Auxiliary Power Unit Safir 5K/G Mi Manual For The Operation and Technical Maintenance

PG 05-01
MANUAL FOR THE OPERATION AND TECHNICAL MAINTENANCE

March 2009
AUXILIARY POWER UNIT

SAFIR 5K/G MI
MANUAL FOR THE OPERATION AND

TECHNICAL MAINTENANCE
PG 05-01
ISSUE 6 - 28.3.2009
PG 05-01
March 2009
Note:
1) The edition No.6 is only formally revised 5th edition, previously distributed and
approved in January 2003. It doesn´t contain any changes or a new
regulations restricting in any way parametres and operation characteristics of
product listed in the 5th edition.
Given changes have been subsequently processed to text of this manual

and are listed detaily in Lists of introduced changes.
2/ All changes in the manual must be listed in List of valid pages and List of
Introduced changes.
All changes in the manual will be approved by form of bulletin and all
changes will be realized by the way of exchange or inserting new page
into the manual.
All changes concerning cancellation of pages, exchange of old pages or

completion of new pages must be forwarded to the organization together
with a new List of valid pages.
-0-
PG 05-01
March 2009
List of valid pages
Date of
Part, chapter, section, subsection Page introducing
into validity
Title-page - -
Approval sheet 0 January 2003
List of valid pages 1 March 2009
List of introduced changes 2 March 2009
Table of contents 3-4 March 2009
List of figures 5 March 2009
Introduction 10 March 2009
Basic technical data 11-14 March 2009
Description of SAFÍR 5K/G МI 15-25 March 2009
Instruction for operation 26-35 March 2009
Instruction for installation and 35-42 March 2009

operation
APU maintenance tasks and intervals 43-47 March 2009
Technology of maintenance operation 48-78 March 2009
Storing, conservation and 79-81 March 2009

unconservation
Failures and methods of their 82-96 January 2010

elimination
Replacement of aggregates 97- 136 March 2009
This document is a property of the joint-stock company První brněnská strojírna Velká Bíteš, a.s. It is forbidden its
reproduction, application, publishing as a whole or by parts for any other purpose than it was intended, without preliminary
written agrrement with the owner of document.
Page 1
PG 05-01
March 2009
LIST OF INTRODUCED CHANGES
№ № of sheets/pages № Signature of
Date of
Change section, № of appendant person
introducing
subsection, of document document, introducing
Changed New Broken the change
point date the change
Pict. description List of figures Page 5 Letter no. Holík 6.5.2003

4/1, 4/2, 17/1, KDLT
17/2 84/03/Ho
During main 4.5.3 Blockage of Page 31

engine starting APU protection
period…. system
…up to +80 °C in 4.6.5 Page 33

fuel system Operational
installation conditions
space...
Indicator scale up Fig. 16 Page 42

to 1000°C
At idle speed see 6.2.3Checking the Page 44

fig. 17/2- APU operation by
Dependence of means of
outtake air instruments and Page 45
pressure at indicators in pilot
ambient cabin
conditions
APU parameter T.C. No.7 Page 70

checking at idle Fig. 32 Control Page 71
speed acc. To. elements of the
Fig. 17/2 APU
Preservation valid 8.2.1 Conservation Page 79

for 30±5 days for period of 30
days
Par. 6.1title Airworthiness Page 3 Holík 11.6.2003
limitation
Table completion. 6. APU Page 43

Main parts service maintenance tasks
life: and intervals
tab.1 Oil exchange List of periodic Page 46

in oil tank after maintenance works
200 h APU
operation or each
2 years
Page 2
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March 2009
Date of
introducing
Additives adding 2.4 Working liquids Page 12 Change no. Holík 6.8.2003
to fuel Z-S5K/G-MI
2368
Oil temperature 4.6.5 Page 33
+ 140 oC Operational
conditions
Nx = ± 0,5 g 4.6.8 a)
Ny = + 2 g ÷ - 1,5 The safety loads
g during the APU
operation
APU service life 6.1.1 Page 43

completion Service life
Completion of List of figures Page 5 Change no. Holík 21.1.2004

fig. 52, 53 Z-S5K/G-MI
Completion of 10.1 List of the Page 97 2432
tech. Cards no. 34 technol. cards Page131-134
and 35
Completed 4.5.2 Operation of Page 30

automatic system signaling system
switch off (LED circuits, time and
OV is shining) control
Filter insert 5.3.2 Prescribed Page 37

cleaning works after the 1-st
cancelation after starting
1st start (point 9/)
Completed 9.3 Troubleshooting Page 86

exhaust gas tab. No. 2
temperature
sensor fault
detection
Completed fig.54 List of figures Page 5 Change no. Tomek 25.7.2005

Z-S5K/G MI-
APU schematic 3. PEJ Safír 5K/G Page 22, 23, 2586
pictures exchange MI APU description 24
APU operation 4.1 Starting the Page 26

time diagram APU
modification
Min. operation 4.5.2 Operation of Page 30

speed change signaling system
circuits, time and
control
4.6.6 Operational Page 33

restrictions –
temperatures,
rotation speeds
Page 2a
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March 2009
Date of
introducing
Completed 4.5.2 Operation Page 30

instruction for of signaling system
attendance at ZV circuits, time and
indicator burning control
light
Completed list of 6.4.2Replacement Page 46

APU parts of APU aggregates
during the operation
7.3.2 Tester of APU'

Completed s SAFÍR 5K/G MI Page 77
possibility of 9. Failures and
using LUN 5274 methods of their
tester for elimination Page 82 ÷ 96
diagnostics
10.1 List of the
technological cards
Completed Page 97
technological card Page135,136
no. 36
Implementation of Table of contents Page 3 Change no. Konečná 21.1.2008
LUN List of figures Page 5 Z-S5K/GMI-
5271.80/CONA Fig.1a Page 7 2864
control box 2.4 Working liquids Page 12,
12a, 12b
Fig.10a Page 25a
4.1.1Arrangement Page 26
made for starting
4.5.2 Operation Page 31
of signaling system
circuits, time and
control
Fig.12 Cyclegram Page 28
of APU operation
4.6.2.2Unsuccessful Page 32
starting of the APU
4.6.3 Takeoff of the Page 32
electrical power
5.2.1 Removal of Page 36
APU from
helicopter
5.2.2 APU Page 37
installation on the
object
5.3.1 Works after Page 37
installation
5.4.2.2 Control Page 38
box.......
Fig. 13 Page 39
6.1 Airworthiness Page 43
limitation
6.4.2 List of parts Page 46
Technological card Page 70
No.7
7.3.2 Tester of Page 77
APU' s SAFÍR
5K/G MI
8.2.3 Conservation Page 79
of the APU
Technological card Page 129
No .33
ISSUE 6 – Change no. Konečná 21.5.2009
28.3.2009 Z-S5K/GMI-
3014
Page 2b
PG 05-01
March 2009
Date of
introducing
Implementation of List of valid pages Page 1 Change no. Holík 22.2.2010

LUN Table of contents Page 3 L-KSS-3059
5271.80/CONB List of figures Page 5
control box Fig.10a Page 25a
Fig.10b Page 25b
4.5.2 APU minoto-
Change of ring indications Page 29
chapter 9 Failures 4.5.2.1 Analog
and methods of indication of APU .. Page 29
their elimination 4.5.2.2 Digital indi-
cation of APU ..... Page 30
4.5.3 Operation of
signaling system .... Page 31
4.5.3.1 Indication of
APU operation ..... Page 31
4.5.4 Blockage of
APU protection .... Page 32
5.4.2.2 Control box
LUN 5271.80, ..... Page 38
Fig. 13a Page 39a
Fig. 14a Page 40a
Fig. 15 Page 41
Fig. 16a Page 42a
6.2.2 Checking the
parameters of ..... Page 44
6.2.3 Checking the
APU operation ..... Page 44
List of aggegates
and APU parts, ..... Page 47
9. Failures and
methods of ...... Page 82-96b
Page 2c
PG 05-01
March 2009
TABLE OF CONTENTS
Page
LIST OF FIGURES 5
1. INTRODUCTION
1.1 Purpose of manual 10
1.2 Review of manual 10
1.3 Abbreviations and nomenclature 10
2. THE BASIC TECHNICAL DATA OF THE APU

2.1 Purpose 11
2.2 The basic technical data 11
2.3 Other technical parameters 11
2.4 Working liquids 12, 12a, 12b
2.5 Lubricants for conservation 12b
2.6 Other lubricant and urease 12b
3. DESCRIPTION OF THE APU SAFÍR 5K/G МI

3.1 Auxiliary power unit 15
3.2 Fuel system 20
3.3 Oil system 20
3.4 Air system 20
3.5 Starting system 20
3.6 System of automatic control 21
3.7 Source of electric power supply 21
4. INSTRUCTIONS FOR THE OPERATION

4.1 Starting the APU 26
4.2 Starting the main aeroengine 29
4.3 Air takeoff for the air condition 29
4.4 Shutdown of the APU 29
4.5 Control and signaling elements 29
4.6 Operational limitation 32
4.7 Instructions when replacing the oil for the other sort 34
4.8 Instructions for operation and technical maintenance 35
5. INSTRUCTIONS ON INSTALLATION AND INTRODUCING INTO OPERATION

5.1 Instructions on APU installation 35
5.2 Instructions on APU replacement during the operation 36
5.3 Introducing into operation 37
5.4 Instructions on installation of aggregates enclosed to the APU 37
6. APU MAINTENANCE TASKS AND INTERVALS

6.1 Airworthiness limitation 43
6.2 First level of the prescribed works 43
6.3 Second level of the prescribed works 46
6.4 Third level of the prescribed works 46
7. THE TECHNOLOGY OF MAINTENANCE OPERATION

7.1 List of technological cards 48
7.2 Safety regulations 76
7.3 List of toolings and equipment 77
7.4 Spare parts 78
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8. STORING, CONSERVATION AND UNCONSERVATION

8.1 Storing 79
8.2 Conservation 79
8.3 Unconservation 80
9. FAILURES AND METHOD OF THEIR ELIMINATION

9.1 General theses 82
9.2 Explanation on schemas 82
9.3 List of algorithms for control of APU function, determination of failure reason and their elimination 83
10. REPLACEMENT OF APU AGGREGATES

10.1 List of technological cards 97
Appendix 1
Technical description and manual for operation and technical maintenance of the source of electrical
power of APU SAFIR 5K/G МI.
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LIST OF FIGURES
Fig.
№. Name of figure Page
1. APU SAFÍR 5K/G MI (general view) 6
1a. Transport frame (drawing for information) 7
2. Drawing of main dimensions of APU, sheet 1 and 2 8,9
3. Dependence of pressure upon the air mass flow takeoff 13
4/1. 4/2. Dependence of pressure of takeoff mass flow upon the ambient conditions 14
5. Section of air generator of APU, sheet 1 and 2 17,18
6. General outline of the APU systems 19
7. Schema of fuel system 22
8. Schema of oil system 23
9. Schema of air system 24
10. Electrical schema of control B3-0488-10823 25
10a. Electrical schema of control B3-0488-11726 CONA 25a
10b Electrical schema of control B3-0488-12205 CONB 25b
11. Block-schema of starting and operation 27
12. Time diagram of starting and operation 28
13. Control box LUN 5271.8, LUN 5271.80/CONA 39
13a Control box LUN 5271.80/CONB 39a
14. Installation of the control box 40
14a Installation of the control box LUN 5271.80/CONB 40a
15. Frame of control box 41
16. Indicator of the exhaust gases temperature LUN 1386 42
16a Description of measuring parameters scale on the multifunction display 42a
17. Control board-panel of the APU 45
18. Removal of fuel collector 52
19. Removal of sensor of temperature of exhaust gases 53
20. Removal of combustion chamber 54
21. Checking the fuel collector and checking the sensor of temperature of exhaust gases 55
22. Checking the conditions of electrodes of spark plugs 55
23. Section of fuel collector with combustion chamber 56
24. Permitted failures of combustion chamber 57
25. Section of fuel nozzle 58
26. Checking the magnetic plug 59
27. Spark plug CH 34630 61
28. Checking the oil filter 63
29. Replacement of oil in oil tank 65
30. Checking the fuel filter from Block of filter and servo-valve 67
31. Checking the Filter of back fuel 69
32. Control elements of the APU 71
33. Removal and cleaning the drain valves of fuel 73
34. Adjustment of the oil pump 75
35. Removal of tube from Block of filter and servo-valve 81
36. Removal of electric starter 101
37. Checking the clutch of electric starter 102
38. Replacement of brushes of electric starter 103
39. Replacement of Block of filter and servo-valve 106
40. Replacement of back fuel filter 108
41. Replacement of fuel pump 111
42. Cleaning the by-pass valve of fuel pump 112
43. Replacement of oil filter 114
44. Replacement of oil pump 116
45. Replacement of temperature switch 118
46. Replacement of float switch 120
47. Replacement of ignition box 122
48. Replacement of cable of spark plug 124
49. Replacement of generator 126
50. Replacement of anti-surge valve 128
51. Replacement of cable packet 130
52. Replacement of back fuel filter bypass valve 132
53. Replacement of Block of filter and servo-valve bypass valve 134
54. Replacement of Pre-blockage pressure switch 136
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Fig. 1. APU SAFÍR 5K/G MI

(General view)
Page 6
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Fig. 1a. Transport frame

(drawing for information)
Page 7
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Fig. 2. APU SAFÍR 5K/G MI – drawing of main dimensions, sheet 1
Page 8
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Fig. 2. ВСУ SAFÍR 5K/G MI – drawing of main dimensions, sheet 2
Page 9
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1. INTRODUCTION
1.1 Purpose of manual

This manual is relevant to the auxiliary power unit SAFÍR 5K/G МI.
It is intended to inform the user about the purpose, description, operation, technical data and rules for installation
and maintenance of the APU.
1.2 Review of manual

The manual contains the following information:
- description of the APU structure and operation,
- basic rules for APU installation,
- the operational limitation,
- block schema of regulation and control system,
- maintenance and repair,
- system of control of APU function and exchange of the APU in process of operation
- safety measures when operation the APU
1.3 Abbreviations and nomenclature

APU - auxiliary power unit SAFÍR 5K/G МI
ISA - international standard atmosphere
TS - technical specifications
TC - technological card
ATS - air-turbine starter
М - mass flow
р - pressure
Н - altitude above sea level
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2. THE BASIC TECHNICAL DATA OF THE APU
2.1 Purpose
The auxiliary power unit SAFÍR 5K/G МI is intended for application as an autonomous source of energy and
supplies the compressed air into the air condition system or into the system of air starters of main engines on the
ground and during the flight. It also generates the electrical energy to be used in the object.
2.2 The basic technical data

The parameters of the air takeoff for the air condition system at operational rpm: n = 49074 rpm
(in section behind the flange of the anti-surge valve of the APU) under the conditions of ISA, H= 0:...... fig.3.
The parameters of the air takeoff for starting the main engine at operational rpm: n = 51000 rpm
(in section behind the flange of the anti-surge valve of the APU) under the conditions of ISA, H= 0:
- takeoff airflow …………………….......................................................... 0,4 kg/s

- overpressure of the air takeoff………………........................................... min 220 kPa (2,2 kgf/cm2)
- temperature of the air takeoff………......................................................... min 165 °C
The parameters of the takeoff air for starting the main engine depending upon the temperature of the ambient air
and altitude above the sea level…………………......………………………………………………......... fig. 4.
Ceiling of starting and operation of the APU…………….................................... 6000 m
The operational rpm – regime of idle run and regime of electrical power takeoff (100%)...... 49 074 rpm
– regime of starting the main engine ..................................................... 51 000 rpm
Fuel consumption................................................................. max. 55 kg/hour
Oil consumption................................................................... max. 100 cm3/hour
Time of continuous operation ............................................. max. 6 hours
The parameters of the electrical generator:

generator P/N 20040-100, generator control unit P/N 2438-100,
transformer P/N 20736-100 (THALES- France)
- operational voltage ..................................... 3 x 115 V/200 V at frequency 400 Hz

- long time takeoff of energy under the condit. of ISA, H=0 ................max. 20kVA
Note:
1/ Takeoff of the electrical power is limited by the temperature of the ambient air, altitude above the sea
level and by the airflow at the same time taken off from the APU (see subchapter 4.6.3 takeoff of the
electrical power in part 4.6 Operational limitation).
2/ The technical manual and handbook for technical maintenance of the source of electrical power APU
SAFIR 5K/G МI is presented in Appendix 1 of this Manual
2.3 Other technical parameters

For APU starting it is needed:
Operational voltage of the source of power supply........................ from 24 to 29 V
Capability of the source of power supply....................................... 25 Аh
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Operational limitations:
- range of temperatures
of ambient air .................................................................. from minus 55°С to +60°С
- altitude above sea level ................................................ from 0 to 6000 m
- relative humidity of the air……….................................. from 20 to 100 %
- speed of side wind………................................................ from 0 to 20 m/s
Mass:
Dry mass of APU with aggregates, installed on APU : ..................................... 63 kg
Including: - Generator P/N 20040-100.....................................................14,9 kg

- Ignition box with connecting cables……………….............1,85kg
- Anti-surge valve……………................................................0,78 kg
Full dry mass of APU with aggregates, installed on the board of the object:......69 kg
Including: - Generator control unit ………… ..........................................2,1 kg

- Transformer ….......................................................................0,215 kg
- APU control unit, including connectors……………..............3 kg
Working liquids and lubrications, which are alowable or prescriebed for using on APU
2.4 Working liquids

2.4.1 Fuels
The APU shall operate satisfactorily throughout the operating envelope with the following fuels:
2.4.1.1 Normal fuels-Primary fuels
Specification
Type of NATO
USA for USA for Others
fuel symbol U.K. CZECH Rep.
civil using military using specif.
ASTM-D-
Jet A* - 1655 - - - -
Type Jet A
ASTM-D- AFQRJOS
MIL-DTL- Def Stan 91-91 AFQRJOS
Jet A-1* F35 1655
83133E AVTUR
VJP-PHM 1-1-L
Type Jet A1
MIL-DTL- Def Stan 91-87
JP8* F34 -
83133E AVTUR/ FSII
- VJP-PHM 1-3-L
ASTM-D-
Jet B** - 1655 Type - - - -
Jet B
MIL-DTL-
Def Stan 91-88
JP4** F40 - 5624T grade
AVTAG/ FSII
- -
JP4
MIL-DTL-
Def Stan 91-88
JP5*** F44 - 5624T grade
AVCAT/ FSII
- -
JP5
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2.4.1.2 Normal fuels-Secondary fuels
NATO Specification
Type of fuel
symbol USA CHINA RUSSIA CZECH Rep.
PRC3 National
Standard No3 - - GB 6537-94 - -
Jet fuel
T1*
- - - GOST 10227-86 -
Kerosene
TS1*
- - - GOST 10227-86 -
Kerosene
TS1*
- - - GOST 10227-86 -
Premium
T2**
- - - GOST 10227-86 -
Wide-cut
RT*
- - - GOST 10227-86 -
Kerosene
*
Kerosene type (destillation 40°-280°C)
**
Wide cut fuel –fraction of petrol and kerosene (destillation 60°-250°C)
***
High flash point fuel
2.4.1.3 Permitted additives
- Anti-ice additive:
• Type EGME- NATO symbol AL-31 (S-748 acc. to DERD 2451)

Maximum concentration by volume: 0,15%
Minimum concentration by volume: 0,10%
• Type DEGME- NATO symbol AL-41 (S-1745 acc. to ASTM D 4171 type III or DERD 2451,
ID.STAN 68252 Issue 2, MIL-DTL-85470)
• Type FLUID I (etilcelozol) acc. to GOST 8313-88
2.4.1.4 Fuel purity
Fuel purity must be in accordance with class 10 – 11 acc. to GOST 17216-71 or class 7 – 8 acc. to NAS 1638.
2.4.2 Lubricants
The APU will operate with the oils specified below:
NATO Specification
Oil type Approved oil trademarks
symbol USA U.K. OTHERS
synthetic 5cSt at MIL-PRF- DEF STAN Aero Shell Turbine Oil 500
O-156 -
100°C 23699F 91-101 /Royco Turbine Oil 500
Class STD Aero Shell Turbine Oil 529
Mobil Jet Oil II
Turbonycoil 600
CASTROL 5000
CASTROL 5050
BP/EXXON Turbo Oil 2380
ELF TURBO JET II*
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TOTAL JET TURBINE 535

Aero Shell Turbine Oil 560
MIL-PRF- Eqivalent DEF
/Royco Turbine Oil 560
O-154 23699F STAN 91-101 -
Mobil JET Oil 254
Class HTS
Aero Shell Turbine Oil 555
DEF STAN
O-160 DOD-L.85734 - /Royco Turbine Oil 555
91-100
Russia
specification
- - - B3V
TU 38-
101295-85
China
HP-8 or HP-8A
- - - specification
GB 439-85
synthetic 7,5cSt DEF STAN CASTROL 98
O-149 -
at 100°C 91-98 Turbonycoil 98
Note 1: For detail information about trademarks of oil see standarts:

- QPL-23699-19
„QUALIFIED PRODUCTS LIST OF PRODUCTS QUALIFIED UNDER PERFORMANCE
SPECIFICATION MIL-PRF-23699
LUBRICATING OIL, AIRCRAFT TURBINE ENGINES, SYNTHETIC BASE NATO CODE
NUMBERS O-156, O-154 and O-152
- QPL-85734-3
„QUALIFIED PRODUCTS LIST OF PRODUCTS QUALIFIED UNDER MILITARY
SPECIFICATION DOD-L-S5724(AS)
LUBRICATING OIL, HELlCOPTER TRANSMISSION SYSTEM, SYNTHETIC BASE
Note 2: The use of oils of specifications, class or trademarks or brands differing from those mentioned above is
subject to APU producer's agreement.
2.4.2.1 Oil purity
Oil purity must be in accordance with class 14 acc. to GOST 17216-71 or class 10 acc. to NAS 1638.
2.5 Lubricants for conservation

- Internal conservation of APU for period of 90 ± 10 days is carried out by new oil MOBIL AVREX M TURBO
201/1010, or Aero Shell Turbine Oil 3, or МК-8 GOST 6457-66, or MS-8P OST 38.011.63-78, or MS-8RK OST
38.013.87-85, or by transfomer oil TK GOST 982-80.
Cleanness and quality of liquid when doing the conservation must in accordance with appropriate standards.
- The metallic surfaces of the APU, which can be subject to corrosion (exhaust pipe, rear part of turbine) must be
lubricated by oil for conservation or by technical vaseline.
see chapter 7 in PG-05-01 the „Operation and maintenance manual of APU SAFIR 5K/G MI“
2.6 Other lubricant and grease

-The threaded sockets are to be lubricated with ….. GLEIT HP 520М or with equivalent lubricant against the seizure
of threaded joints.
- The heat-stressed threaded socket are to be lubricate with …. Pulver MF, or with an equivelant lubricant against
seizure of strong heat-stressed threaded joints.
see chapter 8 in PG-05-01 the „Operation and maintenance manual of APU SAFIR 5K/G MI“
- Spherical bearings and shaft splining of AC generator are to be lubricate with …. Aero Shell Grease 22 or with
equivalent lubricant
- The sealing rings is to be lubricated with......... CIATIM 201 or with equivalent lubricant
Page 12b
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ISA: ТH= 15ºС, Н=0 m, n= 49074 rpm, without takeoff of electrical power
2.5
pbl
( kgf/cm2) 2.4
2.3
2.2
2.1
1.9
1.8
0 200 400 600 800 1000 1200 1400 1600 1800
2
pbl - overpressure of the takeoff air, kgf/cm Mbl (kg/h)
Mbl - mass flow of takeoff air, kg/h
n - frequency of APU rotation, rpm
Fig. 3. Dependence of pressure upon the takeoff airflow.
n = 51000 rpm, without takeoff of the electric power
2.8
P2 (atm)
pbl 2.7
(kgf/cm2) 2.6 t =-40°C
2.5
2.4
2.3 t =-10°C
2.2
2.1 t =15°C
2
1.9 t =35°C
1.8
1.7
1.6 t =50°C
1.5
1.4
1.3
1.2
1.1
1
0.9
0.8
0.7
0.6
0.5
0 1000 2000 3000 4000 5000 6000
H (m)
(m)
pbl - overpressure of the takeoff air, kgf/cm2
Fig. 4/1. Dependence of the takeoff air pressure upon ambient conditions.
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n= 51000 rpm , without takeoff of electric power
3.5
3.4
3.3
3.2
3.1
3.0
2.9
2.8
2.7
2.6
2.5
2.4
H= 0 m
2.3
2.2
[ata])
2
2.1
(kgf/cm
2.0
pbl p2c
1.9
1.8
1.7
H=2500 m
1.6
1.5
1.4 H=4000 m
1.3
1.2
1.1
1.0
H=6000 m
0.9
0.8
0.7
0.6
0.5
-60 -50 -40 -30 -20 -10 0 10 20 30 40 50
t [°C]
pbl - overpressure of the takeoff air, kgf/cm2

t - temperature of air at APU inlet, оС
H - altitude above sea level, m
n - frequency of APU rotor rotation, rpm
Fig. 4/2. Dependence of the takeoff air pressure upon the ambient conditions.
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3. DESCRIPTION OF THE APU SAFÍR 5K/G МI
3.1 Auxiliary power unit

3.1.1 APU arrangement and layout
SAFÍR 5K/G МI consists of generator of the compressed air and agregates for fuel, oil, air systems and also of
systems of engine starting and control.
3.1.2 Description of APU design

The auxiliary power unit SAFÍR 5K/G МI is a small-size single shaft gas turbine engine, equipped with a single
stage radial compressor, annular combustion chamber and double stage axial-flow turbine. The surplus of turbine
power output is used for driving the aggregates, situated on the drive box and also for compression of the air in
compressor. The part of the compressed air it is supplied into the object air system or it is passed to the
atmosphere.
Section of APU is shown in fig. 5
The basis parts of the compressed air generator are as follows:
- gearbox and compressor casing (1)
- gas generator (2)
- fuel collector with combustion chamber (3)
Gearbox (1)
It carries out mechanical joining the rotor of gas generator with driven aggregates. The joining of the gearbox with
rotor of the gas generator is made by means of the long torsional element. The all transmissions are made by
means of gear wheels with straight teeth. The drive box is equipped with four drive exits:
Frequency of
№. of Transmission
Name of aggregate Sense of rotation rotation Output power [kW]
drive ratio
[rpm]
1 Electr. generator 0,24453 left 12000 max. 25
2 Reserve drive 0,075865 right 3723 2
3 Oil pump 0,121021 right 5939 0,1
4 Electr. starter 0,509435 left max. 20000 min. 1,15
The working rpm are - 49074 rpm. The generator drive is situated coaxially with APU rotor, the other drives are
situated under it as follows, i.e. from the left to the right in order № 2, 3 and 4.
Electrical generator - it is a source of electrical power on the ground and in flight.
Oil pump - it is a gear type pump with regulation of the supply pressure. The pump carries out the oil supply for
lubrication of bearings of the drive box and gas generator rotor.
Electrical starter – it is electromotor of direct current with series connection, intended for short time operation,
equipped with a clutch (overrunning centrifugal and protection frictional). Its task it is to carry out starting the
APU in autonomous regime.
On the side of gearbox, there is installed the oil filter, including the filtrating element, switch off according to
minimum oil pressure, device signaling the contamination of the filter, electromagnetic valve. In the bottom part
of the drive box, there is situated the flange for fixation of oiltank. The rear part of the gearbox is at the same time
the inlet part of the compressor, here is also placed the double circuit sensor of the rpm (9) of the APU rotor. In the
upper part of the gearbox, there is situated the oil inlet socket from oil filter and also the oil collector, providing
the oil supply to the gears and bearings. The air, separated in oil separator, which is placed on the upper part of the
gearbox, is passed by tube (34) into exhaust pipe. The protective net (32) is situated at compressor inlet.
Compressor casing (16) is connecting the gearbox with gas generator (2). The coupling of the gearbox with gas
generator rotor is made by means of torsional clutch (15). Between the compressor casing and gas generator there
is radial diffusor (19) and air distributor, dividing the compressed air into two parts: 1/3 is passing into the sleeve
of takeoff air and the other 2/3 into combustion chamber.
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Gas generator (2) consists of turbine casing (21), rotor of APU and bearings (20), upon which there is situated the
rotor. The annual space between the turbine casing and casing of bearings creates the axial blade diffuser of
compressor. The turbine casing is fixed together with bearings casing by means of pins. In bearing casing there is
placed the holder with two ball bearings, lubrication bushing and spring, which serves as a spacer for radial-axial
bearings. The oil is supplied through oil socket (12) with filter in the upper part. The socket of oil exit (7) from
bearings is placed in the bottom part of the turbine casing. The APU rotor consists of single-stage radial
compressor wheel (17), double-stage axial-flow turbine and intermediate shaft (22). The compressor wheel is set
on the shaft through splainway connection and in the axial direction it is locked by special nut (10), which at the
same time serves as gear wheel of the induction sensor of rpm measurement (9). The wheels of the 1-st and 2-nd
stage of turbine (25, 26) are joint to the shaft by means of three bolts. On the inner side of turbine and compressor,
there are bushings of the labyrint oil seal, which is sealing the oiled space of the APU. On the flange of bearing
casing, there are fixed the stator vanes of 1-st stage (23) and 2-nd stage (24) of turbine.
Fuel collector (3)

