ROLLS] (ROTCE! VIPER 535 ENGINE CHANGE UNIT ria MAINTENANCE MANUALPLEASE ADDRESS ALL TECHNICAL ENQUIRIES TO: ROLLS-ROYCE pic * MILITARY ENGINE GROUP PRODUCT SUPPORT ENGINEERING ANSTY, COVENTRY CV79IR, ENGLAND ‘Telephone: Coventry 102031628403, Teles 518361RRIMDG) ALL OTHER ENQUIRIES SHOULD BE ADDRESSED TO: ROLLS-ROYCE pic TECHNICAL PUBLICATIONS DEPARTMENT [ANSTY. COVENTRY CV79IR, ENGLAND “Telephone: Coventry (0203) 24175 “Telex: 16361RR MOG)NTED IN ENGLAND FOREWORD THE REGISTERED HOLDER OF THIS MANUAL IS RESPONSIBLE FOR MAKING ARRANGEMENTS WITH ROLLS-ROYCE plc TO ENSURE THE RECEIPT OF AMENDMENTS AND IS ALSO RESPONSIBLE FOR THE EFFECTIVE EMBODIMENT OF AMENDMENTS TO THIS MANUAL. DISREGARD THE ADDRESSES GIVEN ON THE REVERSE OF THE TITLE PAGE AND READ AS FOLLOWS:- PLEASE ADORESS ALL TECHNICAL ENQUIRIES TO:- ROLLS-ROYCE ple AERO BUSINESS GROUP PRODUCT SUPPORT ENGINEERING ANSTY, COVENTRY CV7 9UR, ENGLAND Telephone: Coventry (0203) 624403 Telex: 37645 ROLROY & ANSMAIL 0 Fax: 0203 624666 ALL OTHER ENQUIRIES SHOULD BE ADDRESSED TO:- ROLLS-ROYCE ple TECHNICAL PUBLICATIONS DEPARTMENT ANSTY, COVENTRY CV7 9JR, ENGLAND Telephone: Coventry (0203) 626175 . Telex: 37645 ROLROY G ANSMAIL O Fax: 0203 624666 mar/90 FOREWORD Rae Page tecto enc.ane i MAINTENANCE VIPER 535 REVISION RECORD Rev tnsereion By Rev | insertion | ay L 13-}1- 6& 32 jane 2 2-64 A DS {AO 09 5 35 6-3 wy Sta1-07 | ad. 36 31-$- 94 S 23-e-7ol_ ae 37 (28g VY o | 2-6-7 | 977 2s | 23-4-55 21 14-¢-F0! $B 39 28-10-95, 2 2) ao |io-g-m A fp 41 le 9- 36 10 . 42 | B/4-37 4 af 43 20-83-84 rs 2, bh | 22-1-3¢ |GBai 13 sek AS S-7-38 14 XB AG 3-4-4 |R. is 47 225-0 | Pe 1b [4s 32-5~9, | Be b 4g 22-s -21 | Ga 3 so | -s-a)| BR wv S| as a WZ I J [ I | L 2b Save <1 W/2U “TT 7 March/68 REVISION RECORD 20847 Page 1‘rmatD w enoLANe VIPER 535 Bl MAINTENANCE TEMPORARY REVISTON RECORD TR Cancelled TR Cancelled No. pate = No. | pate FS pane ~ jy fists] ys 16-370 me Iewsel Gs PD es sol Ct ST eet Teno at) 78-3 [part 22-|-33 a [ [ yy-2 ie March/68 ‘Tw20848 TEMP. REVISION RECORD Page 1RISTOL ENGINE DIVISION MAINTENANCE VIPER 535 TABLE OF CONTENTS TITLE PAGE FOREWORD ‘TABLE OF CONTENTS REVISION. RECORD TEMPORARY REVISION RECORD MODIFICATION STATEMENT INTRODUCTION CHAPTER 5 - ‘TIME LIMITS 70 - STANDARD PRACTICES - ENGINE 72 - POWER PLANT 72 - ENGINE, 73 - ENGINE FUEL AND CONTROL 74 - IGNITION 75 - AIR 76 - ENGINE CONTROLS 7 - ENGINE INDICATING 78 - EXHAUST 79 - orb 80 - STARTING Dec/76 TABLE OF CONTENT: v3sMooL PageEG ROLLS-ROYCE Ri. VIPER WM warwtenance ~ ax.935 MODIFICATION STATEMENT Modifications which have an annotation in the “Coverage” column have been investigated and any necessary data incorporated in the Manual. Annotations may be one of the following. * Full coverage P Partial coverage NE No effect on Manual NA Not applicable € Cancelled Modifications in the 7000 range, up to’ and including CV.7601 (pre~ July, 1969) and the 3000 range (starting with CV.3313, July, 1969) up to and including CMV.3999 have been considered and incorporatec a8 necessary in this Manual. Modifications now commence at Mod. cmv. 8000. For information concerning modifications not yet embodied in the Manual refer to Service Bulletins. Mod. No. Coverage © Mod. No. Coverage = Mod. No. Coverage cuv. 8000 NA cMy..8027 Ne emv.805% NE cmv.8001 NE ozs 8055 cmv.8002 NA cMv.8029 NA 8056 cmv.8003 NA 8030 cmv.8057 NA cmv.8004 NA 8031 cmv.8058 NE cMv.800S NE cuv.8032 NE 3059 cmv. 8006 NE 8033 cmv. 8060 NE cuv.8007 NE 8034 cMv.8061 NE 3008 cMv..8035 NE cmv. 8062 NA cmv.8009 NE. cmv.8036 NE cmv. 8063 NA 010 cmv. 8037 NE 8064 cmv.8011 NA cmv. 8038 NA cmv. 8065 NA 8012 8039 CMV. 8066 NE cMv.8013 NA CMV. 8040 NE 8067 cmy.8014 NE cMv.8041 NA 8068 cmv, 8015 NA cmv. 8042 NA 8069 : cmv. 8016 NE 8043 8070 3017 CMV. 8064 Ne cmv.8071 nA 3018 3045 cmv.8072 NA cMv.8019 NA 8046 8073 cmv. 8020 NE cmv.8047 NA cMv.8074 NA 3021 8048 cuv. 8075 NA 3022 8049 8076 3023, cuv.8050 8077 8024 cmv. 8051 NE 078 3025 ans2 3079 3026 8053 cmv. 8080 Ne Jun / 86 MoD. STATEMENT Rep Page 1#@8 ROLLS-ROYcE Modification Statement (Continued) Coverage Mod. No. 3081 aoa2 8083 cmv. 8084 8085 8086 8087 3088 3089 3090 3091 cav.8092 8093 809% 3095 8096 3097 8098 3099 8100 3101 3102 8103 8108 8105 8106 3107 8108 8109 8110 aint art2 8113 8116 a115 8116 ant? 8118 3119 3120 gi2t 3122 8123 MOD. STATEMENT Page 2 Coverage NA Ne NA Ne NA NA NA NA NA NE Ne NA NA NE Mod. No. 8124 8125 8126 8127 8128 8129 3130 8131 8132 8133 8134 8135 8136 8137 8138 8139 3140 8141 3142 81463 8144 8145 8146 8147 8148 8149 8150 8151 8152 8153 8154 8155 8156 NE NA NE NE NE NE NE NA NE NE NE NE NE NE NE NA NA Pages 3 and & not Ri, VIPER AN marntewance ~ mK.535 used Mod. No. Coverage Oct/87 REPRj MAINTENANCE MODIFICATION STATEMENT (JET PIPE) D.1.S.759 AND D.1.$.782 Modifzcations which have an annotation in the "Coverage" column have been investigated and any necessary daca incorporated in the Manual, Annotations aay be one of the following:- + Full coverage P Partial coverage NE No effect on Manual NA Not applicable C Cancelled For infornation concerning aodifications not yet embodied in the Manual refer to Service Bulletins. Mod. No. Coverage. D.I.s. Mod. No. Coverage —_D.I.S. Applicability Applicability cv.7335uP a 759 and 781 cv. 783857 NE 759 and 781 cv. 7407 37 : 759 and 781 cv. 75547 NA - ov.751357 XE 759 and 781 cv. 759157 * 738 and 781 ALL succeeding modifications come within the range of sod. numbers beginning with Mod. CV. JP.170 5 mA - 6 NA - 7 NA - cv. sP.170 cv. gp.171 cv. gp 172 cv. gP.173 aL 781 Sebesobebs bb NE MA MA 5 = ggggggggge RBRE8 Mm 5 759 and 781 759 and 781 BABE ooBERRAB AS i 759 759 781 781 a 3 am and and 759 and 782 759 ana 782 a % § aa 7 5 8 Moo. STATEXENT Jun/aé Page 5 vasmaca1 2. Maren/68 AIST OL ENGINE DIVISION ik RR| MAINTENANCE VIPER 535 INTRODUCTION. Organisation ‘This E.C.U. Maintenance Manual contains descriptive information on the engir assemblies, systems and items of equipment to the level required to service ‘the engine change unit, to trouble~shoot a system, to remove and install uni and to carry out approved repairs, Information is also given on packaging, acceptance checks, storage instructions and for the return of units to the manufacturer or base, ‘The manual has been prepared basically in accordance with the requirements o Specification No,100 issued by the Air Transport Association of America, Chapterisation conforms to the Specification requirements, so that the conte of this manual can readily be integrated into the Aircraft Maintenance Manua for a specific aircraft type, as dictated by the A.T.A, specification requir ments, Since, however, the technical content of this manual is confined to ‘the engine change unit, a number of token pages have been inserted to mainta continuity of the breakdown, Those pages indicate where the subject requir ments have no application to the Viper engine or where the information shoul contributed by the aircraft manufacturer. Chapterisation and Page Numbering A.TLA, Specification No.100 requires the subject matter of manuals to be organised on three levels: Chapter - Section - Subject; these are identif by a three-element numerical system, Thus, the first element indicates the Chapter, the second indicates the Section and the third indicates the Subjec Alternative terms are System, Sub-system and Unit respectively, The number: are located at the bottom outer corner of each page, The following is an example of a three-element identification: - 13 - 10 - 21 Section: Subject: Sub-system: Unit: ENGINE FUEL DISTRIBUTING FUEL PUMP AND CONTRAL, At the beginning of each Chapter, and Sections where applicable, the first ‘two element numbers only are used (for example 73-00 and 73-10), This shors that the information is of a general nature: 73-00 gives a brief overall description of the engine fuel and control system; 73-10 relates to fuel distribution within that system, INTRODUCTI T2021BRISTOL ENGINE DIVISION IR) MAINTENANCE Introduction - Continued ‘Tho arrangement of information within the Chapter ~ Section - Subject breakdown is by Topic, each topic being contained within a block of pages, thus:~ Description and Operation +4, see see + 1 to 100 ‘Trouble Shooting (where applicable) «+. 