280[D]

41~ KEY TO FIGURE 305

10. NUT (IPC FIG. 5) 130. CLAMP


20. BOLT 140. TEE
30. CLAMP 150. REDUCER
40. CLAMP 160. PACKING
60. CLAMP 170. CLAMP
7O. TUBE ASSY 180. CLAMP
80. TUBE ASSY 190. CLAMP
90. BRACKET 200. PACKING
100. CLAMP 210. UNION
110. ELBOW 220. SPACER
120. NUT 230. BOLT
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GTCP36-280[D]

10
20
70

, !

i Ill,/"
/
I

'1---90
f

10: '
70
110
""~t
~'i10
20 f 7O
120 80 8O
130 100 A A3800504PL191

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 305A (Sheet 1 of 2)
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GTCP36-280[D]

10
20 150
80 140 160 50
100 150 170 180

A --.--I~

10 10 10 10 10
70 20 20 20 20
80 70 70 70 190
110 100 100 200
120

120

A
A3800504PL192

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 305A (Sheet 2)
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GTCP36-280[D]

41~ KEY TO FIGURE 305A

10. NUT (IPC FIG. 5A) 110. BOLT


20. BOLT 120. SPACER
30. TUBE ASSY 130. CLAMP
40. ELBOW 140. PLUG
50. PACKING 150. PACKING
60. NUT 160. NUT
70. CLAMP 170. ELBOW
80. CLAMP 180. UNION
90. TUBE ASSY 190. BRACKET
100. CLAMP 200. CLAMP
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GTCP36-280[D]

THIS PAGE INTENTIONALLY LEFT BLANK


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GTCP36-280[D]

170A 10
170B 20
210A 160 70
170 210

I I
,
\ i

511

: !
IL."
. . . . . . . ,i_

#I . .
90

/
#s
/
J
10 10 10
70 20 20
110 80 70
120 100 80
130
X3800504PL189

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 305B (Sheet 1 of 2)
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GTCP36-280[D]

10
20 150
80 140 160 50
100 1~ 170 1;~

,.-~
A
t
f

I 1

10 t0 10 10 10
70 20 20 20 20
80 70 70 70 190
110 100 100 200
120 A

8O
110
120 t~..~__)

A A3800504PL199

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 305B (Sheet 2)
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GTCP36-280[D]

~KEY TO FIGURE 305B

10. NUT (IPC FIG. 5B) 150. PACKING


20. BOLT 160. NUT
3O. TUBE ASSY 170. ELBOW
40. ELBOW 170A. UNION (POST SB 49-7578)
50. PACKING 170B. SWIVEL FITTING (POST SB 49-7578)
60. NUT 180. UNION
70. CLAMP 190. BRACKET
80. CLAMP 200. CLAMP
90. TUBE ASSY 210. PACKING
100. CLAMP 210A. SEAL (POST SB 49-7578)
110. BOLT
120. SPACER
130. CLAMP
140. PLUG
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GTCP36-280[D]

10
4O
60 10
10 70 20 10
30 250 40 20
10 40 120l / 1~ 5; 40
20 20
200 70 90 / 80
40 140
GO 240

\
I

100/ / 210
' /17() [ _ , = J - 1 5\0 ~ \ 10
110 220 170 t 160 250 3O
230 180 / 170 260 70
190 25O
X3800504PL147

Disassemble the Plumbing and Electrical Installation (Part No. 3615682)


(Code A) (Partial Breakdown)
Figure 306
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GTCP36-280[D]

~KEY TO FIGURE 306

10. NUT (IPC FIG. 6) 140. TUBE ASSY


20. BOLT 150. TEE
30. CLAMP 160. REDUCER
4O. CLAMP 170. PACKING
50. CLAMP 180. REDUCER
60. CLAMP 190. LOP SWITCH
70. SPACER 200. RETAINER
80. CLAMP 210. TUBE ASSY
90. DE-OIL SOLENOID 220. UNION
100. REDUCER 230. PACKING
110. PACKING 240. PACKING
120. TUBE ASSY 250. BOLT
130. TUBEASSY 260. RETAINER
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GTCP36-280[D]

t0 10 10
90 120 10 90
110 200 20 110
120 210 40 260 280 120
190 220 240 250

20
170
180
160

10
20
120
130

10 80 70 60 40 30 10 10 10 320 360 320


90 50 40 20 20 90 330 370 330
100 120 130 110 350 380 340
110 130 190 390 350
280
A3800504PL193

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 306A
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GTCP36-280[D]

~lm KEY TO FIGURE 306A

10. NUT (IPC FIG. 6A) 210. CLAMP


20. BOLT 220. SPACER
30. REDUCER 230. REDUCER
40. PACKING 240. TUBE ASSY
50. LOP SWITCH 250. TEE
60. TEE 260. TUBE ASSY
7O. UNION 270. PACKING
80. TUBE ASSY 280. CLAMP
90. BOLT 290. CLAMP
100. CLAMP 300. BOLT
110. SPACER 310. IGVTUBE RETAINER
120. CLAMP 320. BOLT
130. CLAMP 330. TUBE RETAINER
140. UNION 340. TUBE ASSY
150. PACKING 350. PACKING
160. UNION 360. TUBE ELBOW
170. RETAINER 370. NUT
180. PACKING 380. PACKING
190. CLAMP 390. TUBE ASSY
200. BOLT
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GTCP36-280[D]

10 10 10
90 120 10 9O
110 200 20 110
120 210 40 260 280 120
19o 220 ~ 24o 2~ ~0

r? i

J f
t'

20
170
180 310
160

140

140
150

10 ~
2O
120
130

/
10 80 70 60 40 30 10 10 10 320 360 320
5O 4O 2O 20 9O 33O 37O 33O
100 120 130 110 350 380 340
110 130 190 390 350
280
A3800504PL200

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 306B
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GTCP36-280[D]

~ l ~ KEY TO FIGURE 306B

10. NUT (IPC FIG. 6B) 210. CLAMP


20. BOLT 22O. SPACER
30. REDUCER 23O. REDUCER
40. PACKING 240. TUBE ASSY
50. LOP SWITCH 250. TEE
60. TEE 260. TUBE ASSY
70. UNION 270. PACKING
80. TUBE ASSY 280. CLAMP
90. BOLT 290. CLAMP
100. CLAMP 300. BOLT
110. SPACER 310. IGVTUBE RETAINER
120. CLAMP 320. BOLT
130. CLAMP 330. TUBE RETAINER
140. UNION 340. TUBE ASSY
150. PACKING 350. PACKING
160. UNION 360. TUBE ELBOW
170. RETAINER 370. NUT
180. PACKING 380. PACKING
190. CLAMP 390. TUBE ASSY
200. BOLT
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GTCP36-280[D]

10
2O

, \ \ \\ ~=,=

. . . . . ---------~--..d./-~-"---"~,..

",-%.

- A

X3800504PLi48

Disassemble the Plumbing and Electrical Installation (Part No. 3615682)


(Code A) (Partial Breakdown)
Figure 306C
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GTCP36-280[D]

41~ KEY TO FIGURE 306C

10. NUT (IPC FIG. 7) 30. CLAMP


20. BOLT 40. BRACKET
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GTCP36-280[D]

30
40
120

11o~

,i t

@
"+" ;_

i
4

i ! ill
!-T:~
!

80 10 30
90 20 40
100 60 50
70
A3800504PL194

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 307A
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GTCP36-280[D]

~ I ~ KEY TO FIGURE 307A

10. NUT (IPC FIG. 7A) 70. BRACKET


20. BOLT 80. NUT
30. SPACER 90. PACKING
40. CLAMP 100. ELBOW
50. BOLT 110. HOSE ASSY
6O. CLAMP 120. BOLT
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GTCP36-280[D]

30
40
120

11o~
.,I

| I

/
I

1
@

.',i 1 !

80 10 30
90 20 40
100 60 50
70
A3800504PL194

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 307B
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GTCP36-280[D]

~KEY TO FIGURE 307B

10. NUT (IPC FIG. 7B) 70. BRACKET


20. BOLT 80. NUT
30. SPACER 90. PACKING
40. CLAMP 100. ELBOW
50. BOLT 110. HOSE ASSY
60. CLAMP 120. BOLT
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GTCP36-280[D]

10
j ,o... 3O 4O
5O

,;.-r-

A B

A B

III
)i
I

~J

A3B00504PL106

Disassemble the Plumbing and Electrical Installation (Part No. 3615682)


(Code A) (Partial Breakdown)
Figure 308
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GTCP36-280[D]

~KEY TO FIGURE 308

10. NUT (IPC FIG. 8) 50. BOLT


20. BOLT 60. SPACER
30. CLAMP 70. WIRING HARNESS
4O. CLAMP
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GTCP36-280[D]

10
3O 100
40 110 120
120 130

'I

150

20
150

!i,Ji
I 160

I
I

170

180

i ~ 190

10 80 70 60 10 220 200
2O 30 210
5O 40
90 50
A3800504PLt95

Disassemble the Plumbing and Electrical Installation (Part No. 3616215)


(Code B) (Partial Breakdown)
Figure 308A
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GTCP36-280[D]

~lm KEY TO FIGURE 308A

10. NUT (IPC FIG. 8A) 120. PACKING


20. BOLT 130. UNION
30. BOLT 140. BOLT
40. SPACER 150. BRACKET
50. CLAMP 160. CLAMP
60. TUBE ASSY 170. TUBE ASSY
70. VALVE ASSY 180. TEE TUBE
80. TUBE ASSY 190. CLAMP
90. CLAMP 200. UNION
100. NUT 210. PACKING
110. ELBOW 220. TUBE ASSY

~t
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GTCP36-280[D]

10 10
20 30 100
50 40 110 120
1t 130

10 10 80 70 80 10 220 200
20 20 30 210
,50 50 40
230 90 50 A3800504PL201

Disassemble the Plumbing and Electrical Installation (Part No. 3616519)


(Code B) (Partial Breakdown)
Figure 308B
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GTCP36-280[D]

~11 KEY TO FIGURE 308B

10. NUT (IPC FIG. 8B) 130. UNION


20. BOLT 140. BOLT
30. BOLT 150. BRACKET
4O. SPACER 160. CLAMP
50. CLAMP 170. TUBEASSY
60. TUBE ASSY 180. TEE TUBE
7O. VALVEASSY 190. CLAMP
8O. TUBE ASSY 200. UNION
90. CLAMP 210. PACKING
100. NUT 220. TUBE ASSY
110. ELBOW 230. BRACKET
120. PACKING
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GTCP36-280[D]

- ,''"10 190
\

100 110
30 f

20
%.

\ 2 , -
'%, I

/
1,o--+~..~.j-~
/
~--'--'50 160- - ~ , / '

j30 ~ 30

X3800504PL6

(Pre SB 49-6658, 6699) Disassemble the Engine Assembly


(Code A) (External Components) (Partial Breakdown)
Figure 309
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GTCP36-280[D]

. B. Disassemble the engine assembly.

(1) (Pre SB 49-6658, 6699) Disassemble the external components. (Refer to Figure 309.)

(a) Remove bolts (10), fan inlet duct (20), clamps (30) and oil cooler duct (40).

(b) Remove clamp (50), fan exit duct (60), bolts (70), washers (80), oil cooler fan
assembly (90) and packings (100, 110). Discard packings. Refer to ATA No.
49-51-75 for disassembly of the oil cooler fan assembly (90).

(c) Remove nuts (120), bolts (130), pressure sensor (140), bolts (150) and sensor
bracket (160).

(d) Remove oil sump temperature sensor (170) and packing (180) from engine
assembly (190). Discard packing.

~KEY TO FIGURE 309

10. BOLT 110. PACKING


20. FAN INLET DUCT 120. NUT
30. CLAMP 130. BOLT
40. OIL COOLER DUCT 140. PRESSURE SENSOR
50. CLAMP 150. BOLT
60. FAN EXIT DUCT 160. SENSOR BRACKET
70. BOLT 170. OIL SUMP TEMPERATURE
80. WASHER SENSOR
90. OILCOOLER FANASSY 180. PACKING
100. PACKING 190. ENGINEASSY
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GTCP36-280[D]

- ~ ' ~ 10 250

1@0 1110
80

220

210~,~

! ~ t I /"-
i" 2oo~ "[]1

~/30 30

40
190
A
X3800504PL7

(Post SB 49-6658, 6699) Disassemble the Engine Assembly


(Code B) (External Components) (Partial Breakdown)
Figure 309A
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GTCP36-280[D]

4. g. Disassemble the engine assembly.

(2) (Post SB 49-6658, 6699) Disassemble the external components. (Refer to


Figure 309A.)

(a) Removebolts (10), fan inlet duct (20), clamps (30) and oil cooler duct (40).

(b) Removeclamp (50), fan exit duct (60), bolts (70), washers (80), oil cooler fan
assembly (90) and packings (100, 110). Discard packings. Refer to ATA No.
49-51-75 for disassembly of the oil cooler fan assembly (90).

(c) Removebolts (190) and transducer assy (200).

(d) Removebolts (210, 220, 230) and bracket (240).

(e) Removeoil sump temperature sensor (170) and packing (180) from engine
assembly (250). Discard packing.

4111 KEY TO FIGURE 309A

10. BOLT 170. OIL SUMPTEMPERATURE


20. FAN INLET DUCT SENSOR
30. CLAMP 180. PACKING
40. OIL COOLER DUCT 190. BOLT
50. CLAMP 200. TRANSDUCER ASSY
60. FAN EXIT DUCT 210. BOLT
70. BOLT 220. BOLT
80. WASHER 230. BOLT
90. OIL COOLER FAN ASSY 240. BRACKET
100. PACKING 250. ENGINEASSY
110. PACKING
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GTCP36-280[D]

170 180

\
25O
~/10
15 70

~Tt ~ '
/

I - 120

" -
_/10

130--~ ,,/15

140
~./10

lO0
'~ 110

90

X3800504PL8

(Pre SB 49-6634, 6658, 6699) Disassemble the External Components


(Code A) (Partial Breakdown)
Figure 310
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GTCP36-280[D]

4. B. (3) (Pre SB 49-6634, 6658, 6699) Disassemble the external components. (Refer to
Figure 310.)

(a) Remove coupling clamps (10, 20), gaskets (15), nuts (30), bolts (40), bleed
duct support bracket (50), bleed duct elbow (60) and load control valve (70).
Refer to ATA No. 49-50-40 for disassembly of the load control valve (70).

