T.0. 2G-GTC85-31 TECHNICAL MANUAL DEPOT OPERATION AND SERVICE INSTRUCTIONS PNEUMATIC POWER GAS TURBINE ENGINE MODELS GTC85-56 GTC85-70A (INCLUDES GTCE85-15) GTC85-71A GTC85-72 ——peenmerged tomate this a GTC85-116 complete publication. arrert ‘Noo049.60.6.0602 (aros) covering Depot Malntonace. They are numbered 7.0. 26-0TC85:31 0. 26-GTC33-13 (NAVAIR 03- dated 15 February 1969 TO. 2G-GTC85-13 dated 15 May 1967 NAVAIR 03-105BC-24 dated 1 September 1979 NAVAIR 03-105BC.27 dated 1 March 1967 dated 1 September 1973 miltary purposes ony, Will be respected, that the recipient wil roport prompty to the United Stat ‘Compromise, and thatthe Information wil be provided substantial the same degree of security afforded iby the Department of Detense ofthe United States. Alba rogadless of any other markings onthe document, wil not be downgraded or declossfid without writen approval ofthe originating Unitd States agency, NN STATEMENT Distribution authorized t the Dopartment of Defense and US. DOD contractors ony, ‘Other requeste shall be referred to OO-ALC/LGVT, Ml AFB, Utah 84056-8820. WARNING: This document contains technica 2, U.S.C, Soe 2751 ot seq) oF the Exp taeq). Violations ofthese export laws are subject to severe criminal penalties. Disseminat ‘wth provisions of DoD Directive 8230.25. 090 export is restricted by the Arms Export Control Rot nitration Act of 1979, as amondd (ite 50, U.S.C. APP eordanee HANDLING AND DESTRUCTION NOTICE: Comply with dstrioution statement and destroy by any method that wi prevent dleclosure of contents oF reconstruction ofthe document. Published under authorty of the Secretary ofthe Alr Foreo 14 APRIL 1986 CHANGE 9 - 16 OCTOBER 20031.0. 26-61C85-31 WP 005 00 1. APPLICABLE SUPPORT EQUIPMENT. Tool No, Nomenclature 280353 ‘Screwdriver and Wrench Assembly wri 281421-1 Positioner Assembly, Ball Valve 2m 2. APPLICABLE TCTOs. None. 3. REFERENCE MATERIAL REQUIRED, General Information, Depot Maintenance Manual 7.0. 2G-GTC85-33-1, WP 003 00 Preparation for Test WP 004 00 This, Manual 4, CONSUMABLE MATERIALS, NOTE Index numbers are for reference to master consumable list T.O. 2G-GTC85- 33-1, All references to consumables in text will be preceded by 33, (Exam- ple: Oil (33-81) Index No, Not 40 Compound Antiseize Shim (Part No. 99867-1 ‘through -12, 9867-82 through -91) ature 5, INTRODUCTION. This work package provides procedures for adjustments and testing of the engine. Each component and adjustment location is shown in illustrated form with detailed instructions outlined, Al special tools and torque values are called out in text. ‘NOTE Engine operating limits in WP 005 00 take precedence over computer response, and the operator shall assume manual control if limits are exceeded. Only current and approved software, computer program identification numbers (CPIN) as determined by CPIN com- 81, shall be used to test the engine on Automated Test Cell (Pacer Comet Engine PIN GTC85-56 81E-GTC8556-U002-00A GTC85-70A 81E-GTC8570-U002-00A GTC85-71A 81E-GTC8571-U002-008 GTC85-72 81E-GTC8572-U002-00A GTC85-116 81E-GTC85116-U001-00A Pacer Comet III System will automatically perform all tests outlined in WP 005 00. The test cell operator is responsible for monitoring engine performance and making manual adjustments. 2 Change 81.0. 2G-GTC85-31 WP 005 00 () Install correct thickness of shims (2, figure 5 continued) on valve assembly (1) () Install valve assembly (1) with 281421-1 ball valve positioner assembly and shims (2) into body ascembly (3). Hold body assembly 8) with wrench and torque valve ‘assembly (1) to 150 to 175 inch-pounds. (k) Loosen middle locknut and turn small adjustment screw on 281421-1 ball valve posit assembly counterclockwise two full turns and remove ball valve positioner assembly from pneu- matic (load control) thermostat (16, figure 1) Failure to hold valve assembly of pneumatic (load control) thermostat (16) when removing or connecting control air line (9) may result in a calibration shift and/or damage. () Hold pneumatic (load control) thermostat (16) with a wrench and install control air lines (9). (em) Torque control air line (9) to 135 to 150 inch-pounds, (a) (GTC85-56/-70A/-71A-116) Start and accelerate engine to no-load governed speed, 42,100 to 42,300 rpm. (GTC85-72) Start and accelerate engine to no-load governed speed, 42,500 to 42,700 rpm. Do not exceed limits (0) Open load control valve (8) (p) Slowly open test cell bleed-air control valve to apply bleed load. jven in table 1 as damage may occur. (@ Engine speed shall not droop more than 1000 rpm below no-load governed speed with steady full bleed load applied. Note and record turbine discharge temperature, Pneumatic (load contral) thermostat (16, figure 1 continued) operating tem- perature must not exceed 1225°F (663°C) at an overload to atmospheric conditions as engine damage may occur. () Noted turbine discharge temperature in step (q) is pneumatic (load control) thermostat (16) operating temperature with engine operating at minimum requirements and shall be 10 to 20°F (5 to 10°C) above turbine discharge temperature established in step (0) If requirements are fot met, readjust shim type thermostat as outined In step (©) (in) or readjust collar type thermostats as outlined in step (9). (6) Adjustable collar type thermostat: Close load valve (8) and test cell bleed-air control valve. Rotate adjustment coliar in clockwise direction (viewed from fitting end) to increase tempera- ture setting. Each index mark on adjustment head equals 2 degree C (4 degree F). Rotate adjustment collar in counterclockwise direction to decrease temperature setting. After adjusting eet teed control) thermostat (16), check operating temperature as outlined in steps (0) rough (t). (0 Close load control valve (8) and test cell bleed-air control valve. (u) Shut down engine. Change 7 43To. 2G-GTC85-31 WP 005 00 (14) Load control valve rate check and adjustment. a) ©) © (a @ 0 {GTCB5-58/-70A/-71A/-116) Start and accelerate engine to no-load governed speed, 42,100 to 2,300 rpm. (CTC85-72) Start and accelerate engine to no-load governed speed, 42,500 to 42,700 rpm. Open test cell bleed-air shutoff valve. While observing bleed-air pressure gage, actuate switch to open load control valve (8). Note time between switch actuation and first peak observed on bleed+-air pressure gage, indicat- ng full-load bleed has been reached. Time shall be 4 to 15 seconds. Close load control valve (8). Complete closing of load control valve (8) must occur within 1.5 seconds. NOTE If load control valve (8) rate 1s adjusted, the pneumatic (load control) ther- ‘mostat (16) operating temperature must be rechecked. If load control valve (8) rate is not within limits, hold adjusting screw (15) and loosen Jocknut (14) Turn adjusting screw (15) clockwise to increase operating time. Tighten locknut (14). 44 Change 77.0. 26-GTC85-31 WP 005 00 (15) Pneumatic (load control) thermostat recheck. (a) With engine operating at no-load governed speed, recheck pneumatic (load control) thermostat (16, figure I continued) at least twice as outlined in step (13)(0) through (). (b) For each check, the turbine discharge temperature must be within +15°F (+8°C) of the turbine discharge temperature obtained in step (13) (0 (16) Cycling check. (2) With engine operating at no-load governed speed, close load control valve (8) and open test cell bleed-air control valve. (0) Open load control valve (8). Engine shall accept bleed load without excessive cycling. (9 Allcycling (bleed-air pressure oscillation) shall be completely damped to within +1 inch Hg. ‘within 15 seconds after the differential pressure hits first peak. (@) Engine speed shall not droop more than 1000 rpm below no-load governed speed with steady full bleed load applied. (6) Average turbine discharge temperature shall stabilize at or below 1225°F (663°C) for all load conditions. (9 Cycling caused by interference between pneumatic (acceleration control) thermostat (18) and pneumatic (load contro)) thermostat (16) is not permissible, (@ _Hengine cycling is within limits, close load control valve (8) and test cell bleed-air control valve (b) Shut down engine. (17) No-load instability check. (a) Close fuel bypass valve. (b) (GTCB5-56/-70A/-71A/-116) Start and accelerate engine to no-load governed speed, 42,100 to 42,300 rpm. (CTC85-72) Start and accelerate engine to no-load governed speed, 42,500 to 41,700 rpm. (@ Allow engine to stabilize for two minutes. NOTE ‘Compressor instability is defined as an operating region of violent pulsating airflow, usually outside the normal operating limits of the engine. (@) Measure compressor instability. Fluctuation shall not exceed 1 psi (2.04 in. Hg) as measured from minimum to maximum values (peak to peak on each wave cycle). Measurement is to be taken for 1 minute, (6) Shut down engine, Change 4 457.0. 2G-GTC85-31 ‘WP 005 00 b. Automatic Run Check. NOTE ‘The engine shall be started and operated under control of automatic control system for all subsequent tests. No further adjustment shall be made on any of the automatic controls during tests. If adjustments are required, correct condition and rerun automatic run from point of adjustment. (1) Automatic: start. (a) Close manual fuel bypass valve installed between fuel pump inlet port (23, figure 1) and fuel pump pressure connection (24), (6) (GTCB5-56/-708/-714/-116) Start and accelerate engine to no-load governed speed, 42,100 to 42,300 rpm, {GTC85-72) Start and accelerate engine to no-load governed speed, 42,500 to 42,700 rpm. (© No-load governed speed must be obtained within 15 to 25 seconds. Do not exceed electrical starter assembly duty cycle of 1 minute on, 4 min- utes off as damage may occur. * Do not exceed operating limits given in table 1 as engine damage may occur. (@) When start switch is pressed, ammeter should not indicate higher than 400 amperage. As engine accelerates to 14,200 to 15,200 rpm +5 percent, ammeter should drop to zero, indicat- ing electrical starter assembly (20) and ignition coil have been electrically disconnected and start indicating light shall go off. (€)_ When engine speed reaches 38,500 to 39,500 rpm +5 percent, the load light should come on, indicating engine is operating at sufficient speed to accept load. Load light should remain on throughout range of no-load to maximum continuous load. (9 (GTC85-56-70A/-71A/-116) Allow engine to accelerated to no-load governed speed, 42,100 to 42,300 rpm, (GTC85-72) Allow engine to accelerated to no-load governed speed 42,500 to 42,700 rmp. @ Open test cell bleedair control valve 46 Change 4é eS T.0. 