It covers the hollow of turbine casing, creates the common block with combustion chamber (27) and provides the
distribution of fuel among the 8 fuel nozzles. The fuel collector is joint to turbine casing by means of quick
coupler ∅284 mm (6). In the fuel collector there are set 2 spark plugs. The distribution of fuel from the drain fuel
block to the fuel nozzles, it is carried out through drilled holes made in the casting of fuel nozzles holder. On the
bottom part of the fuel collector there is situated drain block of the fuel equipped with one fuel drain valve II, with
two drain valves I, which provide the exit of surpluse fuel from fuel collector and from the hollow of combustion
chamber into the drainage tank (31). In the internal part of collector there is situated the exhaust tube (4), with a
stator vanes of turbine. In the exhaust tube there is installed the sensor of temperature of exhaust gases (11)
equipped with 3 chromel-alumel sensing elements (thermocouples).
The chromel-alumel outlet wires of sensor are joint to the holder of the compensation line (13).
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12 22 21 3
1 15 9 10 20 23 24
33
Рис.5. Разрез ВСУ, лист 1
26
32 16 17 19 18 25 27 31
5 13
11
14 14 30
Fig. 5. Section of APU, sheet 1
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34 12 28 29
4 6
DESCRIPTION
1 Gearbox 18 Air distributor
2 Gas generator 19 Diffuser
3 Fuel collector with combustion chamber 20 Bearing casing
4 Exhaust tube 21 Turbine casing
5 Air inlet 22 Shaft
6 Quick coupler 23 Nozzle guide vanes of 1-st turbine stage
7 Socket of oil drain 24 Nozzle guide vanes of 2-nd turbine stage
8 Air tube 25 Wheel of 1-st turbine stage
9 Sensor of rpm LUN 1308 26 Wheel of 2-nd turbine stage
10 Teeth nut 27 Combustion chamber
11 Sensor of exhaust gas temperature 28 Rear assembly unit
12 Inlet oil socket 29 Front assembly unit
13 Holder of compensation line 30 Front units of APU fixation
14 Rear units of APU fixation 31 Drain tank
15 Torsional coupling 32 Net
16 Compressor casing 33 Fuel drain block
17 Compressor 34 Tube of oil separator
Fig. 5. Section of APU, sheet 2
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FUEL EXIT ins. diam. 6mm

Back pressure max. 20 kPa
FUEL INLET ins. diam. 8mm 12 3 1

Pressure from 50 to 150 kPa
7
Fuel mass flow 120 l/hour
11
9
10
BY-PASS FROM
DRAINAGE TANK
AIR TAKEOFF FROM APU
6 5 4 2
AIR BY-PASS TO 13
ATMOSPHERE
1 - GENERATOR OF THE ALTERNATE CURRENT

2 - ELECTRICAL STARTER
3 - OIL FILTER
4 - OIL PUMP
5 - OIL TANK
6 - FUEL PUMP
7 - BLOCK OF FILTER AND SERVOVALVE
8 - FILTER OF THE BACK FUEL
9 - DRAIN VALVE DV I – 2 ps
10 - DRAIN VALVE DV II
11 - SPARK PLUG – 2 ps
12 - IGNITION BOX
13 - ANTI-SURGE VALVE
Fig.6. General outline of the APU systems
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3.2 Fuel system

The fuel system features the low pressure system with constant fuel mass flow at inlet of 8 by-pass fuel nozzles and
with electromagnetic throttle-valve (servo-valve) in the line of fuel by-passing. The fuel is delivered to the nozzles
through the heat exchanger and collector of nozzles by means of electrical gear pump. Takeoff of the fuel is carried out
from the fuel system of the object.
The fuel system consists of the aggregates as follows:
- block of filter and servo-valve
- fuel pump
- filter of the back fuel
The fuel system comprises:
- block of filter and servo-valve, that comprise of electromagnetic valve, thermostat, filter 12 µm with by-pass valve
and device for signaling the contamination of filter element, servo-valve (electromagnetic valve), blow through valve
and single stroke valve.
- electrical fuel pump with a regulator of fuel flow supply, by-pass valve and filter 63 µm;
- fuel collector with nozzles, drain block of fuel, drain tank and drain valves,
- filter of back fuel l2 µm with device signaling the contamination of the filter element.
3.3 Oil system

The oil system is an autonomous closed system with forced circulation and it provides the lubrication and cooling of the
bearings and gear wheels of the drive box and gas generator rotor. The oil pump driven by drive box supplies the oil
from oil tank at mass flow about 70 dm3/hour at working pressure of 150 kPa.
The oil system consists of the aggregates as follows:
- oil tank
- oil filter
- oil pump
The oil system consists of oil tank, oil pump, oil filter, lubricating nozzles, oil separator and connecting tubes. In the oil
tank, there is a heat exchanger of the „fuel-oil“ type, sensor adjusted on maximum temperature of oil, the sleeve for oil
filling with bayonet lock and net of 200 µm, discharging plug, signaling device of min. oil level and indicator of min.
oil level. The indicator of the oil level placed on the front side of the tank is equipped with mark MIN and MAX and
indicates the amount of oil in the oil tank. Capacity up to the mark MIN means about 1300 ml of the oil in oil tank and
the mark MAX means capacity about 1800 ml. The oil pump is sucking the oil from the tank through net 200 µm and
delivers it to the oil filter. Through the filter, which contains the filtrating element 35 µm, by-pass valve, signaling
device of contamination, switch adjusted on the min. oil pressure and electromagnetic valve, the oil is delivered to the
lubricating nozzles of the rotor and drive box. The developing oil fog is led back through tank and drive box. The air
separated in the oil separator at the drive box is led by pipe into the exhaust tube.
3.4 Air system

The air system is intended for delivery of compressed air from APU compressor into the air system of the object for
starting the main aeroengine or for feeding the air condition system, also for purpose of APU protection from
overloading, by means of limiting the air mass flow of the takeoff air.
The air system consists of air takeoff tube having the internal diametr ∅ 48 mm and anti-surge valve with nozzle
Venturi ∅32 мм.
3.5 Starting system

The starting system provides the APU starting in range of permitted operational conditions.
The system comprises as follows:
- electrical starter, i.e. engine of the direct current, equipped with overrunning clutch
- double-channel ignition box, two cables for spark plugs and spark plugs.
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3.6 System of automatic control

The electronic system provides the automatic starting of the APU, keeping and regulation of the frequency of rotation of
the APU rotor, control of the appropriate APU operation and stopping thereof in case of occurence any malfunction.
The system comprises as follows:
- control box,
- sensor of rpm,
- sensor of exhaust gas temperature,
- sensor of oil maximum temperature, located in oil tank,
- signaling device of the minimum oil level, located in oil tank,
- signaling device of contamination of the oil filter,
- signaling device of contamination of the fuel filter,
- switch off operating on minimum oil pressure,
- signaling device of contamination of back fuel filter,
- control box of electrical generator.
3.7 Source of electrical power supply
It is intended for supply of electric power 400 Hz to cover the needs of helicopter on the ground and in flight.
The system contains the following aggregates:
- generator P/N 20040-100
- generator control box P/N 2438-100
- transformer P/N 20736-100
Note:
The technical description and manual for operation and technical maintenance of the source of electrical power
APU SAFIR 5K/G МI is presented in Appendix 1 to this Manual.
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Legend for Fig. 7
A- FUEL INLET TO APU FUEL SYSTEM

B- FUEL RETURN FROM APU FUEL SYSTÉM
C- FUEL INLET TO FUEL COLLECTOR
D- FUEL RETURN FROM FUEL COLLECTOR
E- SUCKING OFF THE FUEL FROM DRAINAGE TANK
F- FUEL OVERFLOW FROM DRAINAGE TANK
1- BLOCK OF FILTER AND SERVO-VALVE

1.1- FILTER 12µm
1.2- PRE-BLOCKAGE PRESSURE SWITCH WITH BY-PASS CLOGGING VALVE
1.3- THERMOSTAT
1.4- ELEKTROMAGNETIC VALVE
1.5- SERVO-VALVE (HYDROELECTRIC VALVE)
1.6- DIFFERENCIAL PRESSURE VALVE p-BY-PASSING AND MIXING OF FUEL
1.7- SINGLE-WAY (RETURN) VALVE
1.8- AIR-RELIEF VALVE
2- ELECTRIC FUEL PUMP
2.1- BY-PASS (PROTECTIVE) VALVE
2.2- FUEL FLOW REGULATOR
2.3- FILTER 63µm
3- RETURN FUEL FILTER
3.1- FILTER 12µm
3.2- PRE-BLOCKAGE PRESSURE SWITCH WITH BY-PASS CLOGGING VALVE
4- FUEL-OIL HEAT EXCHANGER (IN OIL TANK)
5- FUEL NOZZLE -8pcs.
6- FUEL COLLECTOR
7- FUEL DRAINING ASSEMBLY
8- DRAINAGE TANK
9- DRAIN VALVE DV2
10- DRAIN VALVE DV1
11- SUCTION ORIFICE Fig. 7 Scheme of fuel systém
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Legend for Figure 8
A – SUCKING OF OIL
B – DELIVERY TO LUBRICATING JETS
C – OIL RETURN
D – INPUT OF RETURN OIL TO THE OIL TANK
E – VENTING OF AIR
1 – OIL TANK
1.1– DRAIN PLUG
1.2– HEAT EXCHANGER FUEL-OIL
1.3– FILLING CAP WITH SCREEN 200 µm 5 – OIL FILTER 7 – LUBRICATING DISTRIBUTER
1.4– OIL FITER 100 5.1- FILTER 35 µm 8 – MAGNETIC PLUG
1.5–OIL LEVEL SIGHT GLASS 5.2- BY-PASS CLOGGING VALVE 9 – OIL OUTLET TRANSFER TUBE3
5.3- LOW OIL PRESSURE VALVE 10 – OIL INLET TRANSFER TUBE WITH
2 – SENSOR OF OIL TEMPERATURE (THERMAL SWITCH)
5.4- PER-BLOCKAGE PRESSURE SWITCH STRAINER 200 µm
3 – SWITCHING DEVICE OF MINIMUM OIL LEVEL 5.5- ELEKTROMAGNETIC VALVE
4 – OIL PUMP 11 – LUBRICATING BUSH WITH JETS
6 – OIL SEPARATOR – CENTRIFUGAL
4.1- PRESSURE RELIEF VALVE 12 – DISTANCE LUBRICATING RING
BREATHER
WITH JETS
Fig. 8. Schema of the oil system
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Legend for Figure 9
A – AIR INLET
B – BLEED AIR
C – EXHAUST GAS OUTPUT
D – AIR BY-PASS TO ATMOSPHERE
1 – ANTI-SURGE VALVE LUN 7527.8

1.1- THROTTLE
1.2- VENTURI NOZZLE Ø32
2 – CONNECTING ELBOW Js 48
3 – AIR INTAKE
4 – MESH CSREEN
5 – COMPRESSOR WHEEL
6 – COMPRESSOR CASING
7 – AIR DISTRIBUTOR
Fig. 9 Schema of the air system
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Fig.10 Electrical schema of control system
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Fig.10a. Electrical schema of control system - control box CONA
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Fig.10b. Electrical schema of control system- control box CONB
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4. INSTRUCTIONS FOR THE OPERATION
4.1 Starting the APU

Before starting the APU and before the false starting there is necessary to turn on the all safety switches of the
APU circuits and fuel delivery pump.
4.1.1 Arrangement made for starting

The automatic starting the APU is carried out by electronic control system. After turning on the safety switch of
the fuel delivery pump and fuel valve, there can be carried out the APU starting. The APU operation during the
starting is presented on the cyclegram of starting and operation (fig. 12) and on the block-schema of the starting
and operation (fig. 11).
For the APU starting it is necessary:
- The switch ”START-FALSE START” on the control board of APU (”START APU”) is to be set into
position ”START”;
- Press the button ”STARTING”.
After this action there begins the operation of the electronic control system.
During the APU starting on the control board there is blinking the signal lamp „APU OPERATION“.
The appropriate switches provide the power supply to the electrical starter and ignition box. At the same time there
is turned on the fuel pump, fuel valve and oil valve. It is blocked takeoff of the electrical power from generator.
The electrical starter begins to rotate and it is turning the APU rotor through clutch and drive box. The fuel pump
delivers to the fuel system the needed amount of fuel and the regulator of fuel mass flow is keeping the constant
fuel mass flow at the inlet into the fuel collector. The servo-valve is open and into the combustion chamber it is
injected the minimum fuel amount. Simultaneously with a rotor rotation, there begins the operation of the oil
pump, providing the lubrication of the bearings and drive box. After ignition of the mixture in combustion
chamber, the rotor rpm are increasing and are settled at value about 25000 min-1 (~ 51%) Approximately at 15-th
second there begins to work the rpm regulation, the servo-valve increases throttling the by-passed fuel, it is
increasing the injection of the fuel into combustion chamber and the rpm regularly increase, stabilizing upon the
regime of about working rpm 49074 min-1 (100±1%). After reaching the appr. 39000 min-1 (80±1%) the control
box stops the supply power to electrical starter, the overrunning clutch disconnects the rotor of electrical starter
and its rpm drop to zero. After reaching the rpm about 44000 min-1 (90±1%), the control box stops power supply
to ignition box and on the control board there is signaled the operational regime (the signal lamp „APU
OPERATION“ permanently shines).
ATTENTION: After 30 sec from the moment of beginning the lamp shining it is possible to takeoff the electric
power or to begin starting the main engine.
4.1.2 False starting

For performing the false starting (cold rotation) it is necessary:
- The switch ”START-FALSE START” on the control board of APU is to be set into position ”FALSE
START;
- Press the button ”STARTING”.
Due to the pressing button „STARTING“ there begins the normal cycle of the APU starting, but without power
supply to the ignition box (see fig. 10. Block-schema of the starting and operation). During the false (dummy)
starting of the APU there is blinking the signal lamp „APU OPERATION“. After reaching the 8-th sec of
electrical starter work, the control box stops the starting cycle and there follows the switching off and APU stops.
4.1.3 APU starting when having the minus temperatures of the ambient air
Before starting the APU on the ground at temperature of ambient air lower than minus 40°С, it is necessary to
carry out heating the APU sector by air heated on temperature no more than 80 °С.
Starting the APU is possible to carry out at oil temperature in oil tank higher than minus 40 °C.
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STARTING
THE APU
Signal from SR to CB up to Beginning the starting cycle

3-rd sec FV, FP, OV, IB, CS turned on to power supply
EG is blocked
Temperature of exhaust Time circuits 3-13-35sec
gases >100°C up to 13-th
sec
Unblocked the program of acceleration, setting

Min. permitted rpm reached
on certain level and then follows the controlled
up to 35-th sec.
acceleration
Temperat. of exhaust gases
>950°C in start. regime
Reached oil pressure after 10-
режиме запуска ВСУ
th sec after attain. 80% of rpm
Attainted minim. permitted rpm ( 80% ) up to
35-th sec CS switched off from the power
Signal lamp shines Attained permitted minim. working rpm (90% )
„APU OPERATION“ IB switched off the power
Temperat. of exhaust gases

Reached the working rpm ( 100% ) > 720°C
on working rpm
EG switched on to the board system
APU SHUTDOWN
“ STOP“
Shines signal lamp ”APU FV, FP, OV switched off from the power
FAILURE” blocking EG
Switched off the power supply toAPU aggregates

does not shine signal lamp
„APU OPERATION“
Abbreviations:
FV - fuel valve FP - fuel pump CS - contactor of electr. starter
ASV- anti-surge valve OV – oil valve EG - electr. generator
SR -sensor of the rpm IB - ignition box CB - control box
Fig. 11 Block – schema of APU starting and operation
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Cyclegram of APU operation
120
5
110
7 4
100
Y
90
X 3 6
80
(%)
Otáčky (%)
Revolutions
70
60
9 α
50
40
30
T 8 2
20 1
Z
10
S
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 58 60 62 64 66 68 70
Doba
Time startu (s)
of operation (sec)
Description:
1 APU shutdown due to low level of signal of rpm sensor (after 3 sec from the moment of starting)
2 APU shutdown due to fail to attain the temperature of exhaust gases 100°C
3 APU shutdown due to fail to attain rpm 80% (after 36 sec from the moment of starting)
4 APU shutdown due to low oil pressure (after 36 sec + 10 sec from the moment of starting)
5 APU shutdown due to attainment of the max. permitted rpm of the APU rotor 112,7 %
6 APU shutdown due to the drop of APU rpm below minimum permitted value
7 Attainment of operational rpm 100 % (49074 rpm ± 1%)
8 APU shutdown at the regime of false starting
9 Beginning of the action of electronic regulation (control of servo-valve)
S Start of APU
Z Ignition of fuel in APU combustion chamber
T Attainment of the temperature of exhaust gases 100°C
X Attainment of the minimum permitted rpm of the APU rotor
Y Attainment of the minimum working rpm of the APU rotor
S - T Setting the beginning current of the servo-valve 30 mА
T-9 Blocking the current of servo-valve (during the 12 sec after attainment the temperature of exhaust gas 100°C)
α1 Acceleration ( 5% / sec )
Permitted range of frequency of APU rotor rotation
Rpm during starting the main engine 103,9 % ( 51000 rpm ± 1%)
Fig. 12. Time diagram of the APU operation during the starting
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4.2 Starting the main engine
APU is operating at 100% of the rpm and shines the signal lamp „APU OPERATION“. By pressing the button
„START“ of the main engine it is provided opening the valve of air starter (AS) of the to be started main engine,
at the same time automatically increase rpm of APU, which equal to APU rpm used for starting the main engine
(103,9%). The anti-surge valve automatically closes during it, there is stopped the by-pass of the air into atmos-
phere and the compressed air is supplied from the APU compressor to the air starter. At the moment of ending the
engine starting, there is turned off the power supply to valve of AS, AS of the started engine closes, during this the
anti-surge valve opens and the compressed air is delivered to atmosphere. Within 3 – 5sec after closing the AS
valve, the rpm of APU automatically are dropping to 100% and APU is transfered to regime of idle run.
If the main engine starting is not successful, the regime of the engine starting continues certain time and after its
passing the APU returns automatically to the original state. After the prescribed time interval (according to the
engine manual) the starting process can be repeated.
Note: The cold rotation of the main engine is made in the same way as starting of the main engine, only at the
moment of ending the cold rotation, it is to be closed the valve AS, during this opens the anti-surge valve and at
the same time decrease the APU rpm till 100%.
4.3 Air takeoff for air-conditioning

APU is working at 100 % rpm, the signal lamp „ APU OPERATION “ shines and the compressed air is by-
passed into atmosphere. After opening the inlet valve into the air-condition system (provided by in-board
installation), the anti-surge valve closes automatically, the by-passing of the air in atmosphere stops and air
condition system is taking the air from APU. The mass flow of received air depends upon the set regime of air
condition and when having the simultaneous takeoff of the electric power from APU, it is limited according to the
temperature of the exhaust gases of APU.
4.4 Shutdown of the APU

At any moment of the starting or operation of the APU, it can be stopped by pressing the button „STOP“. In this
case it is interrupted the power supply to control box, it is closed the cock of fuel delivery and APU stops.
4.5 Control and signal elements

4.5.1 Buttons, control and signal elements
Control board of the APU in pilot cabin:
Buttons - APU starting „START“
- APU shutdown „STOP“
control and signal lamps
- APU working regime „APU OPERATION“
- indication of APU malfunction or stop „APU FAILURE“
- signaling the oil system „OIL“
- signaling the fuel system „FUEL FILTER“
4.5.2 APU monitoring indications

The control box LUN5271.80/CONB in addition to control box LUN5271.80/CONА is equipped by two-way
electronic serial interface RS 422. It allows two possibilities of equipment using on helicopter either by means of
standard analog equipment or alternatively to use digital signal from control box serial interface RS 422 to the
some multifunction display. Control box LUN5271.80/CONB transmits one data packet that contains complete
information about the actual state of the APU every second all the time.
That means user of APU equipped by control box LUN5271.80/CONB has two possibilities of monitoring APU:
- to use standard analog equipment - indicators and signal lamp
- or to use digital signal from control box serial interface RS 422 to the some multifunction display
4.5.2.1 Analog indication of APU parameters

Checking and control of APU operation is carried out by means of signal lamps in pilot cabin, situated on the
control board of the APU (board of APU starting) and also by means of indicators:
- indicator of gas temperature (EGT APU):
Indication of the temperature of exhaust gases of APU (°С) at turned on power supply to control box of the
APU.
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- indicator of air pressure (AIR PRESS APU):

Indication of the overpressure of air (kp/cm2) at air takeoff from APU in front of air starters of the main engines
– indicator is not in completion of APU delivery
- control lamp "APU OPERATION ":

During the starting and (false) dummy starting of APU the lamp is blinking. The permanent shining is attained
when operating at the working rpm and lamp continues to shine when the rpm are in the prescribed range. When
having the shining lamp ”APU OPERATION”, there is allowed the power takeoff from APU.
- signal lamp "OIL":

The shining of this lamp can occur when having one of three following cases: contaminantion of the oil filter,
minim. amount of oil in oil tank (only on the ground) or exceeding the temperature of oil in tank.
Note: In flight of the helicopter the circuits of signaling device of the minimum oil level are disconnected.
If lamp „OIL“ shines on the ground, it is necessary to turn off the APU.
In extreme cases it is allowed to continue the APU operation up to 5 min after panel OIL lights up.
After APU shutdown it is to be checked and recorded the level of oil in oil tank, checked the magnetic plug,
cleaned the filter in accordance with technological card No 3 of chapter 7 of this Manual.
If lamp „OIL“ shines in flight, it is necessary to turn off the APU.
When it is necessary, it is allowed to continue the APU operation for 15 min after lamp OIL lights up.
- signal lamp „FUEL FILTER“:

Shining is signaling the contamination of the inlet fuel filter in the Block of filter and servo-valve or the filter of
the back fuel.
After lighting up it is necessary to turn off the APU. In the extreme cases it is possible to end the working
regime of the APU after maximum 5 min work of APU at regime. After turning off the APU it is to be done the
cleaning of filters, in accordance with technological cards №. 5 and of chapter 7 of this Manual.
- signal lamp "APU FAILURE":

Shining is signaling, that the APU has been switched off by the APU safety system of automatic protection. If
the APU has been switched off as a result of failures out of the APU systems, it is possible to carry out starting
and operate APU again. In an opposite case, it is necessary to clarify the sort of failure on the signaling board of
failures and proceed in accordance with point 4.6.2. (APU starting) or in accordance with chapter 9 of Manual
(Analysis and the methods of elimination of failures). The reason of APU switching off can be determined on the
board of failures – shining of the certain light diod is signaling the reason of the APU switching off. The
signaling will be turned off when making the following APU starting, i.e. including dummy and unsuccessful
startings! The information about the reason of failure is not saved!
4.5.2.2 Digital indication of APU parameters from serial interface RS 422 of control box LUN5271.80/CONB
Checking and control of APU operation is carried out by means of digital signal from control box serial interface
RS 422 to the boarding multifunction display. When is switched on power supply of control box
LUN5271.80/CONB, digital output of data transfer from serial interface RS 422 to transmit data automatically
every one second. To the output of serial interface RS 422 is possible to connect 16 pcs of standard RS422
receivers. The parameters of APU and essential information about APU operation that are provided by the control
box serial interface RS 422 – this is value of gas temperature, some APU error or operation messages is possible
to display on the boarding multifunction display. Therefore it is not necessary to install the indicator of gas
temperature, standard control board of the APU in pilot cabin with control and signal lamps neither panel of
signaling the failures with light diodes.
There are several possibilities for full usage this serial interface of control box LUN5271.80/CONB:
a) Signalling the attainment of periodic service works- the attainment of APU operating hours, exchange of oil,
replacement of spark plugs and signalling the exceeding of APU parameter- APU gas temperature, APU speed,
For this signalling is recommended to use tricoloured LED with three outputs on common anode. Yellow color
will be created by shining of red and green LED at the same time on the identical chip.
Note:
Each of the monitored parameters has 2 values configured in the memory module: „orange” and „red” (the red is
always higher). When all of the monitored parameters are OK (lower than the set limits), the LED lights up green
for 3 seconds always after the power supply of the control box is turned on, then the LED does not light. If one of
the monitored parameters exceeds the preset value, the corresponding LED lights up and lights permanently in
orange or red.
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b) Throw serial interface RS 422 are transferred following APU parameters and information:
- APU gas temperature, APU speed, current of servo valve for control of APU speed
- APU starts and hours counting (record)
- APU failure indication
- APU operation record – history of APU operation (record data from APU 1,5 hours operation)
c) There is possible to connect personal computer (throw serial interface RS 422 of control box
LUN5271.80/CONB) for APU operation evaluation, transmit of date is ensured by data transfer reducer from
RS422 to USB connected to the PC with special software “PEJ CONB” for evaluation all data.
Detail description of control box LUN5271.80/CONB serial interface RS 422 for data transfer packet of current
condition, instruction for operation and service of control box LUN5271.80/CONB are presented in “Operation
and service manual” № PRP-581-602-03-001.
4.5.3 Operation of signaling system circuits, time and control

The control box is equipped with time circuits, checking circuits and provides the exit signals of protection, which
might be used e.g. for panel of signaling the failures or throw control box serial interface RS 422 to the
multifunction display. It is also equipped with an internal diagnostics, which is checking the operation of the basic
modules, connecting aggregates of the equipment, it is comparing the APU operation with prescribed programs
and existing appropriate commands and information. In case of deviation from the program the microprocessor
provides the interruption of power supply to aggregates and stops the APU automatically.
After APU switching off there does not shine the control lamp „APU OPERATION“ and lights up the signal
lamp "APU FAILURE". In the control box there is provided recording of the failures (defects) of APU with a
possibility of further evaluation. The shining of the certain light diode (there are 9 light diodes) on the panel of
failures is signaling the sort of failure, which caused the APU switch off. The circuits of signaling the failures in
the control box are permanently powered from the voltage of board system, power supply is continuing also after
switch off of the APU. The power supply of this circuit can be stopped only by switching off the certain safety
element, when also the light diodes are switched off. These light diodes are also switched off when making the
following APU starting.
4.5.3.1 Indication of APU operation and failure detection accommodation

Checking and control of APU operation is carried out by means of signal lamps and indicators in pilot cabin,
situated on the control board of the APU or is carried out by means of information on the boarding multifunction
display which obtain relevant digital signal for evaluation from control box LUN5271.80/CONB serial interface
RS 422.
A/ Analog indication of APU failures on the panel of failures

The adjustment of the level of activity of signaling system:
- APU ready (operation)
shines the lamp "APU OPERATION " in range of rpm from 90 to 109 % ± 1%
- contamination (blockage) of fuel filter or back fuel filter
shines the lamp "FUEL FILTER“, if the pressure drop on filter element of the back fuel filter attained value
(25±5) kPa or the pressure drop on the filter element of block of filter and servo-valve attained a value (25±5)
kPa
- contamination (blockage) of oil filter or minimum amount of oil or maximum oil temperature
shines the lamp "OIL“, if the pressure drop on filter element of oil filter attained the value (40±12) kPa or if
the amount of oil in oil tank attained value 1 liter or if the oil temperature in oil tank attained the value
(135+10-5) °C
The adjustment of level and time for automatic switch off the APU
Starting regime of the APU:

