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Pratt & Whitney

JT8D ENGINE MANUAL (PN 481672)

INTRODUCTION

1. Introduction

This publication is compiled and issued by the Customer Services

Department of Pratt & Whitney, Division of United Technologies
Corporation, East Hartford, CT 06108−0969 USA. It includes
approved and recommended procedures required for uninstalled
maintenance of JT8D Series engines.

The information and instructions contained herein are based upon

actual experience acquired under varied and exacting conditions.
The utmost in dependable engine performance will be gained by
conforming to these instructions.

Repair processes, inspection procedures, and accept/reject

criteria contained herein should be used together with the Pratt
& Whitney Standard Practices Manual (PN 585005). In the event
of a conflict, the information specified in this manual takes
precedence.

In many cases, supplementary information (such as coating

thicknesses, cleaning processes, non−destructive inspections,
riveting requirements, and other specific information) will
be necessary when you do the procedures in this manual. In
such cases use the information specified in the Pratt &
Whitney Standard Practices Manual (PN 585005) together with the
instructions in this manual.

Unusual problems concerning engine maintenance should be

presented to the Customer Services Department either through
its field representatives or by direct contact. All possible
assistance will be provided toward the solution of these
problems.

Requests for pertinent information not covered by this

publication or the Pratt & Whitney Standard Practices Manual,
and suggestions for modification or amplification of these
instructions so as to increase their usefulness, will be
welcomed by the Pratt & Whitney Customer Services Department.

This publication will be revised as necessary to incorporate the

latest approved data.

SUPPLEMENTARY PUBLICATIONS

Maintenance Manual − The Part No. 481671 Maintenance Manual

contains the instructions required for the line maintenance of
the engine and accessories.

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Component Maintenance Manuals − The instructions required for

the major overhaul of the accessory components are contained in
individual manuals for each component.

Illustrated Parts Catalog − The Part No. 481675 Illustrated

Parts Catalog lists and illustrates all salable engine parts and
those accessory parts not covered by the Accessory Manuals.

Engine Overhaul Standard Practices Manual − The Part No. 585005

Standard Practices Manual contains approved and recommended
standard practices information, instructions, and procedures
used repeatedly on various engines manufactured by Pratt &
Whitney.

Service Bulletins − Service Bulletins are issued as required

to provide information or instructions for modifying earlier
production engines or parts to the latest configuration.

Support Equipment Numerical Index − The Part No. 760092,

Support Equipment Numerical Index lists all P&W special
tools, cross−referenced against manual location, engine model
effectivity, and maintenance requirement. This index, when
used in conjunction with the engine manual and the P&W Support
Equipment master data sheet aperture cards, provides the
operator with greater self−sufficiency in logistics planning and
in the technical aspects of special P&W support equipment.

The Part No. 760092 Index has the support equipment necessary
at all maintenance levels. On request an alternate index, Part
No. 808987, is available which has the support equipment for
maintenance levels "A1" through "B2", and "T1".

PARTS AND SERVICE

Customer Services Department − Pratt & Whitney maintains a

Customer Services Department to assist its customers in the
operation, maintenance, and overhaul of Pratt & Whitney engines.
Customer Services Department representatives maintain contact
with operators and engine service activities and are available
for the investigation of any specific difficulty or problem.
Any request for assistance should be addressed directly to the
Customer Services Department, Pratt & Whitney, East Hartford, CT
06108−0969 USA.

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Ordering Parts − Whenever possible, refer to the applicable

Illustrated Parts Catalog when ordering parts. In case a parts
list is not available, give engine model, manufacturer's engine
serial number, and a full description of the part and where it
is used. All spare parts orders should be addressed directly to
the Commercial Parts Support Department, Pratt & Whitney, East
Hartford, CT 06108−0969 USA.

Because some parts require special or expensive equipment for

assembling and cannot be fabricated except in a specially
equipped shop, they are not furnished individually and must be
purchased as assemblies. If an order is received for a unit
of an assembly coming under this classification, the complete
assembly will be shipped.

VENDORS

Vendor Services − The names of any companies provided in this

publication as a possible source for required services or
supplies are furnished for information purposes only.

EXCEPT FOR WORK OR SUPPLIES TO BE PERFORMED OR FURNISHED BY

PRATT & WHITNEY, IT IS UNDERSTOOD THAT PRATT & WHITNEY DOES NOT
ENDORSE THE WORK PERFORMED BY THE COMPANY OR COMPANIES NAMED
HEREIN OR ANY OTHER COMPANY AND DOES NOT ACCEPT RESPONSIBILITY
TO ANY DEGREE FOR THE SELECTION OF SUCH COMPANY OR COMPANIES FOR
THE PERFORMANCE OF ANY WORK OR PROCUREMENT OF SUPPLIES.

