ROLLS-ROYCE l!

MWIT
MAINTENANCE
ENGINE

CHAPTER 82 - WATER INJECTION

LIST OF ROLLS-ROYCE EFFECTIVE PAGES

T h i s c h a p t e r c o n s i s t s of t h e f o l l o w i n g pages

CHAPTER
SECT ION
AND PAGE DATE

L i s t of e f f e c t i v e paces
(R) 1 Oct.82

82 Table of c o n t e n t s
1 Apr. 1/60

82-00-1
1 June 14/62
2 June 14/62
3 J u n e 14/62
4 June 14/62
5 J u n e 14/62
201 J u l y 15/70
202 Oct. 7/68
(R) 203 Oct.82
204 Oct. 7/68
205 Oct. 7/68
206 Nov.15/72
2 07 Nov. 15/72
208 Nov. 15/72
20 9 June 77
210 June 77
211 June 77
212 June 77

L i s t of e f f e c t i v e pages
82
Page 1
 ROLLS-ROYCE
MAINTENANCE .

TMLE OF CONTENTS

Cha~ter82 - Water in.iection

General
~ater/methanol c o n t r o l unit

Apr. l/60 82
S Page 1
 ROLLS-ROY CE V '
MAINTENANCE
,ER0 ENGINE

June 14/62 82 -00-1

Page 1
 ROLLS-ROY CE AERO E N G I N E

Water/methanol unit - Description and operation (cont.)

General

When the engine is operating under high ambient temperature conditions, with
a corresponding decrease in mass air flow, fuel flow is reduced by the fuel
trimmer to maintain engine temperature within acceptable limits. For take-
off only, the power is boosted by the injection of water/methanol mixture
into the first-stage compressor through drillings in the rotating guide vanes
and impeller (fig.1).

Injection of the water/methanol is controlled by a metering unit which is

sensitive to propeller shaft torque through torque meter oil pressure,
ambient pressure through two opposed capsules, and engine speed by
interconnection with the throttle and r.p.m, controls.

The watedmethanol unit is mounted on the port side of the engine, and
determines the amount of water/methanol discharged into the compressor,
according to engine requirements and outside air temperatures.

Operation

The flow of water/methanol is regulated by a control (metering) valve which

is normally held in the closed position by spring pressure; this valve is
opened when the servo control valve admits oil from the engine high pressure
system to the servo cylinder. A restriction in the supply passage between
the servo control valve and servo cylinder eliminates oscillation of the
water/methanol metering valve and prevents engine hunting.

The servo control valve is arranged to meter engine oil pressure according to
the forces acting on the capsule assembly stem.

Torque meter pressure, transmitted to the capsule stem through a piston and
the upper push rod, tends to close the servo valve. This force is opposed
by spring pressure transmitted through the lower push rod tending to open
the servo valve.

The effect of atmospheric pressure on the capsule assembly modifies the

forces operating through the push rods on the control assembly and renders
the unit sensitive to altitude. Out of balance forces permit movement of
the servo control valve to vary the servo oil pressure which acts on the
metering valve to control the water/methanol flow into the engine.

The capsule assembly consists of two capsules, one evacuated and the other
open to ambient pressure. The capsules are arranged to move the servo
control valve towards the closed pcsition when atmospheric pressure
decreases; this controls take-off power to the I.S.A. value at the
particular aerodrome altitude.

June 14/62 82-00-1

Page 3
 ROLLS-ROYCE ,ER0 EWGiWE

unit - Description and operation (cont. )

Watedmethanol control u n i t
Fig.2

A s t h e water/methanol is vaporized on passing through t h e compressor, it both

reduces t h e temperature of t h e a i r and increases t h e mass flow. The
increased mass flow reduces t h e turbine i n l e t temperature and enables water/
methanol burnt i n t h e combustion chambers t o boost engine power up t o t h e
nominal value a t each a l t i t u d e independent of changing a i r i n l e t temperature.

82 -00-1 June 14/62

Page 4
 ROLLS-ROYCE AERO EHGME
MAINTENANCE

B
Water/methanol unit - Description and operation (cont.)
Engine power is thus varied due to-the effect of the water/methanol until
the resulting torque meter pressure balances the opposing forces and
equilibrium is reached.

With the injection system switched on, water/methanol is supplied to the unit
as the throttle approaches the take-off position when, by means of control
interconnection, the oil cock in the unit is opened to permit engine oil to
reach the servo control valve.