101 to 200 Maintenance Practices pera rete) 202 to 300 Storage Instructions eeey ere te 701 to 800 Approved Repairs (where applicable) ... 42. 801 to 900 Where, however, the "Maintenance Practices" are extensive or complicated, the individual procedures are allocated the following page block numbers? Servicing pee 301 to 400 Romoval/Installation ... s+. 401 to 500 S01 to 600 Adjustment/Test : Inspection/Check + 601 to 700 3. List of Effective Pages A list of Effective Pages is located at the beginning of each chapter. This enables the user to establish whether the chapter is complete and if it contains the latest issue of all pages. On each list, the date quoted against each page should correspond to the date on the relevant page. 4, Revisions Revisions to this manual will be made when necessary and holders will receive copies without request. Both "Permanent" and "Temporary" revisions may be issued, In a Permanent revision, new or revised technical matter will be indicated by a vertical line in the left-hand margin of the page, except when a section is re-issued in a completely revised form, Where revision action causes re~location of the text on to pages otherwise unaffected by the revision, a vertical line is placed against the Chapter/Section/Subject caption of the pages concerned. INTRODUCTION oct/75, Page 2 vaSMol3mi] ROLLS-ROYCE R| VIPER MAINTENANCE ~ MK.535 Temporary Revisions, printed on yellow paper, will be issued to notify operators - at the earliest opportunity ~ of important changes which affect the manual, operation and safe handling ot the engine or to provide advance information on some modifications. Terminoloay Where the terms "Left" and “Left-hand” or “right” and “right- hand" are applied to the engine or the positioning ot an engine component, the engine is viewed from the rear. 6. Engine Identification To differentiate between engines with different applications and component requirements, a suffix is added to the engine mark number. Engine identification is as follows: 759 - VIPER 535-1 seRtes Country Saudi Arabia Viper 535 - 1A Viper $35 - 18 Viper $35 ~ 1c South Arabia Federation Muscat and Oman D.L.S. 781 - VIPER 535-2 SearEs Viper 535 - 20 Singapore Viper 535 - 26 Kuwait 7. Deviation trom 2. h A procedure exists to help operators who wish to deviate from the instructions given in this Manual. A request should be made to Service Department, Rolls-Royce plc, Aero Division on a Form Eng.5133, Application for Approval of Customer's Local Engineering Proposal. The application will be considered and the operator will be formally notified of the Rolls-Royce ple decision on a Form Eng.5134, Deviation from Published Instructions. Copies ot Forms £ng.5133 and Eng.5134 together with further information, if required, can be obtained from Aero Service, Rolls-Royce plc, Aero Business Group, Ansty, Coventry, CV? 9JR, England. INTRODUCTION oct/89 Page 3 KEP(GD) ROLLS-ROYCE TR AYIEER Sass Observance of Manual Instruction: The instructions for Maintenance and Maintenance Practices of the engine contained in this Manual, particularly those related to removal, installation, and repair of high-duty parts, have been devised to preserve the integrity of the parts during their service Lives. Instructions are written to permit, wherever possible, the use of routine practices in the performance ot tasks and to give flexibility where appropriate. However, where instructions are specific as to means and method, it is important. that alternatives are not used unless agreed with Rolls-Royce plc, since even minor deviations from the specified parameters may require careful evaluation to avoid abuse which may not be detectable by routine inspection. Where changes to the specified instructions are agreed, Rolls-Royce will consider revising the manual to include the change as an alternative. Assembly of parts - Owing to the physical similarity certain engine parts can be assembled into the wrong Location and/or engine types for which they were not intended. Such mal- assembly could possibly result in failure, therefore each part number should be carefully checked to ensure correct - usage. COMMON PROCEDURE - PRECAUTIONS TI AKEN BY PERSONNE! ORKING ON MATERIALS CONTAINING THORIUM 1. General Certain castings in this engine which are made from magnesiun- zirconium alloy (D.1.D.5005) contain thorium which is radio active material. The percentage of thorium used is very small and the Level of radiation from castings containing thorium is below the Level which constitutes any danger to health; however, there is a danger from the inhalation of magnesium-zirconium alloy dust. The following health precautions should be taken when handling or working magnesium-zirconium alloy. B fons uh: Alloy, D.1.0,5005 A. When milling, drilling or turning dust is not produced and the only precaution necessary is to wash the hands thoroughly on completion of work and before eating, drinking or smoking. INTRODUCTION oct /89 Page & Repoct /89 REP ROLLS-ROYCE —_ Fi. VIPER fey MAINTENANCE ~ MK.535 When polishing, filing Chand or power) or rubbing down with emery or garnet paper, dust is produced and the following precautions should be observed. (1) Carry out the work in a suitable booth fitted with dust extraction plant. (2) The operator snould wear a suitable mask and overalls. (3) Thoroughly wash the hands and face on completion of the work or handling of the component, especially before eating, drinking or smoking. Do not eat or drink in any workshop where work on magnesium-zirconium takes place. INTRODUCTION Page 5/6ROLLS-ROYCE R VIPER MAINTENANCE = MK.S35 Chapter 5 TIME LIMITS LIST OF EFFECTIVE PAGES Page pate ° x 3 Contents 1 sep/7& ai 5-00 z 7 oct/89 3 2 oct /39 : 3 oct /39 z 4 oct /89 $=10-00 7 Jan/83 2 Jan/37 3 oct /39 oct /a9 TIME LIMITS 5 nes10006 Effective Pages..15-00 5-10-00 Sep/74 v35M383 Chap./Sect./Sub. fay OR IS TOL ENGINE DIVISION IR] MAINTENANCE VIPER 535 Chapter 5 ‘TIME LIMITS LIST OF CONTENTS ENGINE GENERAL Group A Parts . . . LIFE CONTROL AND LIMITATIONS Generales 00 oar Page : L c 1 ‘TIME LIMITS Contents. .1Poowreo wn enatano a) ROLLS-ROYCE RR as VIPER. MAINTENANCE - MK.535 General Engine parts that are subject to a life limitation are identified as Group 'A' Parts and Group ‘8! Parts. Group 'A' Parts consist of Life Limited parts whose fai could result in damage to the aircraft so extensive as an unacceptable hazard. Group '8' Parts are other parts which have a Life Limit Group "A! Parts These parts are subject to strict Life Limitations base the cyclic stresses imposed upon them during service. Life Limitations are established at Rolls-Royce ple, by sampling and cyclic rig testing ot new and service-run and these Limits must not be exceeded in service. ture to be ation. don The parts, NOTE Fla Und in It is emphasised that the approved tie between engine overhauls, as published in the relevant Service Bulletin, is still applicable. An engine aust be withdrawn from service if either the approved tine between overhauls is reached, or, any Group 'AY Part, has completed its maximum permitted flight cycle life. ght Cycle System ler this system, lives of Group ‘A’ Parts will be given units of Flight Cycles. It is the responsibility of the operator to monitor service Lives of Group ‘A' Parts to ensure that the approved lives are not exceeded, and tha the 8. Pro. The fol om oct/39 Res 006 es of these parts are made known to t the service L returned. overhaul facility when an engine cedure responsibilities ot those concerned are detailed as lows: . Engine Manufacturer Rolls-Royce ple, hereafter referred to as the engine manufacturer, will be responsible for establishing, by suitable testing, the safe flight cycle lives of Group ‘A’ Parts. These lives are detailed in Chapter 5-10-00. 