(b) Remove bleed duct support bracket (80), bolts (90), packing (100), bleed duct
(110), bolts (120), transducer assembly (130) and flow sensor gasket (140).
Discard packing. Refer to ATA No. 49-51-83 for disassembly of the
transducer assembly (130).

NOTE: Do not remove cap screws (150) and identification plate (160)
unless it is damaged.

(c) Remove bolt (170) and pressure sensor tube (180).

(d) Remove drilled head bolts (190), immersion thermocouples (200) and
thermocouple gaskets (210).

~1~ KEY TO FIGURE 310

10. COUPLING CLAMP 140. FLOW SENSOR GASKET


15. GASKET 150. CAP SCREW
20. COUPLING CLAMP 160. IDENTIFICATION PLATE
30. NUT 170. BOLT
4O. BOLT 180. PRESSURE SENSOR TUBE
50. BLEED DUCT SUPPORT 190. DRILLED HEAD BOLT
BRACKET 20O. IMMERSION THERMOCOUPLE
60. BLEED DUCT ELBOW 210. THERMOCOUPLE GASKET
70. LOAD CONTROL VALVE 220. BOLT
80. BLEED DUCT SUPPORT 230. IGNITION EXCITER
BRACKET 240. INSULATOR
90. BOLT 250. FLATHEAD SCREW
100. PACKING 260. IGNITION BOX BRACKET
110. BLEED DUCT 270. NUTPLATE
120. BOLT 280. DRILLED HEAD BOLT
130. TRANSDUCER ASSY 290. ENGINE ASSY
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GTCP36-280[D]

WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS


AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE
AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-
ENERGIZED AND GROUNDED BEFORE THE INPUT AND
OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE
CENTER CONTACT OF OUTPUT TERMINAL.

4. B. (3) (e) Remove bolts (220, 280), ignition exciter (230), insulator (240), flathead
screws (250) and ignition box bracket (260) from engine assembly (290).

NOTE: Disconnect ignition lead before removing ignition exciter. Do not


remove nut plates (270) unless they are damaged.
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GTCP36-280[D]

'80

40
I t A
40

5o (o ED>A

20 ~, , ~ J _ _ ~ 180

\ ,r.-250
2O0
190

10

,....15 _ ~/,70
./ Z
.... 220
i 210

f t

B
360 120~L~~
150 ~--- 15

~J
!
100
110

90
7
0504PL9

(Post SB 49-6634, 6658, 6699) Disassemble the External Components


(Code B) (Partial Breakdown)
Figure 310A (Sheet 1 of 2)
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GTCP36-280[D]

I
I

330
340
350
~ -..__~2)
330
\
33O

310 320

~ . BLEED
I ~ ~ ~. _ _ DUCT

I,, " U

/
300
SECTION ~ -

X3B00504PL49

(Post SB 49-6634, 6658, 6699) Disassemble the External Components


(Code B) (Partial Breakdown)
Figure 310A (Sheet 2)
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GTCP36-280[D]

4. B. (4) (Post SB 49-6634, 6658, 6699) Disassemble the external components. (Refer to
Figure 310A.)

(a) Remove screw (270), washer (280) and cover (290) from flow sensor (300).

(b) Remove bolts (120), flow sensor (300) and gasket (130) from bleed duct
(110).

(c) Remove bolts (330), Iockwasher (340), seal (350), packings (310) and
pressure static sensor (320) from flow sensor (300). Discard packings.

(d) Remove coupling clamps (10, 20), gaskets (15), nuts (30), bolts (40), bleed
duct support struts (50, 80), bleed duct elbow (60) and load control valve (70).
Refer to ATA No. 49-50-40 for disassembly of the load control valve.

(e) Remove bolts (90), packing (100), bleed duct (110) from engine assy (360).
Discard packing.

NOTE: Do not remove cap screws (140) and identification plate (150)
unless damaged.

~ l n KEY TO FIGURE 310A

10. COUPLING CLAMP 180. DRILLED HEAD BOLT


15. GASKET 190. IMMERSION THERMOCOUPLE
20. COUPLING CLAMP 200. THERMOCOUPLE GASKET
30. NUT 210. BOLT
40. BOLT 220. IGNITION EXCITER
50. BLEED DUCT SUPPORT 230. INSULATOR
STRUT 240. FLATHEAD SCREW
60. BLEED DUCT ELBOW 250. IGNITION BOX BRACKET
70. LOAD CONTROL VALVE 260. NUTPLATE
80. BLEED DUCT SUPPORT 270. SCREW
STRUT 280. WASHER
90. BOLT 290. COVER
100. PACKING 300. FLOW SENSOR
110. BLEED DUCT 310. PACKING
120. BOLT 320. PRESSURE STATIC SENSOR
130. FLOW SENSOR GASKET 330. DRILLED HEAD BOLT
140. CAP SCREW 340. LOCKWASHER
150. IDENTIFICATION PLATE 350. SEAL
160. BOLT 360. ENGINE ASSY
170. PRESSURE SENSOR TUBE
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GTCP36-280[D]

WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS


AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE
AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-
ENERGIZED AND GROUNDED BEFORE THE INPUT AND
OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE
CENTER CONTACT OF OUTPUT TERMINAL.

4. B. (4) (f) Remove bolts (210), ignition exciter (220), insulator (230), flathead screws
(240) and ignition box bracket (250).

NOTE: Disconnect ignition lead before removing ignition exciter. Do not


remove nut plates (260) unless they are damaged.

(g) Remove bolt (160) and pressure sensor tube (170).

(h) Remove drilled head bolts (180), immersion thermocouples (190) and
thermocouple gaskets (200).
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UP200456

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GTCP36-280[D]

210 190 146 "--~ ~ I


22o 20,0 f! .~i 12o....~
Lji,'!~iL
~ 13o....

.,;t.,/./ 2,0 ',

10

{ROTATED
A)

,0

, 'L,~I

2o~ , ~ ~*" \
,o~ \ \ so
301 ~ ~5 40
X3800504PLll

(Pre SB 49-6742, 6658, 6699) Disassemble the External Components


(Code A) (Partial Breakdown)
Figure 311
UP200456

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MAINTENANCE MANUAL
GTCP36-280[D]
AIRLINES

4. B. (5) (Pre SB 49-6742, 6658, 6699) Disassemble the external components. (Refer to
Figure 311 .)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(a) Remove bolts (10), washers (20) and oil temperature regulator assembly (oil
cooler) (30).

(b) Remove bolts (40, 45) and oil cooler bracket (50).

NOTE: Do not remove nut plates (55) unless they are damaged.

(c) Remove coupling clamp (60), starter motor (70) and packing (80). Discard
packing. Refer to ATA No. 49-41-08 for disassembly of the starter motor (70).

(d) Remove nut (90), bolts (100, 120), washers (110, 130) and hoist bridge (140)
from gearbox assembly (230) and engine assembly (240).

NOTE: Do not remove bolt (145), ring hoist (146) or insert (147) unless
they are damaged.

(e) Remove bolt (150), washer (160), motional transducer (170) and packing
(180). Discard packing.

(f) Remove bolt (190), tube retainer (200) sump vent fitting (210) and packing
(220) from engine assembly (240). Discard packing.

NOTE: Do not remove caution label (235) unless damaged.

~lm KEY TO FIGURE 311

10. BOLT 130. WASHER


20. WASHER 140. HOIST BRIDGE
30. OIL TEMPERATURE 145. BOLT
REGULATOR ASSY (OIL 146. HOIST RING
COOLER) 147. INSERT
40. BOLT 150. BOLT
45. BOLT 160. WASHER
50. OIL COOLER BRACKET 170. MOTIONALTRANSDUCER
55. NUTPLATE 180. PACKING
60. COUPLING CLAMP 190. BOLT
70. STARTER MOTOR 200. TUBE RETAINER
80. PACKING 210. SUMP VENT FITTING
90. NUT 220. PACKING
100. BOLT 230. GEARBOXASSY
110. WASHER 235. CAUTION LABEL
120. BOLT 240. ENGINEASSY
UP200456

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Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

210 190
22o ~.o

A
m
\

m~

J
10
,.p
J
m ""ILiL"11~l~-s f
210
~..qO",-Q.(f"
Y.380050~L39

(Post SB 49-6742, 6658, 6699) Disassemble the External Components


(Code B) (Partial Breakdown)
Figure 311A
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GTCP36-280[D]

4. B. (6) (Post SB 49-6742, 6658, 6699) Disassemble the external components. (Refer to
Figure 311A.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(a) Remove bolts (10), washers (20) and oil temperature regulator assembly (oil
cooler) (30).

(b) Remove bolts (40, 45) and oil cooler bracket (50).

NOTE: Do not remove nut plates (55) unless they are damaged.

(c) Remove coupling clamp (60), starter motor (70) and packing (80). Discard
packing. Refer to ATA No. 49-41-08 for disassembly of the starter motor.

(d) Remove nut (90), bolts (100, 120), washers (110, 130) and hoist bridge (140)
from gearbox assembly (230) and engine assembly (280).

(e) Remove bolt (150), washer (160), motional transducer (170) and packing
(180). Discard packing.

(f) Remove bolt (190), tube retainer (200) sump vent fitting (210) and packing
(220). Discard packing.

NOTE: Do not remove caution label (240) unless damaged.

(g) Remove bolts (250), pressure sensor (260), bolts (10) and sensor bracket
(270).

~ KEYTO FIGURE311A

10. BOLT 140. HOIST BRIDGE


20. WASHER 150. BOLT
30. OIL TEMPERATURE 160. WASHER
REGULATOR ASSY (OIL 170. MOTIONAL TRANSDUCER
COOLER) 180. PACKING
40. BOLT 190. BOLT
50. OIL COOLER BRACKET 200. TUBE RETAINER
55. NUTPLATE 210. SUMP VENT FITTING
60. COUPLING CLAMP 220. PACKING
70. STARTER MOTOR 230. GEARBOX ASSY
80. PACKING 240. CAUTION LABEL
90. NUT 250. BOLT
100. BOLT 260. PRESSURE SENSOR
110. WASHER 270. SENSOR BRACKET
120. BOLT 280. ENGINEASSY
130. WASHER
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GTCP36-280[D]

7O
. /
110

~'~..~" 140
\
170 w

20\ ~ ~ \ ~o
150
\ 30 4O
160

10

X3800504PL48

Disassemble the External Components (Partial Breakdown)


Figure 312
UP200456

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GTCP36-280[D]

4. B. (7) Disassemble the external components. (Refer to Figure 312.)

(a) Remove coupling clamp (10), fuel control assembly (20) and packing (30).
Discard packing. Refer to ATA No. 49-30-97 for disassembly of the fuel
control assembly (20).

(b) Remove plug (40) and packing (50). Discard packing.

(c) Remove tube nuts (60, 100), lube pump adapters (70, 110) and packings (90,
130). Discard packings.

NOTE: Do not remove inserts (80, 120) unless they are damaged.

(d) Remove bolts (140, 160), washers (150), and lube pump (170) from engine
assembly (230). Refer to ATA No. 49-91-53 for disassembly of the lube
pump.

(e) Remove transfer tubes (180, 200) and packings (190, 210, 220). Discard
packings.

~ KEYTO FIGURE 312

10. COUPLING CLAMP 130. PACKING


20. FUELCONTROLASSY 140. BOLT
30. PACKING 150. WASHER
40. PLUG 160. BOLT
50. PACKING 170. LUBE PUMP
60. TUBE NUT 180. TRANSFER TUBE
70. LUBE PUMP ADAPTER 190. PACKING
80. INSERT 200. TRANSFER TUBE
90. PACKING 210. PACKING
100. TUBE NUT 220. PACKING
110. LUBE PUMP ADAPTER 230. ENGINEASSY
120. INSERT
UP200456

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GTCP36-280[D]

,o,A~0,A

\
B

X~O~O~LI4

Disassemble the External Components (Partial Breakdown)


Figure 313
UP200456

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Hone vell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

4. B. (8) Disassemble the external components. (Refer to Figure 313.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(a) Remove nuts (10), washers (20), gearbox assembly (30) and oil packing (40)
from engine assembly (200). Discard packing.

(b) Remove bolts (50), washers (60), flow divider valve assembly (70), packings
(80, 90) and unions (100, 110). Discard packings. Refer to ATA No. 49-32-07
for disassembly of the flow divider valve assembly.

WARNING: THE OUTPUT VOLTAGE OF THE IGNITION UNIT IS DANGEROUS


AND COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE
AND CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-
ENERGIZED AND GROUNDED BEFORE THE INPUT AND
OUTPUT LEADS ARE DISCONNECTED. DO NOT TOUCH THE
CENTER CONTACT OF OUTPUT TERMINAL.

(c) Removeigniter lead (120), igniter plug (130) and metal gasket (140).

(d) Remove nuts (160, 180), sleeves (170, 190) and ecology drain tank (150).

41~ KEY TO FIGURE 313

10. NUT 110. UNION


20. WASHER 120. IGNITER LEAD
30. GEARBOXASSY 130. IGNITER PLUG
40. OIL PACKING 140. METALGASKET
50. BOLT 150. ECOLOGY DRAIN TANK
60. WASHER 160. NUT
70. FLOW DIVIDER VALVE 170. SLEEVE
80. FUEL PACKING 180. NUT
90. FUEL PACKING 190. SLEEVE
100. UNION 200. ENGINEASSY
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Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

PLENU~'30~~~.R
rURBINE
(EF)
40 ~EF)

\
T / f ",,

1,o \ ~ / ,,,,~ ISA~.\


10 45~
30-. - I ~

1.~ A

~o\ ~ ,o
j14o
150

-~ ~'--170

110 120

X3B00504PL53
(Post SB 49-6634 and 6675) Disassemble the External Components
(Code B) (Partial Breakdown)
Figure 314
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HoneTwell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

4. B. (9) (Post SB 49-6634 and 6675) Disassemble the external components. (Refer to
Figure 314.)

(a) Remove coupling clamps (30), surge duct (20), nut (60), bolt (70), support
strut (55), exhaust surge duct (40), clamps (10), surge control valve (50) and
surge bleed duct (45).