2G-GTC85-31 WP 005 00 CAUTION, Do not exceed limits given in table 7 as damage may occur {nh} Open load contro! valve (8. figure 1 continued) (i) Nove time between switch actuation and First peak on bleed-air pressure gage. indicating full-load bleed has been reached, Time shall be 4 to 15 seconds (j)_ All cycling (bleed-air pressure osci! lation) shall be completely damped to within #1 inch Kg within 15 seconds after the differential pressure hits first peak (k) Engine speed shall not droop more than 1000 rpm below no-load governed speed (1) Close toad control valve (8) and test cell bleed-air contro! valve. (nm) Shut down engine. NOTE (GTC85-56/-72/-116) Maximum starting time during the rolling start test shall not exceed 25 seconds There is no minimum starting time (1) (GTC85-56/-72/-116) in addition to the preceding start, perform two con- secutive successful automatic starts as outlined in steps (a) through (e): the last start shal! be made while engine is still rotating (rolling) at a speed below 14,000 rpm; the other starts shall be made from a Stendst it! (GTC85-70A/-71A) In addition to the preceding start. perform two conse- cutive successful automatic starts a5 outlined in steps (a) through (e) (0) Record pertinent data on Figure 2 (2) Acceptance test. (a) (GTCBS-56/-70A/-71A/-116) Start engine using automatic control and ac- celerate to no-load governed speed, 42,100 to 42,300 rpm (GTCBS-72) Start engine using automatic contro! and accelerate to no- load governed speed, 42,500 to 42,700 rpm. a7T.0, 2G-GTC85-31 WP 005 00 CANTON. Do not exceed limits given in table 1 as engine damage may occur (b) Open test cel! bleed-air contro! valve (©) Open load contro! valve (8, figure 1). (4) Operate engine at full bleed-air load for 20 minutes. Note and record actual bleed-air total temperature and actual bleed-air total pressure (e) Note and record temperature, pressure and pressure differential readings at bleed-air flow measuring section. (f) Calculate actual bleed-air Flow using readings obtained in step (e) and chart or graft for particular airflow measuring section being used Record calculated figure for actual bleed-air flow. {g) Correct actual bleed-air flow to 59°F (12°C), 29.92 inches Hg, NACA STD SL Day conditions using calculation instructions given in step a. (7) (n) Corrected value obtained in step (g) shall meet bleed-air flow system requirement of table 2 (i) Close load contro! valve (8) and test cell bleed-air contro! valve (J) During performance testing and immediately after engine shutdown, check engine for fuel and oi! leaks. Refer to table 1 for allowable leakage limits (k) Shut down engine (3) Engine thermocouple temperature and bleed-air contamination check (a) Disconnect test cel! bleed-air duct from load control valve (8) (b) Check for oi! spray in test cel! bleed-air duct and interior of load con~ trol valve (8) (©) If oi! spray is evident, determine cause and correct if possible or reject the engine (8) (GTCB5-56/-70A/-71A/-116) Start and accelerate engine to no-load gov- erned speed, 42,100 to 42,300 rpm. (GTC85-72) Start and accelerate engine to no-load governed speed, 42,500 to 42,700 rpm 48@ (ny 0 0 Co) 0 (m) {n) © ) Do not exceed limits given in table 1 as engine damage may occur. 7.0. 2G-GTC85-31 WP 005 00 Open load control valve (B. figure 1 continued) to discharge bleed-alr to atmosphere, Run engine for 2 minutes or until test cell ambient temperature reaches 130°F (54°C), Engine speed shall not droop more than 1000 rpm below no-load governed speed and turbine discharge temperature shall not exceed 1225°F (663°C) Record minimum engine speed on figure 2. Record average turbine discharge temperature and unit thermocouple value. The unit thermocouple reading shall be no more than 25*F (13°C) lower or 75°F (41°C) higher than the average turbine discharge temperature. Record maximum turbine discharge temperature on figure 2. Observe bleed-air for evidence of smoke or oil spray. If engine emits smoke from load control valve (8, figure 1) during run or following shutdown or if evidence of oll spray is found in load control valve (8), determine cause and correct if possible or reject the engine. Close load control valve (8). Shut down engine. Record number of starts and operating time on figures 2 and 3. (GTC85-71A) Remove thermocouple unit and replace with cover (P/N 75072) and gasket (PIN 75559). Tighten bolts and torque to 20 to 25 inch-pounds. Lockwire bolts using lockwire (46-27). Change 6 49/(50 Blank)T.0. 2G-GTC85-31 TECHNICAL MANUAL DEPOT OPERATION AND SERVICE INSTRUCTIONS PNEUMATIC POWER GAS TURBINE ENGINE MODELS GTC85-56 GTC85-70A (INCLUDES GTCE85-15) GTC85-71A GTC85-72 GTC85-116 No0019.80.6-0602 (aros) ‘This publication is one of 4 manuals covering Dopet Maintenace. They are numbered 7.0. 26-4TC85-31 (NAVAIR not applicable) and T.0. 26-GTCa6-33-1 (NAVAIR 03-1088C-32) trough T.0. 26-GTC33-43 (NAVAIR 03- 41088C-22:12). Afterall 44 manuals are received, the following manuals, Including all changes and supple ‘ments, wil be superseded: 7.0, 2G-GTC85-3 dated 15 February 1969 7.0. 2G-GTC85-13 dated 15 May 1967 NAVAIR 03-105BC-24 dated 1 September 1979 NAVAIR 03-105BC-27 dated 1 March 1967 NAVAIR 19-105B-13 dated 1 September 1973 DISCLOSURE NOTICE: This information Is furnished upon the condition that It wll not be released to another ‘nation without the specifi authort ofthe Department ofthe Aly Force ofthe United States, that It will be used for ‘illtary purposes only, that Individual ot corporate rights originating in the Information, whether patented or not, 4, that tho rociplont will report promptly United States, any known or suspected information will be provided substantially the same degree of seculty afforded ithy the the United States. Also, regardiss of any other markings on the document, t wil not ‘the originating United Statos agency. DISTRIBUTION STATEMENT D; Distribution authorized to the Department of Defense and US. DOD contractors ‘only, 14 Apr 1986, Other requests shall be referred to OO-ALC/84 MSUG/GBMUT, Hill AFB, Utah 840565820, WARNING: This document contains technical data whose export Is restricted by the Arms Export Control Act {Mie 22, US.C,, Sec 2753 at 20q) of the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et 209). Violations of these export laws are subject to severe criminal penalties, Disseminate in accordance ‘with provisions of DoD Directive 5290.25. HANDLING AND DESTRUCTION NOTICE: Comply with dlstibution statement and destroy by any method that will of prevent diaclosure of contents or roconstru jocument. Published under authority ofthe Secretary ofthe Alr Force 14 APRIL 1986 CHANGE 10 - 5 JULY 2006To. 26-6Tc85-34 RECORD OF CHANGES 14 April 1986 30 April 1987 15 May 1988 "15 October 1990 15 March 1991 15 November 1991 Bune 15 June 1995 30 January 1996 w.4 September 2001 1.16 October 2003 5 July 2006 Original Change Change Change Change Change Change ‘Total Number of Pages in this manual is 156 LIST OF EFFECTIVE FRONT MATTER PAGES Page Chany No. No. Title 40 ry 0 NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES NOTE Only those work packages assigned to this manual are listed in this index, Insert changed pages in front matter, and in applicable work packages. Text affected in a changed or revised WP is indicated by change bars or change symbol R in outer margin of each column of text, Changes to illustrations are indicated by pointing hands or change bars. Changes to wiring diagrams are indicated by shaded areas. we/swP Number Title 001 00 Alphabetical Index... 888822 ggsses 00 Introduction. Principles of Operation Preparation for Test. Test. Preservation and Bost ‘Test. ‘Troubleshooting Preparation for Shipment or Storage. ‘*Zero in this column indicates an original WP/SWP. A. Change 10T.0, 26-GTC85-31 we 001 00 WORK PACKAGE ALPHABETICAL INDEX DEPOT OPERATION AND SERVICE INSTRUCTIONS EFFECTIVITY: ENGINE MODELS GTC85-56 GTCgs-72 GTCB5-70A GT C85-116 GTCB5-71A LIST OF EFFECTIVE WP PAGES RECORD OF CHANGES Original .... 0 14 Apr 86 Total Number of Pages in this WP is 4 PAGE CHANGE NO. NO. 14 APRIL 1986T.0. 26-GTC85~31 WP 001 00 ALPHABETICAL INDEX Subject WP/SHP No. Introduction... 902 00 Abbreviations/Symbols Description of Manual Instructions for Use Introduction Operation, Principles of . Post Test, Preservation and . Preparation for Shipment or Storage Inspection and Maintenance of Stored Engines Installation of Engine into Shipping and Storage Container Preservation Preparation for Test sees General Testing Instructions Calculations Switches and Valves Test Setup ‘Air Systems Test Connections Electric, Speed and Vibration Systems Test Connections Fuel and Lubrication Systems Test Connections Nount Engine for Testing Preservation and Post Test s+. Post Test Preservation Principles of Operation ssssssssessersseseeeeeseeeees Air System Controls Systen Engine Operation Fuel Systen Ignition/Starting System Indication System OiT Systen 003 00 006 00 908 00 904 00 006 00 teseeeeeeeeee 003 00 Shipment or Storage, Preparation for 908 00 Storage, Preparation for Shipment or 008 00 TeSt seseessreeeseseraeaeeeeesenenees 905 00 Preliminary Test Procedures Fuel Pump and Control Unit Acceleration Limiter Valve Adjustment General Requirenents Oi] and Fuel System Priming Safety Precautions Start and Run-In Prelininary Run Preliminary Oil Filter Element Check Testing Automatic Run Check Function Tests and AdjustmentsSubject Test, Preparation for +. Troubleshooting «« Instructions For Use Schematics and Diagrams Troubleshooting Procedures Troubleshooting Tables ALPHABETICAL INDEX (CONT) 7.0, 26-6TC85-31 WP 001 00 WP/SUP Ne 004 00 + 907 00 3/(4 blank)7.0, 26-6TC85.31 WP 002 00 WORK PACKAGE INTRODUCTION DEPOT OPERATION AND SERVICE INSTRUCTIONS EFFECTIVITY: ENGINE MODELS GTC85-56 GT C8572, GTC85-70A, GTC85-116 GTCS5-7T1A LIST OF EFFECTIVE WP PAGES RECORD OF CHANGES 14 Apr 86 15 May 88 Original... 0. Change .... 2 Total Number of Pages in this WP is 4 PAGE CHANGE, NO. NO. 14 APRIL 1986 Change 217.0. 2G-GTC85-31 ‘WP 002 00 1, INTRODUCTION, This work package provides a description of this manual, instructions for use and a list of abbreviations/symbols. 2, DESCRIPTION OF MANUAL. This manual provides depot level maintenance procedures for fuel components of the Pneumatic Power Gas Turbine Engine Model No, GTC85-56)-70A/-7IA/-72/-116. Included is an alphabetical index of work packages. 3. INSTRUCTIONS FOR USE, Follow these steps to select the correct work package. a. The work package number is at the top of each page. Turn to work package 001 00 in the manual. This is the alphabetical index. b. In the alphabetical index, find the information needed. For example: ‘Subject WEISWP Now Preparation for Shipment or Storage 008 09 Preparation for Test 004 00 003 00 Principles of Operation ¢. Find the work package in the column to the right of the subject. Turn to this work package and find the needed information 4. ABBREVIATIONS/SYMBOLS. The use of abbreviations are held to a minimum. Those abbreviations use will be in accordance with the requirements of MIL-STD-12, The terms for new abbreviations and symbols will be provided in a list of abbreviations/symbols. Abbreviations/Symbols Definitions c CentigradeCelsius Delta P, Pressure conversion factor at T.; Delta T, ‘Temperature conversion factor at T, Delta W, Flow conversion factor at T, F Fahrenheit In, Hg ABS. Inches mercury absolute In, He ga Inches mercury gage NACA STD SL Day National Advisory Council Aeronautic Standard Sea-Level Day P, Observed bleed-air pressure in inches Hg absolute Pistd Corrected bleed-air pressure per (59°F (15°C), 29.92 inches Hg) NACA STD SL Day Sigma Barometer conversion factor which is calculated by dividing observed barometer pressure in inches Hg by 29.92 swe Subordinate Work Package T, Observed bleed-air temperature in degrees Fahrenheit Tistd Corrected bleed-air temperature per (59°F (15°C, 29.92 inches Hg) . NACA STD SL Day T Observed compressor inlet air temperature in degrees Fahrenheit Ww, Observed bleed-air flow in pounds per minute W,std Corrected bleed-air flow per (59°F (15°C), 29.92 inches Hg) NACA STD SL Day wP Work package 2 Change 27.0. 2G-GTC85-31 WP 002 00: 5. GENERAL SAFETY PRECAUTIONS. The following is a list of general shop safety precautions by category, a alvCleaners/P, ers/Fucl, Some chemicals, cleaners, paints. primers, and fuels have an adverse affect on skin, eyes, and respiratory tract, Observe manufacturer's warning labels and current safety directives, Use only in authorized areas. Unless otherwise indicated in the text, use, as described in this, T.0., should not result in any immediate health concerns. Consult the local bioenvironmental engineer for specific protective equipment and ventilation requirements, ticresyl phosphate, This additive is poisonous and can be readily authorized areas. b. Synthetic Oil, Lube oil may contai absorbed through the skin. Use only . Compressed! Air, Use of compressed air can create an environment of propelled foreign particles. For cleaning, air pressure is restricted to less than 30 P.S.1. and used with effective chip guarding and personal protective equipment. 