5-00 Page 105] ROLLS-ROYCE RR). VIPER MAINTENANCE = MK.535 Where the Life of any part is the ultimate for that particular standard, this is indicated by an "S" suffix against the life; parts that do not have an "S" suffix will, where appropriate, form the subject of further suitable testing by the engine manufacturer who will amend the Manual as necessary. Until this is done, the Lives currently quoted are mandatory. The recommendation by the engine manufacturer of a cyclic Life for a specific part, does not imply that this part will achieve the stated Life, as rejections for other reasons may be necessary; therefore this does not constitute a warranty on behalf of the engine manufacturer. The appropriate warranty agreements between the engine manufacturer and the operator will apply. (2) Operator The sole responsibility for controlling the Lives of Group ‘A’ Parts in service rests i the operator. When engines are returned to an overhaul facility it is the responsibility of the operator to indicate in the engine log book the total flying hours and number of Flight Cycles achieved by the Engine. (3) Qverhaut Facility The overhaul facility will be responsible for maintaining an internal record system covering every Group 'A' Part, whether in service, held serviceable in stores pending issue to an engine or scrap. These records are of vital importance to the Life control of Group 'A' Parts and must, therefore, be accurate and up-to-date at all times. The part description, serial number and modification standard must be recorded with total Life in terms of flying hours and Flight Cycles both expressed numerically. This record system should index parts under description, part number, and serial number so that rapid location of Group ‘At Parts can be established. Each overhaul facility should record, and make known | to the engine manufacturer the reason for rejection of any Group 'A' Part. fh The overhaul facility should also determine the residual Life of Group 'A' Parts and decide whether or not the parts can be refitted in an engine without becoming time expired in advance or the operator's requirement. 5-00 oct /a9 Page 2 85006oct/89 Resous ROLLS-ROYCE IR AMBER. - ws The overhaul facility should advise operators ot the serial numbers and life completed in Flight Cycles and engine hours (expressed numerically) on all the Group 'A' Parts that have been fitted into an engine during shop visits. This advice must be included with the Forms that accompany the engine when it is returned to the operator and the same information must also be sent to Rolls-Royce alc. A suitable way to transmit this information is on the Engine Build Log Form A.R.2. NOTE: Engines overhauled by the engine manufacturer will have this information Listed on Form A.R.2 which will be inserted into the Engine Log Sook and will cross refer to the Engine Inspection and Test Certificate. Group 'A' Parts with insufficient Life remaining to warrant refitting to an engine are to be crack detected, and, if satisfactory, placed in a Part Life Store. Those Group 'A' Parts approaching their ultimate Life, which is designated S in the Life Limitations Table, are to be crack detected before disposal. The results ot the examination are to be recorded, with the serial number ot the engine concerned, the Life of the part, and for turbine discs, the measured diameter. The recorded information, together with any part found to be cracked, is to be return for evaluation to Aero Service, Aero Business Group, Rolls-Royce plc, Ansty, Coventry CV7 9JR, England. 5-00 Page 3ROLLS-ROYCE VIPER MAINTENANCE = MK.535 GROUP ‘A’ PARTS ENGINE BUILD LOG ‘openaron — [OvERNAUL aASE | ENGINE TYPE [eWcIne wo. Las Joare ‘PART DESCRIPTION | PART SERIAL Ne. | MODIFICATION | Pant TOTAL | PART, fa aoe ary . | I T AUTHORISING SIGNATURE, Typical Engine Build Log Form Figure 1 5-00 oct /89 Page 4 R85 006() ROLLS-ROYCE LIMITED R VIPER MAINTENANCE ~ 535 LIFE CONTROL AND LIMITATIONS - GROUP 'A' AND GROUP '8' PARTS 1, General The lives of Group 'A' Parts for these engines, related to modification standard, are listed in Table 1. The lives of Group 'g' Parts for these engines, related to modification standard, are Listed in Table 2. Parts whose Lives are marked with the suffix @ are to be quarantined, on completetion of the permitted hours, pending further Life extension, The suffix $ indicates that the testing of these parts, with a view to further Life extension has ceased. Jan/33 5-10-00 Res 10006 Page 1(25) ROLLS-ROYCE FR) VIPER HAINTENANCE = MK.535 teed fe Control and Limitations Continued Comonent Modi tication Standard Cleared Lite in Hours ) = Singapore 3 0004 Turbine rotor blade ) - R.S-A.A.F. (Saudi Arabia) 2 500 a d= RINZLAL FS 2 sou a ) = Other Operators 2 100 a Turbine Lacing wire Not to be refit once removed from the turbine disc assembly. Fuel pump coupling - One engine overhaul piece Ute 8 Hydraulic pump - One engine quilshaft overhaul Lite § Flexible pipe ) 8388251 ) One engine 8356247 - ) overhaul Life $ 8394507 ) Rotating shroud Zero - 1st stage Salvaged to V.46088 One engine overhaul life Ss . Centre sections One engine extension unit overhaul Life $ bolts 8378109 CALENDAR LIFE Hose Assemblies Rubber Flexib Hose assemblies which have completed an engine overhaul. \ife, or are removed from an engine during repair and are more than 20 years old are to be scrapped. Unused hose assemblies which are over 15 years old are to be subjected to checks on serviceability before fitment to an engine. Group "8 Parts Table 2 oct /89 3-10-00 Res 10UUG Page 3fe Controt ROLLS-ROYCE LIMITED R VIPER MAINTENANCE - #K.S35 and Limitations Continued Component Modification Cleared Life Equivalens Standard in flight Cleared cycles (Assumina S_cyetes/hre) Compressor rotor discs Zero stage - 37 900 7 400 s 1st stage Pre-Mod.CMV.3859 12 500 2 500 $ ist stage Mod.cMV.3859 32 500 6 500 § 2nd stage - 23 500, % 700 § 3rd stage - 20 100 4 020 4th stage - 23 700 4 740 $ 5th stage - 18 000 3 600 $ th stage - 18 000 3 600 § 7th stage Pre-Mod.cMV.7449 5 750 1150 5 7th stage Post=mod.CMV.7449 © 32 500 6 500 Compressor rotating shrouds 3rd-Gth stage 25 000 5 000 a Gth-Sth stage 25 000 3 000 a Sth-6th stage 25 900 3 000 @ Gtn-7th stage Pre-Mod.CMV.7423 8 250 1250s th-7th stage Post Mod.CMV.7423 25 000 5 000 a Compressor nainsnatt 38 000 7 600 a Turbine mainshatt 25 000 3 000 a Turbine disc 42 300 8 560 s Group ‘A’ parts Table 1 5-10-00 Jan/87 aas10006 Page 2IR) MAINTENANCE