(b) Remove nut (60), bolts (190), bracket (210) and stiffener (200) from turbine
and compressor assembly (160).

(c) Removenut (110), PCD tee (120) and air packing (130). Discard packing.

(d) Remove primary manifold (140) and secondary manifold (150) from fuel
nozzle assy.

(e) Removeplumbing and electrical (170) from engine assembly (220).

~1~ KEY TO FIGURE 314

10. CLAMP 140. PRIMARY FUEL MANIFOLD


20. SURGE DUCT 150. SECONDARY FUEL
30. COUPLING CLAMP MANIFOLD
40. EXHAUST SURGE DUCT 160. TURBINE AND COMPRESSOR
45. SURGE BLEED DUCT ASSY
50. SURGE CONTROL VALVE 170. PLUMBINGAND ELECTRICAL
55. SUPPORT STRUT 180. WASHER
60. NUT 190. BOLT
70. BOLT 200. STIFFENER
110. NUT 210. BRACKET
120. PCD TEE 220. ENGINEASSY
130. PACKING
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Hone)~vell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

,o,,
J@O(REF) 7~OJ[REF) A ~

" A~;}
180

,j?% 110 120

X3800504PL16

(Pre SB 49-6634 and 6775) Disassemble the External Components


(Code A) (Partial Breakdown)
Figure 314A
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COMPONENT USE BY:MANUAL
MAINTENANCE ASERCA AIRLINES
GTCP36-280[D]

4. B. (10) (Pre SB 49-6634 and 6675) Disassemble the external components. (Refer to
Figure 314A.)

(a) Remove clamps (10), surge exhaust duct (20), coupling clamp (30), surge
duct (40), surge control valve (50), nut (60), bolt (70), bleed duct support
brackets (80, 90) and surge valve bracket (100).

(b) Remove primary fuel manifold (140) and secondary fuel manifold (150)from
turbine and compressor assembly (160).

(c) Removenut (110), PCD tee (120) and air packing (130). Discard packing.

(d) Removeplumbing and electrical (170) from engine assembly (180).

~ KEYTO FIGURE 314A

10. CLAMP 100. SURGE VALVE BRACKET


20. SURGE EXHAUST DUCT 110. NUT
30. COUPLINGCLAMP 120. PCD TEE
40. SURGE DUCT 130. PACKING
50. SURGE CONTROL VALVE 140. PRIMARYFUEL MANIFOLD
60. NUT 150. SECONDARYFUEL
70. BOLT MANIFOLD
80. BLEED DUCT SUPPORT 160. TURBINE AND COMPRESSOR
BRACKET ASSY
90. BLEED DUCT SUPPORT 170. PLUMBING AND ELECTRICAL
BRACKET 180. ENGINEASSY
UP200456

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Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

110

IOOB
2O
\

70
5O
\
10
\\ ~o
40 80 100
3O
X3800504PL149

Disassemble the External Components (Partial Breakdown)


Figure 315
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GTCP36-280[D]

4. B. (11) Disassemble the external components. (Refer Figure 315.)

(a) Remove packings (10, 20) from turbine and compressor assembly (110).
Discard packings.

(b) Remove retaining ring (30) and spacer (40).

(c) Remove packing (50). Discard packing.

(d) Remove quill shaft (60) and packing (70). Discard packing.

(e) Remove bolts (80), washers (90) and IGV actuator (100 or 100B) from turbine
compressor assembly (110). Refer to ATA No. 49-50-02 for disassembly of
IGV actuator assembly.

~1~ KEY TO FIGURE 315

10. PACKING 80. BOLT


2O. PACKING 90. WASHER
30. RETAINING RING 100. IGV ACTUATOR
4O. SPACER 100B. IGV ACTUATOR
50. PACKING 110. TURBINEAND COMPRESSOR
60. QUILL SHAFT ASSY
70. PACKING
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Hone)~vell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

IOA

Q C>

20
\
50
130

330

( ~ \ 310"/ ~. /-/

240
28o/-~ ~ -/~ ~
N .. -/ '- I-ol
" =

=~,.. 210
~~ "--- 200
~1~60150 ~~~. ~.~ ~
1 180/
1 t
/ ~ ,-,' 170 100
190
X3800504PL18

Disassemble the Gearbox Assembly (Part No. 3863019)


(Code A) (Partial Breakdown)
Figure 316
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Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

4. C, Disassemble the gearbox assembly.


(1) (Part No. 3863019) Disassemble the gearbox assembly components. (Refer to
Figure 316.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.
(a) Remove oil fill cap (10 or 10A), ring (15), bolts (20), washers (30), sight glass
(40) and packing (50). Discard packing.

(b) Remove bolt (60), washer (70), scupper oil fill housing (90) and packing (80).
Discard packing.

(c) Remove retaining ring (230), oil tube assembly (240), with 2024084-1 tube
puller, packing (260) and filter screen (250). Discard packing.
(d) Remove plug (300) and magnetic plug (280). Remove packings (290, 310)
and discard.
(e) Remove bolts (190), washers (200), sump cover (210) and packing (220).
Discard packing.
(f) Remove bolts (140), washers (150), temperature sensor adapter (160) and
packing (165). Discard packing.
(g) Remove metal plug (170) and packing (180). Discard packing.

~ KEYTO FIGURE 316

10. OIL FILL CAP 165. PACKING


10A. OIL FILL CAP 170. METAL PLUG
15. RING 180. PACKING
20. BOLT 190. BOLT
30. WASHER 200. WASHER
40. SIGHT GLASS 210. SUMP COVER
50. PACKING 220. PACKING
60. BOLT 230. RETAINING RING
70. WASHER 240. OIL TUBE ASSY
80. PACKING 250. FILTER SCREEN
90. SCUPPER OIL FILL HOUSING 260. PACKING
100. SCREW -270. MAGNETIC DRAIN PLUG
110. OILCOVER PLATE 280. MAGNETIC PLUG
120. PACKING 290. PACKING
130. PACKING 300. PLUG
140. BOLT 310. PACKING
150. WASHER 320. IDENTIFICATION PLATE
160. TEMPERATURE SENSOR ADAPTER 330. GEARBOX ASSY

- ITEM NOT ILLUSTRATED


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GTCP36-280[D]

4. C. (1) (h) Remove screws (100), oil cover plate (110) and packings (120, 130). Discard
packings.

NOTE: Do not remove identification plate (320) from gearbox assembly


(330) unless the gearbox assy is damaged. The nameplate must
stay with the gearbox.
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THIS PAGE INTENTIONALLYLEFT BLANK


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Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

10

SO
40 8O<

160
270 -" ~ ,
2~o\~~ ~so280
150.."
J > /
I -/.-" L O

I<I"/ "-~ Jl,

222 o - .
2 3 0 " - - , - ~ 20~) 190 180 1~ X3800504PL19

Disassemble the Gearbox Assembly (Part No. 3863136)


(Code B) (Partial Breakdown)
Figure 316A
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GTCP36-280[D]

4. C. Disassemble the gearbox assembly.

(2) (Part No. 3863136) Disassemble the gearbox assembly components. (Refer to
Figure 316A.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT, IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(a) Remove oil fill cap (10), bolts (20), washers (30), oil sight indicator (40) and
packing (50). Discard packing.

(b) Remove bolts (60), washers (70), oil fill housing scupper (90) and packing
(80). Discard packing.

(c) Remove retaining ring (260), and filter screen (270) from gearbox (300).

(d) Remove magnetic drain plug (280) and packing (290). Discard packing.

(e) Remove retaining ring (230), sump cover (240) and packing (250). Discard
packing.

(f) Remove bolts (170), washers (180), temperature sensor adapter (190) and
packing (200). Discard packing.

(g) Remove metal plug (210) and packing (220). Discard packing.

(h) Remove screws (130), oil cover plate (140) and packings (150, 160). Discard
packings.

41~ KEY TO FIGURE 316A

10. OIL FILL CAP 160. PACKING


20. BOLT 170. BOLT
30. WASHER 180 WASHER
40. OIL SIGHT INDICATOR 190. TEMP SENSOR ADAPTER
50. PACKING 200. PACKING
60. BOLT 210. METAL PLUG
70. WASHER 220. PACKING
80. PACKING 230. RETAINING RING
90. OIL FILL HOUSING SCUPPER 240. SUMP COVER
-100. HOUSING 250. PACKING
-110. SCREEN 260. RETAINING RING
-120. SCUPPER 270. FILTER SCREEN
130. SCREW 280. MAGNETIC DRAIN PLUG
140. OIL COVER PLATE 290. PACKING
150. PACKING 300. GEARBOX ASSY

- ITEM NOT ILLUSTRATED


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GTCP36-280[D]

IOOE
100C , ~ ~ ) ~.. 1000

150~ . ~
140
200

210 \ ..

120~

~ 0 140, \
\
\
\
'

80--_ 200
s

I
\ 70
I

65
l
10
0
._ ~~ 40A
50
IJ " \85
!"----3o
X3800504DY218

Disassemble the Gearbox Assembly Components (Part No. 3863019)


(Code A) (Partial Breakdown)
Figure 317
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GTCP36-280[D]

4. C. (3) (Part No. 3863019) Disassemble the gearbox assembly components. (Refer to
Figure 317.)
(a) Removeslave nuts (10), washers (20), generator pad cover (30), bolts (40A),
washers (50), flanged seal assembly (60), shim (65) and packing (70).
Discard packing.
CAUTION: GENERATORGEARSHAFT ASSEMBLY MAY FALL OUT AFTER
ADAPTER (80) IS REMOVED. DO NOT LET GEARSHAFT
ASSEMBLY FALL OUT.
(b) Removehi-torque screws (85). Use 2024293-1 puller with 2024254-1 adapter
to remove generator adapter (80). Remove and discard packing (90).
(c) Removegearshaft (150) from gearbox assembly (200).
NOTE: Do not remove plug (160) and insert (140) from gearshaft (150)
unless damaged.
(d) (Pre SB 49-6940) Remove seal rotor (100) from gearshaft (150).
(e) (Pre SB 49-6940) Remove tetra seal (110) from rotor seal (100).
(f) (Post SB 49-6940/7660) Straighten the bent tab of the locking tab (220) and
use spanner wrench (2024465-1) to remove retaining nut (210) from gearshaft
(150).
(g) (Post SB 49-6940) Remove the locking tab (220), rotor seal (100A) and
spacer (135A) from the gearshaft (150).
(h) (Post SB 49-7760) Remove locking tab (220), rotor seal (100C) and drive ring
(100D) from gearshaft (150).
(i) (Post SB 49-7760) Remove packing (100E) from drive ring (100D). Discard
packing.
(j) Use a 833985-2 bearing puller plate set and a 833978-1 bearing removal
adapter to remove generator roller bearings (120) from gearshaft (150).

~ KEYTOFIGURE317

10. SLAVE NUT 100D. ROTOR (POST SB 49-7660)


20. WASHER 100E. PACKING (POST SB 49-7660)
30. GENERATOR PAD COVER 110. TETRA SEAL
40A. BOLT 120. GENERATOR ROLLER BEARING
50. WASHER 135A. SPACER
60. FLANGEDSEALASSY (POST SB 49-6940)
65. SHIM 140. INSERT
70. PACKING 150. GEARSHAFT
80. GENERATORADAPTER 160. PLUG
85. SCREW 200. GEARBOXASSY
90. PACKING 210. RETAINING NUT
100. SEAL ROTOR (POST SB 49-6940)
100A. SEAL ROTOR 220. LOCKINGTAB
(POST SB 49-6940) (POST SB 49-6940)
100C. DRIVE RING (POST SB 49-7660)
-ITEM NOT ILLUSTRATED
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GTCP36-280[D]
AIRLINES

IOOD
IOOE '~
1 0 0 C ~ ~

150
140
120
1~00B105 ~'~ 180
190 \
200
/
160

j 150--.~i
140
\
120
110 \. "~.

X3800504DY219

(POST SB 49-7660) Disassemble the Gearbox Assembly Components (Part No. 3863136)
(Code B) (Partial Breakdown)
Figure 317A
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GTCP36-280[D]

4. C. (4) (Part No. 3863136) Disassemble the gearbox assembly components. (Refer to
Figure 317A.)
(a) Removeretaining ring (10), shim (20), seal assy (30) and packing (40).
Discard packing.
CAUTION: GENERATORGEARSHAFT ASSEMBLY MAY FALL OUT AFTER
ADAPTER (50) IS REMOVED. DO NOT LET GEARSHAFT
ASSEMBLY FALL OUT.
(b) Removehi-torque screws (75). Use 2024293-1 puller with 2024254-1 adapter
to remove generator adapter (50). Remove packing (70), retaining ring (80)
and shim (90). Discard packing.
(c) Removegearshaft (150) from gearbox assembly (180).
NOTE: Do not remove plug (160) and insert (140) from gearshaft (150)
unless damaged.
(d) (Pre SB 49-6940) Remove rotor seal (100A) from gearshaft (150).
(e) (Pre SB 49-6940) Remove tetra seal (110) from rotor seal (100A).
(f) (Post SB 49-6940/7660) Straighten the bent tab of the locking tab (200) and
use spanner wrench (2024465-1) to remove retaining nut (190) from the
gearshaft (150).
(g) (Post SB 49-6940) Remove the locking tab (200), rotor seal (100B) and
spacer (105) from the gearshaft (150).
(h) (Post SB 49-7660) Remove locking tab (220), rotor seal (100C) and drive ring
(100D) from gearshaft (150).
(i) (Post SB 49-7660) Remove packing from drive ring (100D). Discard packing.
(j) Use a 833980-9 bearing puller plate set and a 833135-203 bearing removal
adapter to remove generator roller bearing (120) and generator ball bearing
(170) from gearshaft (150).