4. Grinding/Machining, Grinding and machining operations create metal pat eye. Use effective chip guarding and personal protective equipment, e. g-Loadled Mechanism, A spring-loaded mechanism can cause injury if released in an uncontrolled manner, Always take eare while working with the mechanism. f, Hot Items, Handling hot items presents a serious burn potential. Non-asbestos, heat-resistant gloves shall be worn les which could enter the .. Protective Ei IF unique local conditions make compliance with the protective lotiiing or other occupational health requirements specified in this manual unnecessary or impractical, obtain an evaluation of the operation from the bioenvironmental engineer. ‘The bioenvironmental engineer will determine the required precautions. Change 2 34 blank)T.0, 26-GTC85-31 wp 003 00 WORK PACKAGE TECHNICAL PROCEDURES PRINCIPLES OF OPERATION EFFECTIVITY: ENGINE MODELS GTC8S-56 GTC85-72 GTCa5-70A GTCB5-116 GTCBS-71A LIST OF EFFECTIVE WP PAGES RECORD OF CHANGES Original .... Os... 14 Apr 86 Total Number of Pages in this WP is 14 PAGE CHANGE NO. NO. 14 APRIL 1986 1T.0. 26-GTC85-31 WP 003 00 1. APPLICABLE SUPPORT EQUIPMENT, None 2. APPLICABLE TCTO"S. None 3, BEBERENCE MATERIAL REQUIRED. None 4 CONSUMABLE MATERIALS. None: 5. INTRODUCTION, This work package provides principles of operation for engine Fuel, ignition/starting, air, controls, Indication and oi! systems 6. ILLUSTRATED SUPPORT EQUIPMENT. None 7, ENGINE OPERATION. a. The engine incorporates contro! components which automatically contro! engine functions and maintain required engine speed and safe temperature from initiation of start through operation at full load b, When the starter is energized, the rotating starter drive clutch engages a jaw In the accessory gearcase and starts driving the gear train. The gear train drives ‘the compressor and turbine rotating parts, the oi! pump assembly, the fuel pump and control unit, oi! cooler fan, multiple centrifugal switch assembly and on GTC85- 70A/-72, @ 12 amp dc generator c. As the compressor and turbine rotating parts start turning, ambient air is drawn through the inlet into the compressor assembly. The alr is compressed by the compressor first stage impeller, then passed through interstate ducts to the con- pressor second stage impeller for further compression. The compressed air is dis- Charged into a vaned deswirl assenbly and from there is directed into the turbine plenum. (Clean bieed-air may be withdrawn fron an outlet in the plenum through a load control valve when the engine reaches governed speed.) From the turbine plenum ‘the compressed air enters the conbustion chamber d. AS engine speed increases, rising oi! pressure (approximately 3 to 5 psig) ac- (ates the oi! pressure switch, which completes circuits to the fue! solenoid shutoff valve, oi! drain solenoid valve and ignition unit. The fuel solenoid shutoff valve is energized to permit fuel flow to the fuel atomizer assembly. The fuel atomizer assembly sprays fuel into the conbustion chamber where the fuel and compressed air mix. The ignition unit causes the igniter plug assembly to ignite the fuel air mixture in the combustion chamber ®. Combustion increases the energy content of the air-fuel mixture. The gases Flow into the turbine torus assembly and through the turbine nozzle assembly to the blades of the turbine wheel. The energy of the gases is absorbed by the rotation of ‘the turbine wheel. The spent gases are discharged through the turbine exhaust. The Power developed at the turbine wheel is used to drive the compressor impellers, the accessory gear train and the driven accessor ies7.0. 2G-GTC8S-31 WP 003 00 f. Acceleration of the engine continues through the combined forces of the starter and energy of the hot gases. When engine speed reaches its required value. the 35 percent switch in the multiple centrifugal switch assembly opens and breaks a circuit to the starter and ignition. Starter rotation ceases and the starter drive Clutch disengages fron the accessory gear train. The normally open acceleration control solenoid valve is open to bleed some of the control air pressure from the acceleration limiter valve diaphragm to eliminate engine surges up to 95 percent of engine speed The engine continues to accelerate under turbine power to a preset value where the 95 percent switch in the multiple centrifugal switch assembly closes and ener- gizes the normally open acceleration control solenoid valve to the closed position and energizes circuits to start operation of start counter and hourmeter. Accelera- tion continues until no-load governed speed is reached h After steady state no-load governed speed is attained, bleed-air loads may be imposed i. Engine speed and exhaust temperature are automatically controlled within es- tablished limits by metering of fuel flow by the fuel pump and control unit. ‘Smooth and proper acceleration is controlled by action of the acceleration limiter valve in the fue! pump and control unit. The valve references compressor air discharge pressure to fuel pressure, then a pressure-actuated diaphragn operates ‘a poppet valve to bypass more or less fuel to maintain the required ratio of fuel Flow to compressor air pressure. During starting, when compressor air pressure is insufficient, the poppet valve is restrained from bypassing fuel by an adjustable spring pressure against the actuating diaphragm, The fuel pressure at which the spring pressure IS overcome is the cracking pressure setting of the fuel pump and control ‘unit, k. Turbine discharge temperature is controlled by action of a pneumatic (acceler- ation control) thermostat, If turbine discharge temperature exceeds a preset value fat any time during acceleration, the bal! valve in the pneumatic (acceleration con- trol) thermostat opens to bleed some of the compressor air from the fuel pump and control unit acceleration limiter valve, which allows the poppet valve to open and bypass fuel, thus reducing the turbine discharge temperature, When the tempereture is reduced below the preset value, the pneumatic (acceleration control) thermostat closes and stops bleeding the compressor air from the acceleration limiter valve. |. Engine speed is controlled by action of the governor in the fuel pump and con- trol unit. The Flyweight-type governor is driven by the main fuel pump drive shaft, which in turn is driven through the accessory gear train. When engine speed exceeds the preset governed speed. the governor flyweights move outward to open a slide valve to bypass fue! and so decrease engine speed. When engine speed drops, as when load is applied, the governor Flyweights move inward to close the slide valve to permit greater fuel flow and so increase engine speed 8. Engine loading during bleed-air loading is automatically controlled within es- tablished limits by moduletion of the load control valve butterfly position7.0. 26-GTC85-31 WP 003 00 n, overloading and consequent excessive turbine discharge temperature is con- trolled by action of a pneumatic (load contro!) thermostat. if turbine discharge tenperature reaches @ preset value, the ball valve in the pneumatic (load control) ‘thermostat opens to bleed some of the control air from the load control valve actua- tor. which causes the actuator mechanism to move the valve butterfly toward a more closed position, thus reducing the load and the discharge temperature. Wnen the temperature is reduced below the preset value, the pneumatic (load control) ther- mostat closes and stops bleeding the control air from the load control valve actuator 0, The engine is provided with certain safety devices which shuts down the engine or completes 9 warning circuit in the event of overspeeding, excessively high oi! ‘temperature or [oss of oi! pressure If engine speed approaches 110 percent of governed speed and governing devices in the fuel pump ané control unit have not metered fuel sufficiently to reduce speed. the Flyweight-actuated overspeed switch in the multiple centrifugal switch assembly wilt open, which opens a circuit to the fuel solenoid shutoff valve. when the fuel solenoid shutoff valve is de-energized, it closes and shuts off fuel flow to the combustion chamber, thus stopping the engine. 4. Low oil pressure protection is provided by the oi! pressure switch. If oil pressure drops belo 1.5 psig minima, curing operation. the oi! pressure switch Will actuate the holding relay circuit to de-energize the fuel solenoid shutoff valve, thereby shutting off fuel flow to the combustion chamber and stopping the engine 1. The engine is stopped by placing the toad switch in the off position and al- lowing the engine to operate under no-load condition for approximately 2 minutes prior to stopping. This will permit gradual cooling of the engine and therefore reduce thermal stress across the turbine wheel, Place the stop switch in the stop position and allow the engine to come to a complete stop before shutting off fuel ‘supply 8, EEL SYSTEM. a, The fuel system automatically regulates fuel flow to maintain constant engine speed and safe operating temperature under varying conditions of starting, accelera- tion, load application and overload operation. b, Fuel is routed to connector (5. figure 1) then through regulator (6) where low pressure fuel is regulated and routed to fuel inlet (4) of the fuel pump and control unit (1) and to fuel pump (7). Excess fuel pressure is routed through relief valve (8), back to inlet side of fuel pump. Fuel pump supplies high pressure fuel through internal fuel filter () to fuel pressure gage connection (10), fuel solenoid shutoff valve (11), acceleration limiter valve (12) and governor (13). Low pressure fuel is routed from acceleration limiter valve (12) to connector (3)sTC85-31, WP 003 00 coupeessor SECTION 2 Tynan EXHAUST 5 ex om = =i esik) \ ‘TURBINE SECTION 4 Dave La ASSEMBLY ma a BuEED-AIR counter a ADJUSTABLE ORIFICE ontrice HIGH PRESSURE FUEL Low PRessune FUEL CONTROL AIR DENOTES CUSTOMER CONNECTION POINT se19A-1404 Figure 1, Fuel and Bleed-Air Control System Schematic1.0. 2G-GTC85-31 WP 003 00 4 Key to Figure 1 Fuel pump and control unit 20, Pneumatic (acceleration Drain control) thermostat Connector (212). Oil temperature regulator Fuel inlet. 21. 041 cooler assembly Connector #22, Oil temperature regulator Regulator 23. Connector Fuel pump 24. Fuel drain valve Relief valve 25. Load control valve Fuel filter 2%. Actuator Pressure gage connect 27, Switcher valve 11, Fuel solenoid shutoff valve 28, Switcher valve solenoid 12, Acceleration limiter valve 29. Rate control valve 43. Governor 30, Differential air pressure “14. O11 cooling fan regulator **15, Air pressure connect ion 31, (GICB5-704/-72 only) 16. Fuel atomizer assembly Generator 71. Igniter plug assenbly 32, Acceleration contro! solenoid 18, Engine thermocouple valve 19. Pneunatic (load contro!) 