VIPER 535 chapter 70 STANDARD PRACTICES - ENGINE ‘There is no information relevant to the Viper 535 engine to be placed in this Chapter. March/68 STANDARD PRACTICE rw20214 Page(SQ) ROLLS-ROYCE VIPER MAINTENANCE - MK.535 chapter 74 POWER PLANT. LIST OF EFFECTIVE PAGES Page pate Pag date m1 522 Jan/83 Contents 1 May/76 523 Jan/a3 Contents 2 Sep/78 524 dan/83 541 Mar! 71 71-00 542 Mar/71 1 Mar/68 543 Dec/72 101 Mar! 68 544 Jan/87 102 Mar/68 545 Nov/73 103 Mar! 68 546 Mar/68 104 Nov/73 547 Jan/79 106A sep/a5 548 Sep/7% 1048 Sep/as 549 Nov / 80 105 Nov/ 73 550 June/8 106 Nov/ 73 551 June /8 107 Nov/ 73 552 June/8 108 Marl 68 353 June/8 109 Jun/ 88 554 dune /8 110 Julss7 555 Dec/89 1408 Jul/37 556 Dec/ 89 Wn Nov/ 73 557 dec/89 401 Jun/ 34 558 Dec/ a9 402 suns 3 359 dec/a9 403 Jun! 3% 561 Sep/73 404 Sep/as 562 Dec/76 405 Sep/as 563 May/70 408 duns 34 564 Mar! 70 407 duns 3s 565 Mar/ 70 501 May/8& 581 Mar! 63 502 May/ 86 503 May/ 84 71-06-0 504 May/ 86 1 Mars 68 505 May/ 84 506 May/ 84 : 307 May/ 84 Mars 68 503 May/ aa 509 duly 37 310 Juts 87 1 Jan/72 Sat Mar/68 2 oct /75, 512 Mar/68 3 dans72 513 Nov/ 84 4 Feb/ 80 514 Feb/80 5 May/76 515 Feb/ 80 6 Feb/30 516 Feb/ a0 a May/ 76 521 Jan/ a3 a may/76 pecs 89 POWER PLANT 71 RB7ILE Effective Pages..1fam] ROLLS-ROYCE RR VIPER MAINTENANCE - MK.535 tof Eftective Pages Continued Page ate Pace pate 71-09-1 1 may/ 84 2 Juss? 3 Jus a7, 6 dul/ 87 5 juts 87 201 Sep/74 202 Sep/74 203 Sep/7s 204 duls a7 204a/2048 Jut/ 87 205 sJut/ 87 206 Juls 37 206A/2068 Jut/ 8? 207 oct /75 71-09-2 1 oct /39 2 oct /39 71-09-11 1 mar/90 71-09-21 1 mars 90 2 mars 90 3 oct /89 4 nar/90 71-09-31 1 Jan/79 2 Jan/79 71-09-41 1 oct /87 2 May/ 86 71-50-11 1 vec/63 2 dec/76 POWER PLANT Mars/90 7 Re71LE Eftective PagesSG) ROLLS-ROYCE IR) VIPER MAINTENANCE = HK.535 (3 Chapter 71 POWER PLANT LIST OF CONTENTS chao. /Sect./Sub 71-00 GENERAL, Sep/8s RB71LT Description and Operation. . ~ Trouble Shooting . « Engine Does not Rotate during Start Cycle. Engine Rotates dut Fails to Light During Starting Cycle (Jet Pipe and Nozzle Dry). Engine Rotates But Fails to Light During Starting Cycle (Jet Pipe and Nozzle Wet) . Engine Lights Up gut Attains Maximus J.P.T. During Start. Engine Lights Up But Fails to Reach Idling Speed . 5 Engine Slow to Accelerate Engine Stalls or Flames-out during Acceleration . Engine Fails to Attain Max. “spete ° Ground High Jet Pipe Temperature Under Ste Running Conditions. Engine Flames-out Under Steady Runn Conditions =. Engine Flames-out on deceleration Removal/Installation . . . Remove Power Plant. . Convert Power Plant to Engine Install Power Plant. . Adjustment/Test Ground Running - General . General Procedures . 5 Ground Running and Flight Limitations =. Starting, Stopping and Motoring Shock Loading Tests. . . « General.» «7 ee Engine Seizure... Heavy Landing se Engine Inspection Checks and Gro Running Checks . + Ground Running Tests Test Procedures. - Ground Running Adjustments Adjustment Procedures. Ground Running - Fire Fighting « ing sey ing ond POWER Page 1 101 101 102 103 104 1048 106 107 108 109 110 m4 sot 401 403 07 sot Sot 504 511 521 521 52t 521 522 541 541 561 361 381 PLANT 71 Contents.-1(5M ROLLS-ROYCE Rl VIPER ] HAINTENANCE = HK.535 Chao. /Sect./Sub Page 71-06-0 DRAINS SYSTEM. «ee ee eee 71-07-0 aUILD LIST =» ee ee ee ee 71-08-0 TOOLING AND EQUIPMENT General wwe ee ee ee ice 6 6 oO 6 GG GF Tool Numerical List . . . 2 . + 6 71-09-1 SERVICING MATERIALS List of Approved Products. . . + + 17 lubricants. . ee ee Jointing Compounds and Solvents. . . 2 Miscellaneous Materials. . . + « & Maintenance Practices» - . + . + 201 Cleaning and Painting » - 5 + + 201 Jointing Compounds» . 5. 3.) + 205 Lubricants . see 206 Misuse of Molybdenum Disulphide Lubricants. . se ee ee 208 Re-use of Self-locking Nuts. . . . 206 7109-2 STORAGE AND PACKING MATERIALS. . . . «1 700 tein A PROVED OT Remerunee scr) Serevent et acct mer ine 71-09-21 APPROVED FUELS» we we ee 71-09-31 NON-MANDATORY TORGUE LOADINGS. . . . «17 74-09-61 INSTALLING PIPES Maintenance Practices... wt 71-30-11 LIGHT DUTY ELECTRICAL HARNESS Maintenance Practices. . . . . 1 Bower PLANT Juts87 1 Ra7tLr Contents.pm SAIS TOL ENGINE DIVISION MAINTENANCE VIPER 535 POWER PLANT - GENERAL - DESCRIPTION AND OPERATION 1, The aircaft is propelled by a Rolls-Royce Bristol Viper turbojet engine, which is fitted in an engine compartment vithin the aircraft fuselage behind the cockpit. Engine thrust is transferred to the aircraft through two horizontally opposed trunnion mounting blocks, fitted to the centre section, which provide the primary engine mounting points. A third point mounting, located on the left side of the air intake casing, is connected to an adjustable link fitted to the fuselage structure. Firewalls at the front end of the engine compartment and at the rear of the centre section, separate the installation into zones 1 and 2 which are ventilated by ram air and protected by a fire detection system of the continuous Firewire type. A 1.5 1b. charge fire extinguisher connects with a spray ring that protects zone 1, which contains the fuel and oil system components and pipelines. Throttle and high pressure fuel cock controls are operated from levers in the cockpit, The h.p. fuel cock lever is mounted on the centre pedestal. Two interconnected throttle levers are provided; one lever is mounted on the pilot's console and the second lever is mounted on the centre pedestal. The engine is equipped with a combined starter/generator, and provision is made for starting by using either internal or external power supplies. The description and maintenance practices for the engine are given in Chapter 72; the jet pipe is treated separately under ‘Exhaust’ in Chapter 78. March/68 Tic ‘rw20215 PageVIPER 535 MAINTENANCE POWER PLANT - TROUBLE SHOOTING ENGINE DOES NOT ROTATE DURING STARTING CYCLE Check (if possible) engine free to rotate by hand OK, check electrical power supply to starter/generator (refer to Aircraft Maintenance Manual). | OK, check starter/ generator and drive. Not OK, Drive OK, change Drive not OK, restore electrical power, starter/generator change driveshaft (See Aircraft extension or Maintenance accessory gearbox Manual). (Chapter 72-60, Accessory Drives - Maintenance Practices or Chapter 72-00, Engine ~ Mainten- ance Practices). March/68 ‘Tw20216 Not OK, check pressure oil filter for contamination and the scavenge filter for ferrous metal. i | OK, check all Not OK, reject accessories for engin freedom of rotation. OK, remove accessory Not OK, change gearbox and check defective for freedom of accessory, rotation. ox, Not OK, change accessory gear~ box. (Chapter 72-00, Engine ~ Maintenance Practices). reject engine. 71-00 Page 101ORISTOL Ewaine DIVISION R Ri MAINTENANCE VIPER 535 Power Plant ~ Trouble Shooting Continued ENGINE ROTATES BUT FAILS TO LIGHT DURING STARTING CYCLE (Jet pipe and nozzle dry, H.£. igniters working) Check that there is ample fuel in tanks and that correct starting procedure i been followed. OK, if L.P. warning light is ON, check that booster pump is running and L.P. fuel cock fully open. OK, attach bleed tool to L.P. filter Not OK, change booster pump drain valve and check fuel flow is (See Aircraft Maintenance Manual) under pressure. Bleed the H.P. and/or open L.P. fuel cock. fuel pump governor and recheck start. Not OK, check the H.P. fuel pump outlet pressure during a wet motoring cycle. (Chapter 73-00). OK, check H.P. fuel cock If low, perform a spill If aero pressure, for correct rigging. test on the b.f.c.u. check for fuel and a.f.r.c. half-ball pump or drive OK, check p.i.v. for valves (Chapter 73-00). ‘failure. freedom of operation. If spillage No spillage Not OK, change OK, change occurs trom change the fuel pump the fuel Not OK, either of fuel pump and/or pump (Chapter change the the half-ball (Chapter accessory 73-10-21). petiv. valves. change 79-10-21). gearbox (Chapter the b.f.c.u. (Chapter 73-10-51), or a.f.r.c. 72-00). (Chapters 73-20-11 and 73-20-21). 