Returning Parts

All material sent back to Pratt & Whitney for investigation goes
to one of the addresses below. All material sent back to Pratt
& Whitney for investigation must have a number five (5) copy of
a Request for Support Allowance (RSA) with it.

NOTE: The Request for Material Return (RMR) number must be on

the Request for Support Allowance (RSA).

USA Based Operators Non−USA Based Operators

UNITED TECHNOLOGIES INTERNATIONAL

PRATT & WHITNEY C/O PRATT & WHITNEY
Receiving Well #5 Receiving Well #5
Customer Parts Return (CPR) Customer Parts Return (CPR) (D
(D Bldg, Col G1−15) Bldg, Col G1−15)
Service Material Service Material Investigation
Investigation
400 Main Street 400 Main Street

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USA Based Operators Non−USA Based Operators

(CONTINUED)
East Hartford, CT 06108−0969 East Hartford, CT 06108−0969
USA USA

A. Engines and modules sent back to Pratt & Whitney Aftermarket

Services for Service Policy Benefits go to one of the
addresses below.

B. All engines and modules sent back to Pratt & Whitney must
have a number five (5) copy of a Request for Support
Allowance (RSA) with them.

C. Engines and modules sent back with the above procedures must
have the operator's charge purchase order to get the correct
billing.

For USA Based Operators For Non−USA Based Operators

PRATT & WHITNEY Aftermarket UNITED TECHNOLOGIES INTERNATIONAL

SERVICES
Cheshire Engine Center c/o PRATT & WHITNEY Aftermarket
SERVICES
500 Knotter Drive Cheshire Engine Center
Cheshire CT 06410 500 Knotter Drive
Cheshire CT 06410
USA

D. Individual parts returned for Service Policy Benefits:

(1) Refer to the Repair Vendors List that is included in

the Introduction Section of this Manual.

(2) Refer to Pratt & Whitney Aftermarket Services (Source

Code 8N802) on the Repair Vendors List.

(3) Individual parts, sent back for Service Policy

Benefits, are sent to the Pratt & Whitney Aftermarket
Services (Source Code 8N802), specified, or other
vendors as specified in that source code.

NOTE: Make a selection of vendor and address by the

product line that is applicable. Refer all
questions to the East Hartford facility at the
number or address given in the Repair Vendors
List.

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(4) All individual parts sent back must have a number five
(5) copy of a Request for Support Allowance (RSA) with
them.

(5) Individual parts sent back with the above procedures

must have the operator's charge purchase order to get
the correct billing.

(6) Use sufficient protection on parts to prevent damage

while they are shipped.

(7) Put individual part tags on parts which are removed

from more than one engine or which have different part
times, and prepare individual RSA's for these parts.

2. EXPLANATION OF MANUAL FORMAT

A. EXPLANATION OF MANUAL FORMAT

Specification

This manual has been prepared per ATA Specification No. 100
as established by the Air Transport Association of America.

The element numbering system employed in this manual

corresponds with that employed in the Illustrated Parts
Catalog. Details on how elements have been assigned are
given in the How To Use section of this manual.

Abbreviations

The use of abbreviations has been avoided as much as

practical in this manual. In some instances however, such
consideration as space limitations, common usage, etc., have
made the use of abbreviations preferable to the use of the
applicable longer terms. Abbreviations used are defined
below:

AMS Aerospace Material Specification

ANPT American National Pipe Thread
approx. approximate
Assem assemble
Assy assembly
ATA Air Transport Association
C centigrade
ccw counterclockwise
CG center of gravity
cm centimeter
CSD constant speed drive

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(CONTINUED)
compr. compressor
dia. diameter
Dim dimension
F fahrenheit
F/D fan discharge
FIR full indicator reading
gpm gallons per minute
ID inside diameter
in. inch
kg kilogram
k Pa kilopascal
KTS knots
lb−in. pound−inch
LH left hand
m meter
matl material
max maximum
min minimum
mm millimeter
N.m Newton − meter
No. number
OD outside diameter
PD pitch diameter
phr pounds per hour
psi pounds per square inch
psia pounds per square inch absolute
psig pounds per square inch gage
P&W Pratt & Whitney
ref. reference
RH right hand
rpm revolutions per minute
SB Service Bulletin
sq−ft square feet
thd thread

B. TOOLS, FIXTURES AND TEST EQUIPMENT

In accordance with federal regulations (14CFR43.13), anyone

performing work on an engine covered by this manual under
the jurisdiction and authority of the Federal Aviation
Administration (FAA) must use tools, equipment and test
apparatus which will assure that such work will be completed
in accordance with industry standards. If Pratt & Whitney
recommends special equipment or test apparatus, each person
performing the work must use that equipment or apparatus
that is acceptable to the Administrator of the FAA. Special
provisions of the FAA regulations regarding tools, equipment

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and test apparatus apply to holders of certain air carriers

operating certificates and certificates issued under certain
specified parts of those regulations.