33. O11 drain solenoid valve thermostat *Customer connection stOptional customer -Furnished ss*Post SEC 1947, GICBS-72 #re SEC 1947, GTCB5-72 ++GTC85-56/-70A/-71A/-116 c. When the start switch is actuated and engine oi! pressure reaches 3 to 5 psig. the oi! pressure switch energizes the fuel solenoid shutoff valve (11, Figure 1 con- tinued) and fuel Is metered by the acceleration limiter valve (12) during starting operation to the fuel atomizer assembly (16). During normal operation, fuel is metered by the governor (13) to the fuel atomizer assembly (76). When fuel pressure is 50 1 psig with Fuel Atomizer Assembly Part No. 75076-7 or 75 +2 psig with Fuel Atomizer Assembly Part No, 75076-32 the fuel atomizer assembly divider valve opens to provide full fuel flow. The fuel pressure needed to overcome spring tension and open the acceleration limiter vaive (12) and meter fuel to the fuel atomizer assem- bly (16) during starting operations is 47 +1 psig with Fuel Atomizer Assembly Part No. 75076-7 and 63 42 psig with Fuel Atomizer Assembly Part No. 75076-32 and is the recorded acceleration limiter valve cracking pressure d. Fuel spray into the combustion chamber is provided by duel orifices in the fuel atomizer assembly (16). The smaller orifice provides proper fuel atomization at lower fuel pressure. The larger orifice combined with the smaller orifice provides proper fuel atomization at higher fue! pressures:T.0, 26-GTC85-31 WP 003 00 fe. Placing the siop switch in the stop position shuts off electrical power to the normally closed fuel solenoid shutoff valve (11, figure 1 continued). When oi! pressure drops below 1.5 psig minimum, the oi! pressure switch de-energizes and opens the circuit to the normaily open oi! drain solenoid valve (33) and allows in- ternal fuel leakage from acceleration limiter valve (12) to drain from drain (2) During normal engine shutdown or after an attempted engine start, fuel wil! drain fron fuel drain valve (24) and connector (23) 9. LGNITLON/STARTING SYSTEM. a. The ignition/starting system is fully automatic in operation; however. an ex- ternal 28 volt de power source and controls are required b. When the start switch is actuated, a starter motor relay and a starting and Ignition holding relay is energized and starter rotation is initiated, The starter accelerates the engine without further action from the operator When the oi | pressure reaches approximately 3 to § psig the oi! pressure switch is actuated, energizing the ignition system, fires igniter plug assembly (17, Figure 1) and opens the fue! solenoid shutoff valve allowing fue! to Flow to the combustion chamber 4. Acceleration continues through the combined forces of the starter and energy of the hot gases Flowing through the turbine. When engine speed reaches the required value, the 36 percent switch in the multiple centrifugal switch assembly opers, causing circuits to the starter and ignition to de-energize fe. The engine continues to accelerate to a preset value where the 95 percent switch in the multiple centrifugal switch assembly closes and energizes a circuit to Close the normally open acceleration control solenoid valve and energizes circuits to start hourmeter and start counter operation. Acceleration continues automati- cally to no-load governed speed 10, ALR SYSTEM a. The air system is fully automatic in operation and only requires an external load switch to initiate air delivery b. Engine surge during acceleration to 95 percent engine speed is control led by maintaining @ gradual increasing contro! air pressure to the acceleration limiter valve (12, figure 1) by bleeding contro! air through the acceleration control sole- noid valve (38) and adjustable orifice c. Turbine discharge temperature during acceleration to 95 percent engine speed is controlled by the pneumatic (deceleration control) thermostat (20). If turbine discharge temperature reaches a preset value. the ball valve in the pneumatic (acceleration contro!) thermostet (20) opens to bleed some of the contro! air fron the acceleration limiter valve (12) diaphragm which allows the poppet valve to open and bypass fuel, thus reducing the turbine discharge tenperature, When the turbine discharge temperature is reduced below the preset value, the pneumatic (acceleration control) thermostat (20) closes and stops bleeding contro! air pressure1.0. 26-GTC8S-31 We 003 00 d. Turbine discharge temperature during overloading is controlled by the pneu- matic (load control) thermostat (19, figure 1 continued). If turbine discharge tem- perature reaches a preset value, the ball valve in the pneumatic (load control) thermostat (18) opens to bleed some of contro! air From actuator (26) which causes the actuator mechanism to move the butterfly valve toward a more closed position, ‘thus reducing the load and turbine discharge temperature. When the turbine dis- charge temperature is reduced below the preset value, the pneumatic (load control) thermostat (19) closes and stops bleeding control air from actuator (26) fe. With the engine operating at no-load governed speed. a portion of compressor alr is directed to the differential air pressure regulator (30). The differential air pressure regulator (30) provides a constant air pressure of 37.6 to 39.7 inches Hg gage (18.5 to 19.5 psig) to the switcher valve (27) in load control valve (25) f. When the external load switch is placed in the load position, the switcher valve solenoid (28) is actuated which repositions switcher valve (27) allowing air pressure to the top chanber of actuator (26) to open integral butterfly. The drop in bleed-air pressure lowers air pressure on bottom side of rate control diaphragm, offsetting rate contro! valve (29) and retards opening of the integral butterfly un- till air pressure equalizes on both sides of rate control diaphragm and results in ‘the integral butterfly moving to a rated open position. Compressed bleed-air now Flows through the load contro! valve (25) to externally connected ducting g. (GTC8S-56/-71a/-116) The engine driven oi! cooling fan (14) produces coo! ing air which is ducted to the oi! temperature regulator (21 to coo! hot engine oi! before returning to oi! tank assembly (GTC85-72, Post SEC 1947) The engine driven oi! cooling fan (14) produces cool ing air which is ducted to the generator (31) for cooling and to the oi! cooler assembly (21) to coo! hot engine 0/1 before returning to ol! tank assembly (GTCB5-72, Pre SEC 1947) Heat produced by generator (31) is vented into the turbine exhaust at the tailpipe flange. Compressor inlet air passing over oi! temperature regulator (22) cools hot engine oi! before returning to oil tank assembly. (GTC85-70A) The engine driven oi! cooling fan (14) produces cooling air which is ducted to the generator (31) for cooling and to the oi! temperature regulator (21) to cool hot engine oi! before returning to oi! tank assembly. 11. CONTROLS SYSTEM. a. The controls system is fully automatic in operation; however, external holding relays and switches are required for operation b. Two armature relays, fuel holding relay and starting and ignition holding relay are part of the electrical control box assembly.1.0. 26-GTCa5-31 WP 003 00 c. Relays are energized when the start switch is pressed. The start switch is a momentary type and allows continuity only as long as the switch is held in the start position. Each of the relays, then initially energized, completes @ circuit through contacts to its holding coil, The starting and ignition holding relays remains energized until 35 percent governed speed is attained, at which time the starter circuit and ignition circuit ere de-energized. The fuel holding relay remains ener- gized until the stop switch or overspeed switch is actuated 4. The seif-actuating and self-resetting muitiple centrifugal switch assembly consists of an input shaft, flyweights, fulcrum, lever, actuator, push rods. springs. three snap-action switches, housing assembly and cover assembly. The func- tion of the multiple centrifugal switch assembly is to control the sequence of oper- ation of the electrical system components by movenent of the Flyweights in response to the speed of the unit. The flyweights cause @ sleeve to exert force on a lever which contains two preadjusted leaf springs and a button to operate each of the snap-action switches. Three push rods. each with an adjustment spring, oppose Flyweight force against the lever to decrease the movement of the flyweights as necessary to actuate the switches in sequence. The switches actuate at approxi mately 35 percent, 95 percent and 110 percent of engine governed speed 12, INDICATION SYSTEM. ‘a. The engine thermocouple (18, figure 1) is located in the turbine exhaust Flange in position to be completely immersed in turbine exhaust gas. The engine thermocouple creates a smal! electrical current which is proportioned to the temper - ature of the exhaust gas during operation. A chronel wire (white) and an @lume! wire (green) carry the signal to the wiring harness receptacle for pickup and con- nection to customer-furnished equi pment 2. During start, rising oi! pressure actuates the cil pressure switch which com- pletes a circuit to the fuel shutoff valve and to the ignition unit c. (GTCB5-86/-71A/-72/-116) The custoner-furnished tachoneter-generator is driven by the oi! pump drive gearshaft. The tachometer-generator generates an elec- trical voltage and frequency which Is proportional to the drive speed, This signal is carried through the engine wiring harness receptacle for customer connection d. (GTCBS-56/-70A/-714/-116 only) The time totalizing meter is energized at 95 percent engine speed and displays operating time in hours and tenths of hours. fe. (GTC85-56/-71A/-72/-116) The start counter is energized at 95 percent engine speed and records once for each start, 13. OU SYSTEM. a. The engine oil system is @ positive pressure, dry-sump system contained within the engine except for the source of supplyT.0. 26-GTC8S-31 We 003 00 b, When the engine is started. oi! is supplied from ol! tank assembly (14. Figure 2, sheets 1 and 2) through check valve (3) to oil pressure pump gears (1) in oil pump assembly. Oi! is pumped through oi! filter (8) unless oil Filter is plugged In this case oil is routed through filter bypass valve (7) to oil temperature indi cating bulb (9) and oil pressure relief valve (10) which routes excess oi! pressure back to suction side of oi! pressure pump gears (1). Oil continues to connection (11), oi! pressure switch (12), accessory drive assembly and to fittings in the en- gine to provide jet and splash’ tubrication. AS the engine accelerates and oi! pres- Sure reaches approximately 3 to § psig, the oil pressure switch (12) actuates and energizes the fuel and ignition systems and completes the circuit to close the nor- mally open oil drain solenoid valve (6). Oil within the engine is returned through oil ‘scavenge Filter (15) to oi! scavenge pump gears (2). Oi! within the accessory drive assenbly is returned to oi! scavenge pump gears (2) (GTC85-56/-70A/-71/-116) Oil is routed From oi! scavenge pump gears (2) to ol! tem- perature regulator (13) and ol! temperature control vaive (4) for cooling before Teturning to oil tank assembly (14) (GTCBS-72, Post SEC 1947) DiI is routed From oi! scavenge pump gears (2. Figure 2 sheet 1) through check valve (16) to oi! cooler assembly (13) for cooling before returning to oil tank assembly (14) (GTCB5-72 Pre SEC 1947) Oil is routed from oi! scavenge pump gears (2, Figure 2 sheet 2) to oll temperature regulator (13) and oi! temperature control valve (4) for cooling before returning to oil tank assembly (14) c. When the engine is shut down and the oi! pressure drops below 1.5 psig mini- mum, the oil pressure switch (12, figure 2, sheets 1 and 2) de-energizes end opens the circuit to the normally open oi! drain solenoid valve (6). The oi! drain sole- noid valve (6) drains excess oi! out connection (5) that has migrated to accessory drive assenbly because check valve (3) Is stuck in open position or failure of oil scavenge pump gears (2) Key to Figure 2 (Sheet o> 1, Ol| pressure pump gear 10, Oil pressure relief valve 2. Oil scavenge pump gear Ti. Connection 3. Check valve 12. Oil pressure switch #4. Oil temperature contro! valve 13. Oil temperature regulator 5. Connection ##13, Oi! cooler assembly 8. Oi! drain solenoid valve "*14. Oil tank assembly 7. Filter bypass valve 18. O41 scavenge filter 8. Oit filter #16, Check valve *8. Oil temperature indicating bulb *Customer-furn shed **Customer-furnished except for GTCBS-116 #Not_used on GTCB5-72, Post SEC 1947 #¥GTC85-72, Post SEC 1947 only 10T.0, 26-GTC85-31 WP 003. 00 zori-vel-s Asnvine Nien aranassy = swins 10 (GTC85-56/-70A/-71A/-116, GTCB5-72 Post SEC 1947) Lubrication System Schematic (Sheet 1 of 2) Figure 27.0. 