71-00 March/68 ‘w20217 Page 102[Ri MAINTENANCE VIPER 535 Power Plant - Trouble Shooting Continued ENGINE ROTATES BUT FAILS TO LIGHT DURING STARTING CYCLE (Continued) Get pipe and nozzle wet) Check that correct starting procedure has been followed. OK, ensure engine attains a speed of 11% rev/ min at least and fuel L.P. warning light remains OUT during the motoring cycle. OK, check igniter aurally selecting relight ON. OK, carry out a dry motoring cycle and again check igniters aurally. OK, check aurally or Not OK, check by feel, the function part of igniter of primer solenoid circuit to engine starting circuitry. Not OK, change the primer solenoid valve (Chapter 73-10-31). OK, recheck starting eyele. Not OK, remove and examine primer adjacent to igniter, check that the primer ring drain orifice 1s clear. OK, recheck start and observe fuel spray eaits from primer ring drain. OK, check p.i.v. for freedom of operation. OK, check the H.P, fuel pump outlet pressure during a vet motoring cycle. (Chapter 73-00). Not OK, refer to procedure laid out in ENGINE ROTATES BUT FAILS TO LIGHT DURING STARTING CYCLE, dealing with low and zero pressure. varch/68 ‘rw20218 Not OK, refer to Trouble Shooting chart:~ ENGINE DOES NOT ROTATE DURING STARTING CYCLE. Iantter plu tol sparking. check tie co Ack, endaay es toe ug (hapeer 8040"), nopoas the operleionat checks 1 Stattate - Thotis sioortie aed tf seceeseny cinage the Riis igor amit. Not OK, change primer units and/or clear blockage from primer ring drain orifice (Chapter 73-10-41), Not OK, change the! primer solenoid (Chapter 73-10-31), Not OK, change the'p.i.v. (Chapter 73-10-51). 71-0 Page 10Ri MAINTENANCE VIPER 535 Power Plant - Trouble Shooting Continued ENGINE LIGHTS-UP NORVALLY BUT ATTAINS MAXIMUM J.P.T. DURING START Check (if possible) engine free to rotate. OK, check air intake Not OK, investigate cause; for obstruction. reject engine if necessary. OK, check that compressor | vtow-off vaive blank is removed. | ok, visuatty check blow-off valve is open. Tf in doubt attach streaners to valve outlet grid and commence dry motoring cycle. | 0%, check voltage of batteries. Not OK. Compressor blow-off valve 1 operation unsatisfactory. Check P1/P2 OK, cheek engine drains clear. valance pipe for blockage (Chapter 75). 1 Ok, check pressure increasing ok, service air bleed Not OK, change balance valve and primer solenoid control valve pipe. - valve close on shut-down. (Chapter 75-30-21). po OK, change 'b.f.c.u, (See Ok, remove compressor Not OK, change control cnapter 79-20-11). blow-off valve and valve (chapter check smooth operation 75-30-21). of piston. j___ OK, change’ pressure Not OK, chknge ratio switch compressor (chapter 75) blow-off valve (Chapter 75-30-11). Nov/73 71-00 v3suo24 Page 104Sepe/85, ABS) ROLLS-ROYCE LIMITED VIPER MAINTENANCE - MK, 535 Intentionally Blank 71-00 Page 104AROLLS-ROYCE LIMITED VIPER MAINTENANCE ~ MK.535 Ri Power Plant - Trouble Shooting Continued (afied axat uo por *(1s-01-£2 a9adey9) “ATT 843 aBuRUD “9 ION aosuuossyp ATLe9¥a32919 “YO snot st paads @uyyueas zy e8eaton Ax930q yo2yD = wareks Baten 330 =no1a 8no311 “spuos9s cz HARIXYH SNIVLLV ae sdzaa ay ea ung XTIVIRION pue yarns aura spanseaad oraz pue not yaqm ButyEap *3TOKO ONTINVLS ONTYRC 1911 OL STIVA Inf saiviou a ut Ino prey aanpagosd 02 49391 ‘y9 10N oanssazg aads Suyqueas yoau9 — |_______ lorem Arp © aauaKMIED TIM aatea aya o9 ssozsossaace pur sasaqty 170 Buryoa49 303 31949 ONLIALS ONTING SIYLO¥ JON $300 3NTONA UF ano P¥eT aanpaoord 02 29391 “YQ ION *paado sey eaten 330-n01q aossorduos 3eya 909 S44 a"C UBT & sey puR ponds Buy ipr ysraa 02 sre urfua ang ‘0 puew pur adyd Burqurta pur SuzaseuuoDs Ep 4q nod sous Ttdae woa3 9a1 eavjosy $9 ION 98 eee Panuyaueg -daaas ONTTGT HON OF Stiva ana aN SNOT GNTONG 71-00 Page 105 | sepessRisto. engine o1vision | MAINTENANCE cd VIPER 535 Power Plant - Trouble Shooting Continued ENGINE SLOW 70 ACCELERATE “GAIL conditions) Check operation of compressor blow-off valve (Chapter 71-00, Test C of Ground Running Tests). | ox, adjust Seceteration Not OK, comprlssor blow-off rate, (See Chapter 71-00, valve operation unsattafactory. Adjuoement € of Ad ustaent/ Check 21/92 balance pipe for Test = cround Running Adjustments). blockage (chapter 75)- Not O€, cheek P2 air pipe ox, servich air bleed Nor OK," change to a.ferse. and Line filter control valve (Chapter balance pipes for danage and security of weet0-8). connections, —— Ok, renove compressor Not OK," change OK, change Aet.r-0. blow-off valve and control valve (Chapter 79-20-21). heck sooth operation (Chapter 78-20-21). of piston. j}_________, OK, change’ pressure Not Of,” change ratio vitor conprensor Cenapeer 75) blow-off valve, (Chapter 75-30-11). 71-00 Nov/73 Page 106 vasM026OaIsTOL ENGINE DIVISION Ri MAINTENANCE amt VIPER 538 Power Plant - Trouble Shooting Continued ENGINE STALLS OR FLAMES-OUT DURING ACCELERATION Examine engine air intake for damage or obstruction, inlet guide vanes and compressor stator blades for damage or malalignnent. Not OK, reject OK, check operation of compressor engine Dlow-off valve (Chapter 71-00, Test C of Ground Running Tests). Not OK, compressor blow-off valve Operation unsatisfactory. Check P1/P2 balance pipe for Wot OK, (valve closes prematurely), check the valve and pressure ratio switen connections for leakage. areemnrenregs | l Ok, service air bleed Not OK, change balance No apparent Leakage, change control valve (Chapter pipe. pressure ratio ssitch and 75-30-21). reccheck valve operation. blockage (Chapter 75). OK, remove compressor blow-off valve and check smooth operation of piston. Not OK, change control valve (Chapter 73-30-21), OK, change pressure ratio Mot OK. change switen (Chapter 75). compressor blow-off valve (Chapter 5-30-11). OK, check acceleration rate, if outside Limits adjust a.f.r.c, to prevent influence on max. fuel flow to engine then determine the highest rate of acceleration by manual control of throttle. Test = Ground funvang Tests). Cehaptoe To ascaie If engine still stalls reject for investigation. Now/73 71-00 ¥35M027 Page 107Power Plant - Trouble Shooting Continued ENGINE FAILS TO ATTAIN WAX. eR ISTOL ENGINE DIVISION MAINTENANCE VIPER 535 SPEED ON GROUND (OTE: The engine will not reach max. rev/min below approximately 5 deg. C, ambient, unless the b.f.c.u. capsule chamber is pressurized to 5 p-Sei-g. maximum, Check that the fuel L.P. warning Light remains out. Not OK, ‘restore fuel supply. If engine fails to exceed 70% rev/ain, change the a.f.r.c. (chapter 73-20-21), OK, adjust max. speed governor. (Chapter 71-00, Test B of Adjustment/ Test ” Ground Running Adjustments), | Engine still not Ox, check a.f.r.c., max. flow piston stop by unscrewing about 0.5 turn and re- checking rev/min. ngine selit not ox, change fuel pump (Chapter 73-10-21). 