To prevent corrosion, a supply of air is tapped from the first-stage impeller

casing to purge all residual watedmethanol from the control unit and from
the supply passages in the impeller.

June 14/62 82-00-1

Page 5
 ROLLS-ROYCE BA W U
MAINTENANCE
A E R O ENGINE

WARNING: THE VAPOUR GIVEN OFF BY METHANOL IS TOXIC, AND METHANOL MUST, THEREFORE,
ONLY BE STORED AND HANDLED IN WELL VENTILATED PREMISES, TO ENSURE THAT
METHANOL DOES NOT CONTACT THE SKIN WHEN INSPECTING OR SERVICING THE
WATER/METHANOL SYSTEM, RUBBER GLOVES AND PROTECTIVE CLOTHING SHOULD BE
WORN.
CAUTION: (1) SCRUPULOUS CLEANLINESS IS ESSENTIAL WHEN FILLING THE WATER/METHANOL
TANKS AND WORKING ON THE SYSTEM. TO PREVENT CORROSION, IMMEDIATELY
WIPE UP ANY MIXTURE SPILT ON THE ENGINE OR POWER PLANT.
(2) THE PROPORTIONS OF WATER TO METHANOL ARE CRITICAL AM) THE ADDITION
OF ANY EXTRA COMBUSTIBLE LIQUID SUCH AS KEROSINE CAN CAUSE INTERNAL
ENGINE EXPLOSION AND OVERHEATING OF THE TURBINE ASSEMBLY, RESULTING
IN SEVERE DAMAGE TO THE ENGINE. IF KEROSINE ENTERS THE SYSTEM IT
MUST BE DRAINED AND PURGED BEFORE RUNNING THE ENGINE. CLEANLINESS
IS ESSENTIAL DURING MIXING OF WATER/METHANOL AND WHEN SERVICING THE
SYSTEM. REPLACEMENT UNITS MUST BE PURGED BEFORE INSTALLATION.

A. Remove water/methanol control unit

(1) Remove the auto-feathering switch as described in Chapter 61-20-3.
(2) Disconnect the control rod from the operating lever on the control unit.
(3) Unlock and disconnect the water/methanol supply pipe and torquemeter oil
pressure transmitter pipe.
(4) Disconnect the drain pipe at the fuel pump end and remove the retaining
clip from the air intake casing, then disconnect the drain pipe from the
water/methanol control unit.
(5) Disconnect the fire extinguisher pipe clip from the right-hand side of
the unit, and disconnect the oil temperature bulb electrical cable clip
from the base of the unit.
(6) Remove the four nuts, spring and bevelled washers securing the unit to the
air intake casing, then fit the extractor HW.34468 and withdraw the unit
from the mounting studs; collect the rubber bush and steel ferrule
flexible mounting assemblies from the mounting feet when the unit is
removed.
(7) Remove the extractor from the unit, then withdraw the transfer tubes
from the engine air intake casing or the unit, using the extractor
tools HW.11455 and HW.15065. Remove and discard all rubber sealing
rings.
NOTE: Ensure that the extractor is of the correct size for the transfer
tube being withdrawn.
.4
S
m
I (8) Drain the unit and flush the water/methanol passages with clean engine
oil, drain again, then blank off all passages.

July 15/70 82-00-1

Page 201
 ROLLS-ROYCE AERO E N G I N E
MAINTENANCE
c o n t r o l u n i t - Maintenance p r a c t i c e s (cont.)

Water/me than01 cont s o l u n i t

Fig. 201
B, I n s t a l l W/M c o n t r o l u n i t

NOTE: (1) Before i n s t a l l i n g a new W/M c o n t r o l u n i t observe t h e water/

methanol check p r e s s u r e (W.M.C.P.) recorded on t h e engine Data
plate. I f t h e Data p l a t e W.M.C.P. exceeds 460 p . s . i . , a Mod. tih3
1369 u n i t should be f i t t e d a s t h e range of adjustment on pre-
Mod.1369 u n i t s i s i n s u f f i c i e n t t o allow a h i g h e r torquemeter o i l 2
pressure setting. I f t h e Data p l a t e W.M.C.P. exceeds 490 p . s . i . , F
a
however, Mod.1369 u n i t s w i l l r e q u i r e increased shimming on t h e
main s p r i n g and, where p o s s i b l e , t h e t h i c k n e s s of t h e washer g:
should be increased by 0.100 in. (approx. ) , a s described i n ' 2.
Adjustment/test' a s t h e range of adjustment on t h e s e u n i t s i s
5
IP
m
M
i n s u f f i c i e n t t o allow a higher torquemeter p r e s s u r e s e t t i n g . I--'

(2) I f a new W/M c o n t r o l u n i t is t o be f i t t e d , remove t h e blanks

and d r a i n o f f any i n h i b i t i n g f l u i d .