26-GTCBS-31 WP 003 00 TIED SCAVENGE PUMP PRESSURE aE Figure 2. (GIC85-72, Pre SEC 1947) Lubrication System Schematic (Sheet 2)j < ey to Figure O11 pressure pump gear Dil scavenge pump gear Check valve Oil temperature control valve Connecti on Oil drain solenoid valve Filter bypass valve on Filter *Customer-furn ished T.0, 26-GTC85-31 WP 003 00 2 (Sheet 2) “9 10 u R 8 4 6 O11 venperature indicating bulb Oil pressure relief vaive Connect ion Oil pressure switch Oi! temperature regulator O11 tank assembly Oil scavenge filter 13/(14 blank)®7.0, 26-GTC85-31 wP 004 00 WORK PACKAGE TECHNICAL PROCEDURES PREPARATION FOR TEST EFFECTIVITY: ENGINE MODELS GTC85-56 GTcas-72 GTC85~70A GTCB5~116 GTCB5~71A LIST OF EFFECTIVE WP PAGES RECORD OF CHANGES Original .... 0s... 14 Apr 86 Total Number of Pages in this MP is 16 PAGE CHANGE nO. ‘NO. 14 APRIL 19867.0, 2G-GTC8S-31 We 004 00 1. APPLICABLE SUPPORT EQUIPMENT ‘Tool No. Nomenclature Aten/F igure No. 253105 Adapter Assembly, Hoisting, Gas Turbine wm Compressor (Hoisting Adapter Assenbly) 257584 Adapter Assembly, Maintenance Stand, Gas am Turbine Compressor Test (Adapter Assembly) 258356 Tank Assembly, Oil Lubricating, Gas Turbine ym Test (Oil Tank Assembly) 258616 Hose Assembly. Metal 5/11 265832-1 Mount Assembly, Vibration Pickup 10/71 281270-0-3 Stand Assembly. Portable. Gas Turbine Engine am (Portable Stand Assenbly) 281326 ‘Adapter Assembly, Maintenance Stand am 281327 Adapter Assembly, Maintenance Stand 3/71 281407-2 Duct. Assembly, Bleed-Air. Gas Turbine 6/1 (Bleed-Air Duct Assembly) 281510-1 Thermocouple Assenbly, Inmersion amt 281520-1 Adapter Assembly, Tail Pipe um 2. APPLICABLE TcTO'S. None 3. REFERENCE WATERIAL REQUIRED. General Information, Depot Maintenance Manual T.0. 2G-GTC85-33-1, WP 003 00 Test wp 005 00 4. CONSUMABLE MATERIALS. This Manual NOTE Index numbers are for reference to master consum- able list T.0. 2G-GTC85-33-1. All references to consumables in text will be preceded by 33 (Example: Oil (33-81)) Index to Nomenclature 54 Fuel el oil 5. INTRODUCTION. This work package provides procedures for preparing the engine for test. Components necessary for testing the engine and test connections are illustrated in schenatic form with detailed instructions. All special tools and torque values are called out in textWe 004 00T1. Support Equipment. (Sheet 2)7.0. 26-GTC85-31 WP 004 00 J, GENERAL TESTING INSTRUCTLQNS a, Calculations. (1) Calculations are required to convert observed values to standard values. Ensure the correct graphs or curves are on hand for support equipment: being used (2) Tables and graphs for calculating engine values are provided in WP G05 00 NOTE At the end of each procedure it shal! be the test cell operator's option to shut down the engine or continue test >, Switches and Valves. At the end of each procedure, when the engine is shut doun turn al] switches and valves to the off or closed position 8. IESTSETUP. Note Steps @ through d are for a typical test setup and is intended to illustrate connection points, valves, Fittings. indicators and necessary equipment to ob- tain correct parameters during engine testing a. Mount Engine or Testing (1) Instat! 253105 hoisting adapter assembly on top boss of second stage dif- fuser housing (2) Attach suitable sling and hoist and position engine to be installed in 281270-0-3 portable Stand assembly. (3) Install engine in 281270-0-3 portable stand assembly using 257584 adapter assembly and 281326 and 281327 maintenance stand adapters (4) Remove sling and hoist from engine (5) (GTCB5-86/-70A/-71A/-72) install 74666-12 tube or equivalent on elbow in- stalled in engine oi! vent connection (2, Figure 1). Position tube away from engine and up (6) Remove plug and packing from oi! pressure connection (3). Install AN815-4J union with $9413-554 packing or equivalent into oi! pressure connection (3) and tighten,7.0. 2G-GTCRS-31 we 004 00 2 LUBRICATION system GTC 85-54/-70A/-71A/-72 only a7 0 esr serurscHemaic fg Bot eapacrre Figure 1. Fuel and Lubrication Systens Test. SetupT.0, 26-GTC85-31 we 004 00 Gey % Favre 1, Oil vent connection (3/4-16 thread for 1/2 inch line) 2. Engine oi! vent connection (3/4-16 thread for 1/2 inch line) 3. Oil pressure connection (9/16-18 thread for 3/8 inch | ine) 4, Oil temperature bulb * 5) Oil inlet connection (1-1/16 thread for 3/4 inch line) 6, Fuel inlet connection (9/16-18 thread for 3/8 inch line) 7, Fuel pressure connection (7/16-20 thread for 1/4 Inch line) 8. Fuel drain connection 9 Oil return connection (3/4-16 thread for 1/2 inch line) 10. Fuel drain valve connection 11. Fuel boost pump 12. Pressure regulator 13. Shutoff valve 14, Fuel filter 15. Fuel Flowmeter 16. Fuel solenoid shutoff valve 47, Temperature indicator (fuel inlet) 0 to 150°F (-18 to 65°C) 18. Pressure gage (fuel inlet) (0 to 20 psig) 18. Manual fuel bypass valve 20, Pressure gage (fuel discharge) (0 to 425 psig) 21\ Pressure gage (acceleration limiter valve cracking) (0 to 100 psig) 22. Oi} tank assembly (part no. 258356) 23, Pressure gage (oil discharge) (0 to 120 psig) 24, Temperature indicator (oi! discharge) 0 to 300°F (-18 to 149°C) *GTCBS-56/-70A/-71A/-72 only **GTCB5-116 only (7) Install hose from P38-5 pump or equivalent on ANB15-4J union installed in oil pressure connection (3. figure 1 continued) and tighten (8) Prime the oj] system with 80 to 90 strokes of the P39-5 pump, approximately 800 cc of of! (33-81) (9) Remove P39-5 pump hose from ANS15-4) union Installed in oi! pressure con- nection (3). Remove AN815-4J union with packing. Install plug with new packing into oi! pressure connection (3) and tighten (10) (GTC85-56/-70A/-71A/-72) Remove 7466-12 tube From elbow instal led in en- gine oi! vent connection (2) (11) Position mounted engine in test setup facility so that all sides, top and bottom of engine are readily accessible and compressor air inlet screen is unobstructed. Secure 281270-0-3 portable stand assembly (12) Remove lockwire from items as required to install test cell connection or make adjustment changesT.0. 26-GTC85-31 WP 004 00 (13) check al! plumbing, ducts and electrical wiring for correct routing and security (14) Remove all port caps and plugs b. Eel and Lubrication Systems Test Connections. (1) Provide @ source of fuel (33-54) with @ supply line to the engine Tue! pup and contro! unit. (2) Install fue! boost pump (11, Figure 1) in fuel supply line to maintain fuel inlet pressure (3) Install pressure regulator (12), shutoff valve (13), fuel filter (14), fuel flowmeter (15) and remote control fuel solenoid shutoff valve (16) in the supply line to control and measure fuel flow. (4) Provide graphs or curves for the particular fuel flowmeter (15) being used (5) Connect_a tee into fuel supply line and install a thermocouple probe in the tee. Connect the thermocouple to a potentioneter or temperature indicator (17) to measure fuel inlet temperature. (6) Install a fitting at fuel inlet connection (6) to provide a connection between fuel supply line, the line from the manual fuel bypass valve (19) and pressure gage (18) to measure fuel inlet pressure (7) Install a tee fitting at fuel pressure connection (7) to provide a connec- tion to a bypass line and to pressure gage (20) to measure fuel discharge pressure (8) Instal! manual fuel bypass valve (19) in bypass line between the tee fit- ‘ting at fuel pressure connection (7) and fitting at fuel inlet connection (6) for manual control of engine speed (9) When checking acceleration limiter valve bypass cracking pressure, remove pressure gage (20) and temporarily instal! pressure gage (21) (10) Connect drain lines at fuel drain connection (8) and fuel drain valve con- nection (10) (11) Install pressure gage (23) in oi! pressure connection (3) (12) Connect temperature indicator (24) to oi! temperature bulb (4) (13) (GTC85-56/-70A/-714/-72) Insta! | 258356 oil tank assembly (22) adjacent to engine and located so that tank outlet is above oi! inlet connection (5); oil level in tank, when filled to correct level, must not be above horizon- tal centerline of engine rotating assemblies.T.0. 26-GTC85-31 we 004 00 (14) (GTCBS-56/-70A/-71A/-72) Connect @ vent line from of! tank assenbly (22 Figure 1 con- tinued) and allow to vent to ambient air (GTCB5-118) Disconnect vent line from oi! vent connection (1) and allow to vent. to ambient air (18) (GTC85-56/-70A/-71A/-72) Connect another vent line from oi! tank assembly (22) to engine oi! vent connection (2) (16) (GTCB5-56/-70A/-71A/-72) Connect a supply line from oi! tank assembly (22) ‘to oil inlet connection (5) (17) (GTCB5-56/-70A/-71A/-72) Connect a return line to oi! tank assembly (22) from oil return connection (9) (18) Service ol! tank assenbly (22) In accordance with WP 005 00 c. Electric. Speed and Vibration Systems Test Connections (1) Provide @ contro! panel with a start switch (13. figure 2), a stop-run switch (12), a bleed load switch (9), a green load light (10), a starter motor relay (18) (500 amp), a voltanmeter (16) (0 to 500 amp), a shunt, 24 vdc battery (17) and an amber starter-operating light (11) (2) Provide @ harness assembly to connect the contro! panel harness receptacle (19) to harness connector (6) at electrical contro! box (3) Provide a lead to connect starter motor relay (18) to electrical starter assembly positive termine! (4) and a lead to electrical starter assembly negative terminal (3) (4) Provide @ lead to connect bleed load switch (9) to unloading air shutort valve electrical connection (8). (5) Provide @ circuit, switches and connectors for remote control operation of the test setup fuel solenoid shutoff valve (25) and test setup bleed-air solenoid shutoff valve (26) and for temporary operation of the acceleration control solenoid valve (2) when adjusting the adjustable orifice (6) (GTC85-70A/-72) Connect 12 amp de generator (14) and generator control pane! (15) to voltemmeter (16) NOTE Ratio of turbine whee! speed to tachometer- generator is 9.162 to 1 (7) (GTC85-56/-71A/-72/-116) Insta! customer-Furnished tachometer-generator (20) on tachoneter-generator mounting pad (5)7.0. 2G-GTC85-31 WP 004 00 a 2 10 weal -2Fesr Sere swiTenes fe 1" cOnmOL PANEL SOT ec (cal Systt™, T-198-1598 Figure 2. Electrical, Speed and Vibration Systems Test Setup1 h R 3 14 8 6 ” 18 19 20 a 2 23 28 Fy es 1.0, 2G-GTC85-31 We 004 00 Ge 20 Figure 2 Vibration pickup mount assembly Acceleration control solenoid valve Electrical starter assembly negative terminal Electrical starter assembly positive terminal Tachometer-generator mounting pad Harness connector 12 amp dc generator mounting pad Unloading air shutoff valve electrical connection Bleed load switch Green load I ight Anber starter-operating | ight Stop-run switch Start switch (GTC85-70A/-72 only) 12 amp dc generator (GTCBS-70A/-72 only) Generator contro! panel Voltameter 24 vde battery Starter motor relay Control panel harness receptacle Tachometer -generator Eput meter and counter Vibration pickup Bandpass filter Vibration meter Test setup fuel solenoid shutoff valve Test setup bleed-air solenoid shutoff valve (8) Connect eput meter and counter (21, figure 2 continued) to tachometer generator (20) to measure turbine wheel speed (9) Renove 253105 hoisting adapter assenbly from top boss of second stage dif fuser housing and instal! 