- unsufficient or zero signal of rpm sensor - up to 3-rd sec (shines light diode SG)
- no attainment of temperature of exhaust gases – up to 13-th sec lower than (100 ± 20) °C (shines light diode TZ)
- no attainment of rpm – in 36-th sec lower than (80 ± 1) % (shines light diode PO )
- no attainment of oil pressure – up to 10-th sec after exceeding the 80 % of rpm (shines light diode TO )
- exceeding the temperature of exhaust gases–for period greater than 1,5 sec value (950 ± l0) °C
(shines light diode VT)
- exceeding the maximum rpm (112,7 ± 1) % (shines light diode NO )
- unsufficient level of signal of rpm sensor - after 3-rd sec lower than 700 mV (pike-pike) (shines light diode SG)
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Operational regime:
- unsufficient level of rpm sensor signal lower than 700 mV (pike-pike)(shines light diode SG)
- exceeding the maximum rpm (112,7 ±1) % (shines light diode NO )
- exceeding the temperature of exhaust gases– for a time higher than 3 sec value (720 + 20)°C (shines light diode VT)
- drop of rpm – lower of minimum rpm (80 - 5) % (shines light diode PO)
- drop of oil pressure – lower of min. level (80 ± 5) kPa for a time period larger than 10 sec (shines light diode TO)
Other reasons for automatic switch off the APU
- failure of circuit of servo-valve or failure of control box relay or failure of sensor of exhaust gas temperature -
(shines light diode OV)
- failure of control electronics (inside of control box)- (shines light diode EL )
Other signaling on the failure panel – it is not reason of automatic APU switch off – it is only signaling
information about the operation !!
- turning over to the reserve system of the rpm sensor - (shines light diode ZV)
LED diode ZV shining does not influence on APU operation and it is possible normal continoue operation of APU
without limitation till next TBO.
B/ Digital indication of APU failures on on the boarding multifunction display

Alternatively it is possible to use digital signal from control box LUN5271.80/CONB - APU failure indications are
transferred through serial interface RS 422 of control box to the boarding multifunction display.
The adjustment of level and time for automatic switch off the APU are presented in previous paragraph A/.
In the following table is presented the description of failures from serial interface RS 422 (information in byte
number 17 of data packet) in comparison with analog indication on the panel of failures, which signaling the sort
of APU failure and caused the APU switch off.
Description of APU failure and concerned failure code

Failure code Description of APU failure and concerned failure code
FF no failure –correct operation of APU
FB failure of control electronics (inside of control box) (designation EL)
F1 turning over to the reserve system of the rpm sensor (designation ZV)
F2 insufficient level or zero signal of rpm sensor (designation SG)
F3 oil low pressure – lower of min. level (designation TO)
F4 no attainment of temperature of exhaust gases (designation TZ)
F5 no attainment of minim. rpm or drop of rpm (designation PO)
F6 exceeding the vibration (N/A for APU SAFIR 5K/G MI)
F7 exceeding the temperature of exhaust gases (designation VT)
F8 exceeding the maximum rpm (designation NO)
F9 (N/A for APU SAFIR 5K/G MI)
FA failure of circuit of servo-valve or failure of control box relay or
failure of sensor of exhaust gas temperature (designation OV)
4.5.4 Blockage of APU protection system
During the starting of the main engine, the electrical board system provides (from the signal ”ENGINE
STARTING” the supply of electrical signal into the control box of APU, which is blocking the all automatic
protection switch offs of the APU, with exception of the switch off caused by exceeding the maximum frequency
of the APU rotor rotation. When connecting the electrical generator APU to the net, the board electrical system of
the helicopter provides turning off the blockage.
4.6 Operational limitation
4.6.1 Source of power
APU can be supplied with power either from board accumulator, from the board main source or from the ground
source of power.
For the reliable work of the APU, it is necessary to provide:
- board accumulator capability….. ...................................................................................................... min 25 Аh
- board system voltage ……. ............................................................................................................... 24 - 29 V
- permitted range of voltage for APU operation………….................................................................... 18 - 31 V
- at beginning of starting cycle the voltage on battery terminals must not be lower than......................... 14 V
- total resistence of cables between the accumulator and starter of APU shall be no more than.......….(23 ± 2) mΩ
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4.6.2 APU Starting
4.6.2.1 Repeating the APU startings
There is permitted to carry out in sequence three startings of the APU (including the false startings) with time
interval between them no less than 1min. The next starting can be accomplished after interval minimum of 20 min.
The repeated starting of APU, carried out after shutdown of the APU operating at the working rpm, it is necessary
to accomplish at temperature of exhaust gases lower than 150°C.
Note: In special cases it is allowed the repeated starting of the APU after shutdown directly following the keeping
the interval 1 min. Number of such startings is limited to 20 startings within the service life of the APU, the
information about such startings must be recorded in the engine service log of the APU.
4.6.2.2 Unsuccessful starting of the APU
In case of unsuccessful APU starting (APU has been switched off automatically by safety system: does not shine
the signal lamp „APU OPERATION“, shines the signal lamp "APU FAILURE", it is necessary to clarify the
reason for shutdown on the signaling board of failures (shining the certain light diode is signaling the reason for
APU shutdown) and after that to determine the possibility of repeated APU starting:
- If there shines the light diode TZ or SG, the next APU starting can be accomplished after interval no less than 1
min.
- If there shines the light diode TO , the next APU starting can be done after interval no less than 1 min and at
temperature of APU exhaust gases lower than 150°C. Next starting can be done after determination of the failure
and its elimination (see the chapter 9).
- If there shines the light diode VT or PO, the next APU starting can be done after interval no less than 1 min and
at temperature of APU exhaust gases lower than 150°C.
- If there shines the light diode NO, or OV or EL, the next starting can be done after determination of the failure
and its elimination (see the chapter 9).
Note: For improvement of the APU starting at temperatures of ambient air less than minus 20ºС it is recommended
to carry out at first the false (dummy) starting of the APU and than after interval of 1 min – the normal starting of
the APU.
4.6.3 Takeoff of the electrical power
- During the APU starting (up to the working rpm) there is blockage of the of the electric power takeoff.
- Long-term work of the APU at the regime of electrical load is limited by temperature of exhaust gases up to
650°C, in flight for a short time it is allowed (within 30 sec) the temperature up to 670°C.
- The takeoff of the electrical power when starting the main engine is limited by max. 3 kVA (i.e. 8,7A AC) in
range of temperature of inlet air of minus 55 to +55 oC .
4.6.4 Limiting the takeoff air (for starting the main engine)
- The minimum air takeoff is not limited.
- The maximum air takeoff for the air-condition system it is limited by Venturi tube ∅32 mm in the anti-surge
valve and also by temperature of the exhaust gases up to 650°C.
- During starting the main engine it is allowed the maximum temperature of exhaust gases 710°C within time no
more than 3 sec
- During starting the APU (up to the working rpm) it is necessary to provide the blockage of air takeoff from APU
– the valve of air starter of the started main engine or the valve in air-condition system, they must be closed!
- During the APU function the number of air takeoffs for starting the main engines is not restricted.
4.6.5 Operational conditions
а/ The starting of the APU and the main engine is provided in the temperature range of inlet air…. from minus 55
to +60 oC.
The producer garantees the operation of APU in range of air temperature in APU sector……… from minus 50
to + 80 °C in region (place) of installation of fuel aggregates, in case that no part of oil and fuel systems is
overcooled under minus 40°С.
Before starting the APU on the ground where the temperature is lower than minus 40°С, if it is supposed, that
the parts of fuel and oil systems attain the same temperature, there can be recommended the heating of APU
part by air having temperature not above 80 °С within at minimum 30 min.
b/ The maximum working temperature:
oil ................................... + 140 oC (in oil tank of the APU)
fuel….............................. + 60 oC (at inlet into APU fuel system)
c/ The minimum overpressure of fuel at inlet into fuel system during the operation of the APU...........50 kPa.
When having the failure of board fuel pump during the APU operation there cannot be reduced the fuel
pressure at APU fuel inlet under ………. 8 kPa.
d/ The fuel mass flow at inlet into APU fuel system .................…from 115 to 125 l/h
e/ The fuel mass flow at exit from APU fuel system ............……from 90 to 50 l/h
f/ Back pressure at exit of APU fuel system ……………..........…under 20 kPа
g/ Fuel temperature at exit of APU fuel system ………………..…max. up to 110 oC
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4.6.6 Operational restrictions – temperatures, rotation speeds

Shutdown of APU due to the attainment of following parameters:
- the maximum temperature of exhaust gases during the starting …......................... .(950 ± 10) oC
- the maximum temperature of exhaust gases at working regime …….….................. (720 + 20) oC
- the maximum rpm of APU rotor……….................................................................... (112,6 ± 1) % - 55300 rpm
- the minimum rpm………............................................................................................(80 - 5) %
4.6.7 Operational time

- the maximum APU starting time….. ......................................... 36 sec
- the mean time of APU operation................................................ 20 min
- the maximum time of APU operation........................................ 6 hours
4.6.8 Safety loads

a/ The safety loads during the APU operation: Nx = ± 0.5 g
Ny = + 2 g ÷ - 1. 5 g
Nz = ± 0.75 g
b/ The safety loads of shutdowned APU
The maximum working overloads in centre of gravity of APU, limiting values of angles and angular speeds
with respect to three axes of the helicopter
- the linear overloads Nх = ± 2 g
Ny = - 4 g ÷ + 2 g
Nz = ± 2 g
- the angular speeds ωx = ωy = ωz = ±0,6 rad/sec
The mounting points (fixation) of the APU and aggregates fixed to the APU are resistent to effects of shocks
having the acceleration 8 g , the width of impulse is from 5 to 10 miliseconds, in all directions.
Diagram of accelerations and speeds

4.6.9 Other restrictions
- the minimum temperature of fuel at inlet into fuel system of the APU
(at exit behind the fuel board pump) ……………………………….. ……………………..max. minus 50 °С
- the minimum temperature of fuel at inlet during the APU starting
limited by maximum viscosity of fuel ……………………………………………………..12 mm2/sec
- the minimum temperature of oil during the APU starting ………………………………… minus 40 °С
- the maximum fuel temperature at inlet into fuel system of APU …………………………. + 60 °С
4.7 Instructions when replacing the oil for the other sort (type)
When replacing the oil used in APU for the other sort oil, it is necessary to keep the following measures:
- As the replacing sorts there are permitted only those sorts of the oil, which are presented in this Manual (point 2.4.)
The application of the other sorts has to be agreed with APU producer. .
- It is not permitted to mix the oils of different sorts.
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When replacing the oil for the other sort it is necessary to carry out the washing of oil system of the APU by the oil
of new sort, as follows:
1/ Drain the oil from the oil filter and oil tank, according to the instructions in technological card № 4.
2/ Fill the oil tank with a new sort of the oil up to the mark „MAX“.
3/ Start the APU, operate it 2 - 3 min at regime of idle run and stop the APU.
4/ Drain the oil from filter and oil tank.
5/ Fill the oil tank with an oil of new sort.
6/ Start the APU, operate it 2 - 3 min at regime of the idle run. Stop the APU. Check the tightness of the oil system.
7/ After APU stop and cooling the oil, fill the oil to the oil tank up to mark „MAX“.
8/ Do record into APU log book about this change of the sort of used oil.
4.8 Instruction for operation and technical maintenance

The maintenance during the APU operation is to be carried out in accordance with instructions of presented
Manual
4.8.1 Replacement of the oil pump

Instructions about the replacement of the oil pump are presented in subchapter 6.4.2 (Replacement of aggregates
and spare parts of the APU in process of operation). After replacement of the oil pump LUN 6320.02 on the drive
box of APU it is necessary to check, starting the APU on the idle run, the oil pressure behind the oil filter, which
has to be (145 ± 10) kPa. The process of measurement of oil pressure and its adjustment by means of the
adjusting screw is to be done in accordance with instructions in technological card № 9.
4.8.2 Installation and replacement of the APU control box

Instructions for installation of the control box are presented in subchapter 5.4.2.2.
- During the removal of the control box the works are to be done in opposite order.
4.8.3 Cleaning of the fuel drain valves

The cleaning of the fuel drain valves is to be carried only when having the wrong operation of the APU, when
on the long-term regime of APU operation the fuel drains through by-pass of fuel of the drainage tank, or when
the APU does not start.
The instructions for cleaning the drain fuel valves are presented in chapter 7 (technological card № 8).
4.8.4 Adjustment of the oil pressure and cleaning the by-pass valve of the oil pump.
The checking and adjustment of the oil pressure is carried out after accomplishing the operational time of the APU
200 hours, in accordance with instructions presented in chapter 6.3, and also in case of automatic shutdown of
APU (shines the lamp ”ВСУ ОТКАЗ”(APU FAILURE) on the board of control and lights up diode TO on the
failures board panel in pilot cabin).
The instructions about the adjustment of oil pressure and cleaning the valve of oil pump by-pass are presented in
chapter 7 (technological card № 9).
4.8.5 Checking the electrical starter

Checking the electrical starter (checking the overrunning clutch and brushes) is to be carried out only when
having the cases of repeating unsuccessful startings of the APU, in cases of automatic shutdowns of APU
during the starting (see chapter 9 Failures and the methods of their elimination).
Instructions for checking the overrunning clutch and replacement of brushes of electrical starter are presented in
chapter 10 (technological card № 21).
ATTENTION. For compleeting these works the APU must be removed from the object.
5. INSTRUCTIONS ON INSTALLATION AND INTRODUCING INTO OPERATION
5.1 Instructions on APU installation

APU SAFIR 5K/G МI is situated horizontally in the rear sector of the fuselage, fixation of the APU in the airframe
of helicopter is carried out by means of hinges and fixation elements – see fig. 2 Outline drawing of the APU.
Placing the aggregates in individual systems of the APU is shown on schemas – see figs. 5 to 8.
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5.1.1 Presumptions of the APU SAFIR 5K/G МI installation on helicopter:
- The installation of APU on helicopter must avoid arising the negative rpm of autorotation.
- Air intake into APU compressor must cause the minimum drop of the pressure at the end of air channel when
APU is operating – the vacuum in the sector of suction (in comparison with atmospheric pressure) must not
exceed …… 1 kPa.
- Design of the air suction at inlet of the APU air intake must in any working case prevent suction of the foreign
objects into compressor, i.e. ice, hail and also the exhaust gases from the main engines or from the other source
and also suction in the dust and rain water in large extent.
- Maximum permitted back pressure behind the turbine of the APU is …… 5 kPa.
- The range of fuel pressure at inlet into APU fuel system must stay in limits from ….. 50 to 150 kPa :
- when starting no less than 100 kPa, but no more than 150 kPa
- on working regime no less than 50 kPa, but no more than 150 kPa
- The back pressure at fuel system exit (behind the block of filter and servo-valve) must be less than ……. 20 kPa
- The maximum permitted fuel pressure at fuel system inlet on not operating APU cannot be more than …300 kPа.
- The fuel mass flow at APU fuel system inlet is from ……. 115 to 125 l/h
5.1.2 For installation of APU on the object, it is necessary to keep the following instructions:
- The installation of individual APU aggregates on the board of object must be confirmed by APU producer. The
installation dimensions are presented in approproate drawings of aggregates and technical description.
- When installing the individual instruments of the air system it is necessary to keep the direction of air flow from
the APU.
- When installing the aggregates on board, removing the plugs from tubes for it, it is necessary immediately
connect the tubes of fuel or air system, keeping them absolutely clean.
- During the connecting tubes at fuel inlet and exit of the APU fuel system, it is absolutely necessary to apply the
appropriate toolings for holding the tubes, in order to avoid their turning or mechanical damage of instrument.
The cap nuts and other parts must be locked by locking wire. When dismantling the sleeves it is necessary to
cover them by plugs again.
For proper installation and checking it is not necessary to apply any fixtures, measuring instruments and special
toolings.
- The all connections of the air system must be leakproof, in order to avoid the loss of pressure.
- Using the ignitian box with inverse polarity of the power voltage or without connection to the spark plug it is
not permitted!
- The electrical connection of the board system of helicopter with APU is to be done with help of central
connector of the APU packet.
- The installation of the control box on the helicopter board and electrical schema of connection – see p. 5.4.2.3
5.2 Instruction on APU replacement during the operation

5.2.1 Removal of APU from helicopter:
1/ Carry out the false (dummy) starting of the APU (conservation)
2/ Drain the oil from oil tank
3/ Remove the electrical cable (connectors) to the APU aggregates – central connector of the APU packet of cables,
connector and compensation cables on the control box.
4/ Remove the inlet and exit sockets of fuel from APU
5/ Cover with plugs the all inlets of APU and board installation
6/ Remove the APU from helicopter and set it into transport frame
7/ Cover on the APU with plugs the inlet of compressor (suction), exit of compressor (air takeoff from APU) and
exhaust tube
8/ Carry out the record into engine log about the APU removal
5.2.2 APU installation on the object

When installing the new APU it is necessary to carry our the following works:
- Unpack the APU, instruments and accessory. Check the completeness according to listing. The external
surfaces (if they are conserved) clean by technical gasoline (the cables and electrical parts protect against
contact with gasoline). The parts washed with gasoline wipe out dry.
- The time period between the unpacking, cleaning from conservation and intruducing the APU into operation on
the object must not exceed three month.
- APU and the other its instruments are to be set, in accordance with instructions of Operational manual.
- When doing the installation the plugs are to be removed step by step, in order to avoid not necessary the
openings to be left uncovered long time.
- The other works relevant to the introducing the APU into operation are to be done in accordance with point 5.3.
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5.3 Introducing into operation
5.3.1 After APU installation on the object it is necessary to carry out the following works
1/ Check the proper connection of the all items according to the general schema of APU systems – see Fig. 6:
- fuel system;
- air system;
- APU electrical connections – joining the central connector and the control box of the APU
- electrical connections of the electrical generator.
2/ Remove the plug protecting the air intake of the APU, exhaust pipe and remove the textile band, protecting the
air suction and air exit for cooling the electrical generator.
Remove the oil tube in front of the inlet into gas generator (on the turbine casing) and inject 50 cm3 of oil
(cleanness of oil higher than 35 µm). The tube is to be mounted back – the cap nuts and the other parts are to
be locked with locking wire.
Note: This work is carried out only when storing the APU was more than 3 months.
3/ Fill the oil tank with oil up to mark ”MAX”.
4/ Check by hand easy turning the rotor of APU – through exhaust pipe by turbine wheel.
5/ Carry out „FALSE START“ of APU – check blinking (8 sec) of the lamp „APU OPERATION“.
6/ Keep interval 60 sec, after APU shutoff.
7/ Carry out „APU START“ of APU and check APU operation by means of special signaling elements on the
control board in pilot cabin:
- blinking and shining the lamp „APU OPERATION” (~ 30 sec from pressing the button „START“.
- no shining the lamp „OIL” and „FUEL FILTER”.
8/ After operation on regime of idle run within 3 min switch off the APU.
9/ Check the time period of APU rotor rotation from pressing the button “STOP“ up to stop of the rotor.
This time period has to be no less than 40 sec.
5.3.2 Prescribed works after the 1-st starting:
1/ Minimum 5min after shutdown check the oil level in the tank and check the tightness of fuel and oil systems.
2/ Carry out „START“ of the APU – after 30 sec from shining the lamp „APU OPERATION“ check the load of
electrical generator and then gradually within 3 sec increase the load up to maximum possible value (20 kW).
3/ Switch off the load of electric generator.
4/ Carry out „FALSE START“ or cold turning or starting the main engine.
5/ Check air takeoff for air-condition system (if there is used on helicopter from APU) –after checking the
different regimes of air-condition, check also the proper work of the APU for the all combinations of the electric
power takeoff and air takeoff for air-condition system.
6/ Shutdown the APU by pressing the button “STOP“.
7/ After APU shutdown check the leaktightness of the fuel and oil systems.
8/ After the full cooling of the oil (up to the temperature of ambient air) fill the oil tank with oil up to the mark
„MAX“.
9/ Record into engine log the information about the APU starting into operation, number of startings and time of
operation.
5.4 Instruction on installation of aggregates enclosed to the APU

5.4.1 Introduction
The presented instructions belongs to the APU SAFĺR 5K/G МI and are to provide the user with information about
the rules of installation of individual aggregates of the APU on the board of object.
The rules about the mounting and installation of individual aggregates of the electric power supply source APU
SAFIR 5K/G МI (transformer P/N 20736-100, control box of generator P/N 2438-100 and generator P/N 20040-
100) are presented in ”Technical description and manual for operation and technical maintenance” of the power
supply source SAFIR 5K/G МI in Appendix to this Manual.
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5.4.2 Operational conditions and rules for installation of the aggregates
5.4.2.2 Control box LUN 5271.80, LUN 5271.80/CONA, LUN 5271.80/CONВ
Operational conditions
- Range of ambient air temperature: from minus 60 to + 85 °C
- Temperature stability: from minus 60 to + 85 °C
- ceiling: up to 8000 m
- resistence against: (valid for control box LUN 5271.80, LUN 5271.80/CONA)
- vibrations from 5 to 500 Hz, 10 g (acc. to standard RTCA/DO-160C , chapt. 8, categ. Т)
- shocks 12 g (acc. to standard RTCA/DO-160C, point 7.3.2)
- linear accelerat. 6 g (acc. to standard RTCA/DO-160C, categ. 7.2)
- resistence against: (valid for control box LUN 5271.80/CONB)
- vibrations acc. to standard RTCA/DO-160D, chapt. 8, categ. R
- shocks acc. to standard RTCA/DO-160D, categ. B
- linear accelerat. 6 g (acc. to standard RTCA/DO-160C, categ. 7.2)
Rules of installation
The control box is installed on the fuselage of the object in the special frame, delivered together with a set of
control box. In place of installation of the control box must not be situated another source of heat and must not be
any heat radiation.
- Unpack the control box, check the completion in set, check in aacordance with a listing the connecting
connectors. The mounting clips are to be fixed to the board. The box is to be inserted in clip and it is protected
by two cap nuts of the clips fixed on object board.
- Connect the milled nut M4 with a screw on the left side from connector. On the screw there are to be set the
solded eyes of the grounding cable of the board and shielding of the wires to thermocouples. After tightening the
nut with milling has to be locked by locking wire. To the terminals marked with CH (chromel) and A (alumel)
there are joint the wires from thermocouples and the screws are locked by locking wire or by locking nuts
(according to model of control box).
- Control box LUN 5271.80 connects the connector of cable packet of APU. After installation the connector must
be locked by screw. On the rear side of the control box there is to be connected connector of the board cable for
signaling panel of failures and it is locked by two screws.
- Control box LUN 5271.80/CONA and LUN 5271.80/CONВ connects both connectors of cable packet of APU
and connectors must be locked by bayonet joint. On the rear side of the control box there is to be connected
connector of the board cable for signaling panel of failures and it is locked by two screws.
- Connect and lock connector of the helicopter´s bording system to the control box LUN 5271.80/CONВ serial
interface -if there is applied.
The main dimensions are shown in fig. 13, the box installation in fig. 14, the main dimensions of the frame are in
fig. 15.
5.4.2.3 Indicator of gas temperature LUN 1386.01

Operational conditions
- Range of temperature of ambient air: from minus 55 to + 70 °C
- Temperature stability: from minus 55 to + 85 °C
- ceiling: to 10000 m
- resistence against:
- vibrations from 5 to 550 Hz , 2 g
- shocks 6g
- linear accelerat. 4,9 g
The mounting rules

The indicator of the temperature of gases is placed into the pilots cabin of the object on the APU board panel of
control. The indicator is inserted from the rear side into the openings in board panel and from the front side it is
fixed by 4 screws M4. The electrical resistence of the wires is allowed up to 4 Om.
The main dimensions are in fig. 16.
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Control box LUN 5271.80
Connector
Connector
Control box LUN 5271.80/CONA
Fig. 13 Control box LUN 5271.80, 5271.80/CONA
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terminals CH-A and grounding for

connection of APU cable harness
connector SJTP02RE-14-35P
connector SJTP02RE-16-26P
serial interface RS 422

connector SJT 07RT-10-35P
connector D-Sub 15
type 871 CANON
Fig. 13a Control box LUN 5271.80/CONB
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FRAME OF
CONTROL BOX
Fig. 14 Installation of the control box
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71,5
Fig. 14a Installation of the control box LUN 5271.80/CONB
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Fig.15 Frame of the control box
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63 ± 0,4
INDICATOR
+ 48 ± 1
-
R6
illumination
48 ± 0,1
M4-5H
9±1
M14 x 0,75
YELLOW RED
670°С-710°С 720°С RED
950°С
94 ± 3
Ø 60
11 ± 1
2,5 +0,5
Indicator
out of operation Ø 60-0,4
GREEN
280°С-670°С
Fig. 16 Indicator of temperature of gases LUN 1386.01
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1/ Scale "Тг" –indicate the value of gas temperature behind the APU turbine
- measurement unit ….°С
- information discontinuity … 5°С
- scale implementation-color, numeric value and limiting:
A/ starting regime of the APU:
- green within the limit Тг < 940;
- yellow within the limits 940 ≤ Тг < 960;
- red within the limit Тг ≥ 960;
B/ APU operation –starting main engine with electric power extraction 3kVA:
C/ APU operation –electric power extraction up to 20kVA:
2/ Scale "Рв" – indicate the value of air pressure (overpressure) of APU bleed air extraction
Hodnota Рв je definována dle grafu (viz podeb na obr. č. 4/1 a 4/2) v závislosti na teplotě okolního
vzduchu a nadmořské výšky.
- measurement unit …… kg/сm2 (bar)
- scale range: 0,3 … 3 kg/сm2
- information discontinuity 0,1
- scale implementation - color, numeric value and limiting:
- green within the limit 0,75 – 2,9
- yellow within the limits Рв < 0,75 a Рв > 2,9;
scale "Tг" scale " Рв "
Fig. 16a. Description of measuring parameters scale on the multifunction display
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6.0 APU MAINTENANCE TASKS AND INTERVALS

6.1. Airworthiness limitation
6.1.1 Service life
The values of service life and periods of operation of the APU are presented in engine log of the APU on basis of
page page 6/12 of the Appendix 4 TPF 01-4939-01.
The designated service life of basic parts:

Name of the part № of part № of drawing Designated service life, number of cycles
(startings of the APU)
Wheel of the 1-st turbine stage 86 14517 B3-0086-10452 9 800
Wheel of the 2-nd turbine stage 86 14518 B3-0086-10453 45 750
Compressor wheel IВW8 488 14721 B2-0488-10400 14 700
6.1.2. Designating and periodicity of the obligatory maintenance tasks

Periodic inspection (prescribed) and required APU maintenance tasks create the basic system of service of the
APU SAFÍR 5K/G МI on the object with respect to keeping the airworthiness.
These tasks comprise the routine inspections, periodic reqired maintenance tasks and checking measurements and
they are accomplished in accordance with technological cards, presented in chapter 7.
The system of maintenance tasks (prescribed works) of the APU is organised on the three-level principle and
consists of:
- periodical inspections A, B, C, which are carried out in time periods shown in p. 6.2.1;
- prescribed works after performing by the APU 200, 400, 600 hours and 1000 startings of the APU;
- major overhaul (2 overhauling repairs)–after attainning the operation hours, shown in engine log.
6.2 First level of the prescribed works