F i t new rubber s e a l i n g r i n g s t o a l l t r a n s f e r tubes i n accordance with

t h e i n s t r u c t i o n s i n 70-11 and smear t h e exposed s u r f a c e s with t h e
l u b r i c a n t s p e c i f i e d i n 70-12.

R e f i t t h e t r a n s f e r tubes i n t h e i r r e s p e c t i v e bores i n t h e W/M c o n t r o l

unit.

Oct. 7/68
 MAINTENANCE

Water/methanol c o n t r o l u n i t - Maintenance p r a c t i c e s ( c o n t , )

(3) Check t h e r u b b e r bushes of t h e a n t i - v i b r a t i o n mounts f o r o i l soakage or

d e t e r i o r a t i o n and renew i f n e c e s s a r y , t h e n assemble t h e r u b b e r bushes
and s t e e l f e r r u l e s i n t h e b o r e s i n t h e c o n t r o l u n i t mounting f e e t .

(4) L o c a t e t h e u n i t on t h e mounting s t u d s and s e c u r e it w i t h t h e b e v e l l e d

and s p r i n g washers and n u t s .

(5) R e f i t t h e low t o r q u e s w i t c h a s i n s t r u c t e d i n Chap.61,

CAUTION: THE ' PALMER' TYPE ELBOWS, ON THE TORQUEETER OIL PRESSURE
TRANSMITTER TO W / M CONTROL UNI: FEED PIPE, HAVE DIFFERENT
ANGLE SETTINGS, I . E. ONE AT 90 AND ONE AT 80°. ENSURE
THAT THE ELBOW SET WITH THE 90' ANGLE IS FITTED TO THE
CONNECTION AT THE FRONT FACE OF THE W/M CONTROL UNIT.
(6) R e f i t t h e d r a i n p i p e , torquemeter o i l p r e s s u r e t r a n s m i t t e r f e e d p i p e
and W/M s u p p l y p i p e , t h e n s e c u r e t h e o i l t e m p e r a t u r e b u l b e l e c t r i c a l
c a b l e and e x t i n g u i s h e r p i p e c l i p s t o t h e c l i p p i n g p o i n t s on t h e W/M
control unit; lock a l l p i p e c o n n e c t i o n s u s i n g 22 S.W.G. l o c k i n g w i r e
a s s p e c i f i e d i n Chap, 70-12.

(7) Connect t h e c o n t r o l rod t o t h e l e v e r on t h e u n i t and c a r r y o u t t h e

t h r o t t l e c o n t r o l s t a t i c checks a s d e s c r i b e d i n Chap.76.

NOTE : I f a new u n i t h a s been i n s t a l l e d , a d j u s t it ' p r o v i s i o n a l l y by

assessment f r i t s nominal s e t t i n of 375 p.s.i. (pre-
o r 405 p . s . i . ode1369) t o t h e W. ,C.P, given on t h e e
p l a t e , t a k i n g i n t o c o n s i d e r a t i o n any adjustment of main s p r i n g
SM washer t h i c k n e s s which may have been made b e f o r e i n s t a l l a t i o n o f
Brn t h e u n i t ; i n c r e a s i n g washer t h i c k n e s s by 0.100 i n . i n c r e a s e s
MDa t h e s e t t i n g by 50 p . s , i . (approx.). This i n i t i a l s e t t i n g w i l l
I& p r e v e n t e n g i n e power exceeding t h e maximum l i m i t d u r i n g t h e
S1 water/methanol check run. The method of adjustment is g i v e n
l a t e r i n ' 2 Adjustment/Test9.

(8) Function test t h e W/ c o n t r o l u n i t and a d j u s t t h e torquemeter p r e s s u r e ,

i f n e c e s s a r y , a s d e s c r i b e d i n '2. Adjustment/Testt.

(9) On completion of t h e f i r s t ground run a f t e r i n s t a l l a t i o n , c h e c k t h e W/

c o n t r o l u n i t and p i p e connection f o r l e a k s .