71-00 Page 108 OK, check and if necessary calibrate. rev/min indicator (Aireraft Maintenance Manual). | OK, bleed engine fuel system. Bléed the rate reset valve at 10% rev/ain. Ground test engine and check ‘dead’ throttle movenent - (Test D of Adjustment/Test - Ground Running Tests). Not OK, examine turbine for damage. Check throttie lever on b.f.csu, reaches stop. OK, change b.f.c.u. (Chapter 73-20-11). March/68 ‘120222GD ROLLS-ROYCE PR! VIPER / 5 diay NAINTENANCE ~ MK.535 HIGH JET PIPE TEMPERATURE UNDER STEADY RUNNING CONDITIONS No: ox, damage. air holes are clear of obstruction If this occurs on the initial run after installation or after change of jet pipe. check nozzle trimmer state against log book. Functionally check that all compressor air bleeds and the primer solenoid valve are CLOSED. No! i Check correct function of primer solenoid valve by selecting relight ON at 60% rev/min. A momentary 6 to 8% rev/min. drop should occur as solenoid valve opens and primer manifold fills with fuel. Select relight OFF, 60% rev/min. should be retained proving solenoid valve is closed. Allow at least two minutes between successive checks. check as far as possible, air intake, comoressor blades (tip clearance), exhaust cone and nozzle for obstruction and/or Check that all thermocouple probe replace damaged 0k, check calibration of Not OK, exhaust cone, jet pipe. engine indicating system nozzle or thermocouples. j.p.t. and rev/min Reject engine for other (Chapter 77-20). damage. 1 Not OK, rectify instrumentation as necessary (Chapter 77-20 and Aircraft Maintenance oe Engine still not OK, reject the engine, Jun/38 71-00 287100NS1 Page 109G0 ROLLS-ROYCE R | VIPER MAINTENANCE ~ MK,S35 ENGINE FLAMES-OUT UNDER STEADY RUNNING CONDITIONS WITH ‘AMPLE FUE! N THE TAN Check indication of fuel pressure warning Light Warning Cignt ON. Warning’ Light our, check for obstruction in fuel supply to engine Prolonged running of fuel pump without fuel flow pe damage and necessitate replacement of pump NOTE: Ok, check L.P. filter element Not 0K, fit new filter element (Chapter 73-10-11) OK, but engine will not stare, fit new filter element, and refer to Trouble Shooting charts: ENGINE ROTATES; UT FAILS To LIGHT DURING STARTING CYCLE - wet or dry as applicable 71-00 Page 110 check for excessive water content in the fuel at LP. filter f"" OK, check engine for Not OK, operate physical damage to all aircraft fuel compressor by the system water ingestion of foreign | drains until objects and/or clear; then renew turbine blade damage filter element and due to blade tip drain fuel system fouling of turbine components by outer casing bleeding fuel from pump governor (Chapter 73-10-11) NOTE Damage may be caused through the intake of 0K, if engine Not oK, 100% water will start reject content by check the H.P, the the H.P, fuet pump engine fuel pum. outlet pressure This will during a wet necessitate motoring cycle the (Chapter 73-00) rejection and replacement of the fuel pump Juls37 R87100KS1$0 tN encLano iR. Viren EBV warntenante ~ me.535 ENGINE FLAMES-OUT UNDER STEADY RUNNING CONDITIONS WITH AMPLE FUEL IN THE TANKS OK, check throttle response to maximum selection. If dead throttle is excessive replace a.ferece or befecwu. (Chapters 73-20-11 and 73-20-21) No spi change the fuel pump (Chapter 73-10-21) Juls/a7 287100Kst lage, Not 0k, perform a spill test on the befeceue and asferece half~ball valves (Chapter 73-00) If spillage occurs from either of the half- ball valves, change the bafeceus oF asferece (Chapters 73-20-11 and 73-20-21) (Continued) | If zero pressure, check for fuel pump or drive failure Not Ok, change fuel pump and/or accessory gearbox (chapters 73-10-21 and 72-00) 0k, change the fuel pump (Chapter 73-10-21) 71-00 Page 110Ai i : BRISTOL ENGINE O1VISION (Ri MAINTENANCE VIPER 535 Power Plant - Trouble Shooting Continued ENGINE FLAMES-OUT ON DECELERATION Check compressor blow-off valve for correct operation. OK, perform spill test on b.f.c.u. and a.f-rec. half-ball valves (Chapter 73-00). OK, examine pressure If spillage occurs from increasing valve piston any half-ball valve, for freedom of operation. change b.f.c-u. or a-f-r.ce (Chapters 73-20-11 and 73-20-21). Not OK, change valve (Chapter 73-10-51). OK, service air bleed control valve (Chapter 78-30-21). Engine still not OK, change h.p. fuel pump (Chapter 73-10-21). OK, remove compressor blow-off valve and check smooth operation of piston. OK, change pressure ratio switch (Chapter 75-30-31). OK, ground run engine. Check and adjust com- pressor blow-off valve setting or the a.f.r-c. setting as necessary. Nov/73 v354031 Not OK, compressor blow-off valve operati« unsatisfactory. Check P1/P2 balance pipe for blockage (Chapter 75). Not OK, change balance pipe. [-————_, Not OK, change control valve (Chapter 75-30-21 -————_} Not OK, change compress blow-off valve (Chapter 75-30-11). no Page 11= ROLLS-ROYCE LIMITED rR VIPER IP; «= MAINTENANCE ~ MK.535 bors POWER PLANT > REMOVAL/ INSTALLATION 1. Removal Power Plant A. Inhibit the engine fuel system prior to engine removal (Chaoter 72-00, Engine - General - Cleaning and Storage Instructions). 8. Remove Power Plant (refer to Aircraft Maintenance Manual). CAUTION: WHENEVER THE HYDRAULIC PUMP IS REMOVED FROM THE ACCESSORY GEARBOX, THE HYDRAULIC PUMP QUILL SHAFT MUST BE REMOVED AND ATTACHED EXTERNALLY TO THE ENGINE, IN A SUITABLE CONTAINER. THE HYDRAULIC PUMP APERTURE SHOULD THEN 8& COVERED USING THE APPROPRIATE BLANK. 2. Convert Power Plant to Engine Certain aircraft parts which are fitted prior to powerplant installation must be removed for fitment to a replacement engine. The removal procedure is as follows: A. Remove Engine Control Rods. (1) Disconnect the adjustable link rod at the throttle valve lever on the b.f.c.u. and at the bell crank lever mounted at the compressor casing joint flange. Retain the two bolts, the plain washer and slotted nut, discard the tabwasher. (2) Disconnect the adjustable link rod trom the h.p. fuel shut-off cock lever on the b.f.c.u. Retain the setbolt and discard the tabwasher. (3) Disconnect the throttle bell crank lever from the support bracket mounted at the compressor casing joint flange. Retain the belt, plain washer and slotted nut. Remove Breather Extension Pipe, : connect and remove the flexible extension pipe from the rigid overboard breather pipe. om (2) Blank off the rigid pipe and both ends of the flexible pipe. Jun/ 86 71-00 Ra7100MS1 Page 601ROLLS-ROYCE LIMITED | VIPER MAINTENANCE = MK.535 C. Remove L.P. Fuel Pipes. (1) Disconnect the flexible l.p. fuel feed pipe from the rigid pips (2) Remove the flexible fuel pipe - L.o. fuel filter constant bleed - from the banjo connection on the lip. fuel filter housing. (3) Blank off the apertures and pipe ends. Remove Fuel Drain Pipes. (1) Remove the fuel pump gland drain pipe from the fuel pump. (2) Remove the o.f.c.u. capsule chamber drain pipe from the b.f.c.u. (3) disconnect the fuel drain pipe from the primer aani- fold drain connection at the base of the centre section casing and at the firewall bulkhead. Remove the pipe. (4) Remove the firewall bulkhead. (5) Blank off the apertures and pipe ends. €, Remove Starter/Generator. (1) Remove the field lead from the starter/generator (refer to Aircraft Maintenance Manual). (2) Remove the starter/generator (refer to Aircraft Maintenance Manual). (3) Remove the generator cooling adapter from the accessory gearbox (refer to Aircraft Maintenance Manual) then fit and secure the blank plate to the accessory gearbox. F. Remove Aircraft Services Air Outlet Adapter Plate. (1) Remove the adapter plate from the top Left-hand side of the centre section casing, then install and secure the blanking plate. G. Remove Blow-off Valve Outlet duct, (1) Remove the air outlet duct from the blow-off valve (refer to Aircraft Maintenance Manual). (2) Fit a blanking cover to the blow-off valve. i 71-00 Jun/ 86 Page 402 287100MS1ROLLS-ROYCE LIMITED R VIPER MAINTENANCE ~ WK,535 wD H. Remove Slow-off Valve Adapter Ring. (1) Refer to Chapter 75-30-11, Compressor Slow-off Valve - Maintenance Practices. 