~ KEYTOFIGURE317A

10. RETAINING RING 100C. ROTOR SEAL


20. SHIM (POST SB 49-7660)
30. SEAL ASSY 100D. DRIVE RING (POST SB 49-7660)
4O. PACKING 100E. PACKING (POST SB 46-7660)
50. GENERATORADAPTER 105. SPACER
-60. PIN (POST SB 49-6940)
70. PACKING 110. TETRA SEAL
75. SCREW 120. GENERATOR ROLLER BEARING
80. RETAINING RING 140. INSERT
90. SHIM 150. GEARSHAFT
100A. ROTOR SEAL 160. PLUG
100B. ROTOR SEAL 170. GENERATOR BALL BEARING
(POST SB 49-6940) 180. GEARBOX ASSY
105. SPACER 190. RETAINING NUT (POST SB 49-6940)
(POST SB 49-6940) 200. LOCKING TAB (POST SB 49-6940)
-ITEM NOT ILLUSTRATED
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GTCP36-280[D]

20 60
1~ ' ~ q 40 50 ~_.:~.---._ j \

.( &,
\\

- -...,.~ ~.~ -~ !0
0
o
J Iso.. --.,.: ' ~ 3
240
, 80 , ~ " ....~ 210 230
110 % ~".~)-~" 200

~~'% ",j i 120

232 /

dl~ : 4 0 ~ 5 0 360

X3800504PL229

Disassemble the Gearbox Assembly Components (Part No. 3863019)


(Code A) (Partial Breakdown)
Figure 318
UP200456

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GTCP36-280[D]

4. c. (5) (Part No. 3863019) Disassemble the gearbox assembly components. (Refer to
Figure 318.)

(a) Remove bolts (10, 15), washers (20), starter cover assembly (30) with
2024291-1 puller and packing (40). Discard packing.

(b) Remove starter gearshaft assembly (70) and spring washer (120).

(c) Use a 833980-9 bearing puller plate set and 833130-1 bearing removal
adapter set and remove starter ball bearings (60) from starter gearshaft
assembly (70).

(d) Remove retaining ring (50), spring washer (130) and shims (140, 150) from
starter gearshaft assembly (70).

(e) Remove splined shaft assembly (90) from starter gearshaft assembly (70)
using 834397-1 puller.

(f) Using a medium duty proto puller with a 834826-1 bearing removal plate and a
833999-1 and 833135-203 bearing removal adapter set, remove starter ball
bearings (80) from splined shaft assembly (90).

~1~ KEY TO FIGURE 318

10. BOLT 190. BOLT


15. BOLT 200. WASHER
20. WASHER 210. COMPOUND IDLER ADAPTER
30. STARTER COVER ASSY -210.A. COMPOUND IDLER ADAPTER
40. PACKING (POST SB 49-7596)
50. RETAINING RING 220. INSERT
60. STARTER BALL BEARING 230. LIP SEAL
70. STARTER GEARSHAFT 230A. CARBON SEAL (POST SB 49-7596)
80. STARTER BALL BEARING 232. PACKING (POST SB 49-7596)
90. SPLINED SHAFT ASSY 234. SHIM (POST SB 49-7596)
-100. PLUG 236. SHIM (POST SB 49-7596)
110. CLUTCH 238. SHIM (POST SB 49-7596)
120. SPRING WASHER 240. PACKING
130. SPRING WASHER 330. BOLT
140. SHIM 340. WASHER
150. SHIM 350. COVER ASSY
160. RETAINING RING 360. PACKING
170. LUBE CLUTCH RESTRICTOR 370. RETAINING RING
180. LIP SEAL 410. GEARBOX ASSY

-ITEM NOT ILLUSTRATED


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GTCP36-280[D]

4. C. (5) (g) Use 834397-1 starter clutch puller to remove clutch (110). Remove retaining
ring (160) and use 2024285-1 lip seal puller to remove lip seal (180).

(h) (Pre SB 49-7596) Remove bolts (190), washers (200) and compound idler
adapter (210) with lip seal (230) using a 2024297-1 seal removal fixture.
Remove packing (240) and discard.

(Post SB 49-7596) Remove bolts (190), washers (200), compound idler


adapter (210A), packing (232), shims (234, 236, 238), packing (240) and
carbon seal (230A) using a 2024018-1 carbon seal removal fixture. Discard
packings.

NOTE: Do not remove insert (220) unless damaged.

(i) Remove bolts (330), washers (340), cover assembly (350) with packing (360)
and retaining ring (370)from gearbox assembly (410). Discard packing.
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GTCP36-280[D]

THIS PAGE INTENTIONALLY LEFT BLANK


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GTCP36-280[D]

4O
\ \
\
\

\
\
..~~'*'~'~"t
~,_~ '70 90 100 380

~, ~ \ ~ , <.

I.... / ~.J I s

. ~, .. ~1.j
~._~ /// 170 ~,-~'~,~,"~ I '~ "~J - i \ ~ , , . .11

~ ~r~ 270 " "

230 300 320

X~00~L~

Disassemble the Gearbox Assembly Components (Part No. 3863136)


(Code B) (Partial Breakdown)
Figure 318A
UP200456

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GTCP36-280[D]

4. C. (6) (Part No. 3863136) Disassemble the gearbox assembly components. (Refer to
Figure 318A.)

(a) Remove bolts (10), washers (20), and starter adapter (30) using a 2024291-1
puller and packing (40). Discard packing.

(b) Remove starter gearshaft assembly (80), spacer (170) and spring washer
(180).
(c) Use a 833123-105 bearing puller plate set and 833130-200 bearing removal
adapter set to remove starter ball bearings (70) from starter gearshaft (80).

(d) Remove retaining ring (60), shims (130, 140, 150) and spring washer (160)
from starter gearshaft assembly (80).

(e) Remove splined shaft assembly (100) from starter gearshaft assembly (80)
using a 834397-1 puller.

(f) Using a medium duty proto puller with a 834826-1 bearing removal plate and a
834622-9 and 833999-1 bearing removal adapter set, remove starter ball
bearings (90) from splined shaft assembly (100).

(g) Remove clutch (120) with 834397-1 starter clutch puller.

NOTE: Do not remove lube clutch restrictor (190) unless damaged.

~ KEYTO FIGURE 318A

10. BOLT 210. WASHER


20. WASHER 220. COMPOUND IDLER ADAPTER
30. STARTER ADAPTER 230. INSERT
40. PACKING 240. PACKING
60. RETAINING RING 250. SHIM
70. STARTER BALL BEARING 260. SHIM
80. STARTER GEARSHAFT 270. SHIM
90. STARTER BALL BEARING 280. SEAL
100. SPLINED SHAFTASSY 290. PACKING
120. CLUTCH 300. BOLT
130. SHIM 310. WASHER
140. SHIM 320. LUBE PUMP COVERASSY
150. SHIM 330. PACKING
160. SPRING WASHER 340. RETAINING RING
170. SPACER 350. SHIM
180. SPRING WASHER 360. SHIM
190. LUBE CLUTCH RESTRICTOR 370. SHIM
200. BOLT 380. GEARBOX ASSY
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GTCP36-280[D]

4. C. (6) (h) Remove bolts (200), washers (210), compound idler adapter (220), packing
(290), shims (350, 360, 370) seal (280), shims (250, 260, 270) and packing
(240). Discard packing.

NOTE: Do not remove insert (230) unless damaged.

(i) Use 2024018-1 seal removal fixture to remove seal (280) from adapter (220).

(J) Remove bolts (300), washers (310), cover assembly (320) with packing (330)
and retaining ring (340) from gearbox assembly (380). Discard packing.
UP200456

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GTCP36-280[D]

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Hone~vell COMPONENT MAINTENANCE MANUAL
GTCP36-280[D]

270 , , ~ /,
260....1./~+,,~ . I .
430 25O
/
~----~------~/" ~ " . 0 420

450

I .P+"

.f

180
170 '
160
150 ~

/
230 1
/-+'+"

""L:~00 ~" % ~ 310 ~ "


,+,\=,oo Z j
' 280 #%/'/
3:,0 ".~\~',~.,,--a~...-'" 1oo \ .
190 "~ 70 /+ ~. ,',# " ""~

.~- /4 ,(~-',~k~% L~ . / ~ r 110

30 X3800504PL153

Disassemble the Gearbox Assembly Components (Part No. 3863019)


(Code A) (Partial Breakdown)
Figure 319
UP200456

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GTCP36-280[D]

4. C. (7) (Part No. 3863019) Disassemble the gearbox assembly components. (Refer to
Figure 319.)

(a) Remove bolt (230), washer (235), plug (240) and packing (245). Discard
packing.

(b) Remove plug (260) and packing (270). Discard packing.

(c) Remove bolt (10), washer (20), screws (30) and bearing retainer (40).

(d) Remove bolts (50), washers (60) and bearing carrier (100).

NOTE: Do not remove inserts (105) unless damaged.

(e) Remove transfer tube assembly (110) with assembled items (130) and
packing (140). Discard packing.

~lm KEYTO FIGURE 319

10. BOLT 235. WASHER


20. WASHER 240. PLUG
30. SCREW 245. PACKING
40. BEARING RETAINER 250. GEARBOX HOUSINGASSY
50. BOLT 260. PLUG
60. WASHER 270. PACKING
70. SCREW 280. BOLT
80. HIGH SPEED PINION JET 290. WASHER
90. PACKING 300. TRANSDUCER PORT COVER
100. BEARING CARRIER 310. PACKING
105. INSERT 320. RING
110. TRANSFER TUBE ASSY 330. HS PINION ROLLER BEARING
130. SUPPORT 340. HS PINION GEAR
140. PACKING 350. ROLLER BEARING
150. BOLT 360. AIR/OIL SEPARATOR
160. PACKING 380. PIN
170. GENERATOR IDLER SHAFT 390. COLLAR
180. PACKING 400. COMPOUND IDLER GEAR
190. GENERATOR IDLER GEAR ASSY 410. GEARSHAFT ASSY
200. GENERATOR IDLER SPACER 420. PLUG
210A. WASHER 430. LUBE GEARASSY
220A. NUT 440. EXPANSION PLUG
230. BOLT 450. BALL BEARING
UP200456

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COMPONENT MAINTENANCE MANUAL
GTCP36-280[D]

4. c. (7) (f) Remove high speed pinion gear (340) from gearbox housing assembly (250).

(g) Remove screws (70), high speed pinion jet (80) and packing (90). Discard
packing.

(h) Remove retaining ring (320).

(i) Use a 833980-9 bearing puller plate set and a 833978-2 bearing removal
adapter set to remove pinion roller bearings (330) from pinion gear (340).

(J) Remove bolt (280), washer (290), transducer port cover (300) and packing
(310). Discard packing.

(k) Remove bolt (150), packing (160) and generator idler shaft (170) using a
2024080-1 puller, with packing (180). Discard packings.
(i) Use 833986-1 removal / installation fixture and 833987-1 support fixture to
remove the generator idler gear assembly (190), generator idler spacer (200),
nut (220A) and washer (210A) from gearbox housing (250).

(m) Remove roller bearing (350) using 833984-1 bearing removal adapter and
833985-2 bearing removal plate, air-oil separator (360), idler gear (400) and
gearshaft assembly (410).

NOTE: Do not remove pins (380), collar (390) or plug (420) unless
damaged.

(n) Use a 2024014-1 bearing removal plate and 833984-1 bearing removal
adapter to remove the air-oil separator (360) from idler gearshaft assembly
(410).

(o) Remove retaining rings (IPC Fig. 40, Item 10)from generator idler gear
assembly (190). Use 833986-1 bearing removal fixture and 833987-1 bearing
support fixture to remove the bearings (IPC Fig. 40, Item 20) from idler gear
(IPC Fig. 40, Item 50). Remove spacers (IPC Fig. 40, Item 30, 40).

(P) Remove lube gear assembly (430) from gearbox housing assembly (250).
Using a 833123-102 bearing puller plate and 833974-1 bearing puller adapter,
remove ball bearings (450) from lube gear (430).

NOTE: Do not remove expansion plug (440) unless necessary.


UP200456

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GTCP36-280[D]

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Hone) well COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

160

380

34O 33O
_ 250
I / J
L
320
310

33O
I I /

210

50

\
~I~ " ~

-'~IF i.. , .++~. I I ~--",~ ~,~ ,~ !Olo0

~3@, ~" 17o . .

t 70 .- " ~'~""L
60 "

"+~ 3 "--190 ',~~.~~]~. 140~+'130


k3 12 X3800504PL124

Disassemble the Gearbox Assembly Components (Part No. 3863136)


(Code B) (Partial Breakdown)
Figure 319A (Sheet 1 of 2)
UP200456

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GTCP36-280[D]

4. c. (8) (Part No. 3863136) Disassemble the gearbox assembly components. (Refer to
Figure 319A.)
(a) Remove bolt (170), washer (20), transducer port cover (360) and packing
(370). Discard packing.

(b) Remove bolt (60) and washer (70), plug (80) and packing (90) from gearbox
assembly (380). Discard packing.

(c) Remove transfer tube (100) and packing (110). Discard packing.

(d) Remove bolts (10), washers (20) bearing carrier (30), retaining ring (120),
transfer tube assembly (40) and packing (50). Discard packing.

(e) Remove pinion gear (140) from gearbox assembly (380).

(f) Remove retaining ring (150) from other end of high speed pinion gear
assembly (140).
(g) Use a 833980-9 bearing puller plate set and a 833978-2 bearing removal
adapter set to remove high speed pinion roller bearings (130) from high speed
pinion gear (140).
(h) Remove bolt (230), packing (220) and generator idler shaft (210) using a
2024080-1 puller, with packing (200). Discard packings.