C. Remove o i l f i l t e r

(1) Disconnect t h e c l i p s s e c u r i n g t h e o i l t e m p e r a t u r e b u l b c a b l e and f i r e

e x t i n g u i s h e r p i p e t o t h e W/ c o n t r o l u n i t , and remove t h e e x t i n g u i s h e r
pipe t o allow access t o t h e f i l t e r .

(2) Remove t h e n u t , tabwasher and b e v e l l e d washer s e c u r i n g t h e o i l f i l t e r

housing c o v e r , f i t t h e e x t r a c t o r HW-25387 (Fig.202); locate the
e x t r a c t o r on t h e c o v e r , screw t h e e x t r a c t o r b o l t i n t o t h e th,readed
a p e r t u r e , t i g h t e n t h e jack screw o n t o t h e r e t a i n i n g s t u d and withdraw
t h e cover p l a t e .

O c t . 82 82-00-1
Page 203
 Water/methanol control - Maintenance practices (cont.)

&n
MDa
OIL FILTER EXTRACTOR TOOL 1s1
S&
228

Removing oil filter housing cover and filter

Fig,202

(3) If the filter remains in the housing, withdraw it using the extractor
tool HW.15326 (Fig.202). Insert the centre piece of the tool into the
filter recess and locate the bush over the filter housing aperature, then
tighten the nut on the bush and withdraw the filter.

D B Install oil filter

(1) Renew the filter or clean it carefully in clean kerosine or white spirit
and dry off with a moi lure-free compressed air blast

-
NOTE: If the engine is not to be run immediately, immerse the filter in
clean engine oil prior to installation. If the original filter was
blocked, examine the main oil filter.

82-00-1
Page 204
 ROLLS-ROYCE ,ER0 ENGINE
MAINTENANCE

Water/methanol control unit - Maintenance practices (cont. )

(2) Refit the filter in the bore of its housing in the W/M control unit.

(3) Renew the sealing ring in the filter cover (70-111, fit the cover to the
control unit and secure it with the bevelled washer, tabwasher and nut;
bend up the locking tabs.

(4) Refit the fire extinguisher pipe, then secure the extinguisher pipe and
oil temperature bulb cable clips to the clipping points on the control
unit.

(5) Function test the W/M control unit as described in ' 2 . Adjustment/Testl.

A. Function test W/M control unit

Run the engine and carry out the W/M injection check described in 71-00
Adjustment/Test; if necessary, adjust the torquemeter pressure as
described in para.B. After stopping the engine examine the unit and
connections for leaks and rectify if necessary.

B. Adjust W/M control unit

-
NOTE: The unit must only be adjusted to restore W/M torquemeter pressure
to the W.M.C.P. recorded on the engine Data plate, corrected for
pressure altitude. D o not make indiscriminate adjustments in an
endeavour to give additional take-off power. The amount of adjust-
, ment required will be determined during the W/M injection check run.
(1) Unlock and remove the domed nut adjacent to the inlet connection and lift
the^ locking device, thus exposed, clear of the castellations (Fig.203);
remove and discard the crush-washer.

ADJUSTING KEY

Adjustment of water/methanol control unit

Fig.203
I Oct. 7/68 82-00-1
Page 205
 MAINTENANCE

Water/methanol control unit - Maintenance practices (cont.)

(2) Using the square shank of the locking device as a key, turn the
adjuster; turning the adjuster anti-clockwise increases the rate of
injection and, thus, the controlling torquemeter pressure.
One-eighth of a turn equals approximately 2 p.s.i. (pre-Mod.1369) or
3 p.s.i. (Mod.1369) torquemeter pressure. ' If the range of external
adjustment is insufficient, adjust the main spring washer as described
in C, and D. as appropriate.
NOTE: Adjustment must be made in multiples of one-eighth of a turn to
enable the locking plate to engage with the castellations after
adjustment; it may be necessary to reposition the locking device
in the centre adjustment to obtain correct engagement.

(3) Fit a new aluminium crush-washer, then refit the domed nut and lock it
to the anchor point with stainless steel wire.

(4) Function test the water/methanol control unit as described in 2.A.

C. Adjust main spring vLasher (water/methanol unit in position on engine)

NOTE: Refer to D. NOTES (1) and (2).

(1) Using firm hand pressure, hold the main spring cover against the spring
pressure, remove the 5 nuts, spring and bevelled washers securing the
. cover then carefully remove the cover together with the main spring,
adjustment washers, spring carrier and push-rod, refer to Fig.204.
NOTE: The spring cover must not be disturbed or separated from the
housing as this would necessitate renewal of the rubber sealing
ring.