WARNING: BEFORE YOU USE ANY OF THE MATERIALS SHOWN IN THIS

PUBLICATION, YOU MUST KNOW ALL OF THE PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR THE SUPPLIER.

THESE PRECAUTIONS TELL YOU HOW TO:

−USE THE MATERIAL SAFELY
−KEEP THE MATERIAL SAFELY
−DISCARD THE MATERIAL SAFELY
IF YOU DO NOT OBEY THE RECOMMENDED PRECAUTIONS, YOU CAN GET
AN INJURY OR BECOME SICK.

EXPOSURE TO HAZARDOUS MATERIALS:

AT ONE TIME SOME ENGINE PARTS CONTAINED ASBESTOS
FIBERS, AND IT IS POSSIBLE THAT SOME OF THESE PARTS
CONTINUE−IN−SERVICE. REFER TO COMMERCIAL SERVICE BULLETINS
FOR A LIST OF PARTS THAT AT ONE TIME CONTAINED ASBESTOS.
IN SOME PARTS THE MATERIAL THAT CONTAINS ASBESTOS CAN BE
THE ADHESTIVE. IT IS IMPORTANT TO USE CORRECT PRECAUTIONS
DURING WORK WITH THESE PARTS. OPERATORS MUST OBEY ALL LOCAL
REGULATIONS AND EMPLOYER WORK POLICIES WHEN PARTS THAT
CONTAIN ASBESTOS ARE TOUCHED OR DISCARDED.

THE ASBESTOS USED IN PRATT & WHITNEY ENGINE PARTS WAS

USUALLY ENCAPSULATED AND WILL NOT RELEASE DUST UNLESS THE
PARTS ARE GROUND, SANDED, CUT, OR BROKEN. WHILE IT IS OUR
EXPERIENCE THAT THESE OPERATIONS DO NOT USUALLY RELEASE
ASBESTOS AT LEVELS MORE THAN PERMITTED EXPOSURE LIMITS,
OPERATORS MUST USE ALL APPLICABLE PRECAUTIONS WHEN THEY
TOUCH SUCH PARTS.

C. ATTACHMENTS TO LOCKWIRE FOR LISTED ITEMS

Safety Cable: Safety cable is permitted at limited

locations as an alternate to lockwire. Install safety
cable by PWA Specification 316 (see the Standard Practices
Manual, Section 70−53−00). Safety cable is permitted at
all external and fan stream locations where the lock−
wire hole is sufficiently large for the cable, except as
specified below. Use safety cable PN AS3510−0218C (0.032
inch diameter) and safety cable ferrule PN AS3510−02F.

Do not use safety cable at these locations:

− Locations where the lockwire hole is more than 0.100 inch
diameter (the safety cable ferrule will pull through a

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hole larger than this).

− Internal engine, gearbox, and accessory areas
− Heat shields (as lacing)
− Vendor−controlled (Category 1) components

D. CORPORATE TRADEMARKS

The following words, acronyms, or designs are trademarks of

United Technologies Corporation. See Figure 1.

Pratt & Whitney

P&W

3. PROCEDURES APPLICABLE TO PARTS

Federal Aviation Regulations require that each Type Certificate

holder provide "Instructions for Continued Airworthiness."
The information contained in this manual is a part of the
data provided by Pratt & Whitney to meet this requirement.
The information contained in this manual applies only to
parts and processes certified by Pratt & Whitney. The
information contained in this manual does not apply to parts
and processes not certified by Pratt & Whitney. An example of
a part/process not certified by Pratt & Whitney would include
parts manufactured under a Parts Manufacturer Approval (PMA)
even though the use of such parts may be authorized by the
Federal Aviation Administration. Accordingly owners, operators,
and repairers (overhaulers) of Pratt & Whitney products should
obtain the required instructions for continued airworthiness
for parts and processes not certified by Pratt & Whitney from
the manufacturer or holder of the authority for the use of such
parts and processes.

NOTE: Repairs are authorized for individual part numbers.

These repairs are applicable to these part numbers and
the model in which a part is used makes no difference in
the repair application.

A. Continued Airworthiness

(1) Maintenance Review Board Reports (MRBR), Airworthiness

Directives (AD Notes), Aircraft Maintenance Manuals,
and other FAA−accepted documents satisfy the inspection
requirements for continued airworthiness for engines
not inducted into an engine repair facility.