265832-1 vibration pickup mount assembly (1) vibration ) (10) Attach vibration pickup (22), bandpass filter (23) and vibration meter (24) to 265832-1 vibration pickup mount. assenbly (1) to measure engine (11) (GTC85-56/-71/-116) If required, instal! customer-furnished 12 amp dc gen- erator on 12 amp de generator mount pad (7) "T.0, 26-GTC85-31 WP 004 00 d, Alc Systems Test Connect ions. qa) 2) (3) @) (5) ©) @ (8) (9) (10) 2 NOTE Test facility exhaust provisions must discharge al! exhaust air and gas to atmosphere conditions without obstructions or restrictions. Gages that read in mercury or inches Hg vacuum may be replaced by gages that read in equivalent psia Instal|_281520-1 tail pipe adapter assembly (17, figure 3) on turbine ex- haust flange (7). Connect opposite end of tail pipe adapter assembly (17) to test facility exhaust provisions Connect 281520-1 tail pipe adapter assembly (17) thermocouples to heat in- dicator (18) to measure turbine discharge temperature NOTE Engine thermocouple (6) heat readings shall not be used for engine test procedures. Connect engine thermocouple (6) to heat indicator (23) to check readings against readings from 281520-1 tail pipe adapter assembly (17) Install 281407-2 bleed-air duct assembly (8) to load contro! valve Flange (5). Tighten clamp bolt nut and torque to 50 to 70 inch-pounds Connect 281407-2 bleed-air duct assembly (8) thermocouples to temperature indicator (16) to measure bleed-air discharge temperature Connect 281407-2 bleed-air duct assembly (8) total pressure probes to mer- cury gage (15) or equivalent to measure bleed-air discharge pressure Connect one end of 258616 metal hose assembly (3) to 281407-2 dleed-air duct assembly (8) and connect the other end to an airflow measuring section (10) The airflow measuring section (10) shal! contain a 4.000 by 6.000 inch square edge orifice plate or equivalent. Ensure the appropriate grephs or curves for the particular airflow measuring section being used are avail- able for determining correct actual air weight flow. instal! two iron constantan thermocouples upstream of orifice plate and connect to heat indicator (14) to measure orifice air temperature for flow calculations. Install two static pressure probes upstream of orifice plate and two static pressure probes downstream of orifice plate7.0, 26-GTC8S-31 WP 004 00 Tubine compressor ACCESSORY STABILIZER TURBINE HAUT a CASEAR ORIFICE EXHAUST BUCTING a an 1-19-1600, Figure 3. Air Systems Test SetupT.0. 2G-GTC85~31 WP 004 00 4 qv to Figure 3 Acceleration contro! solenoid valve (GTC85-86/-71A/-72/-116) Cap (GTC85-70A) Cap Compressor air inlet screen Accessory drive assenbly negative pressure port Load control valve flange Engine thermocouple Turbine exhaust Flange Bleed-air duct assembly Metal hose assembly Airflow measuring ‘Section Bleed-air solenoid shutoff valve (0 to 150 pound per minute) 450°F (232°C) Water manometer (or equivalent) (Flow orifice differential) (0 to 100 inch water) Mercury gage (or equivalent) (flow orifice air) (0 to 100 inch Hg) Heat indicator (flow orifice air) 0 to 600°F (-18 to 315°C) Mercury gage (or equivalent) (bleed-air) (0 to 150 inch Hg) Temperature indicator (bleed-air) 0 to 600°F (-18 to 315°C) Tail pipe adapter assenbly Heat indicator (turbine exhaust) 0 to 1500°F (-18 to 815°C) Mercury gage (or equivalent) (barometer) (ambient air) (0 to 30 inch Hg) Heat. indicator (ambient air) 0 to 150°F (-18 to 65°C) Vacuum gage (accessory drive assembly negative pressure) (0 to 10 inch Hg) Pressure gage (stabilizer control air pressure) (0 to 30 psig) Heat indicator (engine thermocouple) 0 to 1500°F (-18 to 815°C) (11) Install @ tee in the upstream static pressure probe line and connect one end to mercury gage (13. figure 3 continued) or equivalent to read upstream pressure. Connect other end of tee to bottom of water manoneter (12) Connect downstream static pressure probes to top of water manometer (12) or equivalent to measure orifice plate differential pressure for flow calculation (12) Install bleed-air solenoid shutoff valve (17) downstream of airflow measur- ing section (10) and connect to test facility exhaust provisions (23) Install 281810-1 immersion thermocouple assembly within 4 inches of the compressor air inlet screen (3) and centered in the air stream to measure inlet air temperature for engine performance calculations and connect to heat indicator (20) (14) Install mercury gage (19) or equivalent adjacent to compressor air inlet screen (3) to measure ambient air pressure for engine performance calculations1.0, 26-GTC85-31 WP 004 00 (15) Install a Fitting Part No. 13605-1 (with an orifice. size 0,023 to 0.032 inch drilled through side wall), Bolt Part No 13506-1 and two Packings Part No, $9412-565 into accessory drive assembly negative pressure port (4, figure 3 continued) (16) Connect vacuum gage (21) to Fitting Part No. 13505-1 to measure accessory drive assenbly negative pressure. (17) (GTCB5-86/-71A/-72/-118) When checking adjustable orifice assembly set- ‘ting, remove cap (2) from deceleration control solenoid valve (1) and con- rect ‘a flex line to fitting. Connect pressure gage (22) to flex line (GTCBS-70A) When checking adjustable orifice assembly setting remove cap (2A) from acceleration contro! solenoid valve (1) and connect @ flex line to fitting. Connect pressure gage (22) to flex line 15/(16 blank)oo.7.0. 26-GTC85-31 ‘WP 005 00 WORK PACKAGE TECHNICAL PROCEDURES TEST EFFECTIVITY: ENGINE MODELS GTC85-56 GTC85-72 GTCE5-70A—_ GTC85-116 GTC85-714, LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP Is 50 Page Change Page Change Page change No. No. No. No. No. No. 23-24 coe oO 39 .. 0 25-26 cow 3 40 | 7 2 8 1-8". 8 23 5 43. woonsnrnnon 7 29-31 8 44249 woocnecne, 10 32 Blank.. 8 50 Blank. 10 33-36 0 37-38 7 Change 10 1.1.0. 26-6TC85-34 WP 005 00 1. APPLICABLE SUPPORT EQUIPMENT, Tool No. ‘Nomenclature ‘No. 280353 Screwdriver and Wrench Assembly vn 2814211 Positioner Assembly, Ball Valve 2/01 2, APPLICABLE TCTOs. None. REFERENCE MATERIAL REQUIRED. General Information, Depot Maintenance Manual Preparation for Test. 4, CONSUMABLE MATERIALS. NOTE TO, 2G-GTC85-33-1, WP 008 00 WP 004 00 This ‘Manual Index numbers are for reference to master consumable list ‘T.O. 2G-GTC85- 33-1. All references to consumables in text will be preceded by 33, (Exam- ple: Oil (33-81) Index No, Nomenclature 40 Compound Antiseize Shim (Part No. 99867-1 through -12, 99867-82 through -91) 8, INTRODUCTION. This work package provides procedures for adjustments and testing of the engine. Each component and adjustment location is shown in illustrated form with detailed instructions outlined, All special tools and torque values are called out in text. NOTE Engine operating limits in WP 005 00 take precedence over computer response, and the operator shall assume manual control if limits are exceeded. Only current. and approved software, computer program identification numbers (CPIN) as determined by CPIN com- pendium 80-1-81, shall be used to test the engine on Automated Test Cell (Pacer Comet, MD. Engine OPIN GTC85-56 81B-GTC8556-U002-00A. GTC85-70A 81E-GTC8570-0002-00A, GTC85-71 81E-GTC8571-U002-008, GTC85-72 GTC85-116 S1E-GTC8572-U002-00A. 818-GTC85116-U001-00A. Pacer Comet III System will automatically perform all tests outlined in WP 005 00. ‘The test cell operator is responsible for monitoring engine performance and making manual adjustments, 2 Change 8T.0, 2G-GTC85-31 WP 005 00 EQUIPMENT, 4 K-19A-1707 Figure T1, Support Equipment. 7. SAFETY PRECAUTIONS, The following is @ list of WARNINGS and CAUTIONS that must be observed during engine testing WARNING During operation of the engine, personne! shal | stand clear of the compressor air inlet, turbine exhaust and planes of rotation of the high-speed turbine and compressor. Extreme care shall be taken to prevent oi!, fuel and other foreign material from entering the air inlet. Turbine or compressor failure, which may be caused by oi fuel and other foreign material entering the en- gine, can be violent and could result in damage to equipment or injury to nearby personnel CAUTION Engine must never be permitted to rotate unless ‘there Is adequate fuel supplied to fuel pump and control unit. Fuel pump lubrication is provided by fuelT.0. 26 GTC8S 31 WP 005 00 ‘CAUTLON When the engine is being tested using computer test cell, the rpm shall be closely monitored during this test and manually shut down if the engine starts to exceed 44,500 rpm. Do not exceed a speed of 43.500 rpm for longer than 10 seconds Do not exceed operating limits given in table 1 es engine damage may occur Failure to hold valve assembly of pneumatic (acceleration control) thermostat (18, figure 1) when removing or connecting control air line (17) may result in a calibration shift and/or damage Failure to hold valve assembly of pneumatic (load control) thermostat (16) when removing or connect- ing control air line (8) may result in a calibra- tion shift and/or damage. Damage to the bal! and seat in valve assenbly (1, Figure 5) ball valve positioner assembly is not used when removing valve assembly (1) from body assembly (3) 8. PRELIMUNARY TEST pRocenupes 2. General Requirements. NOTE Figures 2 and 3 are required only when the engine is manually tested (1) Record engine hourmeter and start counter readings on copy of Figures 2 and 3 (2) Observe Figure NOTE Gages that read in mercury or inches Hig vacuum nay be replaced by gages that read in equivalent psia and record baronetric pressure readings at intervals indicated on 2. Adjust mercury gage or equivalent, as necessaryT.0, 26-GTC85-31 WP 005 00 Table 1. Operating Limits Observation Condition Node! No Limit Requirenents ‘CAUTION Stop engine if indicated values exceed or persist at these limits Compressor inlet air Sustained operation 130°F (64°C) ‘temperature (exiimun) Turbine discharge Sustained operation 1200°F (649°C) ‘temperature (ax imum) 18 seconds maximum 1278°F (691°C) during test. (maximum) 60 seconds maximum 1228°F (663°C) during test (maximum) 40,000 rpm or 1275°F (691°C) higher (maximum) Never exceed 1300°F (704°C) (maximum) Turbine wheel speeds Sustained operation GTC85-56/-70A/ 42,100 to 42,300 (no-load) -T1A/-116 rpm rces-72 42,500 to 42,700 rpmT.0. 2G-GTC85-31 WP 005 00 Table 1. Operating Limits (Cont) Observation Condition Model No Limit Requirements CAUTION Do not exceed a speed of 44,500 rpm at any time as engine damage may occur Turbine wheel speeds Never exceed 44,500 rpm (Cont) (shut. down immedi - (maximum) ately If this speed is reached) ‘CAUTLON Do nol exceed a speed of 43,500 rpm for longer than 10 seconds as engine damage may occur 10 second operation 43,500 rpm (max imum) Fuel temperature Any operating MOF (43°C) (measured at condition (max imum) pump inlet) Oi! temperature Any operating 125°F (69°C) above condition compressor inlet air temperature (maximum) Oi! pressure Cold engine 130 psig (maximum) (measured at pres- 65 to 130°F sure connect ion) (-54 to 54°C) 30,000 rpm or 90 £10 psig higher. Allowable fluctu- 33 psig (maximum) ation at steady stateTable 1. Operating Limits (Cont) 1.0. 2G-GTC85-31 WP 005 00 Observation’ Oil Consumption Condition Model No. Any operating condition Limit Requirements 25 pounds per hour (maximum) Accessory drive assembly pressure At governed speed operation Do not operate the engine continuously at any speed where vibration exceeds 0.6 mil as engine damage may occur. 2 to -22 in, Hg age 0.6 mil (maximum) Vibration amplitude Any operating (GTC85-56/-70A/ condition. 116) Maximum peak vibrations greater than the limits shown may occur at certain critical turbine wheel speeds of 18,000 to 22,000 rpm. (GTC85-71A-72) (0.6 mil (maximum) Maximum peak vibrations greater than the limits shown may occur at certain critical turbine wheel ‘speeds from 28,000 10 32,000 rpm. Electric starter Duty cycle 450 amps maximum. assembly 1 minute on, 4 (May be exceeded minutes off for no more than To prevent 2 seconds during damage, cool start) starter 30 ‘minutes. after 4 duty cycles. Bleed-air oscillation Steady state. +1.0 in. Hg gage Change 17T.0. 26-G1c8-3 We 005 00 Table 1. Operating Limits (Cont) Observation Condition Node! No Limit, Requirements Light-of F time after ol! pressure 5 seconds reaches 5 psig (maximum) Leakage Qi! leakage from One drop in 15 any one shaft. seal minutes (maximum) Oi! leakage from Three drops (max. first-stage com- imum) presser seal during or after shutdown Fuel leakage from One drop per min- pump and control uve (maximum) unit drain Fuel leakage from None, except on turbine drains. false start or blowout, Air leakage (other None, except ‘than load contro! turbine drains at valve bleed holes, slow speed Pressure regulator, acceleration limiter valve cap and plenum drain valve during reduced speed operat ion)T.0, 26-GTC85-31 WP 005 00 Figure 1, (GTC8S-56/-71A) Component and Adjustment Locations (Sheet 1 of 8)T.0. 