6.2.1 Routine inspections
The first level of the prescribed works consists of three periodical inspections:
Inspection А It is to be carried out after each flight of the helicopter, when it has not been performed the
inspection B or C, and before each take-off of the helicopter.
Inspection B It is to be carried out once a day after completing the flights of helicopter, when it has not been
performed the inspection C.
Inspection C It is to be carried out once per 15 ±2 day of the flight operation.
The table of inspections of the type А, B, C
Prescribed works А B C
1. Check visually the the fixation of APU aggregates and accessory. - - Х
2. Check visually fixation of connectors and conditions of the electrical cables of the APU - - Х
3. Check visually the APU fixing. - - Х
4. Check visually the sector of APU installation, air intake channel and exhaust pipe
- Х Х
and be sure, that there are not any foreign elements.
5. Check visually the tightness of the fuel system. Wipe out the found leakage of the fuel,
clarify its reason and eliminate it. Х Х Х
6. Check visually the tightness of oil and hydraulic systems. Wipe out the found leakage,
clarify the reason and eliminate it. Х Х Х
7. Check the oil level in oil tank. If the level is lower than is mark MAX, more than by 1 cm,
Х Х Х
fill the oil up to the mark MAX. The amount of oil: mark MAX ~ 1.8 l; mark MIN ~ 1.3 l.
8. Check and record into APU log the operating hours and the number of starting. - Х Х
9. Check manually easy rotation of the APU rotor (through exhaust pipe for turbine wheel).
In case of hacking or high resistence, remove the APU from operation and contact the - - Х
producer.
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6.2.2 Checking the parameters of the APU
On regime of starting the main engine there are to be checked the parameters of the APU (according to indicators
in pilot cabine or by means of information on the boarding multifunction display) – once per 30 days and record
them into the log.
6.2.3 Checking the APU operation by means of instruments and indicators in pilot cabin.
1/ Checking the APU (also checking according to p. 6.2.2) is to be carried out on indicators situated in pilot cabin
on the control board panel of the APU or on the boarding multifunction display (see fig. 17/1 and fig. 16a):
- gas temperature
........ limitation of temperature of exhaust gases up to 670°C (see p. 4.6.3) – during the takeoff of the
electric power
........ limitation of temperature of exhaust gases up to 710°C (see p. 4.6.4) – during the starting of
main engine
- air pressure
.......minimum permitted value of overpressure of air at takeoff from APU (pbl [kgf/cm2])
- during starting the main engine see. Figs. 4/1 and 4/2
- on idle regime see. Figs. 17/2
In APU operation (on APU idle regime and during engine starting) it is allowed air pressure (pbl) degrease of
value 0,1[kgf/cm2].
2/ When operating the APU on helicopter, so by means of signaling lamps there is provided the following
information about the APU operation:
а) Starting the APU (blinking the lamp ”APU OPERATION ” – signaling during the starting (and also false
starting) of the APU.
b) Readiness of APU (shines the lamp ”APU OPERATION ”- signaling the normal operating regime of the
APU.
c) Contamination of the fuel filter in Block of filter and servo-valve or of back fuel filter (shines the lamp
”FUEL FILTER ”. After light up the lamp it is necessary to switch off the APU.
In the extreme cases it is possible to takeoff the electrical power or air from the APU, i.e. after light up the
lamp ” FUEL FILTER” within the period of 5 min of APU operation on regime – see p. 4.5.1. After the
APU shutdown, when making the inspection of type B it is to be carried out cleaning the filters according to
technological cards №. 5 and 6 of chapter 7 in this Manual.
d) The contamination of oil filter or minimum amount of oil in oil tank or exceeding the temperature of the oil
in tank (shines the lamp ”OIL”) . After light up the panel OIL on the ground it is necessary to switch off
the APU. In the extreme cases it is allowed to continue the APU operation within 5 min after light up the
panel “OIL”.
After shutdown of the APU it is to be checked and recorded the oil level in the oil tank, checked the magnetic
plug, carried out cleaning the filter in accordance with technological card №. 3 of chapter 7 of Manual.
When having the light up of the panel OIL in flight, it is necessary to shutdown the APU.
When necessary, it is allowed to continue the APU operation within period of 15 min after light up of the
panel OIL.
3/ The registration of failures after automatic APU shutdown on the board panel of failures signaling (there
shines the lamp ”APU FAILURE” after APU shutdown). The algorithms of determination of individual
failures are presented in chapter 4.5.2.
4/ In all cases, when the measured parameters of the APU operation are outside of acceptable limits, the APU
must be switched off, checked the correctness of data of measuring instrument or issue of appropriate signal
and if this all is correct, it is to be approached the process of elimination of APU failure.
5/ The failures and methods of their elimination – see chapter 9. The failures must be eleiminated by means of
replacement or repair of aggregates in accordance with instructions in chapter 6 ,7 and 10.
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«STOP» APU
(SHUTDOWN)
«START» APU Indicator of air pressure
Switch «START» APU Indicator of temperature

«FALSE START» APU of gases
(„DUMMY STARTING“)
Control lamp «OIL»
Control lamp « APU OPERATION»

Control lamp « FUEL FILTER »
Control lamp «APU FAILURE »
Fig 17 Control panel of the APU
Idle regime of APU

rotation speed n = 49000 rpm , without electric extraction from APU
pbl 2,6
P2 (atm)
2,5
2,4
(kgf/cm2) 2,3 t =-40°C
2,2
2,1
2 t =-10°C
1,9
1,8 t =15°C
1,7
1,6 t =35°C
1,5
1,4
1,3 t =50°C
1,2
1,1
1
0,9
0,8
0,7
0,6
0,5
0 1000 2000 3000 4000 5000 6000
H (m)
Fig.17/2. Dependence of the takeoff air pressure upon the ambient conditions on idle regime.
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6.3 Second level of prescribed works
The second level of prescribed works consists of prescribed works, which are to be carried out after attaining the
operation hours of the APU 200, 400, 600 hours and 1000 APU startings. These works are carried out both on the
object board and on the removed from board individual aggregates. (see table 1).
6.3.1 General theses
Observing the periodicity of prescribed works must be carried out with precision of ± 10 %.
Table 1 List of prescribed works
Works to be completed after hours of APU

№ operation
technol. Name of work 1000 and
card 200 hours 400 hours 600 hours 2000
startings
1 APU checking Х Х X -
2 Replacement of spark plugs - - - Х
3 Washing the oil filter Х Х X -
Or after
Х or each
4 Exchange of oil in oil tank - - each two
2 years
years
Washing the fuel filter of the Block of filter and
5 Х Х X -
servo-valve
6 Washing the fuel filter of Back fuel filter Х Х X -
7 Checking the APU functionality Х Х X -
9 Checking the oil pressure X - - -
6.3.2 Necessary checking facility and instruments:
The checking instruments and toolings are presented in chapter 7.3.
6.3.3 The prescribed works when having intervals in operation
- When having the time interval in APU flight operation it is necessary to carry out starting and operation of APU
on regime of idle run within 5 min each other month of the operation interruption.
- When having the long-term time intervals in APU operation or in case of helicopter conservation, it is necessary
to carry out the conservation of APU according to the instructions, presented in chapter 8.2.
6.4. Third level of prescribed works

6.4.1. Overhaul
The APU overhaul is carried out in the special repair plant or in plant of the producer of APU, after attainment
the number of hours of operation presented in APU log.
There is possible the APU operation „on condition“ – in accordance with individual instructions of the producer.
6.4.2. Replacement of APU aggregates during the operation

The instructions on replacement of aggregates are presented in chapter 10. In process of operation there is
possible to carry out the replacement of failured aggregates, listed in table.
About the replacement carried out, it is necessary to make record in APU log.
The disabled aggregate must be sent to the producer plant of the APU, together with description of the failure,
completing the form for aggregate in question.
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List of aggregates and APU parts, which can be replaced by user during the process of operation
Order Number of technological card
Name of aggregate, part Type designation
№ or chapter of Manual
1. Block of filter and servo-valve Draw. No B1-0488-10276 card № 22
2. Fuel pump Draw. No B2-0488-10381 card № 24
3. Ignition box 90 49800-4 card № 29
HE 3410
86 500.03
4.а Cable of spark plug Draw. No B3-0488-10792 card № 30
4.b Cable of spark plug Draw. No B3-0488-10757 card № 30
4. Spark plug CH34630 card № 2
5. Return fuel filter Draw. No B3-0488-10791 card № 23
LUN 5271.80 point 4.8.3 и 5.4.2.2
6. Control box of the APU LUN 5271.80/CONA
LUN 5271.80/CONB
7. Anti-surge valve LUN 7527.8 card № 32
8. Oil pump LUN 6320.02 card № 26
9. Oil filter LUN 7627.02 card № 25
10. Temperature switch Draw. No B3-0488-10827 card № 27
11. Float-type switch SP 03 Draw. No B2-0445-10393 card № 28
12. Generator P/N 20040-100 card № 31
13. Control box of generator P/N 2438-100 Appendix 1-chapter В/ point 5
14. Transformer P/N 20736-100 Appendix 1-chapter В/ point 5
15. Electric starter Draw. No B2-0488-10346 card № 21
16. Combustion chamber Draw. No В1-0488-10293 card № 1, point 1,2 и 11-16
17. Drain valve I DV1-00 card № 8, point 1,2 и 5,6
18. Drain valve II DV2-00 card № 8, point 3 и 5,7
20. Indicator of gas temperature LUN 1386.01 point 5.4.2.3
21. Packet of cables Draw. No B3-0488-10822 card № 33
B3-0488-11728
22. Brushes of Electric starter 4S 65046 card № 21
23. Bypass valve of Return fuel filter Draw. No B2-0488-10407 card № 34
(P/N 488 744 01)
24. Bypass valve of Block of filter and Draw. No B2-0488-10407 card № 35
servo-valve
25. Pre-blockage pressure switch LUN 1491.13 card № 36
(signaling of fiter contamination) of
Oil filter
List of aggregates and APU parts, which can be replaced in process of operation only by representative of plant –
APU producer
Order № Name of aggregate, part Type designation

1. Sensor of the rpm LUN 1308-8
2. Sensor of temperature of exhaust gases LUN 1385.81
3. Oil tank Draw. No B1-0488-10251
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7. THE TECHNOLOGY OF MAINTENANCE OPERATION
The periodic maintenance tasks, intervals (prescribed works) and checking the aggregates of the
APU are to be carried out in accordance with the following technological cards, in accordance with
prescribed periods of these works and requirements, presented in chapter 6.
7.1 List of technological cards (Required maintenance tasks)
Card Designation of work (maintenance operation) Page Number

№ number of pages
1 APU checking 49 11
2 Replacement of spark plugs 60 2
3 Washing the oil filter 61 3
4 Replacement of oil in oil tank 64 2
5 Washing the fuel filter of the block

of filter and servo-valve 66 2
6 Washing the filter of back fuel 68 2
7 Checking the functionality and

measuring the parameters of APU 70 2
8 Cleaning the fuel drain valves 72 2
9 Checking and adjustment of oil pressure,

cleaning the oil pump 74 2
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TECHNOLOGICAL CARD № 1
Work designation: APU CHECKING Description applies to figs.: 18 ÷ 26
Content of operation and the technological requirements.
The works are to be performed in following order:

1) Removal of fuel collector (see.fig. 18 and 19)
а/ Unlock the nuts (1), (2) (fig. 18). By spanner 22 screw off the nuts (1), (2) and remove the connecting cables from
the right and left sides of spark plugs (31), (32).
b/ Unlock and by spanner 17 screw off the cap nut (3) of the deaeration tube.
c/ By means of spanners 8 and 7 screw off the nuts (5) (fig. 19). Remove from the holder (4) the outputs of
compensation wire of the bundle of cables (28) and also the outputs of the compensation line (10) of the sensor of
exhaust gas temperature.
d/ Unlock and screw off by spanner 17 the cap nuts (6) and (7) of the fuel tubes. The inlet (29) and exit sockets (30)
(fig. 20) and free fuel tubes are to be blinded by threaded plugs М12х1 and М14х1.
e/ Unlock and by spanner 8 screw off two nuts (9) and remove the fixing band (19) (fig. 18) and three segments of V-
type collar (36) (see fig.23).
е/ By spanner 7 screw in three bolts M4x10 into the threaded holes (8) and, turning them, shift the fuel collector (14)
off from the turbine casing (15) (fig. 18).
f/ Remove the fuel collector (14) with combustion chamber (16) and exhaust pipe (17) (see figs 18 and 20).
ATTENTION. When removing the fuel collector, it is necessary to pay the attention to the sealing ring of the
rounded cross section (34) of the drain valve nipple in the lower part of the fuel collector (figs.21 and 23).
2) Removal and cleaning the combustion chamber
а/ Remove the combustion chamber (16) (fig.20). For this purpose by spanner 10 screw off 5 bolts (18) and remove
the combustion chamber.
b/ The holes of the screw of suction fuel (11) (see fig. 21), are to be cleaned by copper wire (∅ 0.8) and washed by
technical gasoline by means of injecting (without dismantling).
c/ By means of scribbler remove the solid deposits of carbon inside the combustion chamber. The whole combustion
chamber is to be cleaned from deposits by means of technical gasoline and brush.
ATTENTION: When cleaning, do not allow the deformation of gaps for air inlet.
3) Check the combustion chamber condition for presence of cracks.

For the following operation, there are permitted the cracks of the next types (see fig. 24):
A – no more than at 8 holes, and no more than 1 crack for one hole. Maximum length of one crack is 10 mm.
В – no more than at 10 holes, and no more than 3 cracks for one hole. Maximum length of one hole is -10 mm. In case of
danger, that two holes could join each other, the combustion chamber must be removed from the operation.
С – no more than at 15 holes, and no more than 3 joined holes.
D – no more than at 30 holes, and no more than 3 joined holes.
Е – (for spark plug hole) – no more than 3 cracks. Maximum length of one crack -10 mm.
F – no more than 3 cracks at a hole. Maximum length of one crack is – 10 mm.
G – on the welding seam in the nearness of bushings the cracks are not allowed.
The other cracks, burnings-in and deformations are not permitted.
In case of finding out the other sorts of cracks, burnings-in or deformations, it is necessary to remove the combustion
chamber from the operation.
ATTENTION: The cracks of the sort А, В are to be finished around their roots by drilling the hole of diameter ∅ 1.5 mm
and by removal of frays on the edges of drilled holes.
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4/ Check the functionality of the sensor of the exhaust gas (see. Fig. 21).
a/ Step by step heat by means of electro soldering lamp three measuring elements (24) of the sensor of exhaust gas
temperature. When heating, it is to be observed the response of reaction on the DC millivoltmeter, which had been
connected to the exit terminals CH-A of the compensation line (10). The exit voltage must be proportional to the
heating of the sensor. The temperature sensor is found congruous, if there are responding all three measuring
elements.
b/ In case of failure of functionality at one of three measuring elements, it is permitted to continue the APU operation.
About the sensor failure there must be done the record into APU log.
c/ In case of failure of functionality at two measuring elements, it is necessary to replace the sensor of temperature!
Such measures can be done only by personel of the plant-producer. After exchange of sensor it is to be done the
record into the APU log.
5) Checking and cleaning the fuel nozzles (see. Figs. 21 and 25).
a/ Clean the caps (25) and faces of nozzles (26) and also the space of the fuel collector between the nozzles by cotton
towel.
b Check the fixation of the nozzle caps in the fuel collector. Three screws M3 must be screwed in and locked by
locking wire (see fig. 21 and 25).
c/ The holes (27) of the nozzles are to be cleaned by copper wire of diameter 0.5 mm.
6) Check the condition of the inlet hole of socket of deaeration tube (33) in the exhaust pipe. By screw driver and cotton
towel it is to be removed the contamination (carbon deposit) (see figs 20 and 23).
7) Check the fixation of spark plugs (31) and (32) in the fuel collector (14) and condition of electrodes (see figs 18 and
22). The contaminated spark plugs are to be cleaned by brush. In case of extensive wear of the working part or in case
of mechanical damage of thread replace the spark plug.
ATTENTION. The working part od the spark plug must no be cleaned by hard items.
8) Check the condition of stator vanes (21) and blades of turbine wheel (22) of the 2-nd stage of turbine. Any cracks or
deformations are not permitted.
9) Check the condition of the inner space of the turbine spacing (15) (see fig. 23). In case of finding out the
contamination, wipe out the later by cooton towel.
10) Push by hand the stator guide vane row (21) in direction of the compressor, by hand carry out the rotor turning (for
turbine wheel (22)) and check the easy rotation. The rotation must be without the noise and seizure. In case of seizing
it is necessary to improve the centring of stator guide vane of turbine and repeat the testing. When repeats the seizure,
clarify the reason or remove the APU from the helicopter and transport it to producer plant for revision.
11) Installation of the combustion chamber. Five bolts (18), equipped with washers (35) (see fig. 20) is to be lubricated
with Pulver MF, or with an equivalent lubricant against seizure of the strongly heat stressed thread joints, tighten by
means of calibrated wrench to torque moment 10 Nm and lock by wire of diameter ∅ 0.8 mm.
Clean the surfaces of flanges of the fuel collector (14) and turbine casing (15). Install back the fuel collector (14) with
combustion chamber (16) and exhaust pipe (17).
The proper orientation of the fuel collector with respect to the turbine casing is given by nipple of drain channel of fuel
collector.
ATTENTION. The increased attention when making the installation should be paid to sealing ring of the rounded cross
section (34) of the drain channel nipple in the bottom part of the fuel collector (see figs 21 and 23)! In case of its
damage it must be replaced.
After mutual installation of the fuel collector and turbine casing, there are to be installed the three segments of V-type
collar (36). It is to be paid care to proper setting the segments (secure the same gaps between them). Set the fixing band
(19). The nut (9) of the fixing band is to be tightened by torque moment 4 Nm by means of the torque moment spanner
and extending socket 8.
In process of the nut tightening it is necessary permanently knock on the individual parts of the band by rubber or
wooden hammer. After nut (9) tightening by prescribed torque moment it is to be locked this nut by locking nut with
holes. The locking nut is to be tightened by torque moment 5-6 Nm and locked by wire ∅ 0,5mm.
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13) Join to the holder (4) the outlets of compensation cable bundle (28) and compensation lines of the sensor of exhaust gas
temperature (10). Lock them with nuts (5).
14) Screw off and remove the threaded plugs from the inlet and exit sockets and from the appropriate fuel tubes (see fig.
20). The threaded sockets (29, 30) are to be lubricated with GLEIT HP 520М or with equivalent lubricant against the
seizure of threaded joints. Install the tubes, tighten the nuts (6) and (7) (see fig.19) and lock by wire ∅ 0,5mm.
15) Socket (33) (see fig 20) lubricate with Pulver MF, or with an equivelant lubricant against seizure of strong heat-stressed
threaded joints. Set the tube for deaeration, tighten the cap nut (3) and lock it by locking wire ∅ 0.5мм (see fig.19).
16) Install the ending junctions of the cables of spark plugs (1) and (2) on the later. Tighten the nuts (1), (2) and lock them
by wire ∅ 0.5mm.
17) Checking the magnetic plug (see fig 26)
а) Remove the locking wire and by spanner 10 screw off the magnetic plug (26) from the casing of drive box. The
oil leakage is to be wiped out by cotton towel. Inspect the plug. Before the back installation of the plug into the
drive box the sealing ring (37) is to be lubricated with CIATIM 201. In case of damage of the sealing ring replace
the later. Screw in the magnetic plug and lock it with locking wire Ø 0.5mm.
b) In case of finding out, when doing the inspection of magnetic plug, the metallic chips, after completing the works
according to this technological card (№ 7) and during completing the tests on functionality of the APU, it is
necessary to carry out the repeated checking of the magnetic plug. If during the repeated checking there are not
found the metallic chips, the APU is found suitable for further operation.
c) If the chips are appearing again, the APU cannot be put into operation! There must be done record in APU log
about it and informed the producer! APU must be removed from the board and transported to the producer plant
for revision.
18) Record about the works carried out must be done into the APU log book.
19) The orientational torque moments of bolts and nuts tightening:

М3- 2,5 Nm, М4- 3÷4 Nm
М5- 6÷7 Nm
М6- 10 Nm
The cap nuts of tubes: internal diameter 4- 20 Nm, internal diameter 6- 25 Nm.
Checking instruments Toolings and fixtures Used material
- voltmeter with range from 0 to - screw M4x10- 3 ps - lubricant GLEIT HP 520М

200 mV - plug М12х1 –1pc, plug М14х1-2 or equivalent lubricant
- soldering elektrolamp ps. (outer thread) against seizure of threaded
- plug М12х1 –1pc., plug М14х1- joints
2 ps. (inner thread) - lubricant Pulver MF, or
- blind of turbine (after removal of equivalent lubricant against
the fuel collector) seizure of heat-stressed
- scribbler of carbon deposit in threaded joints
combustion chamber - technical gasoline
- soft brush - locking wire ∅ 0,5
- copper wire Ø 0,8 and Ø 0,5 - cotton towel
- calibrated wrench, open spanners
for 7, 8, 10, 17 mm, socket for
8mm, pliers, side pincers
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32 31
17
15
19
6 13 7 11 3 8 14
Description to the figs 18 - 26
1. cap nut of the connecting cable of the spark plug (left) 21. stator guide vane of the 2-nd turbine stage
2. cap nut of the connecting cable of the spark plug-right 22. wheel of the 2-nd turbine stage
3. cap nut of the deaeration tube 23. screw М3х8
4. holder of the compensation wire 24. sensor of exhaust gas temperature
5. а) nut М5, б) nut М4 25. cap of the fuel nozzle
6. cap nut of the fuel tube 26. facing of the fuel nozzle
7. cap nut of the fuel tube 27. holes of the nozzle
8. threaded hole 28. compensation wire of the cable bundle
9. nut М5 29. threaded socket of the fuel inlet
10. compensation line 30. threaded socket of the fuel exit
11. screw of fuel suction 31. right side spark plug
12. tube of fuel suction 32. left side spark plug
13. tube of overflow 33. threaded socket of the deaeration tube
14. fuel collector 34. rubber ring of the rounded section 5,7х1,9
15. turbine casing 35. washer
16. combustion chamber 36. V-type collar
17. exhaust pipe 37. rubber ring of the rounded section 7,7х1,9
18. bolt М6х42
19. fixing band
20. drain tank
Fig. 18 Removal of fuel collector

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3 5b
5а
28
10
17 12 11 8
Fig. 19 Removal of sensor of temperature of exhaust gas

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14
33
17
35
18 29 13 30 4 16
Fig. 20 Removal of combustion chamber
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24
24
Exit voltage
(mV)
23
24
10
25
8 11
34
Fig. 21 Checking the fuel collector and the sensor of temperature of exhaust gas
31
32
Fig. 22 Checking the condition of electrodes of spark plugs
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22
33
24
21
17
18
34
19
16 20 15 36
Fig. 23 Section of fuel collector with combustion chamber
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Fig. 24 Permitted failures of combustion chamber
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23
25
23 23
23
27
26
25
Fig. 25 Section of fuel nozzle
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26
26 37 26
Fig. 26 Checking the magnetic plug

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Work designation: REPLACEMENT OF SPARK PLUGS

Description applies to fig.: 27
Content of the operation and technological requirements
Removal of the old and installation of the new spark plug is to be carried out as follows:
1) Remove the locking wire, screw off by wrench 22 the cap nut (4) and remove the cable of spark plug.
2) Screw off the spark plug (1), (2) by wrench 17 from fuel collector (3). Pay attention to removal of the sealing
washer (2).
3) The new spark plug taken from the set of spare parts, equipped with sealing washer (2), screw in the bushing (5) of
the fuel collector (3), slightly tighten by wrench to reach the contact. After that finally tighten by wrench up to 15 -
300 .
4) Screw in on the spark plug the cap nut (4) of the cable of spark plug.
5) Lock the cap nut of the spark plug cable by means of locking wire Ø 0.5mm.
6) About the works carried out make a record into the APU log book.
- spanners 17 and 22mm - spark plug

- side pincers CHAMPION CH 34630 –2ps
- long pliers - locking wire ∅ 0.5
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1l
3
4
1r
3 2
Description.
1l. left side spark plug

1r. right side spark plug
2. sealing washer
3. fuel collector
4. cap nut
5. bushing
Fig. 27 Spark plug CH 34630
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Work designation: WASHING THE OIL FILTER

The description applies to fig. 28
Content of the operation and technological requirement.
Note: Inspection and washing the oil filter is to be carried out when making the prescribed works
according to p. 6.3.1 or in case of signaling the filter contamination during the operation (shining the
lamp-signal ”OIL ”in pilots cabin).
The works are to be carried out in order as follows:
1) Unlock, screw off and remove the pot (1) of oil filter with filtration element (2). Drain the oil from the inner space of
filter. The volume of drained oil ~ 200 ml.
NOTE: For draining the oil from the inner space of the oil filter it can be used the outlet valve (10). For this purpose
it is to be removed the locking wire from the rounded cap nut (7) of the outlet valve (10). Turn by hand the nut (7)
clock-wise, the oil will flow off from the outlet valve. After draining the oil the nut (7) is to be returned in opposite
direction into the former position and locked in two places by wire.
2) After draining the oil it is necessary to press the spring ring (8) and remove the filtration element (2). The pot (1)
and filtration element (2) are to be washed in technical gasoline or in aviation kerosene, using the soft brush.
NOTE: It is recommended to apply the ultrasound washing machine. Time of washing no less than 20 min.
3) The sealing rings (3, 4) are to be lubricated by CIATIM 201. In case of their damage, replace them.
4) The washed filtrating element (2) is to be set into pot (1), and locked by ring (8). Pot (1) is to screwed into filter
casing (5) and locked by locking wire.
ATTENTION:
- When handling the oil filter it is not allowed the contamination of the inner space of the filter.
NOTE:
- For checking the pressure loss on the oil filter or for measurement of the oil pressure at exit of oil pump it can be
used the holes blinded by plug (6) (pressure in front of filter), and by plug (9) (pressure behind the filter). Into the
holes (thread М8х1) is to be inserted the manometer 0÷300 kPa.
- After 5 min of APU operation (during the summer) and after 10min of operation (during the winter), are to be
measured both pressures. The difference of both values must not exceed 25 kPa.
- The procedure of measuring the oil pressure and adjustment of oil pressure behind the oil tank is to be
accomplished with respect to instructions presented in technological card № 9
5) About the works carried out it is to be done record into APU log book.
Checking instruments Toolings and fixtures Material used
- threaded connection (int. diam. - open spanners size 19, 11mm - lubricant CIATIM 201
3 mm, thread М8х1) – 2ps. - soft brush - locking wire ∅ 0,5
- tube (hose) - container of volume no less than - technical gasoline
with manometer 0÷300 kPa – 0.3 l
2ps. - side pincers
- long pliers
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6 9
3 6 9
7
4
10 2
6 11 11 9
Description.
1. pot
2. filtrating element
3. sealing rubber ring 14,6 х 1,9
4. sealing rubber ring 47 х 2,5
5. filter casing
6. plug М8х1 (hole for measuring the pressure in front of filter)
7. rounded cap nut
8. locking ring
9. plug М8х1 (hole for measuring the pressure behind the filter)
10. outlet valve
Fig. 28 Checking the oil filter

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Work designation: REPLACEMENT OF OIL IN THE OIL TANK

Content of the operation and technological requirements.
Note: Replacement of the oil is to be carried out after washing the oil filter, with respect to the
instructions presented in technological card № 3.
ATTENTION: Replacement of the oil it is recommended to carry out at oil temperature

exceeding 400C.
1) Unlock and remove the cover of oil tank (1).
2) On the throat (5) of the outlet valve (2) fix the hose for oil drain. Open the valve (2). For this purpose turn anti-
clockwise to the end (~ 40°) the lever (6) of the valve control and drain the oil. The volume of the oil drained ~ 2 l.
3) From the filling throat (3) remove the net (4) and wash it in clean gasoline.
4) Close the outlet valve (2) (turn the lever of valve control clockwise) and set net into filling throat.
5) Fill the tank with clean oil up to the mark МАХ.
6) Close the filling throat by cover (1).
7) Carry out the dummy starting of APU, add the oil up to the mark MAX, check the absence of leakages of oil and lock
the cover (1) by wire.
8) Do record in APU log book about the works carried out.
- hose (internal diameter ~ 10 mm) - technical gasoline

- container of volume no less than - locking wire ∅ 0,5
2l
- side pincers
- long pliers
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1 2 5
1 3 2 2 5
Description.
1. oil tank cover

2. outlet valve
3. filling throat
4. net
4
5. throat of the outlet valve
6. lever
Fig. 29 Replacement of oil in oil tank
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Work designation: WASHING THE FUEL FILTER OF THE BLOCK OF FILTER AND
SERVO-VALVE
Note: Washing the fuel filter is to be carried out when performing the prescribed works in accordance
with p. 6.3.1 or in case of signaling the contamination of filter during the operation
(shining the lighting panel ”FUEL FILTER” in pilots cabin).
The works are to be carried out in the following order:
1) Remove the locking wire and screw off the pot (1).
2) Remove the filtrating element (2). Filtrating element (2) and pot (1) are to be washed in technical gasoline using the
soft brush.
NOTE: It is recommended to apply the ultrasound washing machine. Time of the washing of filtrating element is to be
no less than 20 min.
3) The sealing rings (3, 4) lubricate with CIATIM 201. In case of their damage, they are to be replaced.
4) The clean filtrating element (2) is to be installed back into casing (5) of the block of filter and servo-valve. Screw in
the pot (1) and lock it by locking wire.
ATTENTION:
When handling the block of filter and servo-valve it is not permitted the contamination of the inner parts of the block.
5) About the accomplished works it is to be done the record in APU log book.
- spanner 17mm - lubricant CIATIM 201

- side pincers - technical gasoline
- long pliers
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5 1
1
Description of the fig.
1. pot
3. rubber sealing ring 14,6 х 1,9
4. rubber sealing ring 47 х 2,5
5. casing of the block of filter and servo-valve
Fig. 30 Checking the fuel filter of the Block of filter and servo-valve
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Work designation: WASHING THE FILTER OF BACK FUEL
Description applies to fig. 31
Note: Washing the fuel filter is to be done when accomplishing the prescribed works according
to p. 6.3.1 or in case of signaling during operation the contamination of filter (shining the
lamp-panel ”FUEL FILTER” in pilots cabin)
The works are to be carried out in following order:
1) Remove the locking wire. Screw off the pot of the filter (1).
2) Remove the filtrating element (2) from the filter сasing (5).
3) Wash the filtrating element (2) and pot of the filter (1) in technical gasoline or in aviation kerosene using the soft
brush.
Note: It is recommended the application of ultrasound washing machine. The minimum time of washing is 20 min.
4) The sealing rings (3, 4) lubricate with CIATIM 201. In case of their damage replace them.
5) The clean filtrating element install back to the filter casing. The pot is to be screwed in filter casing and locked by
locking wire.
ATTENTION
When handling the filter it is not permitted the contamination of internal parts of filter.
6) Do record about the accomplished works in the APU log book.
- spanner of size 17mm - lubricant CIATIM 201

- long pliers
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Description
1. filter pot
3. rubber sealing ring 11,6 х 1,9
4. rubber sealing ring 26 х 2
5. casing of filter of back fuel
Fig. 31 Checking the Filter of the back fuel
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Work designment: CHECKING THE FUNCTIONALITY OF APU AND MEASURING THE

APU PARAMETERS Description applies to fig. 32

1. Checking the APU functionality :
а/ Carry out the false start (dummy starting) of the APU and after APU shutdown visually check the tighteness of the
fuel and oil systems, i.e. absence of leakage.
b/ Carry out APU starting and check the following functions of APU on the control board:
- blinking the lamp APU OPERATION during the APU starting
- the permanent shining the lamp APU OPERATION, informing about the fact, that APU attained the working
regime (appr. after 30 sec from the moment of pressing the button APU START).
c/ After attainment of the working regime it is to be checked:
- Air takeoff from the APU for air-condition system (if the one is on the board of object) – check APU operation
for the all possible combinations of electrical power takeoff and air takeoff.
- On regime of the cold turning of the main engine (ME) or starting the main engine check the proper operation of
the anti-surge valve of the APU, i.e. after opening the valve of air starter of ME the anti-surge valve has to close
the by-passing of air into atmosphere ( in accordance with p. 4.2).
- Loading the electrical generator by means of gradually (at minimum within 3 sec) increasing the load up to the
maximum possible value on the object board (it is allowed the maximum value of total current no more than 58A
AC), after that to eliminate the load.
d/ By pressing the button“STOP“ switch off the APU and measure the time of run-out of the APU rotor, i.e the time
from pressing the button STOP up to the complete stop of the APU rotor rotation.
This period of time has to be at least 30 sec.
In case of shorter run-out time, it is necessary to clarify the reason for it or to remove the APU from the helicopter
board and transfer it to the plant of producer for performing the revision.
e/ After shutdown it is necessary to check the tightness of the all APU systems.
2. Measuring and checking the APU parameters.