~KEY TO FIGURE 319A (SHEET 1)

10. BOLT 180. GENERATOR IDLER SPACER


20. WASHER 190. GENERATOR IDLER GEARASSY
30. BEARING CARRIER 200. PACKING
40. TRANSFER TUBEASSY 210. GENERATOR IDLER SHAFT
50. PACKING 220. PACKING
60. BOLT 230. BOLT
70. WASHER 240. COMPOUND IDLER BEARING
80. PLUG 250. AIR-OILSEPARATOR
90. PACKING 270. PIN
100. TRANSFER TUBE 280. COLLAR
110. PACKING 290. LGE COMPOUND IDLER GEAR
120. RETAINING RING 300. COMPOUND IDLER GEARSHAFT
130. HS PINION ROLLER BEARING 310. PLUG
140. HS PINION GEAR 320. COMPOUND IDLER BEARING
150. RETAINING RING 330. LUBE PUMP BALL BEARING
160. NUT 340. EXPANSION PLUG
370. PACKING 350. LUBEGEARASSY
170. BOLT 360. TRANSDUCER PORT COVER
380. GEARBOX ASSY
UP200456

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Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

, ..<

140
\15o
130 ~ . ~ ~ "
160 ~ ,i ~

130 140
160 A
X3800504PL221

Disassemble the Gearbox Assembly Components (Part No. 3863136)


(Code B) (Partial Breakdown)
Figure 319A (Sheet 2)
UP200456

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GTCP36-280[D]

4. C. (8) (i) Use 2024019-1 removal/installation fixture to remove the generator idler gear
assembly (190), generator idler spacer (180), nut (160) and washer (20) from
gearbox housing assembly (380).

(J) Remove compound idler bearings (240, 320) using 833984-1 bearing removal
adapter and 2024020-1 bearing removal plate, air-oil separator (250), large
compound idler gear (290) and compound idler gearshaft assembly (300).

NOTE: Do not remove pin (270), collar (280) or plug (310) unless
damaged.

(k) Use a 2024014-1 bearing removal plate and 833984-1 bearing removal
adapter to remove the air-oil separator (250) from compound idler gearshaft
(300).
(1) Remove retaining ring (IPC Fig. 40, Item 10)from generator idler gear
assembly (190). Use 2024019-1 bearing removal fixture to remove the
bearing (IPC Fig. 40, Item 20) from idler gear (IPC Fig. 40, Item 30).

(m) Remove lube gear assembly (350) from gearbox assembly (380).

(n) Using a 833123-102 bearing puller plate and 833974-1 bearing puller adapter,
remove lube pump ball bearings (330) from lube gear assembly (350).

NOTE: Do not remove expansion plug (340) unless necessary.

(o) (Post SB 49-7598) Remove retainer (160), oil jet (130), and packings (140,
150). Discard packings.

~lm KEYTO FIGURE 319A (SHEET2)

130. OIL JET (IPC FIG. 33A) 150. GENERATOR IDLER SPACER
(POST SB 49-7598) (POST SB 49-7598)
140. PACKING 160. RETAINER
(POST SB 49-7598) (POST SB 49-7598)
UP200456

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GTCP36-280[D]

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Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

20D
\

20B 3O
/

\
\ 20C

20F

\
20E
X3800504PL26

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 320
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GTCP36-280[D]

4. D. Disassemble the turbine and compressor assembly.

(1) Disassemble the turbine and compressor assembly components. (Refer to


Figure 320.)

(a) Remove turbine plenum blankets (20B through 20F) from turbine and
compressor assembly (30).

~1~ KEY TO FIGURE 320

20B. SIDE BLANKET 20E. SIDE BLANKET


20C. FLANGE BLANKET 20F. UPPER BLANKET
20D. FLANGE BLANKET 30. TURBINE AND COMPRESSOR ASSY
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GTCP36-280[D]

ic:i

40

,-4--t 20

4-t30

l~ /12o

1
J 60

\
10
110 X3800504PL27

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 321
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GTCP36-280[D]

4. D. (2) Disassemble the turbine and compressor assembly components. (Refer to


Figure 321 .)

(a) Remove inlet duct assembly (10), quick coupler strap assembly (20), T-bolt
strap assembly (30) and seal (40) from turbine and compressor assembly
(150).

.NOTE: Do not remove rivets (50, 130) and nutplates (60, 140) unless
damaged.

(b) Remove bolts (80), washers (90), data memory module (100) and packing
(105). Discard packing.

.NOTE: Do not remove nut (70) unless damaged.

(c) Remove screws (110) and compressor inlet screen (120).

41~ KEY TO FIGURE 321

10. INLET DUCTASSY 90. WASHER


15. INLET DUCT BAFFLE 100. DATAMEMORY MODULE
20. QUICK COUPLER STRAP 105. PACKING
ASSY 110. SCREW
30. T-BOLTSTRAPASSY 120. COMPRESSOR INLET
40. SEAL SCREEN
50. RIVET 130. RIVET
60. NUTPLATE 140. NUTPLATE
70. NUT 150. TURBINEAND COMPRESSOR
80. BOLT ASSY
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GTCP36-280[D]

; ." if(""
/t ""
. ./:~..,,:" / / ..,/..-/

"%' : ,t# /

,o--e 7 .

,,,,,,
t,..v'-..... /,"1

,/ //".i.~
B i U"
;'J

A
A
20

;!

'\ ,.

30

" 110
~; (REF)
J . /
B u:~'! t.( ~
k._22- - - ~ r . ,
_ /(REF, lOO

' I
, !
! I/
/ 90
41) (REF)

e~.Z)
,, SO

X3800504PL156

(Post SB 49-7473, Pre SB 49-7587) Disassemble the Turbine and Compressor Assembly Components
Figure 321A
UP200456

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GTCP36-280[D]

4. D. (3) (Post SB 49-7473, Pro SB 49-7587 ) Disassemble the turbine and compressor
assembly components. (Refer to Figure 321A.)

(a) Remove bolts (70, 80, 90, 100, 110).

(b) Remove bracket (60), flange (50), and shield segments (20, 30, 40).

~ KEYTO FIGURE 321A

20. TOP CONTAINMENT SHIELD 60. CONTAINMENT SHIELD BRACKET


SEGMENT (IPC, 49-26-45, FIGURE 26A) 70. BOLT
30. SIDE CONTAINMENT SHIELD 80. BOLT
SEGMENT 90. BOLT
40. BOTTOM CONTAINMENT SHIELD 100. BOLT
SEGMENT 110. BOLT
50. CONTAINMENT SHIELD FLANGE
UP200456

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GTCP36-280[D]

170
5O
100 90 8~) \

-- II
70 60

4O 30 20 10

160 t
150 140 130 1:1
110
X3800504PL28

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 322
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GTCP36-280[D]

4. D. (4) Disassemble the turbine and compressor assembly components. (Refer to


Figure 322.)

(a) Remove bolt (10), temperature sensor (20), and packings (30, 40) from
turbine and compressor assembly (170). Discard packings.

(b) Remove lock pin (50), locking plate (60), bolt (70), fuel nozzle assembly (80),
gasket (90), and fuel nozzle shroud (100). Discard packings.

(c) Remove clevis (110), screw (120), nut (130), tube assembly (140), and
packings (150, 160). Discard packings.

4~lm KEY TO FIGURE 322

10. BOLT 100. FUEL NOZZLE SHROUD


20. TEMPERATURE SENSOR 110. CLEVIS
30. PACKING 120. SCREW
40. PACKING 130. NUT
50. LOCK PIN 140. TUBEASSY
60. LOCKING PLATE 150. PACKING
70. BOLT 160. PACKING
80. FUEL NOZZLE ASSY 170. TURBINEAND COMPRESSOR ASSY
90. GASKET
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GTCP36-280[D]

30A
42
30
75
60 120

50

110

100

111 70

~, J " 80

=-,-~,',~ f
10 -""~ 90
X3800504PL190

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 323
UP200456

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Hone vell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

4. D. (5) Disassemble the turbine and compressor assembly components. (Refer to


Figure 323.)

(a) Remove upper bolts (10), washers (20), vent fitting (30 or 30A) and packings
(40 or 41 and 42). Discard packings.

(b) (Pre SB 49-6840) Remove metal gaskets (50) and oil scavenge tube shield
(60). Use 833184-1 tube removal fixture and remove oil scavenge tube (70).

(Post SB 49-6840) Remove metal gaskets (50) and oil scavenge tube shield
(60). Use 833184-1 tube removal fixture and remove oil scavenge tube (75).
Discard packings.

(c) Remove lower bolts (10), washers (20), lube adapter assembly (80) and
packing (40). Discard packing.

(d) Remove metal gaskets (50) and oil scavenge tube shield (60).

(e) Remove oil pressure tube (100) and packings (110). Discard packings.

(f) Use 833184-1 tube removal fixture and remove oil scavenge tube (70).

NOTE: Do not remove inserts (90) unless damaged.

~1~ KEY TO FIGURE 323

10. BOLT 70. OIL SCAVENGE TUBE


20. WASHER 75. OIL COOLED SCAVENGE VENT
30. VENT FITTING TUBE ASSY (POST SB 49-6840)
30A. VENT FITTING (POST SB 49-6840) 80. LUBE ADAPTER ASSY
40. PACKING 90. INSERT
41. PACKING (POST SB 49-6840) 100. OIL PRESSURE TUBE
42. PACKING (POST SB 49-6840) 110. PACKING
50. METAL GASKET 120. TURBINE AND COMPRESSOR ASSY
60. OIL SCAVENGE TUBE SHIELD
UP200456

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Hone~vell GTCP36-280[D]

110

10
/ ' 10/20/80 /
/

2o . .~ \ /

\
\ 120
t30

"~
140

X3800504PL30

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 324
UP200456

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MAINTENANCE MANUAL
GTCP36-280[D]
AIRLINES

4. D. (6) Disassemble the turbine and compressor assembly components. (Refer to


Figure 324.)

(a) Remove nuts (10), washers (20), bolts (30, 40) and hoist mount (50).

(b) Remove bolts (60, 70), engine mount spacer (80), left aft engine mount (90),
and right aft engine mount (100).

(c) Remove turbine plenum assembly (110), combustion chamber (120) and
turbine seal (130) from turbine and compressor assembly (140).

~lill KEY TO FIGURE 324

10. NUT 90. LEFTAFT ENGINE MOUNT


20. WASHER 100. RIGHTAFT ENGINE MOUNT
30. BOLT 110. TURBINE PLENUMASSY
40. BOLT 120. COMBUSTION CHAMBER
50. HOIST MOUNT 130. TURBINE SEAL
60. BOLT 140. TURBINEAND COMPRESSOR
7O. BOLT ASSY
80. ENGINE MOUNT SPACER
UP200456

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GTCP36-280[D]

37\ ,

"" 25%

240

J >
~J
f"

i j

330 340
'35o ~32O
290
~'~. 1 0 % t l ", 270
\ zso
, 180
170
160
\ 38o
39O
f "~..
v \
3O0

150
130, 110
J
.~
120~,~
140"~_ , 10
X3800504PL31

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 325
UP200456

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-Honeywell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

4. D. (7) Disassemble the turbine and compressor assembly components. (Refer to


Figure 325.)

(a) Unstake nut (10).

CAUTION: DO NOT APPLY MORE THAN 3900 PSIG (26910,0 KPA) RAM
PRESSURE.

(b) Use 833094-1 shaft stretching fixture and apply 2790 psig (19251,0 kPa) to
permit the round nut to be loosened.

NOTE: If unable to loosen nut (10), pressure can be increased in 50 psig


(345,0 kPa) increments, but not more than 3900 psig (26910,0
kPa) total pressure.

(c) Remove shaft (20), bolts (30) and compressor bearing carrier assembly (40).

(d) Remove nuts (50), washers (60), bearing carrier assembly (70) with
assembled items (80, 90, 100, 110).

~11 KEY TO FIGURE 325

10. NUT 210. CARBON RING


20. SHAFT 220. SEAL
30. BOLT 230. WASHER
40. CPRSR BEARING CARRIER 240. WAVE SPRING WASHER
ASSY 250. HOUSING
50. NUT 270. CPRSR DRIVEN COUPLING
60. WASHER SEAL ASSY
70. BEARING CARRIERASSY 280. SPRING PIN
80. PIN 290. LABYRINTH SEAL
90. PASSAGE PLUG 300. CPRSR DRIVEN INSULATOR
100. PIN 310. SEAL HOUSING ASSY
110. PIN 320. INSERT
120. VENT TUBE 330. PACKING
130. PACKING 340. PACKING
140. PACKING 350. PACKING
150. AIR PACKING 370. CURVIC RING SEAL
160. SPACER 380. CPRSR SEALROTOR
170. CPRSR BEARING SPRING 390. ROLLER CYLINDER BEARING
180. SPACER 400. TURBINE AND COMPRESSOR
200. RETAINER ASSY
UP200456

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GTCP36-280[D]

4. D. (7) (e) Remove vent tube (120), packings (130, 140, 150), spacer (160), compressor
bearing spring (170) and spacer (180). Discard packings.

(f) Remove retainer (200), carbon ring (210), seal (220), washers (230), wave
spring washers (;~0)~and housing (250).

(g) Remove compressor driven coupling seal assembly (270) with assembled
items (280, 290) and compressor driven insulator (300).

(h) Remove seal housing assembly (310), packings (330, 340, 350), and curvic
seal ring (370). Discard packings.

NOTE: Do not remove inserts (320) unless damaged.

(i) Remove compressor seal rotor (380) and roller cylinder bearing (390) from
turbine and compressor assembly (400).
UP200456

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Hone3~well COMPONENT MAINTENANCE MANUAL
GTCP36-280[D]

110 /
140 170 12o7
f

130 I'

J
/
f

/ /
f

~.. T -,,.,,ram
/
f

\ 3O

/
\
~ ' " 10

X3800504PLI55

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 326
UP200456

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GTCP36-280[D]

4. D. (8) Disassemble the turbine and compressor assembly components. (Refer to


Figure 326.)