26-GTC85-31 WP 005 00 Key to Figure 1 NOTE This key applies to all sheets of figure 1. Select sheet showing engine model under test. Ol pressure switch (GTCB5-56L-71A-72-116 only) Cap 3. Acceleration control solenoid valve 4 Locknut 5. Adjusting serew 6. Air pressure line 1. Fitting 8) Unloading air shutoff valve (oad. control valve) 9. Control air line 10. Fitting Li. Differential air pressure regulator 12, Locknut 13. Adjusting screw 14. Locknut 15. Adjusting serew 16. Pneumatic (load control) thermostat b. Oil and Fuel System Priming. 11, 18. 20 24 2 23 2 % 26. aT. 2, 29, 20 31. Control air tine Pneumatic (acceleration control) thermostat Plug and bleeder Electrical starter assembly Oil pump assembly Fuel shutoff valve Fuel pump inlet port Fuel pump pressure connection Locknut Adjusting screw Loeknut Adjusting screw Control air line (GTC85-70A only) Cap (GTC85-70A/-72 only) 12 amp de generator (GTC85-116 only) Oil tank assembly (1) (GTC85-56/-70A/-71A/-72) Service an external oil tank assembly with a minimum of 4 quarts of oil specified in table 2. (GTCR5-116) Service oll tank assembly (32, figure 1) to FULL mark on dipstick with oil specified in table 2, NOTE ‘Add one quart of oil when oil level reaches minimum oil level mark. One quart of oil will put the oll level to the full mark, (GTC85-56/-704/-71A/-72) Ensure oil supply line from ‘external oil tank assembly to engine is bled of air. I (2) (GTC85-56/-70A/-71A/-72) Loosen oil supply line at engine until all air is bled from oil supply line (this is a gravity feed operation). Tighten oil supply line. 10 Change 1Figure 1 1.0. 26-GTC85-31 WP 005 00 FeI9A-7351 (GTCB5-86/-71A) Component. and Adjustment Locations (Sheet 2)1.0, 2G-GTCR-31 WP 005 00 Figure 1 ROTATED an 9A 8 F-19A-7350, (GTCB5-70A) Component and Adjustment Locations (Sheet 3)T.0, 26-GTC85-31 WP 005 00 Fe19A-7349 Figure 1, (GTC85-70A) Component and Adjustment Locations (Sheet 4)1.0, 2G-CTCa5-31 een I ve is u " Figure 1. (GTCBS-72) Component and Adjustment Locations (Sheet 5)T.0. 2G-GTCRS-31 WP 005 00 Figure 1. (GTC85-72) Component and Adjustment Locations (Sheet 6)Figure 1. (GTC85-116) Component and Adjustment Locations (Sheet 7)a a Figure 1 T.0. 26-GTCt 31 WP 005 00 ‘ . R Zi a MB 2 soon (GTCB5-116) Component and Adjustment Locations (Sheet 8) v2G-GTCA5-31 7.0 WP 005 00 fray | >is eLsrataea | om TE —J ‘wroae w are Quy mao] Figure 2, Test Record Sheet (Use Only when Engine is Manual ly Tested) 87.0. 26-GTC85-31 we 005 00 DATE PAGE NO. ‘Test CREW ‘TEST LOG SHEET Assy. NO, CELLNO. SERIAL NO. —_ sTaRt|sToP} RUN "TIME |TIME| MIN. froran. -19A-370 Figure 3. Test Log Sheet (Used Only When Engine is Manually Tested)20 7.0, 26-6TC85-31 We 007 00 PROCEDURE 9 ENGINE FALLS 70 ¢¢ (\ secen (CONT) OK-CHECK FOR CORRECT AIR PRESSURE. IF- NO-LOAD CONTROL Not OK-REPLACE SOLENOID VALVE |GTC85-33-4 AND 1 ACCELERATION CONTROL, REFER TO T.0. 26- T.0. 2G-GTCa5-33- PRESSURE NOT OK-ADJUST ADJUSTABLE ORIFICE TO OBTAIN CORRECT NO-LOAD CONTROL AIR REFER TO WP 005 00.1.0, 26-61¢85.31 ‘WP 005 00 Table 2, Engine Requirements - Continued ‘SYSTEM REQUIREMENT OPERATING/LIMIT Bleed-air Oscillation Steady state operation within 41.0 inch-Hg maximum the operating limits of the engine. NOTE ‘A four percent deviation from bleed system values is permissible for (GTC85-70A/-71AV-72 only) newly overhauled engines. A six percent deviation from bleed system values is permissible on OCM and repaired engines. This deviation applies to all parameters collectively. For exam- ple. if bieed:-air flow is four percent less than specified, other parame- ters must meet requirements specified. Flow Steady state operation with full **** 122.2 pounds per bleed-load applied minute minimum, Pressure Steady state operation with full ****105.7 inches-Hg. bleed-load applied. abs minimum ****Corrected value for a 59°F (15%)C, 29.92 inch Hg, NACA Standard Sea Level Day. Change 8 210. 266108531 WP 005 00) (3) (GTC85-56/-70A/-71A/-72) Check and reservice external oil tank assembly, if necessary, with oil specified in table 2. (4) Remove fuel discharge pressure gage from fuel pressure connection (24, figure 1), and install a drain line. (5) Disconnect electrical connector from oil pressure switch (1) to prevent fuel shutoff valve (22) from ‘opening and allowing fuel to flow to combustion chamber. (6) Supply a source of pressurized fuel specified in table 2 to fuel pump inlet port (23). Loosen fuel bypass line, and allow all air to bleed from line. Tighten fuel bypass line. (7) Supply electrical power specified in table 2. + Electrical power supplied to engine must have a 500-AMP maximum over- load protection circuit. + During operation of the engine, personnel shall stand clear of the compres- sor air inlet, turbine exhaust, and planes of rotation of the high-speed tur- bine and compressor. Extreme care shall be taken to prevent oil, fuel, and ‘other foreign material from entering the air inlet. Turbine or compressor failure, which may be caused by oil, fuel, and other foreign material enter- ing the engine, can be violent and could result in damage to equipment or injury to nearby personnel. + Engine must never be permitted to rotate unless there is adequate fuel supplied to fuel pump and control unit. Fuel pump and control unit lubrica- tion is provided by fuel. + Do not exceed electric starter assembly duty cycle of one minute on, four minutes off, as damage may occur. (8) Rotate engine using electrical starter assembly (20), and allow fuel to flow from drain line into suitable container until all air is bled from fuel pump and control unit. (9) While engine is rotating, prime oil pump assembly (21) by pushing in primer button on oil pump assembly; continue rotating engine until oil pressure is indicated. If no oil pressure is indicated within 15 seconds, shut down engine, and correct trouble before proceeding. If oil pressure is indicated, continue rotating engine for 60 seconds maximum. 22 Change 8T.0, 26-GTC85-31 WP 005 00 (10) (G1C86/-70A/-714/-72) Check oi! level in oi! tank assembly and replenish if required with oi! specified in table 2 (GTCB5-116) Check oi! level in oil tank assembly (32, figure 1 continued) and replenish if required with oi! specified in table 2 cc. fuel Puna and Control us (1) Disconnect contro! air line (29, Figure 1) at acceleration limiter valve on fuel pump and contro! unit. (2) Remove drain line from fuel pump pressure connection (24) and install a 0 ‘to 100 psig fuel pressure gage at fuel pump pressure connect ion (3) Supply a source of fuel at pressure specified in table 2 and electrical power to engine. WRUNG During operation of the engine, personne! must stand clear of the compressor air inlet. turbine exhaust and planes of rotation of the high-speed turbine and compressor. Extreme care must be taken to prevent any foreign material fron entering the air inlet, Turbine or compressor failure, which may be caused by foreign material entering the en- ™ gine, can be violent and could result in damage to equipment. or injury to nearby personnel CAUTION Do not exceed electrical starter assenbly cycle of 1 minute on, 4 minutes off as damage may occur. (4) Motor engine at starter speed. Check cracking pressure of acceleration limiter valve on fuel pressure gage at fuel pump pressure connection (24) Refer to table 2 for acceleration limiter valve cracking pressure limits, . (5) While engine is rotating, use 280353 screwdriver and wrench assenbly to loosen locknut (27) while holding adjusting screw (28). Turn adjustin 1g adjusting djusting screw (28) clockwise to increase cracking pressure and counterclockwise to decrease cracking pressure | (6) Hold adjusting screw (28) in position and tighten locknut (27) | (1) Shut off electrical power to starter 23T.0, 26 GTCa6 31 WP 005 00 NOTE Operation of engine at fuel inlet pressure other than used at this adjustment will require recheck and readjustment of the cracking pressure. (8) Record cracking pressure and fuel inlet pressure on figure 2 (9) Connect electrical connector to oi! pressure switch (1, figure 1) (10) Connect contro! air line (29) at acceleration limiter valve on fuel pump ‘and contro! unit (11) Remove 0 to 100 psig fuel pressure gage from Fuel pump pressure connect ion (24) on fuel pump and contro! unit and instal! 0 to 425 psig fuel discharge pressure gage. 9. START AND RUN IN CAUTION. Engine must never be permitted to rotate unless there is adequate fuel supplied to fue! pump and contro! unit. fuel pump contro! unit lubrication is provided by fuel Do not exceed operating limits given in teble 1 as engine damage may occur NOTE When the engine is being tested using computer test cell, the computer will automatically contro! the engine during al! manual starts Control of the engine is accomplished by manual ly bypassing more or less fuel from fuel pump pressure connection (24, figure 1) to fuel pump inlet port (23) At the end of each procedure it shall be the test cell operator’s option to shut down the engine or continue test. a. Preliminary Bun. (1) Mark the position of adjusting screw (26, Figure 1) (2) Using 280353 screwdriver and wrench assembly. loosen locknut (25) while holding Fuel pump governor adjusting screw (26). Turn adjusting screw (26) three Full turns clockwise and tighten locknut (25) 247.0. 2G-GTC85-31 WP 005 00 (3) deleted (4) deleted NOTE Resonate vibration usually occurs at approximately 18,000 to 22,000 rpm for the CTC85.56/-7OA/-116 and 28,000 to 32,000 rpm for the GTC85-71A/-72, Accelerate rapidly through speeds that create resonate frequencies. Shut down engine and determine and correct cause of trouble if vibration persists above maximum run-in speeds. (5) (GTC85-56/-70A/-71A/-116) Start engine and rapidly increase speed to 42,100 to 42,300 rpm and operate for 3 minutes. (GTC85-72) Start engine and rapidly increase speed to 42,500 to 42,700 rpm and operate for 3 minutes. (© Check for fuel, oll and air leaks and operation of hourmeter and start counter during run-in (@ Shut down engine (6) Record required data on figure 2. ». Preliminary Oil Filter Element Check. (1) Check oil filter element in oil pump assembly (21, figure 1). Replace oil filter element if ‘contaminated, (2) Flush oil system (@) Prime ofl pump assembly (21) after oil filter element change or removal. (4) (GTC85-56/-70A/-71./-116) If oil system was flushed because of contamination, operate engine ‘at 42,100 to 42,300 rpm for 15 minutes. (GTC85-72) If oll system was flushed because of contamination, operate engine at 42,500 to 42,100 rpm for 15 minutes. (6) Recheck oil filter clement. If foreign particles or metal chips are present, cause shall be deter- mined and corrected before proceeding with test. 10. TESTING. | a. Function Tests and Adjustments. (1) Multiple centrifugal switch assembly check Do not exceed operating limits given in table 1 as engine damage may occur. (@) Start and accelerate engine gradually: at 14,200 to 19,200 rpm the 35 percent switch (starter cutout) shall operate and shutoff electrical power to electrical starter assembly (20, figure 1). (©) Continue accelerating engine; at 38,500 to 39,500 rpm the 95 percent switch (ready to load) shall operate and turn on indicator’ light, indicating engine is ready to aecept bleed-air loading When the engine is being tested using computer test cell, the engine rpm shall be closely monitored during this test and manually shut down if the engine starts to exceed 44,500 rpm. Do not exceed a speed of 43,500 rpm for Tonger than 10 seconds as engine damage may occur. Change 3 257.0. 