(2) Proceed with D. (5) to ( 7 ) inclusive.

(3) Locate the push rod and carrier in the water/methanol unit, ensuring
that the conical ends of the push rod are located correctly in the
capsule stem and main spring carrier then fit the main spring and
cover assembly in position.

(4) Repeat D. (9).

(5) Re-set the external torquemeter adjustment provisionally to allow for

the change of main spring adjusting washer thickness, taking into
consideration the initial setting of the unit, to ensure that the
W.M.C.P. recorded on the Data plate is not exceeded during the initial
ground run. '

(6) Repeat D. (11).

82-00-1 Nov.15/72
Page 206
 MAINTENANCE

Water/methanol control unit - Maintenance practices (cont.)

1 D. Adjust main spring washer (water/methanol unit removed)

NOTE: (1) A range of 4 main spring adjusting washers are provided which
vary in thickness from 0.075 in. to 0.150 in. in graduations 02
0.025 in., thus allowing adjustment of washer thickness by
increments of 0.025 in. between 0.075 in. and 0.275 in. Not
more than 2 washers must be fitted and the total thickness of
washers must not exceed 0.275 in. Increasing the washer thick-
ness by 0.050 in. increases the torquemeter pressure setting by
25 p.s.i.

(2) Some water/methanol control units may not have a shim fitted
under the main spring, and where there is insufficient adjustment
in the 'screw up' position (i.e, maximum torque too low), an
adjusting washer can be fitted, but if there is insufficient
adjustment in the 'screw down' position (i.e. minimum torque
too high), the unit must be rejected.

(1) Remove the water/methanol control unit as described in '1.A. Removal/

Installation'.

(2) Position the unit on a bench with the main spring cover, refer to
Fig. 204, uppermost.

(3) Remove the 5 nuts, spring and bevelled washers securing the main spring
cover, holding the cover down against the spring pressure, and
carefully release the cover.

(4) Lift off the cover together with the main spring and any adjustment
washers, leaving the spring carrier and push-rod in position.
NOTE: The spring cover must not be disturbed or separated from the
housing as this necessitates renewal of the rubber sealing rings.

(5) Remove the main spring and any adjusting washer from the cover, refer
to Fig.204, measure the thickness of the washer and calculate the
dimension required, as follows:

(a) If there is insufficient external adjustment in the 'screw down'

position, i.e. minimum torque too high, select adjusting washers
from the range to decrease the thickness by 0.050 in.; if no
washer is fitted or reduction in washer thickness is not possible,
reject the water/methanol unit.

Nov.15/72 82-00-1
Page 207
 OLLS-ROYC E R 0 ENGINE
MAINTENANCE

Water/methanol control unit - Maintenance practices (cont.)

(b) If there is insufficient external adjustment in the 'screw up'
position, i.e. maximum torque too low, select adjusting washers
from the range to increase the existing washer thickness by
0,050 in.; if no washer is fitted, select the thinnest washer in
the range (0.075 in.). If the required adjustment increases the
total thickness of the washer to more than 0.275 in., or it is
necessary to fit more than 2 adjusting washers, reject the unit.

(6) Clean the joint faces on the main spring cover and the control unit
casing, ensuring that there are no damage marks, then apply a thin
coat of the jointing compound specified in 70-12 to both joint faces
in accordance with the instructions in 70-26.
MAIN SPRING COVER

WASHERS

'HANOL CONTROL UNIT

SPRING CARRIER MB
Mhl
n
MDa
I&
SI

\
Removal of main spring adjusting washer
Fig. 204
82-00-1 Nov. 15/72
Page 208
 MAINTENANCE

Water/methanol c o n t r o l u n i t - Maintenance p r a c t i c e s (cont.)

( 7 ) Locate t h e s e l e c t e d a d j u s t i n g washers on t h e s e a t i n g i n s i d e t h e main

s p r i n g cover, t h e n i n s e r t t h e main s p r i n g i n t o t h e cover.