а/ Measuring the parameters it is to be carried out by means of indicators on the control panel of the APU:
- indicator of exhaust gas temperature (EGT APU)
- indicator of the air pressure (AIR PRESS)
b/ During the checking of the APU functionality according to the point 1c) it is to be recorded the pressure of air
takeoff taken from the APU, temperature of the exhaust gas of APU, voltage and current intensity of the electrical
generator on the regimes as follows:
- At idle run of the APU;
- On regime of air takeoff from the APU for air-condition system (if such a one is installed on the board)
- On regime of cold turning or starting the ME, with takeoff the electrical power at the same time 3 kW, i.e. 8,7A
AC – see chapter 4 (total current of APU up to 100А DC – 27,5V DC) and without the takeoff of electrical
power, including the APU operation after ending the ME starting.
- On generator regime (without takeoff of air from APU) with maximum takeoff of electrical power possible on
the object board (maximum value of total current no more than 58A AC)
c/ During the APU operation on the all checked regimes it is not allowed the surge of compressor or automatic
shutdown of the APU.
d/ It is allowed the maximum temperature of the exhaust gas:
- up to 650°C on the generator regime at maximum takeoff of electric power. For a short time it is allowed 670 °C
(within no more than 30 seс) ;
- up to 710°C (no more than 3 seс) when starting the ME with simultaneous takeoff of the electrical power 3 kW.
e/ The pressure of takeoff air from the APU must be in accordance with values presented in figs 3, 4/1 and 4/2. The
air pressure of idle regime the APU must be in accordance with values presented in fig 17/2.
It is allowed the reduced air pressure of takeoff from the APU, at value 0.1 kp/cm2, on idle regime, regimes of air
takeoff for air- condition system or for starting the engine (see fig. 3, fig 4/1, 4/2 and 17/2).
In case of improper operation of the APU (compressor surge, automatic APU shutdown) or in case of excessive
increase of temperature of exhaust gas, or reduction of pressure of air takeoff, which exceed the presented limits,
it is necessary to proceed in accordance with p. 6.2.3. 4/ and 5/, complete the checking of tubes for air takeoff
and replace the anti-surge valve.
3. About the works it is to be done the record into APU log, includ. the measured parameters of APU (accord. to p.2b/).
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«STOP» APU
(SHUTDOWN)
«START» APU Indicator of air pressure
Switch «START» APU Indicator of temperature

«FALSE START» APU of gases
(„DUMMY STARTING“)
Control lamp «OIL»
Control lamp « APU OPERATION»

Control lamp « FUEL FILTER »
Control lamp «APU FAILURE »
Control panel
Panel signaling the failures
Fig. 32 Control elements of the APU
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Work designing: CLEANING THE FUEL DRAIN VALVES

The content of operation and the technological requirements.
Cleaning the drain fuel valves is carried out only when having the improper APU operation, when
during the long-term operational regime of APU the fuel drains through by-pass of the drainage tank,
or when the APU does not starts.
The works are to be done in order as follows:
1) Unlock and by spanner 7 screw off 2 bolts (6) of the drain valve DV-I (4) on the left and right sides of the block
of drain valves (3).
2) Turn the drain valve (4) on the left and right sides by 90° in any direction by means of the long pliers, holding for
the valve flange. Remove the valve from the block of drain valves.
3) Unlock and by spanner 17 screw off and extract the drain valve DV-II (5) with by-pass (2) and with two sealing
rings 1,6 х 1,9 (8).
ATTENTION: Do not allow the contamination of the holes of drain valves after their removal.
4) The valves (4), (5) are to be washed in technical gasoline or in aviation kerosene. The holes of drain valves are to
be cleaned by injecting the clean technical gasoline or the aviation kerosene and the holes are to be blinded by
plugs (the plug – diameter 12 mm – 2 ps, the plug with thread М10х1 -1 pc).
Note: It is recommended the application of the washing machine. The minimum time of washing is 20 min.
5) The sealing rings (7), (8) of drain valves are to be lubricated by CIATIM 201. In case of their damage, they should
be replaced.
6) The clean valves (4) are to be installed into block of drain valves (3), screwed on by the bolts (6) and fixed by
means of locking wire.
7) The valve (5) with by-pass (7) and with two sealing rings 11,6 х 1,9 (8) screw into the block of drain vlaves and
fix it by locking wire.
About the works carried out is to be done the record into the APU log book.
The orientation torque moments of tightening the threaded joints:

- bolts (6) М4х10 - 4 Nm
- drain valve DV-II (5) - 15 Nm
- spanner of size 17 and 7mm - lubricant CIATIM 201

- long pliers - locking wire ∅ 0,5
- plug of diameter 12mm- 2ps.
- plug with thread М10х1- 1pc.
- soft brush
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8
8
5
2
1 5 4
3 6
Drain valve DV-I Drain valve DV-II
hexagonal 17mm
7
7
Description
1. drainage tank 6. bolt М4х10

2. by-pass 7. sealing rubber ring 8,7 х 1,9 (2ps )
3. block of drain valves 8. sealing rubber ring 11,6 х 1,9 (2ps)
4. drain valve DV-I (2ps)
5. drain valve DV-II,
Fig. 33 Removal and cleaning the drain fuel valves
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Work designing: CHECKING AND ADJUSTMENT OF THE OIL PRESSURE,

CLEANING THE OIL PUMP Description applies to fig. 34
Checking or adjustment of the oil pressure are carried out after attainment of the 200 APU operational hours in accordance
with instructions, presented in chapter 6.3.
The adjustment of the oil pressure and cleaning the by-pass valve of the oil pump are to be done also in case of automatic
shutdown of the APU (shines the lamp ”APU FAILURE ” on panel of control and also the light diod TO on the signal
panel of failures in pilots cabin).
1) For measurement of pressure behind the oil pump it is to be used the hole (in casing of the oil filter), blinded by plug
(9). The plug is to be screwed off by spanner 11 and into the hole (thread M8x1) it is to be connected the manometer
0÷300 kPa.
2) Carry out APU starting and after 5 min of the APU operation in summer and 10 min in winter it is to be measured
pressure – the pressure (overpressure) must be (145 ± 10) kPa. When having difference of pressure out of frame of
the given value, it is necessary to perform the oil pressure adjustment.
3) Oil pressure adjustment.

а/ Remove the locking wire and seal from the protective cap (6) and by spanner 11mm screw off the cap. Release the
locking nut (10) of the screw for adjustment of pressure (7), keeping the screw in fixed state by screwdriver.
Adjustment of the pressure – one turn of the screw clockwise increases the pressure by ∼ 10kPa and vice versa.
b/ Tighten the locking nut (10) keeping the screw in fixed state by screwdriver.
4) Start the APU and measure the oil pressure (according to p. 2). When measuring the appr. same pressure as in first
case (p. 2), it is necessary to carry out the washing of by-pass valve of oil pump (according to p. 5) and also repeat
the oil pressure adjustment.
5) Removal and cleaning the by-pass valve of the oil pump.

In order to improve the comfort of work, it is recommended to remove the oil pump from APU (see the
technological card № 26).
а/ Screw off the screws (5), remove the holder (8) with an adjusting screw (7).
b/ Remove the support of spring (3), spring (2) and piston (4), during this operation check the easy motion of the
piston in the regulation bushing (1) and proper position of the spring (free one) – on the spring support (2) and
piston (4).
c/ The removed parts and regulation bushing in oil pump are to be washed by clean technical gasoline.
d/ The washed parts (2), (3), (4), (7) and (8) install in opposite order into the oil pump. Tighten the screws (5).
6) Start the APU and measure the oil pressure (acc. to p. 2).
7) Set on the protective cap (6), set the seal and lock by wire.
8) Disconnect the manometer. The sealing ring (11) (see fig. 28) is to be lubricated by CIATIM 201. In case of its
damage, replace it. Screw in the plug (9), lock by locking wire.
9) After the next starting and shutdown of the APU check the tighteness of the oil system.
About the works done make a record into the APU log book.

- thread connection (inner - spanner 12, 7 and 11mm - lubricant CIATIM 201
diameter 3mm, thread М8х1) - screwdriver (length max 100mm) - locking wire ∅ 0,5
- tube (hose) with manometer of - soft brush, long pliers - technical gasoline
0÷300 kPa - side pincers
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12 4 2
Sealing ring
3 7 16,6х1,9
10 13
8 11 6
9 oil filter 6 oil pump

Description.
1. regulation bushing
2. spring 8. holder
3. spring support 9. plug М8х1 (hole for pressure measuring)
4. piston 10. locking nut М4
5. screw М3х8 11. sealing rubber ring 7,7 х 1,9
6. cap 12. sealing rubber ring 13,6 х 1,9
7. screw of pressure adjustment 13. oil pump casing
Fig. 34 Adjustment of the oil pump
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7.2 Safety regulations
7.2.1 APU testing
- Before to start the testing, it is necessary to provide the free space around the object and make
arrangements for anti-fire facilities. Before the APU starting it is necessary to warn all
members of the service personal about beginning the testing.
- In course of any APU testing, which are carried out during the introducing APU into
operation, when checking the functionality during the revisions or during the finding out and
elimination of the failures, during these works there must not be allowed to be present the
person, who did not participate on the teaching process.
- It is forbidden to be present in the nearness of the exhaust pipe, air intake of the APU and air
intake of the generator of the alternate current of the APU.
- When doing inspection of the APU after its shutdown, it is necessary to handle it with care, in
order to avoid burns up when contacting the hot parts.
- The cleaning and wiping out the working liquids in locality of APU cannot be done during the
APU operation.
7.2.2 Technical maintenance of the APU.
- For performing any works with APU on the object, it is necessary to use the prescribed
auxiliary devices – i.e. working ladder and working platforms. The persons must be equipped
with appropriate foot-wear and prescibed working clothing.
- Before beginning the works on APU, there is necessary to be carried out measures, avoiding
the APU starting during performing the works.
- The object must grounded by means of connecting the current leading parts of undercarriage
with a ground.
- The transferable lamps must be in „anti-explosive make“.
- For cleaning the APU parts, for which there is prescribed the gasoline washing, it is to be used
the technical gasoline. This restriction does not apply to such parts, which are removed from
the APU and their cleaning is to be performed out of the object.
- The workers, participating on works of the object, must have antistatic foot-wear and they are
not allowed to wear the clothes from synthetical fibres, this applies also to toolings and
materials for cleaning. The cloth and shoes have to be clean.
- The combustion liquids must not be left spilled both on platform under the object nor in space
of APU locality. The reserve cleaning material is to be stored in metallic (of sheet) containers
at distance as minimum 10 metres from the object.
- In radius up to 10 meters from the APU it is forbidden to smoke or to handle the open fire.
- Around of the object there must be prepared the anti-fire equipment.
- When handling the all working liquids and cleanings materials, there must be observed the
sanitation and hygiene standards. It is necessary to avoid the direct contact with them and
breathing their vapours. After the work it si necessary to wash hands by soap and warm water.
- In case of insinuation of these materials into eyes, it is necessary to wash the eyes by flowing
water at minimum 5 min and keep the eyelids open during it. Contact the physician after it.
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7.3 List of toolings and fixtures
The technical maintenance and prescribed works, carried out on APU, do not requir any special
toolings or fixtures (equipment). After client wish, together with the APU it is possible the delivery
the mounting bag containing the following standard toolings and fixtures, needed for performing the
works on operation and technical maintenance of the APU:
List of toolings:
Name of the tool size, marking

Spanner double-ended (9 pcs) 5,5 x 7 8 x 10 9 x 10 1 1 x 12 13 x 17 14 x 17
18 x 21 19 x 22 24 x 27
Socket wrench double-ended (2 pcs) 18 x 19 16 x 17
Barrel spanner (2 pcs) 9 17
Torque moment wrench TMK - 0,5 (limit 0-5 Nm, accuracy to 10 %)
Barrel socket (5 pcs) 5,5 7 8 9 10
Extending rod OK8
Handle (2 pcs) 4 8
Screwdriver (3 pcs) 0,6 x 4,5 x 100 100 (80) 160
Long pliers TPX1093-25-57
Long rounded pliers №. 322
Side pincers №. 335
Locking wire - 10 ps 0,5 x 500
Locking wire - 5 ps 0,8 x 500
Wire - 2 ps 1,2 x 80
Wire for nozzle cleaning 0,5 x 1000
Key for M62 nut 499 451.471
Tweezers 1145000119
Cotton towel
Bolt - 3 ps M4 x 12
Blind 6 ps ONL 3998 M12 x 1
Blind 6 ps ONL 3998 M14 x 1
Blind 6 ps ONL 3999 d = 12
Blind 6 ps ONL 3999 d = 14
Scribbler for removal of carbon deposit
Paste HYLOMAR
Lubrication paste CHETRA (or lubricant CIATIM 201)
List of fixtures:
Testing tube with manometer 0÷300 kPa (accuracy 1.5 %) for checking the oil pressure (2 ps).
List of checking instruments:

- Voltmeter in range 0 ÷ 200 mV (accuracy 1 %, inlet resistence 10 MOm)
- Soldering electrolamp.
7.3.2 Tester of APU´s SAFÍR 5K/G MI

This instrument (TESTER LUN 5274) serves for laboratory testing of APU´s control box, for
testing of APU´s regulation system in aircraft for monitoring of APU´s working in simulated
operation. After client wish, it is possible the delivery the Tester of APU. Using the following
instrument it can be determined the likely reason of failures and set the methods of their remedy
in accordance chapter 9. During the checking and testing the APU with Control box LUN
5271.80/CONA is necessary to use for connecting with TESTER LUN 5274 cable reduction,
which is delivery for individual order.
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7.4 Spare parts
For accomplishing the inspections, technical maintenance and repair of the APU, together with
each set of APU it is delivered also a set of spare parts.
The set of spare parts can be ordered also separately.
7.4.1 Spare parts

The set of spare parts for APU SAFÍR 5K/G МI contains:
- spark plug - 2 ps
- sealing rubber rings of rounded section (see table)
SPARE PARTS OF THE APU SAFÍR 5K/G MI 1:1

Number Type marking /
Name
of ps application
100 065 43 /
2 Rubber ring of rounded cross section 47 x 2.5 Block of filter and servo-valve
Oil filter
100 065 33 /
2 Rubber ring of rounded cross section14.6 x 1.9 Block of filter and servo-valve
Oil filter
100 065 51 /
1 Rubber ring of rounded cross section 26 x 2
Filter of back fuel
100 065 29 /
3 Rubber ring of rounded cross section11.6 x 1.9 Filter of back fuel
Drain valve DV II
10 065 54 /
1 Rubber ring of rounded cross section16.6 x 1.9
Oil pump
85 065 04 /
2 Rubber ring of rounded cross section 5.7 x 1.4
Oil filter
81 065 13 /
Drain valve DV I
83 065 07 /
APU
81 065 20 /
APU
CH 34630/
2 Spark plug
APU
4S 65046
4 Brush
Electrical starter of APU
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8. STORING, CONSERVATION AND CONSERVATION REMOVAL
8.1 Storing
It is not allowed to carry out storing of the APU (in store) straight on the ground, on the open air and at localities
with spilled water.
When storing the APU on board of the object, the inlet and outlet channels of APU must be covered with special
blinds.
8.2 Conservation
8.2.1 Conservation for period of 30 ± 5 days on the object board
When having the long-term time intervals of the summer operation or in case of conservation it is necessary to carry
out starting of APU at least once a 30 ± 5 days. The time of operation in this case is to be – 5 min.; working regime
of APU – idle run. The conservation is active for 30 days. During this storing of APU the air intake and exhaust pipe
must be covered by blinds. In emergency cases, when it is not possible to carry out the APU starting with operation
on idle run, it is allowed to carry out two, one after another, false (dummy) startings of the APU.
If it is impossible to carry out APU starting once a 30 ± 5 days, it is necessary to accomplish the internal
conservation for period of time 90 days in accordance with p. 8.2.2.
8.2.2 Internal conservation for period of 90 ± 10 days on the object board
Internal conservation of APU for period of 90 ± 10 days is carried out by new oil MOBIL AVREX M TURBO
201/1010, or Aero Shell Turbine Oil 3, or МК-8 GOST 6457-66, or MS-8P OST 38.011.63-78, or MS-8RK OST
38.013.87-85, or by transfomer oil TK GOST 982-80.
Cleanness and quality of liquid when doing the conservation must in accordance with appropriate standards.
NOTE: For conservation of the APU fuel system it is necessary to have available the facility with oil tank of
volume at least 0.5 l, providing the delivery of concerving oil under pressure (90 ± 30) kPa.
The conservation is to be carried out without removal of APU from the board in following order:
- Remove the tube (1) of the outlet of fuel from APU. The open throttle (2) of tube and socket (3) of the block of
filter and servo-valve are to be covered by plugs (see fig. 32).
- On the inlet into fuel system of the APU (i.e. in front of the block of filter and servo-valve ) by means of special
facility through the valve of conservation of the object it is delivered the liquid for conservation under the
pressure of (90 ± 30) kPa.
ATTENTION. In order to avoid the oil burning, the conservation is to be carried out with cooled engine.
- The oil tank it is to be refilled with the appropriate type of oil for lubrication of APU up to the mark „MAX“.
- Carry out two, one after another, false (dummy) startings when it is delivered the oil from the conservation
facility.
- The conservation is valid within three months.
- After expiration of this period the conservation for 3 months can be repeated still once.
8.2.3 Conservation of the APU, being removed from the object for period of 1 year.
In case of removal the APU from the board of object for storing or in case of expiration of the conservation period of
doubled conservation for 3 months on the object board (p. 8.2.2) (i.e. in total 6 months) and without intention to
bring the APU into operation, the APU can be subject to conservation for storing. Devices of the fuel and oil systems
are not dismounting from the helicopter, but they are filled by oil listed in article 8.2.2
The works for conservation of the removed engine are to be carried out in following order:
- Carry out the internal conservation of APU in accordance with p. 8.2.2.
- Remove the APU from the board (see p. 5.2.1 point 2 ÷ 8), APU is to be situated on the transport frame
ATTENTION. The all connections must be blinded by plugs.
- The metallic surfaces of the APU, which can be subject to corrosion (exhaust pipe, rear part of turbine) must be
lubricated by oil for conservation or by technical vaseline.
- APU is to be packed into the paraffin paper and inserted into the polyethilene tare. Into tare it must be inserted
the bags with drier of amount 1,6 кг and the polyethilene tare is to be welded hermetically.
- APU is to be placed into case, take care in order to avoid the damage, and store it at store in dry room under
temperature 5 - 45 оС, with maximum humidity of the air 65%.
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- Together with APU into the case it is to be inserted also technical documentation, control box of the APU,
control box of the generator and transformer.
- Conservation is valid wihin 12 months.
8.2.4 Conservation and packing the aggregates of APU for transport to the producer.
- For the transport of aggregates to producer in order to carry out their repair, reclamation, revision etc., it is
necessary to carry out conservation and packing the aggregates to be sent, in order to avoid their corrosional or
mechanical damage during the transport.
- Conservation and packing the aggregates can be done similarly to the process described in point 8.2.3.
- The aggregate when situated into transport case must be packed and fixed with help of soft elastic material
(polystyrene, paralon, rubber etc.) in order to fix it and avoid the motion.
8.3 Removal of the conservation
8.3.1 Removal of conservation – in case of delivery from producer
The works for removal conservation in case of delivery from producer are to be carried out in following order :
- Unpack the APU, aggregates and instruments. Check if they are complete.
- The conserved outer surfaces wash by gasoline, after it wipe out dry.
ATTENTION. Not to allow contact od gasoline with parts of electrical equipment and electrical connectios.
- APU and the other aggregates install on the board in accordance with instruction (p. 5.2.2)
- The other works, relevant to introducing the APU into operation are to be carried out in accordance with p. 5.1.
and 5.3.
8.3.2 Removal of conservation after conservation for period of 90 days
The works for removal conservation are to be carried out in following order (see fig. 35):
- Remove the plug (blind) and to the threaded socket (3) of the fuel outlet from APU connect the tube for drain of
the conserving oil. Prepare the container for drain off the oil when making conservation removal having the
volume at least 0.5 l.
- Carry out twice washing the fuel system by means of fuel, through performing two dummy startings of APU
following one after another.
- Remove the tube for drain of the oil and to the socket (3) of the outlet of fuel of block filter and servo-valve join
the tube (1) of the fuel exit from APU (see fig. 35).
8.3.3 Removal of conservation after storing the APU in the store.
The works for removal conservation after storing the APU in the store are to be carried out in following order:
- Unpack the APU. Be sure about absence of outer damage and absence of corrosion .
- Install the APU on the board in accordance with instructions p. 5.2.2.
- Perform the works in accordance with p. 8.3.2
ATTENTION.
After storing the APU in store above 3 months after the conservation removal, there must be carried out cleaning
the filtering elements of the aggregate of block filter and servo-valve, filter of the back fuel and oil filter in
accordance with instructions presented in technological cards № 3, 5 and 6 of the chapter 7.
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5 4 1 2 3
Description of fig .
38. tube of fuel exit from APU

39. cap nut
40. socket
41. plug M16х1
42. plug M14х1
Fig. 35. Removal of tube of block filter and servo-valve
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9. FAILURES AND METHODS OF THEIR ELIMINATION
9.1 Purpose - in general

In this chapter there are presented the typical failures and defects, which may occur during the first starting or
during the further APU operation.
Using the following presented schemas and light diodes of signaling panel of failures and eventually through
usage of TESTER APU (No. LUN 5274), it can be determined the likely reason of failures and set the methods of
their remedy.
9.2 Explanation and marking

9.2.1 Marking the connectors on APU cable harness
Marking Name of APU equipment or location of connector connection on APU

CP Fuel pump
SV Servovalve of Block of filter and servo valve
FP Fuel filter of Block of filter and servo valve
EV1 Electromagnetic valve of Block of filter and servo valve
FVP Strainer of Return fuel filter
EV2 Electromagnetic valve of Oil filter
FO Strainer of Oil filter
TS Oil-pressure switch of Oil filter
RS1 RS2 Control box
GND Grouding of APU equipment on holder of Block of filter and servo valve
VT Thermocouple compenzation cable CH-A + GND
connection to the control box terminal
VT Thermocouple compenzation cable CH-A
connection of Transmitter of exhaust gases temperature
SO Speed sensor
TO Oil-temperature switch in oil tank
ZZ Ignition device
MO Minimum Oil level switch in oil tank
9.2.2 Marking the light diodes on signaling panel of failures –see para 4.5.2
Marking Reason of failures

ZV Failure of one circuit of rpm sensor, the alternate circuit of rpm sensor is
working
Note: Indication of ZV does not influence on APU operation and it is possible
normal continue operation of APU
OV Failure of circuit of servo-valve or failure of relay inside the APU control box or
failure of exhaust gas temperature
EL Damage of electronics of the APU control box
NO Overspeeding the maximum rpm of APU rotor
TZ No attainment of the prescribed value of exhaust gas temperature
TO No attainment of the prescribed value or drop of oil pressure
PO No attainment of prescribed value or drop of APU rotor rpm
VT Exceeding the prescribed value of the exhaust gas temperature
SG Unsufficient level of signal of the rpm sensor
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9.3 The method of failures elimination

9.3.1 Generally- using the tables and schemas
By means of the following schemas it is possible to determine the likely reason of failure and the method of its
remedy.
In case of unsuccessful startings or automatic shutdown of the APU during the operation, it is necessary to check the
panel of signaling the failures.
9.3.2 Tester APU
For more reliable location of failures APU reason it is possible to use „TESTER APU“ LUN 5274 (After client
wish, it is possible the delivery the Tester) according to methods described in „Operating manual“ (Appendix
No.4 in TPF 01-7226-03) which is as part delivery of TESTER.
This instrument (TESTER LUN 5274) serves for laboratory testing of APU´s control box, for testing of APU´s
control system in aircraft for monitoring of APU´s operation in simulated regime – TESTER simulated servo-valve
current, exhaust gas temperature, signal from speed sensor and the other control signals for normal APU operation.
TESTER is possible to use also for monitoring all input and output signals of APU´s control box without any
interferences on aircraft APU´s working monitoring at APU´s system real operation. TESTER monitor 4 analog
signals: servo valve current, turbine speed, output gas temperature and APU´s supply voltage, and 50 distable (digital)
signals. TESTER picture analog signal funds through display and digital signal situation is indication with LED diode.
There is record behaviour picture on display, storage recording elapsed time and percent of filled storage. Stored
record in RAM is possible to transfer with serial extension to PC, where can be analyse in detail.
9.3.3 Serial interface RS 422 of APU control box LUN 5271.80/CONB
APU failure indications are transferred through serial interface RS 422 of control box LUN5271.80/CONB on the
boarding multifunction display.
There is possible to connect personal computer throw serial interface RS 422 of control box LUN5271.80/CONB.
Transmit of date from RS422 to USB connected to the PC with using special software (“PEJ CONB”)-software can be
delivered according special request – as a option and perform APU operation evaluation. This is the best way for
analyses of APU parameters and determination of the likely reason of failures.
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9.4 LIST OF TABLES FOR ELIMINATION OF FAILURES

FAILURES DURING STARTING OR ON REGIME OF WORKING RPM
TABLE 1 The starting of APU did not occur ......................................................................................85

TABLE 2 The starting of APU is only 3 sec-failure designation SG..................................................87
TABLE 3 APU operates only 13 sec -failure designation TZ .............................................................88
TABLE 4 During the APU starting occurred the shutdown of the APU-failure designation VT ......90
TABLE 5 During the APU starting or on regime of working rpm occurred the shutdown of the APU
-failure designation NO.......................................................................................................91
TABLE 6 During the APU starting or on regime of working rpm occured the shutdown of the APU
-failure designation PO .......................................................................................................92
TABLE 7 During the APU starting or on regime of working rpm occurred the shutdown of the APU
-failure designation TO .......................................................................................................93
FAILURES ON REGIME OF WORKING RPM
TABLE 8 On the APU operation occured the shutdown of the APU -failure designation SG ..........94
TABLE 9 On the APU operation occurred the shutdown of the APU -failure designation VT ........95
TABLE 10 It cannot be performed requested electrical power .........................................................96
TABLE 11 During starting of main engine it cannot be performed requested bleed air
from APU..........................................................................................................................a
TABLE 12 It cannot be performed requested bleed air into the ECS .................................................b
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TABLE 1 The starting of APU did not occur

When pressing the button „START“ the starting of APU did not occur (signal lamp „APU ON“ is not blinking).
Symptoms- failure indications: There isn´t no signaling of failure (or signaling of failure EL)- follow the table 1a
Signaling of failure OV- follow the table 1b
Table 1a The starting of APU did not occur and no signaling of failure
Possible reasons
1. Switched off the protective switches of APU systems

2. Defective switch of electric starter
3. Defective APU cable harness
4. Defective control box (automatic switch off the APU after duration of APU starting only 1 sec- signaling of failure EL)
Failure remedy
Indicator of gas temperature doesn´t

yes operate before pressing the button no
„START“ (see fig. 1)
No No Check and
Board system voltage Check the Panel (or signaling) of Remove
is correct power supply failure is correct defect
Yes Yes
Checking all procedures before starting of APU Check CB by TESTER No Replace
Protective switches of the APU Control box is OK Control box
are switched on
Yes
Electric boarding No Remove

system is correct defect
Yes
APU cable harness is No Replace cable harness
OK Technological card 33
Indicator of gas temperature after switch-on the power supply of APU:

is operating - pointer is indicating 0 °C or more and it is
shining light of indicator
is not operating - pointer is indicating on red triangle

and it is not shining light of indicator
Indicator of gas temperature is not operating
Fig.1. Indication of Indicator of gas temperature operation
Note: With using the information from serial interface of control box to the multifunction boarding system is possible to
determine the same information (as mentioned at fig.1) about correct function of control box and switch on APU power
supply.
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Table 1b The starting of APU did not occur and it is signaling of failure OV
Possible reasons
1. Incorrect connection of thermocouple wires or defective transmitter of exhaust gases temperature

2. Defective electric circuit of servo-valve of Block of filter and servo valve
3. Defective APU cable harness
4. Defective control box
Failure remedy
Check connection of compensation wires

(thermocouple) of the terminal ends of
transmitter of exhaust gases temperature. No Connect equipment (BFS and EGT
Check connection of servo-valve connector transmitter) correctly.
on Block of filter and servo valve..
Is it connection this APU equipment correct?
Yes
Check transmitter of exhaust gases

temperature.
Internal resistance of EGT transmitter must No
be greater than 1±0,5Ω.
Internal resistance is correct.
Yes
Measure insulation resistance the Sensor of

temperature of exhaust gas by Ohmmeter at No
DC voltage 100V.
Ohmmeter by one end connect to output
clamps CH-A of thermocouple compensation Replace exhaust cone with EGT transmitter
cable and the other end at body on EGT To be done only by empowered personel of
transmitter. APU producer.
Measured insulation resistance is greater than
1 kΩ.
Yes
Measure insulation resistance of servovalve.