(a) Remove load compressor diffuser (10), packing (20), special bolts (30), and
compressor rotor assembly (50). Discard packing.

(b) (Pre SB 49-A6653) Remove turbine support shaft (60).

(c) Remove nuts (70), washers (80) and driven compressor scroll (90).

(d) Remove screws (110), washers (120), driven compressor shroud (130),
packings (150, 160).

NOTE: Do not remove inserts (140) unless necessary.

(e) Remove IGV cover assembly (210), inlet guide vane housing assembly (170),
cotter pin (180), spring pin (190), and IGV shaft assembly (200).

(f) (Pre SB 49-A6653) Remove compressor shaft (230), turbine shaft support
(240), retaining ring (250) and turbine shaft support (260) from turbine and
compressor assy (270).

(Post SB 49-A6653) Remove compressor shaft (230A) from turbine and


compressor assy (270). Remove curvic seal gasket (280) from compressor
shaft (230A). Discard gasket.

~1~ KEY TO FIGURE 326

10. LOAD COMPRESSOR DIFFUSER 160. PACKING


20. PACKING 170. INLET GUIDE VANE HOUSING ASSY
30. SPECIAL BOLT 180. COTTER PIN
50. COMPRESSOR ROTORASSY 190. SPRING PIN
60. TURBINE SHAFT SUPPORT 200. IGV SHAFT ASSY
70. NUT 210. IGV COVER ASSY
80. WASHER 230. COMPRESSOR SHAFT
90. DRIVEN COMPRESSOR SCROLL 230A. COMPRESSOR SHAFT
100. COMPRESSOR SCROLL LINER 240. TURBINE SHAFT SUPPORT
110. SCREW 250. RETAINING RING
120. WASHER 260. TURBINE SHAFT SUPPORT
130. DRIVEN COMPRESSOR SHROUD 270. TURBINE AND COMPRESSOR ASSY
140. INSERT 280. GASKET, SEAL CURVIC
150. PACKING (POST SB 49-7307)
UP200456

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GTCP36-280[D]

,.o.,y/y f ~ / . ~ ~

~oo..,~

A3800504PL78

(Post SB 49-6608) Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 327
UP200456

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GTCP36-280[D]

4. D. (9) (Post SB 49-6608) Disassemble the turbine and compressor assembly components.
(Refer to Figure 327.)

(a) Remove bolts (10, 30), washers (20) and containment shield segment
assemblies (40, 50).

(b) Remove nuts (60), washers (70), compressor inlet housing (100), shims (110)
and packings (120) from turbine and compressor assembly (130). Discard
packings.

NOTE: Do not remove bolts (45, 55) unless damaged.

~11~1 KEY TO FIGURE 327

10. BOLT 70. WASHER


20. WASHER 80. INLET ADAPTER
30. BOLT 90. PLENUM SEAL
40. CONTAINMENT SHIELD 100. COMPRESSOR INLET
SEGMENT ASSY HOUSING
45. BOLT 110. SHIM
50. CONTAINMENT SHIELD 120. PACKING
SEGMENT ASSY 130. TURBINE AND COMPRESSOR
55. BOLT ASSY
60. NUT
UP200456

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Hone)~vell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

""" 1

..,,.
/
ao,,~ ~ . ".,.. 120 ( ,x/
\.
20. .~_:'>'~!
: .2L
10,~ " ~ .,*"'70

140

60

"---40
lO0----b~lOL X3800504PL33

(Pre SB 49-6608) Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figu re 327A
UP200456

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GTCP36-280[D]

4. D. (10) (Pre SB 49-6608) Disassemble the turbine and compressor assembly components.
(Refer to Figure 327A.)

(a) Remove bolts (10, 100), washers (20) and containment shield segment
assemblies (40, 70).

(b) Remove bolts (10, 30), washers (20), compressor inlet housing (110), shims
(120), plenum inlet seal (130), inlet adapter (140) and packings (150)from
turbine and compressor assembly (160). Discard packings.

_NOTE: Do not remove rivets (50, 80) and nutplates (60, 90) unless
damaged.

4~KEY TO FIGURE 327A

10. BOLT 90. NUTPLATE


20. WASHER 100. BOLT
30. BOLT 110. COMPRESSOR INLET
40. CONTAINMENT SHIELD HOUSING
SEGMENT ASSY 120. SHIM
50. RIVET 130. PLENUM INLET SEAL
60. NUTPLATE 140. INLET ADAPTER
70. CONTAINMENT SHIELD 150. PACKING
SEGMENT ASSY 160. TURBINE AND COMPRESSOR
80. RIVET ASSY
UP200456

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GTCP36-280[D]

130

70

~ fJ ~
120

X3800516PL139

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 328
UP200456

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Hone well COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

4. D. (11) Disassemble the turbine and compressor assembly components. (Refer to Figure
328.)

(a) Remove compressor housing assembly (10), rotor (50) and engine
compressor baffle (60).

NOTE: 1. Do not remove stepped pins (20, 30, 35) unless damaged.

2. Do not remove dampers (15) unless damaged.

(b) Remove compressor diffuser (70), spacer (80), shims (90), engine
compressor deswirl (100) and shims (110).

(c) Remove curvic ring seal (120) from turbine and compressor assembly (130).

d~lm KEY TO FIGURE 328

10. COMPRESSOR HOUSINGASSY 80. SPACER


15. DAMPERS 90. SHIM
20. STEPPED PIN 100. ENGINE COMPRESSOR DESWlRL
30. STEPPED PIN 110. SHIM
35. STEPPED PIN 120. CURVIC RING SEAL
50. ROTOR 130. TURBINEAND COMPRESSORASSY
60. COMPRESSOR BAFFLE
70. COMPRESSOR DIFFUSER
UP200456

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Hone3~well COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

40

5O
\ /
3O
\

/ >

/
J

C
.,../"

80
100

90

2O
10 X3800504PL157

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 329
UP200456

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HoneTwell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

4. D. (12) Disassemble the turbine and compressor assembly components. (Refer to


Figure 329.)

(a) Remove bolts (10), washers (20), containment ring (30) and turbine nozzle
assembly (40).

(b) Remove turbine wheel shims (50), turbine rotor (80) using 833429-1 coupl!ng
puller and back shroud shims (90) from turbine assembly (100).

~KEY TO FIGURE 329

10. BOLT 50. TURBINE WHEEL SHIM


20. WASHER 80. TURBINE ROTOR
30. CONTAINMENT RING 90. BACK SHROUD SHIM
40. TURBINE NOZZLE ASSY 100. TURBINEAND COMPRESSOR ASSY
UP200456

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Hone~vell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

210
' _ 180

\
\
15O

\_
5O

60 \
s
70

Y
. J
5O
100
130
lW

2O
\

10
\
3O

A3800517PL21

Disassemble the Turbine and Compressor Assembly Components


(Partial Breakdown)
Figure 330
UP200456

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Hone vell COMPONENT MAINTENANCE MANUAL


GTCP36-280[D]

4. D. (13) Disassemble the turbine and compressor assembly components. (Refer to


Figure 330.)

(a) Remove bolts (10), bearing carrier heat shield (20), compressor seal
assembly (30), seal (40), turbine seal assembly (50), seal (60) and turbine
bearing shims (70).

(b) (Pre SB 49-6883) Remove spring tension washer (80), turbine bearing spacer
(90), hydraulic mount seal (100).

(Post SB 49-6883) Remove spring tension washer (80) and turbine bearing
spacer (90A).

(c) Use 833092-3 bearing removal tool to remove annular ball bearing (140) and
turbine seal rotor (130) from coupling half (170).

(d) Remove retainer to carrier bolts (180), turbine back shroud retainer (190),
retainer shims (200) and metal ring seal (210).

(e) Remove back turbine wheel shroud (220), back shroud shims (230) and back
shroud support ring (240) from turbine bearing carrier assembly (250).

~KEY TO FIGURE 330

10. BOLT 130. TURBINE SEAL ROTOR


20. BRG CARRIER HEAT SHIELD 140. ANNULAR BALL BEARING
30. COMPRESSOR SEAL ASSY 170. COUPLING HALF
40. SEAL 180. RETAINER TO CARRIER BOLT
50. TURBINE SEAL ASSY 190. TURBINE BACK SHROUD RETAINER
60. SEAL 200. RETAINER SHIM
70. SHIM 210. METAL RING SEAL
80. SPRING TENSION WASHER 220. BACK TURBINE WHEEL SHROUD
90. TURBINE BEARING SPACER 230. BACK SHROUD SHIM
-90A. TURBINE BEARING SPACER 240. BACK SHROUD SUPPORT RING
100. HYDRAULIC MOUNT SEAL 250. TURBINE BEARING CARRIER ASSY

- ITEM NOT ILLUSTRATED


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GTCP36-280[D]

CLEANING

. Equipment and Materials

A Table 401 shows the equipment and materials necessary to clean the equipment.

NOTE: This section includes all the general procedures recommended by Honeywell to clean the
equipment. Refer to Table 402 to find which methods are applicable to the equipment in
this manual.

Table 401. Equipment and Materials

Equipment/Material Description/Manufacturer

NOTE: Equivalentequipment/material can be used.

Abrasive cloth (ANSI B74.18) Commercially available

Alkaline cleaner (Ridoline 909) Henkel Surface Technologies, 32100 Stephenson


(MIL-S-5002) Hwy, Madison Heights, MI 48071
Phone: 800-521-6895 (248-583-9300)

Electrocleaner (FS) Henkel Surface Technologies, 32100 Stephenson


Hwy, Madison Heights, MI 48071
Phone: 800-521-6895 (248-583-9300)

Magnetic base oil (Magnaglo Carrier II) Magnaflux, A Division of Illinois Tool Works, Inc.,
3624 W. Lake Ave., Rt 27 and Vineyard Rd.,
Edison NJ 08818
Phone: 847-657-5300

Methyl-ethyl-ketone (MEK) (ASTM D740) Commercially available

Muriatic acid (35 percent HCL, Commercially available


commercial grade)

Oil (MIL-PRF-7808) Commercially available

Power source (0 to 7 volt DC) Commercially available

Stripper, Rust Stripper (Oakite Rustripper) Chemetall Oakite, 50 Valley Rd,


Berkeley Heights, NJ 07922-2712
Phone: 800-526-4473 (908-464-6900)

Sand (120 Grit) (MIL-A-22262) Commercially available

Solvent (Isopropyl alcohol, Federal Commercially available


Specification TT-I-735)
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2. General Cteaninq Practices

A. Each part must be cleaned with the procedures referred to in this section or the equivalent
procedures used by an approved overhaul facility. Solutions specified must be made with the
instructions in this manual or to the instructions supplied by the product manufacturer.

B. These procedures agree with good shop procedures as used by the Honeywell overhaul
facility. Clean parts are important to satisfactory overhaul and operation.

. General Cleanin.q Instructions

WARNING: CLEAN PARTS IN AN AREA OPEN TO THE AIR, THAT HAS GOOD LIGHT AND
SUFFICIENT SAFETY AND FIRE PREVENTION EQUIPMENT.

A. Clean all metal parts to remove oil grease, rust, and dirt. Clean the flange areas and sealing
surfaces to remove old gaskets and compounds.

g. Clean painted parts but do not remove old paint if it is still serviceable.

C. Remove carbon and combustion contamination.

D. Heat discoloration of metal surfaces (not to include overheat due to malfunction) is permitted.
Remove scale that can come loose and damage the unit.

E. Remove all light surface corrosion from parts and treat base metal to prevent corrosion. Refer
parts with heavier corrosion to inspection personnel for analysis.

CAUTION: USE THE APPROVED CAPS, PLUGS AND BARRIER MATERIALS TO PROTECT
THE PART AFTER CLEANING. DO NOT USE TAPE, PLASTIC, OR RAGS TO
PROTECT CLEAN PARTS. DAMAGE TO THE PARTS COULD OCCUR.

F. Cap, plug or seal all ports and orifices of cleaned parts. Make sure the parts are protected in
storage.

. Clean Dissimilar Materials

CAUTION: AN ASSEMBLY MUST NOT BE CLEANED IN A SOLUTION THAT IS HARMFUL TO


ONE OF THE PARTS IN THE ASSEMBLY.

A. Dissimilar materials must be cleaned one at a time. Refer to REPAIR Reference Tables.

CAUTION: DO NOT CLEAN BRASS OR BRONZE WITH CHROMIC ACID SOLUTION.

B. Clean the assemblies that contain brass, bronze, steel, or cadmium with the procedures that
are applicable to the base metal.
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. C. Carefully clean synthetic or natural materials with a Cleaning Method that will not damage the
material.

. Preparation of Cleanin.q Solutions

A. Prepare alkaline cleaner solution.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURERS INSTRUCTION FOR EACH CHEMICAL.

(1) Mix 4 to 6 ounces (113 to 170 g) of alkaline cleaner in each gallon (3,8 L) of water.

(2) Keep the solution at 130 to 180F (54 to 82C) in an air-agitated tank.

B. Prepare rust remover solution.

WARNING: USE THE CORRECT PERSONAL PROTECTION. RUST REMOVER


SOLUTION FUMES CAN BE DANGEROUS. MIX THE WATER AND ADD
THE RUST REMOVER SO THE SOULUTION DOES NOT BECOME TOO
HOT.

(1) Mix 3 to 5 pounds (1,4 to 2,3 kg) of rust remover in each gallon (3,8 L) of water.

(2) Keep the solution at 160 to 200F (72 to 93C).

C. Prepare electrocleaner solution.

(1) Mix 9 ounces (255 g) of electrocleaner with one gallon (3,8 L) of water.

(2) Keep the solution at 160 to 200F (72 to 93C).

. Clean Component Parts

A. The material composition or physical properties of each part is listed in REPAIR.

B. Clean the parts with the specified procedures shown in Table 402. When more than one
procedure to clean a part is shown in the table, use only the procedure necessary to
satisfactorily clean the part.