(2) Minimum Inspection Recommendations For Engines Inducted

Into An Engine Repair Facility.

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Corporate Trademarks
Figure 1 INTRO
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B. General

(1) The information which follows is being provided to

clarify the Engine Manual requirements for continued
airworthiness for owners/operators without and approved
maintenance/reliability program.

(2) Engine repair facility definition: An engine repair

facility is an FAA approved engine repair station that
is capable of compliance with the minimum inspection
requirements defined by this section. The engine is
considered inducted into the repair facility when the
engine is accepted by the repair facility for any type
of work regardless of whether the work is performed on
a charge or no−charge basis.

C. Requirements

(1) The following items define the minimum requirements

that Pratt & Whitney series engines must comply with to
ensure the continued airworthiness of the engine. It
is recognized that individual engine repair agencies
may desire to go beyond these requirements to perform
inspections, repairs, modifications and/or conversions
to address the economics of engine operation and
maintenance.

NOTE: All performed cleaning, disassembly, assembly,

inspection, repair, modification, test, storage,
preservation and other tasks must adhere to the
requirements defined in this manual and in
supporting FAA−accepted documents such as
Illustrated Parts Catalogs, Standard Practices
Manual, and Service Bulletins.

(a) Engine testing, which is defined by this manual

based on the extent of disassembly, must be
performed per the testing requirements defined in
Section 72−00−00.

(b) All applicable requirements of Airworthiness

Directives must be complied with. See Section
05−10−00 regarding Airworthiness Directives issued
by the United States FAA and other regulatory
agencies against the models of P&W engines covered
by this manual.

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(c) All parts installed on the engine must be in

compliance with the specific engine model build
list and manufactured in accordance with OEM
and/or FAA requirements/approved data.

(d) Regardless of the extent of disassembly, no

parts which exceed their life limits as defined
in Section 05−10−00 may be present in the engine
following repair.

(e) Regardless of the extent of disassembly, all

applicable Maintenance Review Board Report tasks
(MRBR) must be complied with.

(f) All gaspath sections of the engine which are

not disassembled for visual or more detailed
inspection must receive a complete borescope
inspection as defined in this manual.

(g) For engines inducted into an engine repair

facility, the reason for the induction must be
corrected.

(h) Parts/components/modules accessed during engine

repair or configuration upgrade (engine repair
not associated with an operational discrepancy)
require only visual inspection to the appropriate
part/ component/module limits per this manual and
the gaspath borescope requirements specified
above.

(i) Parts/components/modules with unacceptable

conditions must be repaired or replaced. All
replacement parts/components/modules must meet the
fit/clearance requirements directly affected by
that part/component/module.

(j) All life limited parts removed from the engine

and disassembled to the individual part level for
overhaul must be nondestructive inspected (NDI)
per this manual. Specific NDI requirements called
out by AD Notes or Service Bulletins must also be
complied with.

(k) Approval of a part for continued service is

not permitted until all necessary inspections
specified in Section 5 are done.

(2) Parts Cleaning/Inspection/Repair Sequence

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(a) Before repairs are started, be sure all necessary

cleaning and coating removal, and all applicable
inspections (including FPI, FMPI, Eddy Current,
and X−ray) are done in the order that follows. If
multiple part repairs are necessary, make sure
that all necessary cleaning and coating removals,
and all applicable inspections (including FPI,
FMPI, Eddy Current, and X−Ray) are completed
before repairs are started. Operations must be in
this order:

1 Clean;

2 Remove Coatings;

3 Do All Applicable Inspections;

4 Repair.

4. Repair Vendors

A. Master Repair Vendors List

(1) For the master list of repair vendors, refer to Section

70−40−00, General−01 (Task 70−40−00−990−001) in the
Standard Practices Manual, PN 585005.

NOTE: Except for work or supplies to be performed or

furnished by Pratt & Whitney, Pratt & Whitney
does not endorse the work performed by the
company or companies identified herein or any
other company and does not accept responsibility
to any degree for the selection of such company
or companies for the performance of any work or
procurement of supplies.

B. Supplemental Repair Vendors List

(1) This supplemental list contains repair source code

information that is new or revised since the last
issued revision of the Standard Practices Manual, PN
585005. Refer to Table 1.

(2) Use this supplemental list with the Standard Practices

Manual, PN 585005 until the next revision to that
document. The next revision to the Standard Practices
Manual will incorporate the information contained in
this supplemental list.

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Source Code Vendor Name/Address

R No new source code information was added since the

R last revision to the Standard Practices Manual, PN
R 585005.

Supplemental Source Code And Vendor Name/Address

Table 1

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