Measured insulation resistance is greater than No Replace Block of filter and servo valve.
75±5Ω for 20°C. Technological card 22
Yes
Check APU cable harness. Replace cable harness

Cable harness is OK ? No Technological card 33
.
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TABLE 2 The starting of APU is only 3 sec-failure designation SG
When switching push button START the APU is working only 3 sec
Possible reasons
1. Defective rpm sensor – no signal or insufficient level of signal from rpm sensor
Remedy of failure
Connection of rpm sensor connector is OK.
Yes
Check the free rotation of the APU rotor Check reason- dismount AC generator and
– by hand from the side of APU turbine check free rotation – in case of failure replace
(through exhaust pipe catching the turbine No of AC generator- Technological card 31.
wheel) . When repeats the big seizure of rotor or rotor
Free rotation of the rotor. does not rotate, clarify the reason or remove
the APU from the helicopter and transport
Yes APU to the service centre or producer.
There is a voltage on terminals of Electric Yes Replace Electric starter.

starter ? Technological card 21
No
There is a voltage on switch of Electric Check CB by TESTER

starter ? Yes Control box is OK
Ne Yes No
Check the electric boarding system. Check the electric Replace

Remove defect boarding system Control box
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TABLE 3 APU operates only 13 sec -failure designation TZ

When switching push button START the APU is working only 13 sec (gas temperature is lower then 100°C)
Symptoms- failure indications:

a/ when occurred burning the fuel in combustion chamber (to determine by noise, visually and by indication of
APU gas temperature on the boarding panel follow the table 3a
b/ when did not occur burning the fuel in combustion chamber follow the table 3b
Table 3a The starting of APU is only 13sec, it is signaling of failure TZ and there occurred burning the fuel in combustion
chamber
Possible reasons:
1. Defective sensor of temperature of the exhaust gas

3. Defective cable harness
Failure remedy:
Attainment of temperature of exhaust gases

100°C?
If occurred burning the fuel in combustion
chamber (later) closely before the 13sec – repeat
the next start after interval 1min according to para
4.6.2.1
Check the functionality of the sensor of the Replace exhaust cone with EGT transmitter
exhaust gas–see item 4 in Technological card 1 No To be done only by empowered personel of
Sensors of EGT transmitter are OK. APU producer (or from service centre)
Yes
Check CB by TESTER Replace Control box.

Control box is OK No
Yes
Check APU cable harness. Replace cable harness

Cable harness is OK ? No Technological card 33
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Table 3b The starting of APU is only 13sec, it is signaling of failure TZ and there di not occure burning the fuel
Possible reasons:
1. Ignition device, High voltage interconnecting cable, spark plug

2. Defective or contaminated drain valves
5. Defective electromagnetic valve of Block of filter and servo-valve
6. Defective fuel pump
Failure remedy:
Check function of ignition unit and spark Check connection and condition of ignition unit,
plug - to determine by noise (clicking). No interconnecting cable and spark plugs. Eventually
There are operating. to replace-Technological cards 29, 30 and 2.
Yes
APU have the improper operation-slow Yes Clean (or replace) the drain fuel valves.
acceleration or the fuel drains through by-pass Technological card 8
of the drainage from boarding drainage pipe.
No
Yes
During starts of APU the fuel drains from To repeat the next start after interval min.
exhaust pipe? 1min for draining fuel.
No
Is it ensure the required fuel pressure and fuel No Remove defect.

mass flow at inlet into APU system ?
Main fuel pump (boarding) is operating?
Yes
There is a voltage on electromagnetic valve No Check CB by TESTER

of Block of filter and servo-valve and on Control box is OK
fuel pump?
Yes No
Yes Replace Control box.
Replace interconnecting cable

Technological cards 33
Is it functional electromagnetic valve of

Block of filter and servo-valve ?
No Replace Block of filter and servo-valve
(when has power supply-it must be opened)
Technological card 22.
Yes
Is it functional fuel pump? No Check or Replace fuel pump

(Injection of the fuel has been provided) Technological card 24.
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TABLE 4 During the APU starting occurred the shutdown of the APU-failure
designation VT
APU does not attain the working rpm –automatic switch off the APU by reason of exceeding the temperature of
exhaust gases for period greater than 1,5 sec value 950°C
Possible reason:
1. Failure of system of air inlet to the APU

2. Defective electrical valve of air starter
3. Defective gas generator of APU
Remedy of failure:
Check the channel of air inlet and APU Clean up and remove foreign objects from
intake – are there some foreign object ? Yes air channel.
No
Check the air tube from APU to the air starter

and ECS. No Remove leakage of air pipe and valves.
Air tube has not air leakage ?
Yes
No
Check APU according to Technological Remove defect.
card 1,APU is OK? (especially check the When it is impossible to solve this defect
turbine – item 10- by hand check free Contact service centre or replace APU
rotation of the rotor and check condition of
blades.
Yes
TEST of APU control system in simulated regime – by TESTER

Control system of the APU is correct
Check the APU operation in monitoring regime – by TESTER
or to use transfering data from serial interface of CB CONB to
the PC.
Analyse measured data and contact service centre.
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TABLE 5 During the APU starting or on regime of working rpm occurred the
shutdown of the APU -failure designation NO
Automatic switch off the APU by reason of exceeding the maximum rpm (112,7%)
Possible reason:
1. Failure of fuel system APU

4. Contamination of filter of RFF
Remedy of failure:
Was it remove some fuel pipes or APU Check fuel way (cleaness, free outlet) behind
equipment from APU system behind fuel Yes fuel collector- fuel pipe and screwed coupling.
collector ? Check pipe connection on RFF and BFS.
Check pipe connection on BFS (on APU
No output)to the fuel boarding system
Wash the fuel filter of return fuel filter

Technological card 6
No
Control box is OK Order this works –see item 5.4.2.2.
Yes
Check APU according to Technological card Remove defect.

1,APU is OK? (especially check the turbine – No When it is impossible to solve this defect
item 10- by hand check free rotation of the Contact service centre or replace APU
rotor and check condition of blades. .
Yes
Check the APU operation in monitoring

regime – by TESTER or with using data from Replace equipment of APU according to
serial interface of CB to the PC result of APU monitoring
Analyse measured data and contact service
centre.
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TABLE 6 During the APU starting or on regime of working rpm occured the
shutdown of the APU -failure designation PO
During the APU starting APU does not attain the working rpm till 36 sec–automatic switch off the APU by reason
no attainment of 80% rpm
During APU operation on regime of working rpm –automatic switch off by reason drop of rpm below 80-5 % rpm
Possible reason:
1. Defective or contaminated drain valves

3. Defective servo-valve of Block of filter and servo-valve
4. Defective fuel pump
5. Defective anti-surge valve
Remedy of failure:
During starts of APU the fuel drains from Yes Clean (or replace) the drain fuel valves.
boarding drainage pipe (through by-pass of Technological card 8
the drainage tank)?
No
Check the APU operation in monitoring regime – by TESTER

or to use tranfering data from serial interface of CB to the PC
Analyse measured data.
Current of servovalve attained more than 155 mA? Yes

Replace Block of filter and servo-valve
(to ensure by TESTER or evaluation of transfering
Technological card 22.
data from serial interface of CB)
No
Perform Checking and cleaning the by-pass

valve or protective valve or Replace fuel
pump -Technological card 24.
No
Control box is OK
Yes
Check APU according to Technological card 1, Remove defect.

APU is OK? (especially check the turbine – When it is impossible to solve this defect
No
item 10 Contact service centre or replace APU
.
Yes
During the APU starting the air is by-passed Ne Replace anti-surge valve.
ito atmosphere.Anti-surge valve is open Technological card 32..
(check the free motion of valve)
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TABLE 7 During the APU starting or on regime of working rpm occurred the
shutdown of the APU -failure designation TO
APU operates over 36 sec –it does not attain the working oil pressure up to 10th sec after exceeding operating rpm
During APU operation on regime of working rpm –automatic switch off by reason drop of pressure lower than level
80 ± 5 kPa for a time period longer than 10sec
Possible reason:
1. Defective oil pump

3. Defective oil filter
Remedy of failure:
Check visually oil level in oil tank. No Fill the oil up in oil tank to the mark MAX.
The level of oil is higher than mark MIN?
Yes
Wash the filter of oil filter

Check and eventually adjust of the oil pressure

No
Measured pressure oil is on requested level Clean the by-pass valve of the oil pump.
(145±10 kPa) Repeat adjustment of of the oil pressure.
When the pressure oil is lower – replace the oil
Yes pump - Technological card 26.
No
Check the start APU- Failure continue Replace Control box.
Check CB by TESTER
Control box is OK
Yes
Failure continue
Replace oil filter
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TABLE 8 On the APU operation occured the shutdown of the APU -failure
designation SG
Automatic switch off the APU on the APU operation by reason no insufficient level or zero signal of rpm sensor
Possible reasons:

3. Defective connector of rpm sensor or defective rpm sensor
Remedy of failure:
No
Check CB by TESTER Replace Control box
Control box is OK
Yes
No
Check connection of connectors of APU cable Replace cable harness
harness. Technological card 33
Cable harness is OK ?
Yes
Measure resistance of coils in rpm sensor – on

the connector (marking SO) of the rpm sensor.
Resistance between pins A-B and E-F has to be
1100Ω ± 200Ω at25±10°C.
Measure insulation resistance of coils rpm
sensor is greater than 2MΩ.
Contact service centre or replace APU
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TABLE 9 On the APU operation occurred the shutdown of the APU -failure
designation VT
Automatic switch off the APU on the APU operation by reason exceeding the temperature of exhaust gases for a
time higher than 3 sec. value 720+20°C.
Possible reasons:
1. Failure of system of air inlet to the APU

2. Defective valve of the air starter
Remedy of failure:
Electric power extraction on APU is in operating

limits-(see item 4.6.3.)
Yes
Check the channel of air inlet and APU Clean up and remove foreign objects from
intake – are there some foreign object ? Yes air channel.
.
No
Check the air tube from APU to boarding air No Remove leakage of air pipe and valves.
system, air starter and valve of ECS.
Air tube and ECS valve has not air leakage ?
Yes
Check APU according to Technological card 1, Remove defect.

APU is OK? (especially check the turbine – No When it is impossible to solve this defect
item 10- by hand check free rotation of the rotor Contact service centre or replace APU.
and check condition of blades.
Check the APU operation in monitoring regime –

by TESTER or to use transfering data from serial
interface of CB to the PC.
Analyse measured data and contact service centre.
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TABLE 10 It cannot be performed requested electrical power

There cannot be made takeoff of electrical power from APU (loading the electrical generator of alternate current)
Possible reasons:
1. Blocked the protective switches (board part of the electrical connections of helicopter).
2. Defective generator control unit (GCU).
3. Defective control box.
Remedy of failure:
Check all precedures provided before take-off

Yes Electric boarding switches No Remove
electrical power.
and breakers are correct defect
Switches and circuit breakers are switch on.
Check the rotation of the APU rotor

– by hand from the side of APU turbine No Check reason- dismount AC generator and
(through exhaust pipe catching the turbine check free rotation.
wheel) . Replace AC generator
Rotor of the AC generator is rotating? – see Technological card 31
on wheel of cooling fan.
Yes
Test of GCU- Switch on the switch of No Replace Generator control unit

generator, and there is supplied the voltage ..
Press the button of SELF-TEST of GCU.
GCU is OK when the testing light diode
shining and goes out after expiring the time
7 ± 1,4 seс
Is it positive result of testing process?
Yes
No
Check CB by TESTER Replace Control box
Control box is OK
Yes
Replace current transformer of AC generator
Check electric boarding system of AC

generator on helicopter- wires, contactors,
relay, etc.
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TABLE 11 During starting of main engine it cannot be performed requested

bleed air from APU
It cannot be performed correct starting of main engine or during starting occured strong pressure drop of air from
APU
Possible reasons:
1. Failure (leakage) of bleed air system from the APU

2. Defective anti-surge valve
3. Defective air valve or leakage of air pipe to the air starter
Remedy of failure: according to following table and alternatively to use instruction in table 12
No
Air by-pass from APU to atmosphere is Replace anti-surge valve
closed on regime of starting main engine? Technological card 32
(closing of anti-surge valve)
Yes
No
The air tube from APU to air starter is Remove leakage of air pipe and valves.
leakproof.
Yes
Check the APU operation in monitoring

regime regime of starting main engine – by
TESTER or to use tranfering data from serial
interface of control box CONB to the PC.
(especially check level of rpm and current of
servovalve)
Analyse measured data or contact service
centre .
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TABLE 12 It cannot be performed requested bleed air into the ECS

It cannot be performed takeoff of requested air mass flow into the air-condition system of the aircraft or strong
pressure drop of air from APU
Possible reasons:
1. Defective electrical valve or lekage of air pipe to the ECS system

2. Seizure of anti-surge valve in open position.
3. Defective Control box
Remedy of failure:
Is it open inlet valve into air-condition No Check the power supply to valve (board part of
system the electrical connections of helicopter)
? Replace the defective valve
Yes
Check CB by TESTER
Control box is OK
No
Replace Control box

.
During the air takeoff for air-condition Yes

system– quickly drops takeoff amount of air?
(see on indicator of APU air pressure –if is
available)
No
Is it occurred APU switches off automaticaly Yes

with signalization VT ?
1/ Check leakproof of the air tube from APU.
2/ Check opening the anti-surge valve
Replace anti-surge valve Technological card 32.
3/ Check cleanness of air inlet channel and
During the air takeoff for ECS system – incorrect air intake
APU operation – surge sounds 4/ Check the APU operation in monitoring regime
or after surge the APU automaticaly switches off. – by TESTER or to use tranfering data from
serial interface of CB to the PC
1/ Replace the anti-surge valve Analyse measured data and contact service
Technological card 32 centre (especially check level of rpm and
2/ Check the APU operation in monitoring current of servovalve)
regime – by TESTER or to use tranfering data When the current of servovalve attained more
from serial interface of CB CONB to the PC than 155 mA- than replace BFS (Technological
Analyse measured data or contact service centre card 22)
5/ Check APU according to Technological card 1
(especially check the turbine – item 10
96b
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10. REPLACEMENT OF THE APU AGGREGATES
Checking the rightness of the aggregates operation and replacement of failed aggregates of the APU, these are to
be carried out in accordance with the following technological cards.
10.1 List of the technological cards
Card Page Number of

Work designation
№ number pages
21 Checking and replacement of electrical starter 99 5

22 Replacement of block of filter and servo-valve 104 3
23 Replacement of filter of back fuel 107 2
24 Replacement and checking the fuel pump 109 4
25 Replacement of oil filter 113 2
26 Replacement of oil pump 115 2
27 Replacement of temperature switch 117 2
28 Replacement of the float-type switch 119 2
29 Replacement of the ignition box 121 2
30 Replacement of the spark plug cable 123 2
31 Replacement of generator 125 2
32 Replacement of anti-surge valve 127 2
33 Replacement of the cable bundle 129 2
34 Replacement of back fuel filter bypass valve 131 2
35 Replacement of Block of filter and servo-valve bypass valve 133 2
Replacement of Pre-blockage pressure switch (signaling of oil
36 filter contamination) 135 2
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Aggregates of APU SAFÍR 5K/G MI, which can be replaced by user in process of operation, in
accordance with technological cards № 21-33.
3 10 9 2 5 11 5 9
13
1 12
12 4 8 6 1 7
front view right side view
12
1 7 4
4
Left side view Back view
1. electrical starter 7. temperature switch

2. block of filter and servo-valve 8. float-type switch
3. filter of back fuel 9. ignition box
4. fuel pump 10. cable of spark plug (see fig. 48)
5. oil filter 11. generator
6. oil pump 12. anti-surge valve
13. cable bundle (see fig. 51)
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Work designation: CHECKING AND REPLACEMENT OF ELECTRICAL STARTER

Description applies to figs. 36, 37 and 38.
Content of operation and technological requirements
The works are to be performed in following order:
Note:
For performing the checking of the electrical starter it is necessary either to remove the APU from the object board
and to place it into the transporting frame of the APU or it is possible only unfasten of APU from mounting points
on the object (it is not necessary to disconnect cable bundle) and to lift up the APU for approximately 150 mm.
In order to make possible the removal of electrical starter without removal of the APU from the object board, it is necessary
to provide approach to the starter, i.e. make a technological entry window in the partition under the board channel of the air
intake.
1) Removal of electrical starter from the APU (see fig. 36):
а) Disconnect the electrical line of power supply from the terminal block of the starter by means of releasing the nuts
(2). Screw off by spanner 8 mm the bolt (6) on the drive box (3) and disconnect the grounding wire of the
electrical starter (5).
b) Unlock and by spanner 8 screw off the nut (1). Remove the clamping band of the V-type collar (4). Remove the
electrical starter from the drive box (3) of the APU.
I case, that removal of the starter by hand is impossible, it is allowed it’s releasing by means of screwdriver, placed
into the groove of the drive box flange.
2) Checking the overrunning clutch is to be done in following order (see fig. 37):
а) Check the clutch functionality:

- when turning the gear wheel of driving the electrical starter (1) to the right (by hand – in clockwise direction) the
clutch must be closed (rotor of the electrical starter is turning together with a gear wheel of the electrical starter),
- when turning the gear wheel of driving the electrical starter (1) to the left (by hand – in anti- clock-wise direction)
the clutch must be disconnected (rotor of electrical starter does not rotate, the wheel of electrical starter rotates
freely). In other case, if rotor does rotate, the electrical starter must be replaced!
Note: Rotation of the rotor of electrical starter can be checked only after the cover (1) removal (see fig. 38).
b) Check the gap V between the lugs of the casing of clutch (2) and separator of clutch (3) in the locked position, by
means of standard gap gauge (calibre) through the holes (4) on the face of starter (see fig 37). Checking the gaps is
to be carried out on the all lugs of the clutch casing and clutch (3) separator.
In case, when the gap is smaller than 0.5 mm, it is necessary to replace the starter!
3) Checking the length and replacement of brushes is to be carried out in order as follows (see fig 38):
а) Unlock and screw off 3 screws (3) and remove the cover (1) of the current scanner from the front casing of the
electrical starter.
b) By means of clean compressed air remove the carbon dust from the current scanner
c) Check the working surface of collector. In case of damage replace the electrical starter!
d) Check the wear and condition of brushes (4) in order as follows:

- screw off the screw (5), remove the spring (7), which presses the brush (4) to the collector and remove the brush
from the brush holder (6).
- brushes, heights of which is less than 11 mm must be replaced by new ones from the set of spare parts.
- insert the new brushes in opposite order.
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- check the free motion of brushes in the holder and the proper position of springs (7).
e) Set the cover (1) back on the front casing (2), screw in the screws (3) and fix them by locking wire.
4) Installation of the electrical starter on the APU (see fig. 36):
а) Inspect visually the rubber sealing ring (5) (see fig. 37). In case of its damage replace it.
b) The ring lubricate by CIATIM 201 and install the electrical starter on the drive box.
Note: Starter is to be oriented with respect to gudgeon in the flange of clamping. When installing it is not allowed to
make an orientation of the starter in proper position holding it by cover (1).
c) Set the clamping band of the V-type collar (4) and tighten the nut (1) by means of the calibrated wrench, torque
moment of tightening 2-3 Nm.
d) Connect the electrical line of power supply to the terminals of the electrical starter. During it there must be observed
the polarity of power supply. Tighten the nuts (2) by torque calibrated wrench; moment of tightening is 2-3 Nm.
e) Connect the grounding wire of electrical starter (5) on the drive box (3) and screw in by spanner 8 the bolt (6) into the
drive box.
5) About the works carried out make a record into APU log book, including the record about measurement of gap V values
and the length of brushes of electrical starter.
- gap gauge 0.5 mm (for measuring - brush 4S 65046 - 2 ps

the gap V)-max. width 5mm - lubricant CIATIM 201
- calibrated wrench - technical gasoline
- open spanners (8, 10) - locking wire ∅ 0.5
- screwdriver
- pliers, side pincers
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4 1
1
3
2
2 6
3 2 1 4 5
1. nut М5
2. nut М6
3. drive box of the APU
4. V-type collar
5. grounding wire of the electrical starter
6. bolt М5х13
Fig. 36 Removal of electrical starter
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3 1 4
1. gearwheel
2. lug of the clutch casing
3. clutch separator
4. hole – diameter 7.5 mm
5. sealing ring 48х2 mm
Fig. 37 Checking the clutch of electrical starter
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5 5
4 4
7 6
1 3
1. cover
2. front casing
3. screw М 3х6 (3 ps)
4. brush
5. screw М4х6
6. brush holder
7. spring
Fig.38 Replacement of brushes on the electrical starter
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Work designation: REPLACEMENT OF THE BLOCK OF FILTER AND SERVO-VALVE

Content of the operation and the technological requirements.