C. Ball or roller bearing assemblies must be replaced or analyzed by a repair facility specializing
in the repair of bearing assemblies.
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Table 402. Cleaning Methods

IPL
Figure Item Cleaning Methods
No. No. Nomenclature 2 3 4 5

All standard metallic hardware X X

9 180 Igniter Plug X

10 30 Oil Level Sensor X


170 Data Memory Module X
190 Oil Cooler Bracket X
340 Pressure Sensor X
350 Oil Sump Temp Sensor X
390 Motional Transducer X

13 120 Immersion Thermocouple X

14 60 Quill Shaft X

15 10 Dipstick Cap X
190 Filter Screen X

16 150 Gearshaft X
180 High Speed Pinion Gear X

17 70 Starter Gearshaft X
90 Splined Shaft Assembly X
110 Clutch X X
300., Large Compound Idler Gear X
310 Small Compound Idler Gear X
390 Lube Gear Assembly X

CAUTION: DO NOT USE 1,1,1-TRICHLOROETHANE TO CLEAN TITANIUM PARTS. HIGH


TEMPERATURE OPERATION OF TITANIUM PARTS AFTER CONTACT WITH
CHLORINATED CHEMICALS CAN CAUSE PART FAILURE DUE TO CRACKS.

18 210 Generator Idler Shaft X


230 Generator Idler Gear X

20 50 Upper Compressor Inlet Duct Assy X


90 Lower Compressor Inlet Duct Assy X

21 20 Compressor Inlet Temperature


Sensor X
8O Nozzle Assembly X
100 Fuel Nozzle Shroud X
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Table 402. Cleaning Methods (Cont)

IPL
Figure Item Cleanin.q Methods
No. No. Nomenclature 2 3 4 5

24 20 Splined Shaft X
40 Compressor Bearing Carrier
Assy X
240 Coupling Seal Assy X

25 10 Load Compressor Diffuser X


50 Compressor Rotor X
90 Compressor Scroll X
200 IGV Actuator Shaft Assy X
230 Compressor Shaft X

26 110 Compressor Inlet Housing X

27 10 Engine Compressor Housing


Assy X
50 Compressor Rotor X
140 Combustion Chamber X
160 Plenum Assy X

28 30 Containment Ring X
40 Turbine Nozzle Assy X

. Cleanin,q Procedures

WARNING: USE THE CORRECT PERSONAL PROTECITON. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE AIRFLOW CAN
CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

CAUTION: USE THESE PROCEDURES TO CLEAN THE PARTS. PARTS CAN BE BADLY
DAMAGED BY THE USE OF THE WRONG PROCEDURE. USE ONLY THE
PROCEDURE RECOMMENDED FOR THE PART.

NOTE: Use clean, dry, filtered, compressed air at a maximum of 20 psig (138 kPa) to dry parts.

METHOD 1

A. Remove grease from parts with a spray.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

(1) Use solvent in a booth open to the outside air.


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. A. (2) Clean the parts until the oil and grease is removed.

(3) Remove the caked grease or soft carbon with the use of a brush with stiff plastic
fibers.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE
AIRSTREAM CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

(4) Dry the parts with compressed air.

METHOD 2

B. Remove grease from parts with a gas.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

(1) Use solvent in a vapor degreaser at a temperature of 165 to 170F (74 to 77C).

(2) Put the part in a rack so the gases touch all the surfaces. The parts that do not drain
completely should be arranged, if possible, to drain the liquid before they are removed
from the degreaser.

(3) Clean the parts, as necessary, to remove the heavy grease particles. Return the parts
to the vapor degreaser for final cleaning.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE
AIRSTREAM CAN CAUSE CUTS DO NOT POINT IT AT YOUR SKIN.

(4) Dry the parts with compressed air.

METHOD 3

C. Clean the aluminum alloy parts.

(1) Use of Method 1 or 2 to remove the grease from the surfaces.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

(2) Put the parts in the alkaline cleaner solution for a maximum of 30 minutes.
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7. C, (2) (a) Clean the surfaces with a stiff fiber bristled brush until clean.

(b) Carefully remove the old gaskets with a blade and scrape the surfaces clean.

(c) Do the soak and clean procedure again or until the part is clean.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE
AIRSTREAM CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

(3) Flush the parts with water and dry with compressed air.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN


ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS
AN ASPHYXIANT, IT IS POISONOUS AND CAN BE ABSORBED THROUGH
THE SKIN.

(4) Use abrasive cloth to remove small surface corrosion on aluminum alloy parts. Use
abrasive cloth and oil to remove small surface corrosion on magnesium alloy parts.

(5) Flush the parts with water at 80 to 110F (27 to 43C). For magnesium alloy parts, flush
again in hot water at 140F (60C) minimum.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE
AIRSTREAM CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

(6) Dry the parts with compressed air.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

(7) Apply touch-up solution to the exposed metal (refer to REPAIR).

WARNING: USE THE CORRECT PERSONAL PROTECTION. THE HEATED PARTS


WILL CAUSE BURNS.

(8) Dry all magnesium alloy parts and any aluminum alloy parts that have dissimilar metal
inserts, crevices, or deep blind holes in an oven at 225 to 275F (107 to 135C) for a
minimum of one hour. Make sure the parts are completely dry.

(9) Keep the parts in a dry place away from gases that can cause corrosion.
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METHOD 4

7. D. Clean steel parts.

(1) Use Method 1 or 2 to remove the grease from the surfaces.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

CAUTION: MORE DAMAGE CAN OCCUR TO NON-STEEL PARTS IF CLEANED WITH


RUST REMOVER SOLUTION.

(2) Put the parts in a rust remover solution for 10 to 20 minutes.

CAUTION: DO NOT DAMAGE THE HIGHLY FINISHED SURFACES. USE ONLY A


BRUSH WITH STIFF PLASTIC FIBERS ON SUCH AREAS.

DO NOT GLASS BEAD PEEN THE PARTS UNTIL A PENETRANT OR


MAGNETIC PARTICLE INSPECTION HAS BEEN DONE.

(3) Remove the parts from the rust remover solution. Flush the part with water, and clean
with a brush with stiff plastic fibers. Remove hard carbon or scale by glass bead
peening surfaces (refer to REPAIR).

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE
AIRSTREAM CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

(4) Flush the parts in water at 80 to 110F (27 to 43C) and dry with compressed air.

(5) Parts that need to have a magnetic particle or a penetrant inspection in eight hours
can be left dry until checked. Put the parts in a clean container.

(6) Steel parts that need a magnetic particle inspection and will be kept for more than
eight hours or up to 48 hours must have a layer of magnetic base oil applied. Put the
parts in a clean container.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN


ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS
AN ASPHYXIANT, IT IS POISONOUS AND CAN BE ABSORBED THROUGH
THE SKIN.

(7) Put the steel parts that do not need a magnetic particle inspection in a dip tank of oil.
Remove and let drain, then put them in a clean container and keep them away from
moisture and gases that can cause corrosion.
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7. D. (8) Stainless steel and some corrosion-resistant steel parts that are usually used where
there is no oil, must be kept dry and protected from moisture that can cause corrosion.

(9) Steel parts to be kept for more than six months or kept in humid conditions must be
protected by corrosion preventive compounds. Refer to MIL-C-15074.

METHOD 5

E. Clean plumbing tubes and fittings.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

(1) Clean the tubes and fittings externally and internally with solvent in a booth open to the
outside air. Make sure that spray fluid flows freely through tubes.

WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE
AIRSTREAM CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

(2) Dry parts with compressed air.

CAUTION: USE APPROVED CAPS, PLUGS, AND BARRIER MATERIALS TO


PROTECT PART AFTER CLEANING. DO NOT USE TAPE, PLASTIC, OR
RAGS TO PROTECT CLEAN PARTS, DAMAGE TO PARTS COULD
OCCUR.

(3) Install plugs or caps at each end of tubes or fittings to protect against contamination
and thread damage.

METHOD 6

F. Clean electrical components.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

(1) Rub parts with a clean lint free cloth dipped in methyl-ethyl-ketone or solvent.

(2) Clean the electrical connectors with cleaning solvent. Remove oily type soil with a
cotton swab dipped in solvent.
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METHOD 7

. G. Clean the metallic filter element.

(1) Use Method 1 or 2 to remove the grease from the filter element.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG DAMAGE.
FOLLOW THE MANUFACTURER'S INSTRUCTION FOR EACH CHEMICAL.

(2) Soak the filter element in a rust remover solution for 30 minutes. Remove it from the
solution and flush it with water.

(3) Put the filter element in an electrocleaner solution for four to six minutes. During this
time, make the filter element an anode for one to two minutes at a potential of 4 to 7
volts DC. Flush filter element in water.

(4) Put the filter element in a solution of equal parts muriatic acid and water, by volume, at
room temperature for one-half to one minute. Flush the filter element with in water.

(5) Put the filter element in electrocleaner solution for four to six minutes. Flush the filter
element with water.

(6) Flush the filter element internally and externally with clean water under pressure.

(7) Put the filter element in a beaker with the open end of the filter down and fill the beaker
with an electrocleaner solution.

(8) Put the beaker, with the filter element, in an ultrasonic cleaner tank and fill the tank to
within three-eighths inch of the top with water.

(9) Operate the ultrasonic cleaner tank for five minutes. Remove the filter element,
discard the contaminated electrocleaner solution, and flush the filter element and the
beaker with clean electrocleaner solution with the use of a plastic squeeze bottle.

(lO) Put the filter element in a beaker and put it in an ultrasonic cleaner tank. Fill the
beaker with electrocleaner solution and operate the ultrasonic cleaner for five minutes
more.

(11) Do steps (9) and (10) again until the electrocleaner solution stays clean after five
minutes of operation.
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WARNING: USE THE CORRECT PERSONAL PROTECTION. COMPRESSED AIR WILL


CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES. THE
AIRFLOW CAN CAUSE CUTS. DO NOT POINT IT AT YOUR SKIN.

7. G. (12) Remove the filter element from the beaker and flush internally and externally with
clean water under pressure. Dry the filter element with compressed air.

(13) Do a test on the cleaned filter element for pressure drop (refer to CHECK).
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CHECK

. Refer to ATA No. 49-26-51 for check procedures.


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REPAIR

. Refer to ATA No. 49-26-51 for repair procedures.


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ASSEMBLY (WITH STORAGE)

. Equipment and Materials

A. Table 701 shows the equipment and materials necessary to assemble the unit and prepare it
for storage.

Table 701. Equipment and Materials

Equipment/Material Description/Manufacturer

NOTE: Equivalent equipment/material can be used for items shown.

Adhesive (RTV106) General Electric Co., GE Silicones 260 Hudson River Rd,
Waterford, NY 12188
Phone: 800-332-3390 (518-233-3330)

Barrier material (PRF-121) Commercially available

Coating, high heat aluminum (DC6571-805) Griggs Paint


(Federal Specification A-A-341A Type I or II, 3635 S 16th PI, Phoenix, AZ 85040-1305
Class A) Phone: 602-243-3293

Compound (MIL-S-46163 Type I, Commercially available


Grade K, or Type II, Grade O)

Desiccant (MIL-D-3464E) Commercially available.

Dry-film lubricant (Molykote 321-R) Dow Coming Corp, 3901 S Saginaw Rd,
P.O. Box 997, Midland, MI 48640

Dykem (Hi-Spot Blue No. 107) The Dykem Co., 8501 Delport Dr.,
St. Louis, MO 63114-5905
Phone: 314-423-0100

Dry-ice Commercially available

Liquid nitrogen (Commercial Item Description Commercially available


A-A- 595O3)

Lint free cloth Commercially available

Lockwire (MS20995C32) Commercially available

Lubricant (OS-124) Monsanto Co., Fibers Business Unit,


800 N. Lindbergh Rd.,
St. Louis, MO 63167

Lubricating anti-seize Lockrey Co, Inc, Lubricants Div, 2517


(Liqui-Moly, Brand NV Thread compound) Finlaw Ave, Merchantville, NJ 08109-3243
MIL-PRF-907) Phone: 856-665-4794

Oil (MIL-PRF-7808) Commercially available


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Table 701. Equipment and Materials (Cont)

Equipment/Material Description/Manufacturer

Oil (MIL-PRF-23699) Commercially available

pH Neutral paper (MIL-P-17667) Commercially available

Primer (MIL-S-22473 Grade T) Commercially available

Assembly Tools

Air-oil separator support (833973-1)

APU assembly stand (287750-1)

Balance adapter (834166-1)

Balance adapter (834248-1)

Balance adapter (834249-1)

Balance adapter (834250-1)

Balance bearing set (833091-1)**

Bearing and seal removal fixture


(835550-1)

Bearing and separator installer (2024021-1 )

Bearing and separator installer (834337-1)

Bearing carrier support (833175-1 )

Bearing hold fixture (834157-1)

Bearing installer (834336-1)

Bearing set installer (833124-1)

Bearing installer (833991-1)

Bearing set installer (833131-1)

Bearing press fixture (833096-2)

Bearing press fixture (833126-1)

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix
Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987
**Consists of: turbine balance bearing 833091-200, compressor balance bearing 833091-201
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Table 701. Equipment and Materials (Cont)

Equipment/Material Description/Manufacturer

Bearing press fixture (833988-1)

Bearing installer (833989-1)

Bearing removal fixture (833440-1)

Bearing removal and replacement fixture


(2024019-1 )

Carbon seal installer (2024017-1 )

Comp bearing centering fixture (833102-1)

Coupling installing tool (833432-1)

Coupling puller (833429-1)

Cut back nut (834347-1)

Dummy L/C coupling (834037-1)

Gearbox housing adapter (2024003-1)

Installation support (294224-1)

IGV adjustment tool (834150-2)

Bearing and rotor seal installer


(833096-2)

Lift fixture (833105-1)

Lifting fixture (834334-1)

Lip seal bullet (833997-1)

Micrometer bridge (833424-1)

Micing fixture (833449-1)

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix
Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987
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Table 701. Equipment and Materials (Cont)

Equipment/Material Description/Manufacturer

Nozzle support tool (833099-1)

Nut stake tool (834120-1)

Pinion gear puller (833095-1)

Portable engine stand assy (833565-3)

Plenum puller fixture (833186-1)

Protective cover (2024398-1)

Rotating group bridge stand (834348-1)

Rotating group cut back nut (834347-1)

Runout check fixture (833097-1)

Runout check fixture (833449-1)

Runout indicator (833449-1)

Runout test fixture (285868-1)

Seal installer (834333-2)

Seal press fixture (833996-1)

Shaft stretch fixture (833094-1)

Shim holding fixture (833871-1)

Spanner wrench (2024465-1)

Sprag clutch guide sleeve installer


(2024392-1)

Support fixture (833998-1) *

Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix
Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987
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GTCP36-280[D]

Table 701. Equipment and Materials (Cont)

Equipment/Material Description/Manufacturer

Support shaft installation fixture *


(833430-1)

Tie bolt arbor (834263-1/-2) *

Turbine backshroud retainer support (834156-1) *

Turbine rotor balance arbor (833158-1) **

Tube installation tool (833184-1) *

Turbine and compressor holding fixture *


(833093-1)

Turbine rotor support tool (834335-1) *

Vacuum check tool (834149-1) *

Vacuum check tool (834303-1) *

*Can be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717 N. Bendix
Drive, South Bend, IN 46628-1000, Telephone: (574) 231-3987

**Designed for Gisholt Balance Machines only


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. General Assembly Instructions

NOTE: The assembly instructions are in the order of the illustration first and then the text on either
the same page or facing pages where practical. All necessary information is given so the
unit can be assembled without reference to another part of the manual.