(8) With t h e b a s e of t h e water/methanol c o n t r o l u n i t uppermost, lower t h e

main s p r i n g and c o v e r assembly on t o t h e c a r r i e r , e n s u r i n g t h a t t h e
c o n i c a l ends of t h e push r o d a r e c o r r e c t l y l o c a t e d i n t h e c a p s u l e stem
E: and main s p r i n g c a r r i e r .
.F4
rj
L)
.-l
Lc ( 9 ) P r e s s down on t h e cover and compress t h e main s p r i n g u n t i l t h e cover
m l o c a t e s on t h e s t u d s , t h e n f i t t h e 5 b e v e l l e d washers, s p r i n g washers
C,
rj
and n u t s ; t i g h t e n t h e n u t s e v e n l y u n t i l t h e j o i n t f a c e s of t h e c o v e r
a, and c a s i n g meet, t h e n t o r q u e t i g h t e n t h e n u t s t o t h e l o a d i n g s p e c i f i e d
Ll
0 i n Chap. 70-01.
G
.rl

a ( 1 0 ) I n s t a l l t h e water/methanol u n i t a s i n s t r u c t e d i n para.l.B., 'Removal/

a,
U I n s t a l l a t i o n ' , and reset t h e e x t e r n a l torquemeter adjustment
E: p r o v i s i o n a l l y t o a l l o w f o r t h e change o f main s p r i n g a d j u s t i n g washer
.rl
Lc
a thickness, taking i n t o consideration t h e i n i t i a l s e t t i n g of t h e u n i t ,
t o e n s u r e t h a t t h e W.M.C.P. recorded on t h e D a t a - p l a t e i s n o t exceeded
d u r i n g t h e i n i t i a l ground r u n a f t e r i n s t a l l a t i o n o f t h e u n i t .

(11) Function test t h e water/methanol c o n t r o l u n i t a s i n s t r u c t e d i n Chap.

71-00, Sub-section 4B, 'GROUND RUN - WET'. Adjust the c o n t r o l u n i t ,
i f n e c e s s a r y , a s i n s t r u c t e d i n 2. ' A d j u s t m e n t / t e s t ' , para.B.

JK
Bmr A. Check t h e c o n t r o l s f o r f u l l and f r e e movement a s i n s t r u c t e d i n Chap.76-10-1,
MDa and examine t h e c o n t r o l r o d and l e v e r f o r s a f e t y and c o r r e c t locking.
I &
S1
B. Examine t h e water/methanol c o n t r o l u n i t and p i p e c o n n e c t i o n s v i s u a l l y f o r
s e c u r i t y of attachment, c o r r e c t l o c k i n g and s i g n s of l e a k s .

C. F u n c t i o n test t h e water/methanol c o n t r o l u n i t a s i n s t r u c t e d i n Chap.71-00,

Sub-section 4B, 'GROUND RUN WET'.-

June 7 7
Water/methanol c o n t r o l u n i t - Maintenance p r a c t i c e s ( c o n t . )

4 . Remove and i n s t a l l t h e s e r v o p i s t o n s e a l

CAUTION: ENSURE SCRUPULOUS CLEANLINESS DURING DISASSEMBLY AND ASSEMBLY

OF THE SERVO PISTON AND METERING VALVE, AS DUST OR GRIT COULD
SCORE THE SERVO CYLINDER ROD OR METERING VALVE SEATING AND
NULLIFY RECTIFICATION.
A. Remove t h e s e r v o p i s t o n s e a l

(1) I f t h e s e r v o p i s t o n s e a l is t o be changed w i t h t h e W . M . C . U . i n s t a l l e d
on t h e e n g i n e , t h e a d d i t i o n a l work, s p e c i f i e d i n ( a ) t o ( e ) f o l l o w i n g ,
w i l l be r e q u i r e d :

( a ) I s o l a t e t h e e l e c t r i c a l s u p p l i e s t o t h e a i r c r a f t water/methanol
cock and pump.

( b ) Detach t h e c a b l e c l i p from t h e b r a c k e t on t h e low t o r q u e s w i t c h .

( C ) Disconnect t h e f i r e e x t i n g u i s h e r p i p e from t h e c o n n e c t i o n s a t t h e
f r o n t s p r a y r i n g and t h e f r o n t of t h e f i r e p r o o f bulkhead, d e t a c h
t h e c l i p s from t h e W . M . C . U . and compressor c a s i n g and remove t h e
pipe.