1) Removal of block of filter and servo-valve from APU.
а) Screw off the plug-and-socket connections of the block of filter and servo-valve (1, 2, 4) and grounding of APU (3),
which are situated on the electric cable on the bunched cable (9).
b) Unlock and by spanner 8 release the bolts of fixing the filter of back fuel (3, 4) (see. Fig. 40).
c) Unlock and by spanner 8 screw off the bolts (8) of the collar of fixation of the cable of cable bundle (9).
d) Unlock and by spanner 17 screw off the cap nut (14) of the tube of fuel outlet from the filter of back fuel. Unlock
and by spanner 17, 19 screw off the cap nuts (5, 6) of the tubes of fuel inlet and outlet from APU. The sockets and tube
are to be blinded by threaded plugs.
e) Unlock and by spanner 13 screw off the bolt of socket (13) and release the bolt of socket (11) of the fuel tube (12).
The tube (12) is to be turned at bottom, for the more comfortable removal of the block of filter and servo-valve.
f) Unlock and by spanner 8 screw off the bolts (15) – 4ps. Unlock and by spanner 7 screw off the bolts (16) – 3ps.
g) Remove the block of filter and servo-valve together with a holder (7) from the APU.
h) Unlock and by spanner 7 screw off the bolts (10)- 4 ps, remove the holder (7) from the block of filter and servo-
valve.
2) Installation of the block of filter and servo-valve.
а) Set the block of filter and servo-valve upon the holder (7), screw in the bolts (10) and fix them by locking wire.
b) The holder with block of filter and servo-valve set on the turbine casing of the APU and holder of the oil filter (17).
Screw in by spanner 7 the bolts (16), by spanner 8 screw in the bolts (15). Screw in the bolts of fixing the filter of the
back fuel (3, 4) (see fig.40) and fix all bolts by locking wire.
c) By spanner 8 screw in the bolts (8) of the clamping collar of fixation of the cable of cable bundle (9).
d) Remove the plugs from the tube (13). The sealing rubber rings 9,7 х 1,9 in the socket of tube (13) are to be
lubricated by CIATIM 201. In case of damage, they are to be replaced. The bolt of socket of tube (13) is to be washed
in technical gasoline or in aviation kerosine and lubricated by lubricant GLEIT HP 520М. Set the tube (12), tighten the
screws (13 and 11) and fix by locking wire.
e) Remove the plugs from inlet and outlet of fuel of the block of filter and servo-valve, threaded socket are to be
lubricated by lubricant GLEIT HP 520М, set on the tubes of inlet and outlet fuel, tighten the cap nuts (5, 6 and 14) and
fix them by locking wire.
f) Set on the plug-and-socket connections of the block of filter and servo-valve (1, 2, 4) and also the plug-and-socket
connection for grounding the APU (3).
3) Carry out the APU STARTING and after working on regime of idle run for 1,5 min the APU is to be switched off.
4) After APU shutdown check the tightness of its fuel system.
5) Carry out record about the works performed into APU log book.
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Orientation torque moments of tightening the bolts and nuts:

М4 - 4 Nm
М5 - 7 Nm
Bolt of tube socket (11, 13) – 15 Nm
Cap nuts of the tubes: internal cross-section 4 - 20 Nm
internal cross-section 6 - 25 Nm
- plug М12х1 –1ps, plug М14х1-2 - lubricant GLEIT HP 520М

ps (outer thread); or equivalent against the
- plug М12х1 -1ps., plug М14х1- seizure of thread connections
2ps (outer thread ); – lubricant CIATIM 201
- blinds for the socket of tube; - technical gasoline
- calibrated wrench, open spanners - locking wire ∅ 0.5
(7, 8, 10, 17, 19), sockets, pliers,
side pincers
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15 4 1 2
Filter of
back fuel 14 7 10 13 9 8 5 6
3 16 17 11 12
fuel pump
8
block of filter
and servo-valve
(upper view)
5. cap nut of the tube of fuel outlet 11. bolt of fuel tube
1. plug-and-socket connection (FP) 6. cap nut of the tube of fuel inlet 12. tube
2. plug-and-socket connection 7. holder of the block of filter and 13. bolt of fuel tube
(ЕV1) servo-valve 14. cap nut
3. plug-and-socket connection 8. bolt М5х13 (2ps) 15. bolt М5х 20 (4 ps)
GND) 9. cable of cable bundle 16. bolt М4х10 (3ps)
4. plug-and-socket connection (SV) 10. bolt М4х10 (4ps) 17. holder of oil filter
Fig. 39 Replacement of the Block of filter and servo-valve
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Work designation: REPLACEMENT OF BACK FUEL FILTER

Content of operation and technological requirements

1) Removal of the filter of back fuel from the APU.
а) Screw of the plug-and-socket connection of filter of back fuel (7) of the cable of cable bundle (8).
b) Unlock and by spanner 17 screw off the cap nuts (1, 2) of the tube of fuel inlet and outlet. The sockets and tubes are
to be blinded by threaded plugs.
c) Unlock and by spanner 8 unlock the screws of fixing the filter of back fuel (3) in holder of the block of filter and
servo-valve (5). By spanner 8 screw off the bolts (4) of fixation of the filter of back fuel in the block of fixation of
the APU (6).
d) Remove the filter of back fuel from the APU.
2) Installation of the filter of back fuel.
а) Set the filter of back fuel on the holder (5) and block of fixation APU (6), by spanner 8 screw in the bolts (3) with
washers and fix them by locking wire. By spanner 8 screw in bolt (4) with locking washer (9).
b) Remove the plugs from the fuel inlet and outlet of the back fuel filter, the threaded sockets lubricate with lubricant
GLEIT HP 520М, install the tubes of inlet and outlet of fuel, cap nuts (1, 2) tighten them and lock by locking wire.
c) Install the plug-and-socket connection (7) of the cable of cable bundle (8).
3) Carry out APU STARTING and after its operation on the idle run for 1.5 min switch off the APU.
4) After the APU stop check the tightness of the APU fuel system.
6) Orientation torque moments of tightening the bolts and nuts:

М5 - 7 Nm
Cap nuts of tubes: 6 - 25 Nm

- plug М14х1-2ps (outer thread) - lubricant GLEIT HP 520М
- prug М14х1-2ps (inner thread) or equivalent against seizure
- calibrated wrench, open spanners of threaded connections
(8, 17), sockets, pliers, side pincers - technical gasoline
- locking wire ∅ 0,5
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2 3
3 3 8
2
5
filter of back fuel 6

1 4 (front view)
1. cap nut of the fuel inlet tube

2. cap nut of the fuel outlet tube
3. bolt М5х 20 (2 ps)
4. bolt М5х 10
5. holder of the block of filter and servo-valve
6. block of fixation the APU
7. plug-and-socket connection (FVP)
8. cable of cable bundle
9. locking washer
Fig. 40 Replacement of filter of the back fuel
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Work designation: REPLACEMENT AND CHECKING THE FUEL PUMP
Description applies to figs. 41 and 42
Content and technological requirements.
NOTE.
For accomplishing the fuel pump replacement and cleaning the by-pass valve of the fuel pump (acc. to p. 2 ), either
it is necessary to remove the APU from the object board and fix it into the transport frame of the APU or unfasten
of APU from mounting points on the object (it is not necessary to disconnect cable bundle) and to lift up the APU
for approximately 150 mm.
Accomplishing the check of conditions of the protective valve (acc. to p. 3), it is possible without APU removal from
the board or without APU lift up.
Checking and cleaning the by-pass valve or protective valve are to be done only when having the APU failure in
operation – at reduced working rpm or at not stable rpm of the APU.
1) Removal of fuel pump from the APU (description applies to fig. 41).
а) Screw off and remove the plug-and-socket connection of the fuel pump (9) of the cable of cable bundle.
b) Unlock and by spanner 17 screw off the cap nut (2) of the tube of fuel outlet (6) from the fuel pump. Unlock and by
spanner 13 release the bolt of socket (3) of the tube of fuel outlet (6). Blind the socket and tube by threaded plugs.
c) Unlock and by spanner 13 screw off the bolt of socket (1). Unlock and release the bolt of socket at inlet of block of
filter and servo-valve (13) (see fig. 39) of the tube of fuel inlet (5). Turn the tube (5) down for improving the
comfort of removal of fuel pump. Blind the socket of tube (5) and by means of threaded plug blind the hole in fuel
pump.
d) Unlock the locking washers (8) and by spanner 8 screw off the bolts (4) of collars (7) of fuel pump fixing the holder
of fuel pump (10). Open the collars and remove the fuel pump from the holder of fuel pump (10).
2) Cleaning the by-pass valve of the fuel pump (description applies to fig. 42).
а/ Unlock and screw off the screws (12) from the plate (11) of regulation block, socket of fuel outlet (1) and cover of
filtrating element (6). Remove plate (11), socket of fuel outlet (1) and the cover of filtrating element (6).
b/ Wash the regulation block with a slide-valve by clean technical gasoline from both sides, using the method of
sprincing. Check the easy motion of the slide-valve (15) in block of regulation (8) and proper position of spring in
the base of socket spring (1) and piston (9). The spring must be in free position.
c/ Wash the filtrating element in clean technical gasoline.
d/ The sealing rings (7) in plate (11) and in cover of filtrating element lubricate with CIATIM 201. In case of their
damage, replace them. Into block of regulation insert the socket of the outlet fuel (1) and the cover of filtrating
element (11). Tighten the screws (12) with washers (13) and lock them by locking wire.
3) Checking the condition of protective valve (description applies to fig. 42).
а) Unlock and screw offf the plug (2).
b) Check, if the spring is in proper position (free) with ball (5).
c) Removed parts (2, 4, 5) wash in clean techniocal gasoline and place in opposite order into the fuel pump. The
plug (2) lock by locking wire.
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4) Installation of fuel pump (description applies to fig. 41).
а) Put the fuel pump upon the holder (10) in proper position, close the collars (7), by means of spanner 8 screw in the
bolts (4) with locking washes (8) and fix the locking washers.
b) Remove the blind from the socket of tube (5) and plug from the hole of fuel pump. The sealing rings (11) in socket
of tube (5) lubricate by lubricant CIATIM 201. In case of damage of the rings, replace them. Wash the bolt of socket
of tube (1) in technical gasoline or in aviation kerosine and lubricate by lubricant GLEIT HP 520М. Set on the tube
(5), tighten the bolts (1) and (13) (see fig. 39) and fix them by locking wire.
c) Remove the plugs from the tube of fuel outlet (6) and the sockets of fuel pump, threaded socket lubricate by GLEIT
HP 520М, set the tube of fuel outlet, cap nut (2) and bolt of socket (3), tighten them and fix by locking wire.
d) Install and tighten the plug-and-socket connection of the fuel pump (9) of the electrical cable of cable bundle.
5) Carry out APU START and after operation on regime of idle run for 1.5 min switch off the APU.
6) After APU stop check the tightness of the fuel system of the APU.
7) About the works carried out make a record in APU log book.
Orientation torque moments of bolts and nuts tightening:

М5 - 7 Nm
Bolts of socket of tube (1, 3) and (13) (fig. 39) – 15 Nm
Cap nut of the tube - 20 Nm
- plug М12х1 (outer thread) - lubricant GLEIT HP 520М

- plug М12х1 and М10х1 (inner or equivalent lubricant against
thread) the seizure of threaded
- blind for socket of tube connections
- calibrated wrench, open spanners - lubricant CIATIM 201
(8, 13, 17), sockets, pliers, side - technical gasoline
pincers - locking wire ∅ 0,5
- socket with outer hexagonal 4
- socket with outer hexagonal 6
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fuel pump
(left view)
8
2 6 8 7 4 7 1
4
10
1
11
9
1. bolt of socket of fuel inlet tube

2. cap nut
3. bolt of socket of tube of fuel inlet into heat exchanger of the oil tank
4. bolt М5х23 (2ps)
5. tube of fuel inlet
6. tube of fuel outlet
7. collar of holder of fuel pump
8. locking nut (2ps)
9. plug-and-socket connection (СР)
10. holder of the fuel pump
Fig. 41 Replacement of the fuel pump
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16
1 8 9 14
15 7
10 11
7 12,13
12,13
12,13
7
1
3 4 5 6
11
12,13
1. socket of fuel outlet

2. plug М10х1of the protective valve
4. spring
5. ball of the valve
8. block of regulation
9. regulating piston
10. spring
11. plate
12. screw М3х 8
13. washer 3,2
14. nozzle
15. slide-valve
Fig .42 Cleaning the by-pass valve of the fuel pump
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Work designation: REPLACEMENT OF THE OIL FILTER
The works are to be accomplished in order as follows:
1) Removal of oil filter from the APU.
а) Screw off the plug-and-socket connections of the oil filter (4, 5, 6) of the electrical cables of cable bundle.
b) Unlock and by means of spanner 17 screw off the cap nuts (1, 2) of the tubes of oil outlet. The sockets and tubes are
to be covered by threaded plugs or blinds. Unlock and by spanner 13 screw off the bolt (3) of the socket of oil inlet
(10).
c) Unlock the locking nuts (8) and by spanner 7 screw off the bolts of fixation of the oil filter (7) in the holder of oil
filter (9).
d) Remove the oil filter from the APU.
2) Installation of the oil filter.
а) Put the oil filter upon the holder of the oil filter (9) and by spanner 7 screw in the bolts (7) with locking washers (8).
b) Remove the plugs and technological blinds from the oil inlet and outlet of the oil filter, the threaded sockets
lubricate by lubricant GLEIT HP 520М, install the tubes of oil outlet, cap nuts (1, 2) tighten them and fix by
locking wire.
c) Remove the plugs from the socket of tube of oil inlet (10). The sealing rings 12,6 х 1,9 in tube socket (10) lubricate
by lubricant CIATIM 201. In case of their damage, replace them. Wash the bolt of socket of tube (3) in technical
gasoline or in aviation kerosine and lubricate by GLEIT HP 520М. Install the tube of oil inlet (10), tighten the bolt
(3) and fix by locking wire.
d) Set on the plug-and-socket connections of the oil filter (4, 5, 6) of electrical cables of cable bundles.
3) Carry out the APU starting and after its operation on regime of idle run for 1.5 min switch off the APU.
4) After APU stop check the tightness of the oil system of the APU.
5) About the works accomplished make record into APU log book.
6) Orientation torque moments of tightening the bolts and nuts:

М4 - 4 Nm
Bolt of socket of tube (3) - 15 Nm
Cap nuts of tubes: inner cross section 4 - 20 Nm

- plug М12х1-2ps (outer thread) - lubricant GLEIT HP 520М
- plug М12х1-2ps (inner thread) or equivalent lubricant against
- blinds for sockets of tube the seizure of threaded
- calibrated wrench, open spanners connections
(7, 13, 17), sockets, pliers, side - lubricant CIATIM 201
pincers - technical gasoline
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4 5
7
8
10 7 9 1
8
1. cap nut of tube of outlet oil

2. cap nut of tube of outlet oil
3. bolt of socket of tube of oil inlet
4. plug-and-socket connection (TS)
5. plug-and-socket connection (FO)
6. plug-and-socket connection (EV2)
7. bolt М4х 10 (3ps)
8. locking washer (3ps)
9. holder of oil filter
10. socket of tube of oil inlet
Fig. 43. Replacement of oil filter
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Work designation: REPLACEMENT OF THE OIL PUMP

1) Removal of oil pump from the APU.
а) Unlock and by means of spanner 13 screw off the bolt (1) of the socket of inlet oil tube (3) and by means of spanner
17 release the cap nut (9) of the tube of oil inlet (7). The socket of tube (3) is to be blinded, the hole in oil pump
blind by threaded plug M 12x1.
The tube (7) turn down, in order to improve the comfort of oil pump removal.
b) Unlock and by means of spanner 13 screw off the bolt (2) of the socket of oil outlet tube (4) and by spanner 13
release the bolt (3)(see fig. 43) of the tube of oil outlet (8). The socket of the tube cover by blind, the hole in oil
pump cover by threaded plug M 12x1.
The tube (8) is to be turned down, in order to improve comfort of oil pump removal.
c) By spanner 7 screw off the nut (5) of fixation of the oil pump on flange of oil pump (6).
d) Remove the oil pump from the APU. Blind the flange of the oil pump.
2) Installation of the oil pump.
а) Set the oil pump upon the flange of oil pump (6) and by means of spanner 7 screw in the locking nuts (5).
b) Remove the blinds from socket (3) of the oil inlet tube (7) and from the socket (4) of the tube of oil outlet (8). The
sealing rings 12,6 х 1,9 in sockets of tube (3, 4) lubricate by lubricant CIATIM 201. In case of their damage, replace
them. The bolts of the tube socket (1, 2) wash in the technical gasoline or in aviation kerosine and lubricate by
GLEIT HP 520М. Set on the tubes, tighten the bolts (1, 2) and bolt (3) (fig. 43) of the tube of oil outlet (8), tighten
the cap nut (9) of the tube of oil inlet (7). The bolts and cap nut fix by locking wire.
3) Carry out the measurement and adjustment (if necessary) of the oil pressure and check the tightness of the APU oil
system.
The process of measurement and adjustment of the oil pressure is carried out in accordance with instructions of
the technological card № 9.
4) About the works carried out make a record into APU log book.
5) Orientation torque moments of bolts and nuts tightening:

М4 - 4 Nm
Bolts of tube sockets (1,2) – 20 Nm
Cap nut of tube (9) - 25 Nm

- blinds for sockets of tubes - lubricant GLEIT HP 520М
- plug M12x1 –2ps (outer thread) or equivalent lubricant against
- blind of the flange of oil pump seizure of threaded
- calibrated wrench, open spanners connections
(7, 13, 17), sockets, pliers, side - lubricant CIATIM 201
pincers - technical gasoline
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6 4 3
5
2 1
8 7
1. bolt of socket of the oil inlet tube

2. bolt of socket of the oil outlet tube
3. tube socket of oil inlet
4. tube socket of oil outlet
5. locking wire М4 (4ps)
6. flange of oil pump
7. tube of oil inlet
8. tube of oil outlet
9. cap nut of the tube of oil outlet
Fig. 44. Replacement of the oil pump
Page 116
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE TEMPERATURE SWITCH
Dscription applies to fig. 45
The works are to be accomplished in following order:

1) Removal of temperature switch from the APU.
Note: Before removal of temperature switch drain the oil from oil tank in accordance with instructions of the
technological card № 4.
а) Screw off the plug-and-socket connection (2) from the electrical cable of the cable bundle.
b) Unlock and by spanner 19 screw off the temperature switch (1) from the throat of the oil tank (3).
c) Remove the temperature switch from the oil tank.
2) Installation of the temperature switch.
а) The thread of the temperature switch lubricate with a lubricant GLEIT HP 520М. The sealing rubber ring 13,6 х 1,9
of the temperature switch lubricate by CIATIM 201. In case of its damage replace it. The temperature switch (1)
screw into the oil tank throat, tighten it and fix by locking wire.
b) Install the plug-and-socket connection (2) of the electrical cable of cable bundle.
3) Start the APU. After attainment of the idle run regime of APU wait 1-2 min and stop the APU.
4) After stopping of APU check the tightness of the oil system of the APU.
6) Orientation moment of tightening the temperature switch - 20 Nm
- calibrated wrench, open spanner - lubricant GLEIT HP 520М

(19), socket, pliers, side pincers or equivalent against seizure
of threaded connections
- lubricant CIATIM 201
- technical gasoline
Page 117
PG 05-01
March 2009
oil tank 3 1
oil tank temperature

switch
temperature
switch
1. temperaure switch
2. plug-and-socket connection (T0)
3. oil tank throat
Fig. 45. Replacement of the temperature switch
Page 118
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE FLOAT SWITCH
Desription applies to fig. 46
1) Removal of the float switch.

Note: For more convenient disassembly it is recommended to open and remove the cover of oil tank
а) Screw off the plug-and-socket connection (1) of the electrical cable of cable bundle.
b) Unlock and by spanner 8 screw off 3 bolts (2) of the fixation of float switch on the throat of the oil tank (4). For the
more comfortable removal of the bolts it is recommended to screw off and remove the tank cover (3).
c) Remove the float switch from the oil tank.
2) Installation of the float switch.
а) Lubricate the sealing ring 26,64 х 2,62 of the float switch by lubricant CIATIM 201. In case of its damage, replace
it. Set the float switch into oil tank throat (4), screw in the bolts (2) (apply the washers) tighten and fix by locking
wire. Install the cover of oil tank (3), screw in and fix by locking wire.
b) Install the plug-and-socket connection (1) of the electrical cable of cable bundle.
3) Start the APU. After reaching the regime of idle run wait 1-2 min and stop the APU.
4) Check the tightness of the APU oil system.
- open spanner (8) - lubricant CIATIM 201

- pliers, side pincers - locking wire ∅ 0,5
Page 119
PG 05-01
March 2009
3 2 2
float switch
oil tank 4 1
float switch
1. plug-and-socket connection (М0)

3. cover of tank
4. throat of oil tank
5. sealing rubber ring 26,64 x 2,62
Fig. 46 Replacement of float switch
Page 120
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE IGNITION BOX
Content of operation and technological requirements.

1) Removal of the ignition box.
а) Unlock and screw off the plug-and-socket connection (3) of the electrical cable of cable bundle.
b) By spanner 22 screw off the cap nuts (1, 2) of the left side and right side cable of spark plug.
c) By spanner 8 screw off 4 nuts (4) of fixation of the ignition box.
d) Remove the ignition box from the air intake (5).
2) Installation of the ignition box.
а) Set the ignition box upon the air intake (5), connect the wire of grounding ignition box (6) to the right side bottom
bolt of the holder of air intake and by spanner 8 screw on the locking nuts (5).
b) Install the plug-and-socket connection (3) of the electrical cable of cable bundle and fix it by locking wire.
3) About the works carried out make a record in APU log book.
4) Orientation torque moments of nuts tightening:

М5 - 7 Nm
- calibrated wrench - locking wire ∅ 0,5

- open spanners (8, 22)
Page 121
PG 05-01
March 2009
2 1 4 4
cable of spark 5 3
6
plug
(left side)
cable of spark
plug
(right side)
1. cap nut of spark plug cable (left side)

2. cap nut of spark plug cable (right side)
3. plug-and-socket connection (ZZ)
4. locking nut М5 (4ps)
5. air intake
6. wire of grounding the ignition box
Fig. 47. Replacement of the ignition box
Page 122
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE SPARK PLUG CABLE
Works are to be carried out in following order:
1) Removal of spark plug cable.

Note: There are being 2 various types of spark plug cable – specially for left spark plug and for right spark plug.
а) Release the locking wire and by spanner 22 screw off the cap nut (1 or 2).
b) Release the locking wire and by spanner 22 screw off the cap nut (5 or 6) of spark plug cable on the spark plug (7l
or 7r) .
c) By spanner 7 screw off 2 nuts (4) of the holder of spark plug cable (3) and distend the holder.
d) Remove the cable of spark plug.
2) Installation of the spark plug cable.
a) Set on the spark plug cable in the order opposite to the order of removal.
- open spanners (8, 22) - locking wire ∅ 0,5

Page 123
PG 05-01
March 2009
cable of spark plug

(left side)
p.No B3-0488-10757
4
(№ 488 510 01)
6
7l
1
cable of spark plug 5 7r 4 3

(right side)
p. No.B3-0488-
10792
(№ 488 510 02)
1. cap nut of spark plug cable (left side)

2. cap nut of spark plug cable (right side)
3. holder of the spark plug cable
4. bolt М4х 8 and locking nut М4 (2ps)
5. cap nut of the spark plug cable (left side spark plug)
6. cap nut of the spark plug cable (right side spark plug)
7l. left side spark plug
7r. right side spark plug
Fig. 48. Replacement of the cable of spark plug
Page 124
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE GENERATOR
1) Removal of generator.
а) Release the bolt (4), remove the cover of terminal block (5) and disconnect the electrical line for power supply from
the terminal board of generator by releasing the nuts of power supply line of generator. By spanner 7 screw off the
bolt (3) on case of generator and disconnect the wire for grounding the generator (7). Screw off the plug-and-socket
connection (6) of the electrical cable of electrical board line and cover by blind.
b) By means of spanner with inner polyhedral 8mm screw off the nut (1), using screwdriver distend the clamping band
of the V-type collar (2). Remove the generator from the drive box of the APU.
2) Installation of generator.
Note:
а) Set the generator on the flange of fixation of generator of APU drive box
b) Set on the clamping band of the V-type collar (2) and by calibrated wrench (socket with inner polyhedral 8) tighten
the nut (1) by torque moment 6-7 Nm.
c) Connect the electrical line of power supply to the terminals of generator, tighten the nuts of the power supply line of
generator.
ATTENTION. When connecting it is necessary to observe and keep the polarity of power supply.
d) Install the cover of terminal block (5) and tighten the bolt (4).
e) Remove the blind and set on the plug-and-socket connection (6).
f) Connect the wire of generator grounding (7) on case of generator and by spanner 7 screw in the bolt (3).
- open spanners (7, 8, 13) - lubricant CIATIM 201

- calibrated wrench
- spanner with inner hexagonal (8)
- screwdriver
- pliers
Page 125
PG 05-01
March 2009
1 4 2
generator
P/N 20040-100 6
3 7
1. nut М6
2. V-type collar
3. bolt М4х8
4. bolt М4х10
5. cover of terminal block
6. plug-and-socket connection
7. grounding wire of generator
Fig. 49. Replacement of generator
Page 126
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE ANTI-SURGE VALVE
1) Removal of the anti-surge valve.
а) Release the bolts of clamping band (2, 3) of the connection of anti-surge valve with an elbow of air takeoff (1),
with tube (7) of air takeoff from APU and with tube (6) of air by-pass into atmosphere. Remove the clamping
bands (2, 3), two segments of V-type collar (4, 5) and the rubber rings of rounded cross-section (8,9).
b) Distend the tubes (6, 7) and remove the anti-surge valve. The throat of tubes (1, 7) and anti-surge-valve cover by
blinds (10, 11).
2) Installation of the anti-surge valve.
а) Set the clamping bands (2,3) upon the appropriate air elbows. Remove the blinds (10,11) and place the anti-surge
valve between the (1, 6, 7) of the air system.
b) On the throats of the anti-surge valve set the sealing rubber rings (8, 9), set two segments of the V-type collar (4, 5)
and the clamping bands (2,3). Tighten the bolts of clamping band.
- screwdriver - blind (81 06753) - 2 ps

- blind (81 06751)
Page 127
PG 05-01
4 2 1 March 2009
3
1
5 11
6
10
anti-surge valve
7 2 4
4 8
anti-surge valve
1
2 4 8
9
8 2
5
3
1. elbow of the air takeoff (part belonging to APU)

2. clamping band 50-70/9-C6W3 - 2 ps
3. clamping band 40-60/9-C6W3
4. two segments of V-type collar (connector 64.7) - 2 ps
5. two segments of V-type collar (connector 52.5)
6. tube of the air by-pass into atmosphere
7. tube of the air take-off from APU
8. rubber ring of rounded cross-section 50x5 - 2 ps
9. rubber ring of rounded cross-section 39,1x5,8
10. blind (81 06753) - 2 ps
11. blind (81 06751)
Fig 50. Replacement of the anti-surge valve
Page 128
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE CABLE BUNDLE
Description applies to fig.51
1) Removal of cable bundle.
а) Release the locking wire and by spanner 8 screw off the bolts (2) of the fixing collar of cable of cable bundle (1).
b) By spanner 7 screw off 3 nuts (4) of the holder of spark plug cable (5) and distend the holder.
c) Screw off the nuts (5) (fig. 19) and remove the compensation wires of the electrical cables of cable bundle. Screw
off the plug-and-socket connections (1, 2, 4) (fig. 39); (7) (fig. 40); (9) (fig. 41); (4, 5, 6) (fig. 43); (2) (fig. 45);
(1) (fig. 46). Unlock and screw off the connection (3) ( fig. 47) and the plug-and-socket connection of grounding of
APU (3) of electrical cable of cable bundle (9). Disconnect the connection of central connector (connection to board
system of the object) and also the connection of control box of the APU (Control box LUN 5271.80/CONA two
connectors).
d) Remove the cable bundle for the APU.
2) Installation of the cable bundle.
a) Install the cable bundle in sequence opposite to the removal. The plug-and-socket connection (3) (fig. 47) lock by
locking wire.
5) Orientation torque moments of bolts and nuts tightening:

М4 - 4 Nm
М5 - 7 Nm
- calibrated wrench, open spanners - locking wire ∅ 0,5

(7, 8,), sockets, pliers, side pincers
Page 129
PG 05-01
March 2009
3 4 5
2
2
cable bundle 4 5 4 5
1. collar of fixation of the cable of cable bundle

3. plug-and-socket connection (GND)
4. bolt М4х 8 and the locking nut М4
5. holder of cable of spark plug
Fig. 51. Replacement of cable bundle
Page 130
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE BACK FUEL FILTER BYPASS VALVE
1) Removal of bypass valve from the back fuel filter.
а) Screw off the plug-and-socket connection of filter of back fuel (1) of the cable of cable bundle (2).
b) Unlock and by screwdriver screw off M3x28 bolts (3) with washers (4).
d) Extract the bypass valve (5).
ATTENTION:
- When handling the bypass valve it is not allowed the contamination of the inner space of the equipments.
2) Installation of bypass valve on the back fuel filter.
а) The sealing rubber rings (6,7) of bypass valve are to be lubricated by CIATIM 201 and insert the bypass valve - on
position according to fig. 52, inside to the back fuel filter. Screw in the three bolts (3) with washers (4) and fix them
by locking wire without sealing.
b) Install the plug-and-socket connection (1) of the cable of cable bundle (2).
3) Carry out APU STARTING and after its operation on the idle run for 1,5 min switch off the APU, during the APU
operation check the don´t shining of control lamp FUEL FILTER.
4) After the APU stop visually check the tighteness of the APU fuel system, i.e. absence of leakage.
- screwdriver (length 25 mm) - lubricant CIATIM 201

- long pliers - technical gasoline
- side pincers - locking wire ∅ 0.5
Page 131
PG 05-01
March 2009
3 1 2
4
filter of back fuel

(front view)
7 6
1. plug-and-socket connection (FVP)

3. bolt М3х 28 (3 ps)
4. washer 3 (3 ps)
5. bypass valve
6. sealing rubber ring 13,6x1,9
Fig. 52 Replacement of the back fuel filter bypass valve
Page 132
PG 05-01
March 2009
Work designation: REPLACEMENT OF THE BLOCK OF FILTER AND SERVO-VALVE

BYPASS VALVE
1) Removal of bypass valve from the block of filter and servo-valve.
а) Screw off the plug-and-socket connection of the block of filter and servo-valve (1) of the cable of cable bundle (2)
b) Unlock and by screwdriver screw off 3 bolts (3) with washers (4).
c) Extract the bypass valve (5).
ATTENTION:
- When handling the bypass valve it is not allowed the contamination of the inner space of the equipments.
2) Installation of bypass valve on the block of filter and servo-valve.
а) The sealing rubber rings (6,7) of bypass valve are to be lubricated by CIATIM 201 and insert the bypass valve - on
position according to fig. 53, inside to the back fuel filter. Screw in the three bolts (3) with washers (4) and fix them
by locking wire without sealing.
b) Install the plug-and-socket connection (1) of the cable of cable bundle (2).
3) Carry out APU STARTING and after its operation on the idle run for 1,5 min switch off the APU, during the APU
operation check the don´t shining of control lamp FUEL FILTER.
4) After the APU stop visually check the tighteness of the APU fuel system, i.e. absence of leakage.
- screwdriver - lubricant CIATIM 201

- long pliers - technical gasoline
- side pincers - locking wire ∅ 0.5
Page 133
PG 05-01
March 2009
5 4 3
filter and servo-valve 2

(front view)
7 6
1. plug-and-socket connection (FP)