A. Remove all corrosion preventive compound and any contaminations from the parts before
assembly.

B. All nuts, bolts, and screws must be tightened to a standard torque unless torque is specified in
text. Refer to FAA Manual AC65-9A, Airframe and Powerplant Mechanics General Handbook,
for the standard torque.

C. Use anti-seize compound for the assembly of all threaded parts as follows.

CAUTION: USE OF TOO MUCH ANTI-SEIZE COMPOUND CAN CAUSE VENTS AND
ORIFICES TO CLOG.

(1) Apply a small quantity of anti-seize compound, to the threads of all male threaded
parts.

(2) Remove any of the compound that remains after assembly of the threaded parts.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN ADDITIVE
CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT, IT
IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN.

D. All the packings must be lubricated before installation. Use a lubricant that has been approved
for the system where the packing is to be installed. For example, packings to be used in the
engine oil system must be lubricated with oil (MIL-PRF-7808 or MIL-PRF-23699).
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. E. Use Iockwire on all hardware (bolts, screws, plumbing, electrical connectors) with Iockwire
holes. Install the Iockwire in accordance with Aerospace Standard 567 (AS567).

F. Installation of electrical connectors.

(1) Installation of threaded connectors.

(a) Align the key of one part with the groove or keyway of the other part to find the
correct position of the plug in relation to the receptacle.

(b) Start the plug in the receptacle with a light forward pressure. Engage the
threads of the coupling ring and receptacle.

CAUTION: NEVER USE FORCE TO ENGAGE CONNECTORS TO


RECEPTACLES. DO NOT HAMMER A PLUG INTO THE
RECEPTACLE. DO NOT USE A TORQUE WRENCH OR PLIERS
TO LOCK COUPLING RINGS.

(c) Carefully push in on the plug and tighten the coupling ring until the plug is
seated and tight. If necessary, use connector pliers to tighten coupling rings
more than finger tight.

(2) Installation of the bayonet connector.

CAUTION: DO NOT USE CONNECTOR PLIERS.

(a) Align the key of one part with the groove or keyway of the other part to find the
correct position of the plug in relation to the receptacle.

(b) Start the plug in the receptacle with a light forward pressure. Engage the
coupling ring and receptacle.

G. When screws or bolts are too long or too short, a longer or shorter standard screw or bolt can
be used if there is a minimum of one full thread more than the face of the threaded part or nut.

NOTE: There is no alternate screw or bolt lengths permitted for blind hole applications.

H. On rivet installation, if the shank of the rivet is too long or too short, use one size longer or one
size shorter rivet as necessary.

. Check Point Notes

The Check Points in this section are used by Honeywell at/or after critical build operations. Use these
Check Points to make sure the assembly was built correctly. Table 702 shows the Check Points.
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GTCP36-280[D]

Table 702. Check Point Summary

Check Point Operation Page

10 Make sure calculations used for shims (140, 150) are correct. 716

10A Make sure calculations used for shims (130, 140, 150) are correct. 720

20 Check gearbox for complete assembly, obvious damage 762


and freedom of rotation.

20A Check gearbox for complete assembly, obvious damage 766


and freedom of rotation.

30 Make sure the shaft stretch is 0.058 to 0.062 inch 772


(1,47 to 1,57 mm).

40 Make sure runout measurements are in limits. 774

50 Make sure the balance measurements are in limits. 778

60 Make sure the tie shaft stretch measurement is 0.058 to 787


0.062 inch (1,47 to 1,57 mm).

70 Make sure runout and balance measurements are in 790


limits and rotating group is marked with dykem. Record serial
numbers of turbine and compressor's impellers.

80 Make sure recorded Dimensions A and BB are correct. 796

90 Make sure calculations for shims (70) are correct. 796


Verify Dim. C.

100 Make sure Dimension BB1 is the same as Dimension BB. 798

110 Dimension C must be the same as Dimension C1 798.4


_+0.00015 inch (0,038 mm) at each of the 4 locations.

120 Make sure the turbine rotor backshroud clearance is 798.17


within limits.

130 Make sure the turbine wheel to the turbine nozzle clearance 798.22
is in limits.

140 Make sure the engine compressor clearance calculations 798.32


are correct.
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Table 702. Check Point Summary (Cont)

Check Point Operation Page

150 Make sure load compressor tip clearance is 0.065 to 0.069 798.59
inch (0,165 to 0,175 mm).

160 Make sure calculations for spacer (150) are correct to 798.68
0.001 inch (0.025 mm).

170 Make sure the shaft stretch (RSL) measurement is correct. 798.71

180 Make sure the runout on surfaces A and B are in limits. 798.73

190 Make sure that a gearbox cavity inspection is accomplished 798.89


before installing the gearbox.
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GTCP36-280[D]

430
\ 4404~,~

45~~~ 1'~ 160~~~

LUBEGEARASSY
120 140 ,L~

GEI~ERATORGEARASSY

3. 10\
HIGHSPEEDPINIONASSY
8,

30
10
GENERATORIDLERGEARASSY

X3800504AY55

Assemble the Bearings and Gears (Gearbox Part No. 3863019)


(Code A) Figure 701
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GTCP36-280[D]

. Assembly Procedures

A. Assemble the Gearbox Assembly.

(1) (Part No. 3863019) Assemble the bearings and gears. (Refer to Figure 701 .)

(a) Use the 833131-1 bearing press fixture to push lube pump ball bearings (450)
on lubrication pump gear assembly (430). Install expansion plug (440) if
necessary.

(b) Use the 834336-1 bearing press fixture to push generator roller bearings (120)
on generator gear assembly (150). Make sure that OUTER THRUST side of
bearings faces away from large gear. Install insert (140) and plug (160) into
generator gear assembly (150) if necessary.

(c) Use 833976-2 bearing press fixture and 833973-1 support fixture to push
pinion gear bearings (330) on pinion gear (340). Make sure OUTER THRUST
side of bearings faces away from gear. Install retaining ring (320).

(d) Install inner spacer (40) and outer spacer (30) into generator idler gear (50).

(e) Use 833986-1 bearing installation fixture and 833987-1 support fixture to
install roller bearings (20) into idler gear (50). Make sure OUTER THRUST
side of bearing faces toward gear.

(f) Install retaining rings (10).

~KEY TO FIGURE 701

10. RETAINING RING (IPC FIG. 40) 150. GENERATOR GEAR ASSY
20. ROLLER BEARING 160. PLUG
30. OUTER SPACER 320. RETAINING RING (IPC FIG. 19)
40. INNER SPACER 330. PINION GEAR BEARING
50. IDLER GEAR 340. PINION GEAR
120. GENERATOR ROLLER BEARING 430. LUBE GEAR ASSY
(IPC FIG. 17) 440. EXPANSION PLUG
140. INSERT 450. LUBE PUMP BALL BEARING
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GTCP36-280[D]

170
150
160

120 140 ~ ~
w ss

150 GENERATORGEARASSY

14o 30,

1
20
HIGHSPEEDPINIONASSY 10

GENERATORIDLERGEARASSY
X3800504AY56

Assemble the Bearings and Gears (Gearbox Part No. 3863136)


(Code B) Figure 701A
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4. A. (2) (Part No. 3863136) Assemble the bearings and gears. (Refer to Figure 701A.)

(a) Use the 833131-1 bearing press fixture to push lube pump ball bearings (330)
on lube gear assembly (350). Install expansion plug (340) if necessary.
Position lube gear assembly in gearbox cavity before installing air-oil separator
assembly.

(b) Use the 834336-1 bearing press fixture to push bearings (120, 170) on
generator gear assembly (150). Make sure that OUTER THRUST side of
bearings faces away from large gear. Install insert (140) and plug (160) into
generator gear assembly (150) if necessary.

(c) Use 833976-2 bearing press fixture and 833973-1 support fixture to push
pinion roller bearings (130) on pinion gear (140). Make sure OUTER
THRUST side of bearings faces away from gear. Install retaining rings
(120,150).

(d) Use 2024019-1 bearing installation fixture to install roller bearing (20) into
generator idler gear (30). Make sure OUTER THRUST side of bearing faces
away from gear on opposite side from retaining ring (10).

(e) Install retaining ring (10).

41~ KEY TO FIGURE 701A

10. RETAINING RING (IPC FIG. 40A) 140. INSERT (IPC FIG. 17A)
20. ROLLER BEARING 150. GENERATOR GEARASSY
30. IDLER GEAR 150. RETAINING RING (IPC FIG. 19A)
120. GENERATOR ROLLER BEARING 160. PLUG (IPC FIG. 17A)
(IPC FIG. 17A) 170. GENERATOR BALL BEARING
120. RETAINING RING (IPC FIG. 19A) 330. LUBE PUMP BALL BEARING
130. PINION ROLLER BEARING (IPC FIG. 19A)
140. PINION GEAR 340. EXPANSION PLUG
350. LUBE GEARASSY
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GTCP36-280[D]

SO .~'y\

|
ViEWA 140 ViEWD
150 ' l0

; 1

I~ DFTAll X DETAIl.Y

ViEWB ~ ... ' " ~ . .

70

90 SO
VIEW C

5O X~O~l~Y14

Assemble the Starter Clutch Components (Gearbox Part No. 3863019)


(Code A) Figure 702
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4. A. (3) (Part No. 3863019) Assemble the starter clutch components. (Refer to Figure 702.)

(a) Use 833124-1 bearing installer and push starter bearings (60) on gearshaft
(70) as shown in View A, with THRUST marking away from gear.

NOTE: Make sure all drain holes on shaft assembly (90) are not blocked.

(b) Use 833991-1 bearing installer and 833998-1 support fixture and push one
ball bearing (80) on shaft assembly (90).

(c) Install clutch (110) on shaft assembly (90).

NOTE: Make sure clutch direction arrow is in the counterclockwise position


when looked at from the splined end of shaft (90) as shown in View
B.

(d) Use 833991-1 bearing installer and 833998-1 support fixture and push the
remaining ball bearings (80) on shaft assembly (90).

(e) Install retaining ring (50) in gearshaft (70). Use 2024392-2 sprag clutch guide
sleeve and install shaft assembly (90) with assembled items in gearshaft (70)
with splines down as shown in View C.

(f) Use a depth micrometer to measure from the top of gearshaft (70) to the outer
race of ball bearing (80). Write the measurement as Dimension A. Refer to
Detail X.

(g) Measure the thickness of retaining ring (50) and write the measurement as
Dimension B. Install retaining ring (50) in gearshaft (70). Refer to View D.

(h) Measure from the top of gearshaft (70) to the top of retaining ring (50). Write
the measurement as Dimension C. Refer to Detail Y.

~KEY TO FIGURE 702

50. RETAINING RING (IPC FIG. 18) 110. CLUTCH


60. STARTER BEARING 130. SPRING WASHER
70. GEARSHAFT 140. SHIM
80. BALL BEARING 150. SHIM
90. SHAFT ASSY
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4. A. (3) (i) Use this formula to calculate the necessary thickness of shims (140, 150).

Formula A - B - C - 0.031 to 0.035 inch (0,8 to 0,9 mm) = the necessary


thickness of shims (140, 150).

Dimension A _ _ inch ( . _ _ mm)


Dimension B - _ _ inch ( . _ _ mm)
Dimension C - _ _ inch ( _ _ _ mm)
minus 0.031 to 0.035 inch (0,8 to 0,9 mm) =
necessary thickness of shims (140, 150) to get +_0.002 (+_0,5 mm) tolerance.

Check Point 10: Make sure calculations used for shims (140, 150) are
correct.

(.i) Remove retaining ring (50) from gearshaft (70).

(k) Install spring washer (130), calculated amount of shims (140, 150) and
retaining ring (50) as shown in View E.
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~_ ___:/_ Y~,

/
~EWA 140 VIEW O
150 ' S.O

,09
CLUTCHDIRECTION

t
0.031TO0.035IN.
I" 7 (0,8TO0,9MM)
~. _1 BUILDDIMENSION

m
; '-'~ o2
ViEWE
m

t,
i

""'120
[J,,d"~ f DIM. C
.a~.jl r",,,$O DIM. A

DETAILX DETAILY

9o /.f" X\
,0 ~ /l " ") ~ "J
140

I / t "