( d ) Remove t h e n u t , s p r i n g washer and chamfered washer from t h e f r o n t

i n n e r r e t a i n i n g s t u d on t h e s e r v o c y l i n d e r c o v e r , remove t h e
r e t a i n i n g p l a t e and d i s c o n n e c t t h e d r a i n p i p e from t h e b o r e i n t h e
b a s e of t h e s e r v o c y l i n d e r c o v e r ; r e f i t t h e n u t and washers IM
temporarily. Bmr
MDa
( e ) Disconnect t h e water/methanol supply p i p e from t h e i n l e t connection I &
on t h e W . M . C . U . S1

( 2 ) Unlock t h e tabwashers and s l a c k e n e v e n l y t h e t h r e e n u t s s e c u r i n g t h e

i n l e t connection, t h e n h o l d i n g t h e connection f i r m l y a g a i n s t t h e
s p r i n g p r e s s u r e on t h e metering v a l v e , remove t h e n u t s and tabwashers
and withdraw t h e c o n n e c t i o n ; i f n e c e s s a r y , u s e t h e e x t r a c t o r HW.15324
t o withdraw t h e connection o r , i f t h e t o o l i s n o t a v a i l a b l e , f i t a
s u i t a b l e h y d r a u l i c p i p e connection a d a p t e r t o t h e threaded union t o
e n a b l e t h e connection t o be l e v e r e d o f f .

( 3 ) E x t r a c t t h e c i r c l i p from t h e groove i n t h e metering v a l v e u s i n g

suitable circlip pliers. Remove t h e r e t a i n i n g p i n and l i f t t h e v a l v e
head o f f t h e s e r v o p i s t o n rod t a k i n g c a r e n o t t o damage t h e s e a t i n g ,
t h e n f i t a b l a n k i n g cover t o t h e connection f l a n g e .

( 4 ) Slacken, e v e n l y , t h e f o u r n u t s s e c u r i n g t h e s e r v o c y l i n d e r cover on
t h e base of t h e W.M.C.U., t h e n hold t h e cover f i r m l y a g a i n s t
t h e s p r i n g p r e s s u r e , remove t h e n u t s , s p r i n g and chamfered washers
and remove t h e cover and s p r i n g , t a k i n g c a r e t h a t t h e s e r v o p i s t o n
does n o t f a l l from t h e c y l i n d e r .

82-00-1 June 77
Page 210
 MAINTENANCE

Water/methanol c o n t r o l u n i t - Maintenance p r a c t i c e s (cont.)

( 5 ) C a r e f u l l y withdraw t h e s e r v o p i s t o n from t h e c y l i n d e r .
NOTE: To e n s u r e c l e a n l i n e s s and t h a t p a r t s a r e not l o s t , p l a c e a l l
components i n a c l e a n c o n t a i n e r a s they a r e removed.

( 6 ) Using c i r c l i p p l i e r s , remove t h e s e r v o p i s t o n s e a l r e t a i n i n g c i r c l i p ,
then remove t h e r e t a i n e r and t h e s e a l from t h e s e r v o p i s t o n ; d i s c a r d
the seal.

(7) Wash t h e p a r t s i n c l u d i n g t h e metering valve, i n l e t connection and

s e r v o c y l i n d e r cover i n c l e a n k e r o s i n e , then d r y o f f i n a moisture-
free a i r blast.

( 8 ) Examine t h e s e r v o p i s t o n rod and t h e s e a t i n g s on t h e metering valve

and i n l e t connection f o r damage, s c o r i n g and p i t t i n g .

B. I n s t a l l the servo piston s e a l

( 1 ) F i t a new s e a l t o t h e upper s i d e of t h e s e r v o p i s t o n w i t h t h e groove

i n t h e s e a l uppermost. Locate t h e f l a n g e of t h e r e t a i n e r i n t h e
s e a l groove and s e c u r e t h e assembly t o t h e p i s t o n w i t h t h e c i r c l i p .

( 2 ) Remove t h e blanking covers, c a r e f u l l y i n s e r t t h e s e r v o p i s t o n rod

i n t o t h e s e r v o c y l i n d e r and through t h e s e a l housing i n t h e
upper chamber, then s l i d e t h e s e r v o p i s t o n i n t o t h e c y l i n d e r
t a k i n g c a r e n o t t o damage t h e l i p of t h e s e a l .

( 3 ) Support t h e s e r v o p i s t o n rod, l o c a t e t h e metering valve on t h e end

of t h e rod and f i t t h e s e c u r i n g p i n and e x t e r n a l c i r c l i p , e n s u r i n g
t h a t t h e gap i n t h e c i r c l i p i s a t r i g h t - a n g l e s t o t h e head of t h e
pin.

(4) F i t a new s e a l i n g r i n g t o t h e i n l e t connection t r a n s f e r p i p e i n

accordance w i t h t h e i n s t r u c t i o n s i n Chap.70-11, l o c a t e t h e connection
on t h e s t u d s , p r e s s t h e t r a n s f e r p i p e i n t o t h e bore, and s e c u r e t h e
connection w i t h t h e t h r e e tabwashers and n u t s ; torque load t h e n u t s
t o 75 l b . i n . , then bend up t h e tabwashers.