3. Preoare Replacement Engine as Power Plant A, Install Blow-off Valve Adapter Ring. (1) Refer to Chapter 75-30-11, Compressor Blou-off Valve - Maintenance Practices. « Install Blow-off Valve Outlet duct. NOTE: If the engine has been treated for Long-term storage remove the temporary rust preventative from the engine and engine components, using white spirit (8.$.245). (1) Remove the blanking cover from the blow-off valve. If necessary, fit the adapter ring (refer to Chapter 75-30-11). (2) Fit the air outlet duct to the blow-off valve (refer to Aircraft Maintenance Manual). Install Aircraft Services Air Outlet Adapter Plate. (1) Remove the blanking plate from the top left-hand side of the centre section casing, Fit a new joint washer, then install the aircraft services air outlet adapter plate. Secure the adapter plate with spring washers and plain nuts; torque-tighten the nuts to 70 to 80 Lbf.in, CAUTION: TO PREVENT FOREIGN MATTER FROM FALLING INTO THE INTERIOR OF THE ENGINE THE TWO OUTLET APERTURES IN THE ADAPTER PLATE MUST BE BLANKED OFF UNTIL AFTER ENGINE INSTALLATION. D. Install L.P. Fuel Pipes. (1) Remove the pressure blank and attach the flexible fuel pipe - lp. fuel filter constant bleed. Tighten and wire-lock the union connection. (2) Attach the flexible l.p. fuel feed pipe to the rigid pipe; tighten and wire-lock the union connection. Jun/ 86 71-00 Re7100Ms1 Page 603ROLLS-ROYCE LIMITED VIPER MAINTENANCE - MK.535 23h €. Install Fuel Drain Pipes. (1) Remove all blanks from the fuel drain apertures and pipe ends. (2) Fits tighten and wire-lock the flexible fuel pipe ~ fuel pump gland drain. (3) Fits tighten and wire-lock the b.f.c-u. capsule chamber drain pipe. (4) Fit and secure the firewall bulkhead and bulkhead seal. (5) Remove the blank and fit the fuel drain pipe to the primer manifold drain connection at the bottom of the centre section casing and at the bulkhead. Tighten and wire-lock the union connections. F. Install Breather Extension Pipe (1) Remove the blanks, then fit the flexible breather extension pipe to the engine overboard breather pipe. (2) Tighten and wire-lock the union connections. . G. Install Starter/Generator. (1) Remove the blank plate, then fit the generator cooling adapter to the accessory gearbox (refer to Aircraft Maintenance Manual). NOTE: Ensure that the engine accessory gearbox, starter/generator aperture is wiped clean to remove any residual oil or contaminate before starter/generator fitment. (2) Fit the starter/generator (refer to Aircraft Maintenance Manual). (3) Secure the field lead to the starter/generator : (refer to Aircraft Maintenance Manual). H. Install Engine Control Rods. (1) Fit the throttle bell crank lever to the bracket mounted at the compressor casing joint flange. Secure the lever with a bolt, plain washer and slotted nut locked with a split pin. sep/as | 71-00 R87100"S1 Page 404is] ROLLS-ROYCE LIMITED R VIPER MAINTENANCE ~ HK. 535 c View LOOKING FORWARD. Arrangement of Trimmers in Propelling Nozzle Figure 401 2) Fit the adjustable link rod to the bell-crank lever and to the throttle valve lever on the b.f.c.u. Secure the rod at the throttle valve with the Setbolt and a new tabwasher and at the bell-crank lever by the bolt, plain washer and split pin. (3) Fit the adjustable link rod to the h.p. fuel shut- | sepvas R87100MS1 off cock lever on the b.f.c.u. Secure the rod at the shut-off cock lever with the setbolt and a new tabwasher and at the bell-crank lever by the bolt, plain washer and split pin. 71-00 Page 405ROLLS-ROYCE LIMITED VIPER MAINTENANCE - MK.535 J. Install Jet Pipe Trimmers (Newly Installed Engine or Jet Pipe). CAUTION: INCORRECT POSITIONING OR NUMBER OF TRIMMERS FITTED MAY ADVERSELY INFLUENCE JET PIPE TEMPERATURE AND CONSEQUENTLY ENGINE PEFORMANCE. (1) On a jet pipe incorporating Mod.CV.7591 the untrinmed propelling nozzle diameter is etched on the nozzle rear stiffener band. If Mod. CV.7591 is not incorporated measure the internal diameter of the propelling nozzle Cuntrimmed) at eight equidistant, diametrically opposed positions and from these figures obtain an average dimension. Etch this dimension (the mean nozzle diameter) on the prop- elling nozzle rear stiffener band and record the dimension in the jet pipe log book. NOTE: Propelting nozzles can deteriorate in service and become oval or mis-shapen. If this has occurred it will cause an increase jn j.p.t. because of the reduced nozzle efficiency. Under these conditions it is permissible to remove a trimmer after the performance check (sub-opara. (5)) in order to maintain the j.o.t. limits. Should it be found necessary to remove more than one trimmer, the engine manufacturer's represen tative Should be contacted. (2) The diameter of the trimmed nozzle used for the engine acceptance test is recerded in the engine log book. Subtract this dimensiotn (the engine acceptance nozzle diameter) from the mean nozzle diameter obtained in (1). The resultant figure is the discrepancy required to be balanced to the nearest approximation by the fitment of the requisite number of trimmers, (3) Fitment of each standard trimmer V.41814 reduces the effective propelling nozzle diameter by 0.030 in. The procedure for determining the amount of trimming required is amplified in the following example: Flight jet pipe mean nozzle diameter 13.60 in. Engine acceptance nozzle diameter 13249 ine Ott in. Discrepancy for trimming correction 71-00 . suns 86 Page 406 R87100KS1Perey Om ENGLAN ROLLS-ROYCE LIMITED oa Ri VIPER HEX narrewance = mx.535 One standard trimmer reduces the effective nozzle diameter by 0.030-in. Therefore correction to the nearest approximation will require four trimmers, MOTE: To allow an additional degree of trimming in circumstances where the fitment of six standard trimmers does not sufficiently reduce propelling nozzle diameter, a special trimmer (V.42954) is provided to replace one or more of the standard trimmers. fach special trimmer reduces the effective nozzle diameter by 0.064 in, (4) Fit the requisite trimmer(s) within the propelling nozzle at the positions specified in fig.401 and secure each trimmer with three mushroom-head bolts (lubricated with graphite grease), plain washers and self-locking nuts. Torque-tighten the nuts to 80 - 90 bf. in. If special trimmers are required, use the fitting sequence given in Fig.404. Any nozzle trimmer location unoccupied aust have the securing bolts, plain washers and self-locking nuts fitted. NOTE: pate +24, (5) Ground run the engine to check performances For acceptance refer to page block 501 par. Notes 1, 2 and 3, 4. Install Power Plant A. Attach new locking wire to the Locking tab adjacent to the pressure oil filter. B. Prime the engine oil system immediately prior to installation (refer to Chaptger 72-00-11). C. Lubricate the trunnion bearings (refer to Chapter 71-09-1), D. Install the power plant (refer to Aircraft Maintenance - Manual). E. Complete Test A of Chapter 71-00, Power Plant - Adjustment/ Test - Ground Running Tests. During this test bleed the