3. bolt М3х 28 (3 ps)
4. washer 3 (3 ps)
5. bypass valve
Fig. 53 Replacement of the filter and servo-valve bypass valve
Page 134
PG 05-01
March 2009
Work designation: Replacement of Pre-blockage pressure switch (signaling of oil filter

contamination LUN 1491.03)
1) Removal of Pre-blockage pressure switch from oil filter.
а) Screw off the plug-and-socket connection (1) of Pre-blockage pressure switch of the cable of cable bundle (2)
b) Unlock and by screwdriver screw off 4 bolts M4x50 (3).
c) Extract the Pre-blockage pressure switch (4) from block of oil filter (5).
ATTENTION:
- When handling the Pre-blockage pressure switch it is not allowed the contamination of the inner space of the
equipments.
2) Installation of Pre-blockage pressure switch on the oil filter.
а) The sealing rubber rings 6,7 x 1,9 (6) are to be lubricated by CIATIM 201 and insert back to the block of oil filter
(5). In case of their damage, replace them.
b) Pre-blockage pressure switch insert back to the oil filter on position according to fig. 54. Pre-blockage pressure
switch screw in the four bolts M4x50 (3) and fix them by locking wire without sealing.
c) Install the plug-and-socket connection (1) of the cable of cable bundle (2).
3) Carry out APU START and after its operation on the idle run for 1,5 min switch off the APU, during the APU
operation check the don´t shining of control lamp „OIL".
4) After the APU stop visually check the tighteness of the APU oil system, i.e. absence of leakage.
- screwdriver - lubricant CIATIM 201

- locking wire ∅ 0.5
Page 135
PG 05-01
March 2009
3
1
1. plug-and-socket connection (TO)

3. bolt М4х50 (4 pcs)
4. signaling of oil filter contamination LUN 1491.03
5. oil filter (front view)
6. sealing rubber ring 6,7 x 1,9
Fig.54 Replacement of Pre-blockage pressure switch
Page 136
PG 05-01, Appendix 1
January 2003
THE AUXILIARY POWER UNIT

SAFIR 5K/G MI
MANUAL FOR THE OPERATION AND

TECHNICAL MAINTENANCE
SOURCE OF ELECTRICAL POWER

SUPPLY
ISSUE 1 of 20.1.2003
Page 0
January 2003
LIST OF VALID PAGES
Date of
Part, chapter,
Page introducing
section, subsection
into validity
Title-page - -
List of valid pages 1 January 2003
List of introduced changes 2 January 2003
Table of contents 3 January 2003
List of figures 3 January 2003
Source of electric power supply 4-5 January 2003
Generator P/N 20040-100 6-14 January 2003
Control box of generator

P/N 2438-100 15-22 January 2003
Transformer P/N 20736-100 23-26 January 2003
Page 1
January 2003
LIST OF INTRODUCED CHANGES
№ № Signature of
Date of
Change
section,
№ of sheets/pages № of appendant person
introduced
change
Changed New Cancelled
Page 2
January 2003
TABLE OF CONTENTS
Page
А/ Source of electrical power supply 5
B/ Generator P/N 20040-100 6
C/ Control box of generator P/N 2438-100 15
D/ Transformer P/N 20736-100 23
LIST OF FIGURES
Fig.
№. Name of figure Page
1. Electrical schema 5
2. Generator P/N 20040-100. Drawing of main dimensions 9
3. Generator rotor 10
4. Generator stator 11
5. General view of generator 12
6. Electrical schema of generator 13
7. Dependence of maximum loading of generator upon the altitude above sea level and upon
temperature of cooling air at generator inlet 14
8. Control box of generator P/N 2438-100. Drawing of main dimensions 19
9. Control box of generator P/N 2438-100 20
10. Inner arrangement of the control box of generator P/N 2438-100 21
11. Frame of fixation of control box of generator P/N S 6201 C04P5 22
12. Transformer P/N 20736-100. Drawing of main dimensions 25
13. Electrical schema of transformer 26
Page 3
January 2003
А/ SOURCE OF ELECTRICAL POWER SUPPLY

1. Purpose
The source of electrical power supply, it is a facility intended to supply to board system of the
object the alternate current of constant frequency. It is used in process of pre-flight
preparation or during the flight, it can also be used as an emergency source of electrical power
supply when occuring failures of main power sources in flight.
2. Technical data
Nominal three-phase voltage 3 x 115/200 V at f = 400 Hz
Nominal power output 20 kVA
3. Description of design
The source of power supply consists of following elements:
• Generator P/N 20040 - 100

• Control box of generator P/N 2438 - 100
• Transformer P/N 20736 - 100
4. Principle of operation
The three-phase generator ‚ driven from the drive box of the APU, transforms the mechanical
energy into electric energy in form of three-phase alternate current 115/200V at frequency of
400 Hz. The control box of generator provides the constant voltage of generator and evaluates
the voltage scanned from the transformers. The transformers P/N 20736 – 100 (situated as
independend part) and P/N 20736 – 100A (it is common part of generator, see fig. 1) have
been designed as through-passing transformers, which are elements sensing maximum current
and differential protection. The control box of generator permanently evaluates the data of
transformers and compares them with programmed values. In case of short circuit on the
terminal block, in case of short circuit on the supply line or in case of exceeding the
programmed maximum current, the control box of generator reduces or switches off the
exciting voltage of generator. In this way it is working the protection of generator against
overloading and possible damage.
5. Installation and connection
- Generator is situated on driven box of the APU co-axially with the engine rotor. The
generator control box and transformer are situated separately on the object board in
section of radio instruments.
- The electrical connections are carried out in accordance with schema, presented in fig. 1.
Page 4
CONNECTORS:
Voltage + 28 V Wires marking Cross-section Nom.
Control box of generator P/N 2468 – 100 Č
J1/A - J1/B – DSXN2R S26P S40P 26-01 ( ARING 404/MIL C81659B ) ( Sogie )
1,34 mm2 16
Generator P/N 20040 100
J1 83723 – OR 16 – 10 - PN ( Souriau / MIL C83723 )
0,6 mm2 20
Transformer P/N 20736 - 100
BS25 10R 10B 6 PN ( Souriau ) ou FDBA 50 10 6 PN ( DEUTCH ) 0,22 mm2 24
10 A
Transformer P/N20736-100 TKC 103 deblock.
C1 C2 C
B1 B2 B
Start. of generat. alter. current

400 Hz
A2
3 x 115V
A1 A
D A B C
power when APU starting

28 VDC
Electr. blocking of takeoff of electr.

Gen.alt.current P/N 20040-100
Page 5
Outlet
Fig. 1 Electrical schema

Control box P/N 2438-100
Transformer Auxil. exiting

P/N 20736-100A
TEST
J1/A J1/B
January 2003
January 2003
B/ GENERATOR (THALES) P/N 20040 - 100

1. Purpose
The electrical generator is used as a source of power supply when performing the pre-flight
preparation or during the flight, it can be used also as an emergency source of electrical power
when having the failure of main generators in flight.
2. Technical data
Nominal three-phase voltage 3 x 115/200 V at f = 400 Hz

Nominal power output 20 kVA
Two-minutes overloading max 87 A
Five-seconds overloading 116 A (each phase)
Current of short circuit 170 - 200 A (max 5 sec)
General distortion of harmonic less than 3 %
Nominal rpm 12000 rpm
Range of rpm 8670 - 14700 rpm
Maximum rpm (2 min without loading) 16000 rpm
Emergency rpm 18000 rpm
Maximum acceleration of rpm 6000 rpm/sec
Maximu torque moment 17,25 Nm
Torque moment without excitation 0,4 Nm
Protection of generator against destruction (weak element)–moment 143 Nm
Temperature range from - 55 to + 70 oC
Maximum operational altitude 10700 m
Range of frequency 340 - 490 Hz
Nominal current 58 A
Nominal frequency 400 Hz
Mass 14,9 kg
Page 6
January 2003
3. Description of structure
The drawing of main dimensions of generator is in fig. 2.

The main elements of generator structure are in fig. 3, 4.
In the outer case (6), there are situated the stator of main generator, stator of auxiliary exciter
(13) and stator of external alternate exciter. To this case, it is fixed the holder of transformer
(4) with transformer of differential and overcurrent protection (7), exit block (5) and
connector (8).
Rotor winding (9) of the main generator of altrnate current, rotor winding of the alternate
exciter (10) and the wheel of radial fan (11) with constant magnets of the auxiliary exciter are
pressed on the common shaft (2) with inner evolvent-type key connection.
The hollow shaft (2) is situated on bearings (3). The bearings are filled with high-temperature
lubricant. The sections of the bearings are tightened by means of chambers with the same
pressure, which are also tightened by labyrinth-type sealings.
The transfer of torque moment from drive box of APU is provided by means of torsional
connecting shaft (12), which is inserted into the slot-type connection of the hollow shaft (2).
4. Description of operation
Three-phase generator, driven from drive box of the APU, transformes the mechanical power
into electrical power in form of three-phase alternate current 115/200 V with a frequency of
400 Hz. Generator is made as brush-less three-stage cascade, consisting of the main generator
of alternate current, alternate exciter with rotating rectifier and auxiliary exciter. Together
with installed current transformer of the differential and overcurrent protection it creates the
single block.
The generator consists of three parts:
The main generator of the alternate current – it is a four-pole aggregate with smooth rotor.
The three-phase winding of the stator with separated node is connected according to schema
„star“. The node of stator winding is connected with one of transformers of differential and
overcurrent protection, situated in holder on the case. The construction of stator makes
possible the effective heat transfer to the case.
Exciter of alternate current - it is a six-pole generator of the alternate current with

protruding poles and with excitation winding on the stator. In grooves of the rotor there is
three-phase working winding connected according to schema „star“, which through the
rotating rectifier supplies the power to winding of the main generator of the alternate current.
The rotating rectifier is designed upon the bridge three-phase schema. The construction of the
alternate exciter provides the safe work up to the rpm 18 000 min-1.
Auxiliary exciter – it is a six-pole generator of the alternate current with an excitation from
cobalt-samarium permanent magnets, situated in casing of radial fan. The three-phase
working winding is connected with collector. Outlet of this exciter is used, at first for
excitation of the second stage of cascade and at second – for supply of block of generator
control. The auxiliary exciter is able to bear the permanent short circuit at exits.
When occurs the rotation of the generator rotor, so in its first stage, i.e. in auxiliary exciter, it
is induced the alternate voltage, which after rectifying in block of generator control, is
stabilised and is powering the winding of excitation of the alternate exciter. Due to it, it is
quaranted the high reliability of the autonomous exciter. The winding of excitation of the
second stage of generator, i.e. alternate exciter, after being powered from the auxiliary exciter
Page 7
January 2003
through block of control, creates the magnetic field. In the three-phase winding, which is
situated in grooves of rotor of alternate exciter, there is induced the alternate voltage, which
after rectifying in rotating rectifier is powering the winding of the third stage of generator, i.e.
the main generator of the alternate current.
The radial fan provides the effective cooling of generator.
5. Rules of assembly (see fig. 5)
- Generator is fixed by means of quick coupler (16) to the transient piece (15). Its position
is given by pin (14). The transient piece is fixed to the flange of drive box of the APU by
six studs M10 x 20 and nuts M10. The position of transient piece with recpect to flange
of drive box of APU is also given by directing pin.
- The transition piece and quick coupler are the parts belonging to the generator supply.
- The electrical schema of generator is in fig. 6.
- Generator is connected to the cable system of the object by means of the cable connector
M83723/86W 16 10N.
- The working conditions, see p. 2.
- Air temperature at generator inlet must be in accordance with diagram presented in fig. 7.
- Generator is grounded to the casing of the APU by means of grounding wire.
Page 8
January 2003
rotation
Direction of
Fig. 2
Generator P/N 20040 – 100 Main dimensions.
Page 9
January 2003
10
3
2
12
13
11
1. Front cover
2. Hollow shaft
3. Bearing
9. Rotor winding of the main generator of the alternate current
10. Rotor winding of the exciter of alternate current
11. Wheel of radial fan
12. Torsional connecting shaft
13. Stator of the auxiliary exciter
Fig. 3
Rotor of generator
Page 10
January 2003
4
3
3. Bearing
4. Holder of the current transformer
5. Terminal block
6. Outer case
7. Transformers of differential and overcurrent protection
Fig. 4
Stator of generator
Page 11
January 2003
14
15
16
14. Directing pin

15. Transition piece
16. Quick coupler
Fig. 5
General view of generator
Page 12
January 2003
Connector 83723 OR 1610 PN Terminal block
Cable appropriate part M83723/86W 16-10N
Fig. 6
Electrical schema of generator
Page 13
January 2003
voltage 115V at frequency 400 Hz
U=115 V, f=400 Hz
8000
7000
6000
5000
Altitude (m)
4000
3000
2000
1000
0
-60 -40 -20 0 20 40 60 80 100 120
Air temperature at generator inlet (°С)
20 kVA 22 kVA 24 kVA 26 kVA
generator loading (20 kVA, 22kVA, 24 kVA, 26 kVA)
Fig. 7
The dependence of maximum loading of generator upon altitude above the sea level and upon
the temperature of cooling air at generator inlet
Page 14
January 2003
C/ CONTROL BOX OF GENERATOR

P/N 2438-100
1. Purpose
The control box of generator – it is the electronic device, intended for regulation of the outlet
voltage and for protection of the electrical generator (THALES) P/N 20040-100.
2. Technical data
Mass 2,1 kg
Nominal voltage of power supply 28 V
Minimum voltage of power supply 10 V
Programmed nominal generator loading 58 A
Temperature of operation from minus 45 to +70 °C
Temperature resistance from minus 55 to + 85 °C
Mean time between failures (acc. to MIL HDBK 217 E ) 29 500 hours
As to the structure, the control box of generator comprises the closed metallic case, in which
there are assembled the electronic boards. The control box features the module-assembly
structure.
On the front wall of the control box there is set the button of testing (8), testing light diod
LED (9), the table of producer plant and mounting handle.
On the rear wall there is set electrical connector (10) with protection against the improper
connection of the poles, bolt of grounding (11) and guiding ledge.
Besides the button of testing (8) there are not any other elements of control on the outer walls
of the control box.
The structure of the base of the control box makes possible the easy setting the later into the
frame of box installation.
The power supply of the control box is provided from generator. Only in case of pressing the
button of testing (8) the control box is powered from the board network with voltage of 28
V of direct current. The permanent takeoff of the current by control box is 0.5 A of the direct
current (top takeoff – 3A for max. 50μsec).
Through connector (10) the control box is connected with generator. Connector is intended
also for power supply and for connection of control box with electrical network of the object.
In the control box of generator there are installed the following electronic circuit boards:
• Board of regulation (1)
• Board of protection (2)
• Board of schemas of logics (3)
• Board of diagnostics (4)
• Board of sources of power supply (5)
• Board of anti-lightning protection (6)
• Board of transformers (7)
Page 15
January 2003
The control box of generator is regulating the exit voltage of generator of alternate current by
means of regulationg the currect of excitation. The basic part of the control box, it is
microprocessor, which applying the recorded programm is carrying the following functions:
• Function of regulation (A)

• Function of protection (B)
• Function of testing (C)
(A) Function of regulation
The control electronic schema carries out the function of regulation, what does mean, that the
exit voltage of generator is kept inside the programmed range (115 – 119 V) by means of
changing the current of generator excitation. The regulation of this current is carried out by
means of impulse modulation according to impulse width. The value of exit voltage is
scanned from the block of exit terminals of the generator. The voltage is regulated up to value
of 117 V ± 2V, in frequency range from 340 to 490 Hz and loading from 0 to 1,5-multiple
value of nominal current. The voltage is stabilised in range of 115 to 119 V, in frequency
range of 340 to 490 Hz at loading from 1,5 to 2-multiple of nominal current value.
The transient and stationary values of voltage are in accordance with requirement of standard
EN 2282.
The frequency of the generator switching on is adjusted to the value of 380± 5 Hz.
(1) Parameters of voltage regulation:
Table 1
Generator Loading Exit voltage Excitation
rpm (A) effective current
(rev.min.-1) (V) (A)
12000 No loading 115 to 119 0,4 to 0,6
12000 58 115 to 119 1,2 to 1,55
It is allowed the jump-type switching on and switching off the nominal loading of 58 А.
When jump-type switching on the loading, the voltage does not drop under 80 V and in the
interval of time less than 100 μsec there occurs setting the nominal value of voltage. When
switching off the loading, the exit voltage does not exceed the value 140 V in period of time
less than 100 μsec.
(2) 1.7- multiple loading:
The generator can be operated within 5 sec for having the 1.7-multiple (97A) value of
nominal current. After switching off the loading, the schemas of regulation are establishing
the nominal state in period of time no more than 150 μsec.
The current of short circuit of generator is from 150 to 250 A.
Page 16
January 2003
(B) Function of protection
The control system is checking the data of measuring transformers of current, the values of
phases voltage and frequencies. In the control box of generator there are programmed the
following parameters of protection.
Overloading
Threshold: 135 ± 2 V, delay 0,7 - 1,1 sec
Action: Disconnecting the generator switch and switching off the excitation current.
Threshold: 210 V, delay 60 μseс
Action: Disconnecting the generator contactor and switching off the excitation current.
(1) Reduced voltage

Threshold: 103,5 ± 2,5 V, delay 6 ± 1 с
Action: Disconnecting the generator contactor and switching off excitation current.
(2) Asymmetry of loading

Threshold: 25 - 35 A, delay 0 sec
(3) Switching off the single phase

Delay less than 3 sec.
(4) Protection against the reduction of frequency

Protection 1: threshold from 320 to 335 Hz, delay 0 seс.
Action: switching off the excitation current.
Protection 2: threshold 375 ± 5 Hz, delay 6 ± 1 sec.
Action: switching off the current of excitation.
After switching the protection and when frequency increases and attains the working range,
then the generator switches on automaticaly (reversible protection).
(5) Protection against increasing the frequency

Protection 1: threshold from 465 to 480 Hz, delay 0 seс.
Protection 2: threshold 425 ± 5 Hz, delay 6 ± 1 seс.
After switching and when the frequency decreases up to working range, the generator does
not switch on automaticaly (nonreversible protection). For switching on the generator it is
necessary manually to switch off and switch on the generator contactor.
(6)Failure of the rotating rectifier

Delay 2 - 3 seс.
Action: disconnecting the generator contactor and switching off the excitation current.
Page 17
January 2003
C. Function of testing
Operation:
Switch on the switch of generator, during this the generator does not rotate and there is
supplied the voltage of 28 V. Press the button of testing (8) on the front wall of control box
(see fig. 9).
When pressing the button (8) in the microprocessor of control box it is activated the testing
programme. The programme step by step provides the testing of individual components,
turned on into the circuits of control and protection of the box. In case of positive result of
testing process, the testing light diode LED (9), shining when pressing the button (8), goes
out after expiring the time 7 ± 1,4 seс. Repeating this test it is possible after elapsing the time
of 10 sec.
5. The rules of installation
- Control box of generator is installed in sector of radio instruments by means of the

installation frame P/N S 6201 C04P5 (see fig 11). In frame there is set the appropriate
part of connector DPX2MA–26S 40S–33B0001‚ which is connected with board network
of the object.
- The electrical schema of the control box is shown in fig. 1.
- The working position of the box – any.
- The cooling is provided through natural air circulation.
- The cleaning of dust is to be done by means of brush and low pressure clean compressed
air.
Working conditions:
- range of temperature of ambient from minus 45°C to +70°C
- heat resistence from minus 55°C to +85°C
- ceiling up to 6000 m
- stability of operation against:
- vibrations from 5 to 2000Hz 3g ( acc. to standard RTCA/DO-160C, chapt. 8, cat. L )
- shocks 15 g ( acc. to standard RTCA/DO-160C, point 7.3.2 )
- linear acceleration 6 g ( acc. to standard RTCA/DO-160C, point 7.2 )
Rules of installation.
-The box of generator control is to be installed separately from APU by means of special
installation frame, supplied in set of supply of the control box of generator. In place of box
installation, there must be not installed neither any other source of heat nor must be felt the
radiation heat.
- The box must be grounded to the case of object airframe.
- The electrical connection of the box with a board network is carried out through plug-and –
socket connection DSXN 2RY26PY40P26. After connection the connector must be locked by
locking wire.
Page 18
January 2003
170
193,5
95
44
368
63,11
Centre of gravity
Fig. 8
Control box of generator P/N 2438 - 100
Drawing of main dimensions.
Page 19
January 2003
CAUTION
BEFORE
INSULATION TEST
UNSCREW THE
GROUNDING SCREW
11 DIELECTRIC TEST
PROHIBITED
CC
CC CCSW
8
TOP
9
10
12
7 5 1 3 4 2
1. Board of regulation
2. Board of protection schemas
3. Board of logics
4. Board of diagnostics
5. Board of power supply
6. Board of anti-lightning protection
7. Board of transformers
8. Button of testing
9. Testing light diode LED
10. Connector J1/A – J/1B – DSXN2R S26P S40P 26 – 01
11. Bolt of grounding
12. Table of producer plant
Fig. 9
Control box of generator P/N 2438 - 100
Page 20
January 2003
Board of regulation
Board of power
supply
Board of protection
schemas
Board of diagnostics
Board of logical schemas
Fig. 10
Inner arrangement of the control box of generator P/N 2438 – 100
Page 21
January 2003
Ø7
2 x Ø 5,2
2 x Ø 5,2
Ø6
Fig. 11
Frame of fixation of control box of generator P/N S 6201 C04P5
Page 22
January 2003
D/ TRANSFORMER P/N 20736-100

1. Purpose
The transformer is used as a sensor od overcurrent differential protection and as a measuring

instrument of exit currents of the source of power supply.
2. Technical data
Type P/N 20736 – 100

Mass 0,215 kg
Number of transformers in source of power supply 2
Power input at normal current 58 A <1W
Loading resistance of secondary winding 100 Оm 3 W ± 5%
Resistence of secondary winding from 3 to 16 Оm
Isolation resistance > 40 MOm
Exit voltage at normal primary current 58 A 5,5 - 6,5 Veff
Accuracy ± 5%
Maximum asymmetry of exit voltage ± 0,15 Veff
A: Transformer P/N 20736 – 100 (fig. 12)
Transformer is situated in the metallic casing with three mounting footers, in which there are
holes of diameter 4,2 mm for fixing the transformer on the airframe of object. Connector (1)
is intended for connecting the transformer with control box of generator.
Transformer of current consists of three toroidal cores, containing the winding of secondary
coil. The power conductors of generator are passing through the holes made in toroids. In
parallel with secondary winding there are joint the loading resistances of 100 Om. The
leadingout wires are connected to connector (1).
B: Transformer P/N 20736 – 100A
Transformer is situated on the outer case of generator. Its structure and technical data are the
same as with transformer P/N 20736 – 100. The leadingout wires of secondary coils are joint
to connector on the generator case. Through the toroidal cores there are conducted the
leadingout wires of stator winding of the main generator of alternate current.
Page 23
January 2003
Action of the differential overcurrent protection:

- In such a case, when the current of generator loading is conducted at the same time
through primary windings of both transformers (i.e. when having the normal operation),
the induced voltages in secondary windings are mutually subtracted and the differencial
voltage must not close the circuit of the differential current protection, which is in the
control box of generator.
- In such a case, when the current of generator loading is conducted through the primary
winding of one transformer only (i.e. when occuring the short circuit of inputs of bus bar
etc.) the differential voltage must provide the switching on the circuits of differential
current protection.
Action of overcurrent protection:

The exit secondary voltage of transformer P/N 20736 – 100A (situated on the case of
generator) it is compared in control box of generator with programmed value of the voltage.
In case of overloading the programme provides the switching off the generator excitation.
5. Rules of situating
- The transformer P/N 20736-100A is situated immediately on the generator (THALES)

P/N 20040-100.
- The transformer P/N 20736-100 is situated on the object airframe in sector of radio
instruments. The connection with electrical network of the object is carried out by means
of connector M83476W 10-06S.
- The electrical schema is shown in fig. 13.
The working conditions:

- range of ambient temperature: from minus 55°C to +70°C
- heat resistance: from minus 55°C to +85°C
- ceiling: up to 6000 м
- stability of operation against:
- vibrations, from 5 to 500 Hz 10g (acc. to stand. RTCA/DO-160C , chapt. 8, cat. T)
- shocks 12 g (acc. to stand. RTCA/DO-160C , point 7.3.2 )
- linear accelerations 6 g ( acc. to stand. RTCA/DO-160C , point 7.2 )
Rules of installation
Transformer is to be set on the aircraft fuselage at any position. It is to be fixed by means of 3
bolts M4 equipped with washers.
Page 24
January 2003
1. Connector MS 3470W 10-6PN

2. Toroidal cores
3. Loading resistance
Fig. 12
Transformer P/N 20736 – 100
Drawing of main dimensions
Page 25
January 2003
White
A
T1 R1
Connector MS 3470W 10-6PN

Red
Connector MS3470W 10-6 PN

B
White
T2 R2
Red
White
C
T3 R3
Red
D
Fig. 13
Electrical schema of transformer P/N 20736 – 100
Page 26

Auxiliary Power Unit Safir 5K/G Mi Manual For The Operation and Technical Maintenance

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Auxiliary Power Unit Safir 5K/G Mi Manual For The Operation and Technical Maintenance

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PG 05-01

MANUAL FOR THE OPERATION AND TECHNICAL MAINTENANCE

AUXILIARY POWER UNIT

MANUAL FOR THE OPERATION AND

Given changes have been subsequently processed to text of this manual

All changes concerning cancellation of pages, exchange of old pages or

List of valid pages

Approval sheet 0 January 2003

List of valid pages 1 March 2009

List of introduced changes 2 March 2009

Table of contents 3-4 March 2009

List of figures 5 March 2009

Introduction 10 March 2009

Basic technical data 11-14 March 2009

Description of SAFÍR 5K/G МI 15-25 March 2009

Instruction for operation 26-35 March 2009

Instruction for installation and 35-42 March 2009

APU maintenance tasks and intervals 43-47 March 2009

Technology of maintenance operation 48-78 March 2009

Storing, conservation and 79-81 March 2009

Failures and methods of their 82-96 January 2010

Replacement of aggregates 97- 136 March 2009

LIST OF INTRODUCED CHANGES

Pict. description List of figures Page 5 Letter no. Holík 6.5.2003

During main 4.5.3 Blockage of Page 31

…up to +80 °C in 4.6.5 Page 33

Indicator scale up Fig. 16 Page 42

At idle speed see 6.2.3Checking the Page 44

APU parameter T.C. No.7 Page 70

Preservation valid 8.2.1 Conservation Page 79

Table completion. 6. APU Page 43

tab.1 Oil exchange List of periodic Page 46

APU service life 6.1.1 Page 43

Completion of List of figures Page 5 Change no. Holík 21.1.2004

Completed 4.5.2 Operation of Page 30

Filter insert 5.3.2 Prescribed Page 37

Completed 9.3 Troubleshooting Page 86

Completed fig.54 List of figures Page 5 Change no. Tomek 25.7.2005

APU operation 4.1 Starting the Page 26

Min. operation 4.5.2 Operation of Page 30

4.6.6 Operational Page 33

Completed 4.5.2 Operation Page 30

Completed list of 6.4.2Replacement Page 46

7.3.2 Tester of APU'

Implementation of List of valid pages Page 1 Change no. Holík 22.2.2010

2. THE BASIC TECHNICAL DATA OF THE APU

3. DESCRIPTION OF THE APU SAFÍR 5K/G МI

4. INSTRUCTIONS FOR THE OPERATION

5. INSTRUCTIONS ON INSTALLATION AND INTRODUCING INTO OPERATION

6. APU MAINTENANCE TASKS AND INTERVALS

7. THE TECHNOLOGY OF MAINTENANCE OPERATION

8. STORING, CONSERVATION AND UNCONSERVATION

9. FAILURES AND METHOD OF THEIR ELIMINATION

10. REPLACEMENT OF APU AGGREGATES

Fig. 1. APU SAFÍR 5K/G MI

Fig. 1a. Transport frame

Fig. 2. APU SAFÍR 5K/G MI – drawing of main dimensions, sheet 1

Fig. 2. ВСУ SAFÍR 5K/G MI – drawing of main dimensions, sheet 2

1.1 Purpose of manual

1.2 Review of manual

1.3 Abbreviations and nomenclature

2. THE BASIC TECHNICAL DATA OF THE APU

2.2 The basic technical data