( 5 ) Ensure t h a t t h e s e r v o c y l i n d e r cover and W.W.C.U. joint faces are

c l e a n , then apply t h e j o i n t i n g compound, s p e c i f i e d i n Chap.70-12, i n
accordance w i t h t h e i n s t r u c t i o n s i n Chap.70-26, t a k i n g c a r e not t o
block t h e d r a i n passages i n t h e cover and W.M.C.U. casing.

( 6 ) Locate t h e s p r i n g on t h e base of t h e s e r v o p i s t o n i n t h e c y l i n d e r
bore, mount t h e cover on t h e end of t h e s p r i n g and compress t h e s p r i n g
u n t i l t h e cover l o c a t e s on t h e s t u d s , e n s u r i n g t h a t t h e s e r v o p i s t o n
rod l o c a t e s i n t h e guide on t h e cover. F i t f o u r chamfered washers,
s p r i n g washers and n u t s , i n t e r p o s i n g t h e bonding l e a d terminal between
t h e s p r i n g and chamfered washers on t h e f r o n t o u t e r s t u d .

June 77 82-00-1
Page 211
Water/methanol c o n t r o l u n i t - Maintenance p r a c t i c e s (cont.)

(7) Tighten t h e f o u r n u t s evenly t o compress t h e s p r i n g u n t i l t h e

j o i n t f a c e s meet, then torque load t h e n u t s t o 75 lb. i n .

(8) If t h e s e r v o p i s t o n s e a l has been changed w i t h t h e W.M.C.U. installed

on t h e engine t h e following a d d i t i o n a l work w i l l be r e q u i r e d :

(a) Connect t h e water/methanol supply pipe t o t h e connection on t h e

W.M.C.U.

(b) Remove t h e n u t , s p r i n g washer and chamfered washer from t h e s e r v o

c y l i n d e r cover f r o n t inner r e t a i n i n g s t u d . F i t a new s e a l i n g
r i n g t o t h e d r a i n pipe, then f i t t h e d r a i n pipe t o t h e W.M,C.U.
F i t t h e r e t a i n i n g p l a t e t o t h e s t u d and t h e d r a i n pipe, f i t t h e
chamfered washer, s p r i n g washer and nut; torque t i g h t e n t h e
r e t a i n i n g nut t o 75 1b.in.

(c) Connect t h e f i r e e x t i n g u i s h e r pipe t o t h e connection on t h e

. ' f r o n t spray r i n g and t o t h e f r o n t of t h e f i r e p r o o f bulkhead, then
s e c u r e t h e r e t a i n i n g c l i p s t o t h e W.M.C,U. and t h e compressor
casing.

( d ) Attach t h e c a b l e c l i p t o t h e bracket on t h e low torque switch.

( e ) Connect t h e e l e c t r i c a l supply t o t h e a i r c r a f t water/methanol

cock and pump,

C. Function test t h e W, M. C. U.
JK
Bmr
MDa
CAUTION: MOVE THE THROTTLF: LEVER CAREFULLY DURING THE INITIAL CHECKS ON
I &
Sl
(1) Ground run t h e engine and c a r r y o u t t h e water/methanol system,checks
a s i n s t r u c t e d i n Chap.71-00, Sub-section 4B, 'GROUND RUN - WET'.

(2) If t h e r e i s any i n d i c a t i o n of i n s t a b i l i t y o r i n t e r m i t t e n t o p e r a t i o n
of t h e W.M.C.U. while ground running t h e engine, set t h e t h r o t t l e t o
o b t a i n 14,100 r.p.m,, switch off water/methanol, then open t h e
t h r o t t l e l e v e r slowly and run t h e engine up t o maximum r.p.m, and
back t o 14,100 r.p.m, s i x or seven t i m e s , t a k i n g approximately one
minute f o r each cycle. This process w i l l bed i n t h e new s e r v o piston
s e a l and should e l i m i n a t e t h e i n t e r m i t t e n t operation.

( 3 ) A f t e r t h e checks have been completed, s t o p t h e engine, a s i n s t r u c t e d

i n Chap.71-00, Sub-section 4B, 'GROUND RUN -
WET', then examine
t h e W.M.C.U. f o r leaks.

82-00-1 June 77
Page 212
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