fuel system (Chapter 73-00, Engine Fuel and Control - Maintenance Practices). F, Replenish the oil tank as necessary (Chapter 79-00, Oil - General - Maintenance Practices). Jun/ 86 71-00 Page 407 RB7100NS1ROLLS-ROYCE LIMITED RI VIPER MAINTENANCE ~ #K.535 POWER PLANT ~ ADJUSTMENT/TEST NO RUNNING 1. General Procedures A, Preliminary Actions Prior to Ground Running. (1) Park the aircraft nose into wind, if possible and positioned so that all buildings and personnel aft of the jet efflux are clear of the danager zones. (2) Ensure that there is no loose debris, tools or equipment in front of or behind the aircraft. (3) Centralise the nose-wheel; apply the parking brake and chock the wheels. If the aircraft is to stand unattended, chock the wheels fore and aft and Lash the chocks together. WARNING: ENSURE THAT THE SAFETY PINS FOR THE EJECTOR SEATS AND CANOPY ARE IN PLACE BEFORE ENTERING THE COCKPIT. (4) Check that the fuel and oil tanks have been replenished. (5) Check that landing gear lock pins are fitted. (6) Ensure that the aircraft has serviceable internal batteries fitted. (7) Position serviceable fire fighting equipment adjacer to the aircraft. (8) Position a suitable external electrical power supply adjacent to the aircraft (refer to para.C). (9) Clear any fuel from beneath or behind the aircraft. (10) Remove all covers and blanks from engine intakes, jet pipe, compressor air bleed valve, pitot head and static vents. (11) Check engine intakes and jet pipe are free from foreign matter. (12) Fit debris guards to the air intake apertures. Apes 84 71-0¢ Page 501 e771 00"ROLLS-ROYCE LIMITED R VIPER MAINTENANCE - MK.535 8. Fire Fighting Equipaent. Refer to the Aircraft Maintenance Manual. €. External Electrical Power for Ground Testing and Engine Starting. The 28 volts from a battery trolley is suitable for ground testing. For engine starting, a power unit capable of producing 28 volts at loads up to 1000 amps. with negligible voltage drop should, where possible, be used. Alternatively, if such a power source is not available, the 28 volts supply from a battery trolley or, if necessary, from the aircraft internal accumulators is normaly adequate for starting. D. Safety Precautions during Engine Running. (1) Hats or Loose clothing must not be worn by persons working on, or in the vicinity of a running engine. (2) Ear protectors should be worn by persons working on, or in the vicinity of a running engine. (3) Keep all persons clear of the danger areas. 7 (4) When running engines during ground pressurisation tests, all persons involved must be made aware of the effect of an emergency depressurisation. E. Engine Handling. CD) Hot starts Starting with the aircraft tail into wind will tend to increase starting j.p.t. Following engine starting, if j.p.t. exceeds 750 deg.c. during a very rapid rise in temperature, stop the engine immediately (to avoid exceeding the max. j.p.t. Limitations) and investigate the cause. (2) Abortive starts If the engine does not Light up within 15 seconds of pressing the starter switch, close the h.p. fuel shut-off cock, allow the engine to complete the full motoring cycle then check the cause. After an abortive start, and before attempting another start, allow excess fuel to drain from the engine (Ground Running Limitations, para.2). After an abortive start, move aircraft clear of any fuel on the ground, or clear fuel from the ground before attempting another start. 71-00 Apr/ 86 a87100KS2 Page 502oa ww (3) <6) eo 8) a Apr/ 84 2871 00NS2 ROLLS-ROYCE LIMITED FRI VIPER MAINTENANCE - MK.S35 Cooling starter/generator F Following three motoring cycles in quick succession, allow the starter/generator to coal (Ground Running Limitations, para.2). Throttling Except during slam checks, operate the throttle slowly and deliberately; frequent and rapid throttling produces thermal stresses which may impair the life and reliability of the engine. Keep ground runing to a minimum. Excessive j.p.t. during ground running. Avoic exceeding the max j.p.t. Limitation, whenever possible, by closing the throttle. Report and recora, in the engine log book, all instances in which the j.a.t. exceeds the Limits specified in Ground Running Limitations (para.2). Compressor surge or stall In the event of a sudden increase in j.p.t. or a rumbling or banging, close the throttle immediately and investigate the cause. Run down time (from 60% r.p.m.) - Establish on initial run and record. Run down times are likely to differ between engines and may be further affected by variations in hydraulic loadings The run-down times recorded should only be used as : guide and not a limitation. During run-down, a chec should be aade to ensure there are no unusual noise: such as rupbing or scraping sounds from the compres- sor or turbine areas, and that the rotating assembly springs back after coming to rest. Operating limitations Do not contravene operating Limitations, given in this paragraph and in para.2. Fuel pump governor overswing and overspeed definitions. An overswing is a momentary occurfenc when the fuel pump governor maximum rev/min (100%) exceeded during a slam acceleration, but swings baci almost imaediately. [t is usual for a limited numb of overswing oscillations to occur until engine rev. ain. stabilizes at 100%. Engine overspeed is when the rev/min exceeds 100% (engine governed speed) and fails to return to 100% rev/min without retracting the throttle. 71-0 Page 50IR 2. Gcound Runnin: A. General. NOTE: Condition Drainage period after abortive start Engine start NOTE: 100% rev/min. ROLLS-ROYCE LIMITED VIPER MAINTENANCE - MK.S35 and Fligh i equals 13760. Rev/min.z Date Lime Deg.e Per Hour 1 minute miniaun 800 Maximum j.p.t. during starting and flight relighting is 800 deg. Cc. relighting must not exceed 740 deg. C. J.P.T. during starting and flight for Longer than five seconds. Idling speed Approach Maximum continuous Maxinum intermediate ~ Maximum take-off Ground running overswing NOTE In accordance 665 Untimited with Fig.561 60 (min.) 665 Unrestricted 95-5 665 Unlimited 98.5 715 30 minutes t 100 (See Note 3) 740 20 minutes 103% A maximum of five overswing oscillations is permitted during an acceleration check. Refer to para.1€ for definition of oversuing. (Limitations continued on next page) 71-00 Page 504 Apes 86 Re7100NS2ROLLS-ROYCE LIMITED R VIPER MAINTENANCE ~ MK.535 Condition Rev/min.%, Max. i.o.t. Tine Per Hour Governed speed 100 (Plus/minus 0.5) The jep.t. recorded at 100% rev/min. aust not exceed the Limitation given in Fig.501. 2. Newly installed engines with j.p.t. acceptance figures above the relevant rev/min. curve (Fig.501) should only be rejected after checking aircraft wiring and instrument calibration, using a potentiometer and Racal type rev/min. indicator 3. Maximum rev/min may be permitted to increase to 101.5% during flight at full throttle for no longer than twenty minutes per hour. Over- speeding between 101.5% and 103% rev/min is per- missible for a period not exceeding twenty seconds on ten separate occasions. Over- speeding between 103% and 105% rev/min is permissible for a period not exceeding five seconds an five separate occasions. Reject the engine if the number of occasions of permitted over-speeding is reached, if the time limit is exceeded or 105% rev/min is exceeded in the period between overhauls. Every occurrence of over-speeding must be recorded in the engine log book. Refer to para.t& for definition of over-speed. 71-00 Apr/ BS Page 505 287100MS2