26-GTC85-31 WP 005 00 (© Continue accelerating engine; at 44,000 to 44,500 rpm the 110 percent switch (overspeed) shall operate and shut down the engine by closing the fuel shutoff valve (22). (@ Repeat the entire multiple centrifugal switch assembly check for a total of two consecutive successful actuations to overspeed and engine shutdown. (6) Record required data on figure 2. (9 Using 280353 screwdriver and wrench assembly, reset fuel pump governor adjusting screw (26, figure 1). Turn adjusting screw (26) counterclockwise back three full turns to original position. (2) Fuel control governor no-load speed adjustment. 26 Change 31.0. 26-67C85.34 WP 005 00 Do not exceed operating limits given in Table 1 as engine damage may occur. (@) (GTC85-56/-70A/-71A/116) Start and accelerate engine to no-load governed speed, 42,100 to 42,300 rpm. {GTC85-72) Start and accelerate engine to no-load governed speed, 42,500 to 42,700 rpm. (0) Close fuel bypass valve. (©) Using 280353 screwdriver and wrench assembly, adjust fuel pump governor by holding adjust- ing screw (Figure 1 continued, 26) and loosening locknut (25). (@) Turn adjusting screw (26) clockwise to increase no-load governed speed and counterclockwise to decrease no-load governed speed. (¢) Hold adjusting screw (26) in position and tighten locknut (25). (Record no-load rpm on Figure 2. (@ Fuel control governor full-load speed adjustment. (a) With the engine operating at no-load governed speed, actuate test cell switch to open load control valve (Figure 1, 8). Do not exceed limits given in Table 1 as engine damage may occur. {b) Slowly open test cell bleed-air control valve until turbine discharge temperature stabilizes at 1200°F (649°C). (0 Engine speed shall not droop more than 1000 rpm below no-load governed speed with steady full bleed load applied. (@ necessary, adjust fuel pump governor adjusting screw (26) to obtain full-load governed speed. (©) Record full load governor rpm on Figure 2. (Recheck no-load governed speed which shall be within limits obtained in step (2)(a) @ Close load control valve (Figure 1, 8) and test cell bleed-air control valve. (t) Allow engine to stabilize for 2 minutes. NoTE Compressor instability is defined as an operating region af violent pulsating airflow, usually outside the normal operating limits of the engine. () Measure compressor instability. Fluctuation should not exceed 1.5 psi (3.06 in, Hg) as mea- sured from minimum to maximum values (peak-to-peak on each wave cycle). Measurement is sure dom fort minute. Listen for instability. Reject engine if excessive rumbling is audible. Ml () (GTC85.56/-714/-116) Shut down engine. (®) Open fuel bypass valve, (4) Adjustable orifice assembly adjustment. (@) (GTC85-56/-71A/-72/-116) Remove cap (2). Install a flexible line and air pressure gage with a range of 0 to 30 psig. getces.708) Remove cap (30). Install a flexible line and air pressure gage with a range of 0 to psig. Change 9 277.0, 2G-4TC8s-31 WP 005 00 o iC) fe) © (H) 0 0 ‘Remove electrical connector from acceleration control solenoid valve (3) ‘Do not exceed limits given in table 1 as engine damage may occur. (GTC85-56/-70A/-71A/-116) Start and accelerate engine to no-load governed speed, 42.100 to 42,300 rpm. (G7C85-72) Start and accelerate engine to no-load governed speed, 42,500 to 42,700 rpm. ‘Note and record no-load control air pressure as indicated on air pressure gage. Determine correct no-load control air pressure required for existing compressor inlet total temper- ‘ature by using curve in figure 4. Adjust no-load control air pressure by loosening locknut (4, figure 1) and turn adjusting screw (5) clockwise to increase pressure and counterclockwise to decrease pressure. Tighten locknut (4). Record final control air pressure and existing inlet temperature on figure 2. Shut down engine. Install electrical connector on acceleration control solenoid valve (3, figure 1). 28 Change 5NO LOAD CONTROL AIR PRESSURE, PSIG 5 4 13) 2 " 10 st 0 20 40 Ci Cy COMPRESSOR INLET TOTAL TEMPERATURE, °F Figure 4. Chart for Determining Correct Control Air Pressure 1.0, 26-G7C85-31 ‘WP 005 00 100 120 Go104068 Change 8 291.0. 2G-61C85-31 WP 005 00 (&) (GTC85-56/-71A/-72/-116) Remove Flexible line and air pressure gage. Install cap (2, figure 1 continued) (GTC85-70A) Remove flexible line and air pressure gage. Install cap (30). () Record control air pressure on figure 2. (8) (GTC85-TOA/-72) 12 amp DC generator output check, {a) With engine operating at no-load governed speed, apply load to 12 amp DC generator (31, figure 1) by means of variable resistor in generator control panel until 12 amp DC generator (Gi) change rate is 12 amperes with 27.5 to 29.0 VDC. (b) Record amperage and voltage on figure 2. (1.12 amp DC generator (31, figure 1) output is not within limits during this check, or if 12 amp DC generator (31) shows any evidence of malfunction during acceptance test, replace 12 amp DC generator (31). (@) Shut down engine. (6) Preliminary performance test. ‘A four percent deviation from bleed system values is permissible for (GTC85-70\/-71A/-72 only) newly overhauled engines. A six percent devia tion from bleed system values is permissible on OCM and repaired engines. ‘This deviation applies to all parameters collectively. For example, if bleed- air flow is four percent less than specified, other parameters must meet requirements specified. (@) Disconnect control air line (9) from fitting (10). Install cap on fitting (10) Do not exceed turbine discharge temperature of 1200°F (649°C) when 10 to 20°F is added during load control thermostat setting, (0) (GTC85-56/-70A/-71A/-116) Start and accelerate engine to no-load governed speed, 42,100 to 42,300 rpm. (GTC85-72) Start and accelerate engine to no-load governed speed, 42,500 to 42,700 rpm. (Open toad contro! valve (8) (@ Slowly open test cell bleed-air control valve to obtain minimum turbine discharge temperature calculated to produce minimum bleed-air flow and pressure as calculated in steps () through (). Do not exceed 1200°F. Allow turbine discharge temperature to stabilize for two minutes. Note turbine discharge temperature. (©) Engine speed shall not drop more than 1000 rpm below no-load governed speed with steady full bleed load applied (9 Record turbine discharge temperature. (@) During full bleed-air load operation, note and record actual bleed-air total temperature and actual bleed-air total pressure. (h) Note and record temperature, pressure, and pressure differential readings at bleed-air flow measuring section. (Calculate actual bleed-air weight flow using readings obtained in step (h) and chart or graph for particular airflow measuring section being used. (Record calculated figure for actual bleed-air weight flow. 30, Change 87.0, 266708531 WP 005 00 (k) Correct actual bleed-air temperature, pressure, and flow to 59°F (15°C), 29.92 inches Hg, NACA STD SL Day conditions using calculation instructions given in steps (7), (8), and (8). () Corrected values obtained in step (k) shall meet minimum bleed system requirements of table 2. Record converted values. (m) Close load control valve (8, figure 1 continued) and test cell bieed-air control valve. (0) Cheek accessory drive assembly pressure indicated on vacuum gage installed in accessory drive negative pressure port. (0) Pressure shall be within -2 to -22 inches Hg, Record pressure on figure 2. (p)_ Shut down engine. (@ Remove vacuum gage, fitting, part No. 13505-1, bolt, part No. 13506-1, and two packings, part No, $9412-556 from accessory drive assembly negative pressure port. (Install plug and bleeder (19, figure 1). (7) Flow correction calculation. The following formula and steps are a typical example for correcting, actual bleed-air flow to the value for a NACA STD SL, Day, We std. NOTE Refer to table 3 for symbol definitions. Wy __ + Delta Wa Signa (@) Assume the actual bleed-air flow, Wg is 115 pounds per minute. Refer to steps (5)(h) through (j) for procedure to obtain actual weight flow. (&) Assume the actual barometer reading is 28.80 inches Hg, Divide 28.80 by 29.92, which equals 0.963, Sigma. (0) Divide bleed-air flow, We, 115 by 0.963, Sigma. This equals 119.4 pounds per minute, Wg “Sigma. Formula: We sa (@ Assume compressor inlet air temperature, Tey is 81°F. Find this value in table 4; then read over to the next column, and find value for Delta We, which is 9.1 (@) Add 119.4 pounds per minute obtained in step (¢) to Delta We, 9.1, obtained in step (d) to obtain 128.5 pounds per minute, This is the actual bleed-air Flow corrected to the value for a 59°F (15°C), 29.92 inches Hg, NACA STD SL Day, Wa std. (Substituting all preceding figures in the formula results in the following: us 128.5 = ZBBO + 9.1 W902" (@ Record bleed-air flow on figure 2. (8) Pressure correction calculation. The following formula and steps are a typical example for cor- recting actual bleed-air pressure to the value for a NACA STD SL Day, Pg std. NOTE Refer to table 3 for symbol definitions. Formula: We sa = W; + Delta Wa Sigma (a) Assume actual bleed-air pressure, Pg is 104 inches Hg absolute. Change 8 31/(32 blank)7.0, 2G-GTCa5-31 WP 005 00 Table 3. Symbol Definition Synbo| Definition Wy represents observed bleed-air flow in pounds per minute » represents observed blead-air pressure in inches lig absolute + represents observed bleed-air temperature in degrees Fahrenheit Woes represents corrected bleed-air flow per (59°F (15°C), 29.92 inches Hg) NACA STD SL Day p represents corrected bleed-air pressure per (59°F (15°C), mee 29.92 inches Hg) NACA STD SL Day T represents corrected bleed-air temperature per (59°F (15°C), vee 29.92 inches Hg) NACA STD SL Day. Tes represents observed compressor inlet air temperature in degrees Fahrenheit Delta Wy represents flow correction factor at Ta. Delta P, represents pressure correction factor at T., Delta T, represents temperature correction factor at T. Signa represents barometer correction factor which is calculated by dividing observed barometer pressure in inches Hg by 29.922G-GTC85-31 7.0. WP 005 00 Performance Correction Factors Table 4 w pe Delta P, Hg ABS) (in Delta W, co) Tes CF) Delta T, (CF) Delta Py (In. Hg ABS) Delta W, co) 42 4a 40 2 38 erst 37 36 35 34 32 Kenen 44 11.0 17 “18 “19 -20 -21 -22 -24 -25 -28 “27 BaaaS 8 4 3 R 10 -28 -28 -30 -32 -33 47.0, 26-GTC85-31 WP 005 00 Table 4. Performance Correction Factors (Cont) T., Delta Wy Delta R, Delta T, Te, Delta W Delta P, Delta T, CF) (PH) (in, Hg ABS) CF) Cr (in. Hg ABS) cr) go 12.9 42 -34 ms 23.4 14 62 113.3 44 -35 6 23.8 15 -64 2 13.7 45 -36 1 24.2 76 -65 3 46 “37 8 8 17 68 4 146 48 -38 9 4 18 “61 % 15.0 49 -40 120 25.5 8.0 -68 6 15.4 5.0 41 1 2.9 8.1 69 1 15.8 5.1 42 2 263 8.2 -70 8 16.2 5.3 -43 326.7 83 n 9 167 54 “44 4 22 85 2 wo 74 5.5 “45 1% 278 8.6 “73 1175 56 “46 6 28.0 87 “14 2 19 5.8 48 7 284 8.8 “15 3 18.3 5.9 -49 8 288 8.9 “78 4 18.8 6.0 -50 9 (29.3 9.0 “17 é 105 19.2 6.1 -51 130 -29.7 a4 -78 2 6 196 6.3 -82 7 20.0 64 -53 8 204 65 -54 9 20.9 67 “56 mo 213 6.8 7 1 27 6.9 20 24 7.0 3 25 a 4 23.0 74 357.0. 2G-GTCaS-3 WP 005 00 (b) Assume the actual barometer reading is 28.80 Inches Hg. Divide this reading by 29.92, This equals 0.963, Sigma (c) Divide bleed-air pressure, P,, 104 by f..963, Signa and record result This equals 108 inches Hg absolute, _'B Sigma (A) Assume compressor inlet air temperature, T.,is 81°F. Find this value in ‘table 4, then read over to the third colum and find value for Delta P,, which is 3.1 (e) Add 108 inches Hg absolute obtained in step (c) to Delta P,, 3.1 obtained in step (d) to obtain 111.7 inches Hg absolute. This is the actual bleed-air pressure corrected to the value for a 59°F (15°C), 29.92 inches Hig NACA STD SL Day. Py.u (f) Substituting all preceding figures in the formula results in the fol low- ing Miia = Zea +1 = 28.80 + 3.1 2.52 (g) Record bleed-air pressure on figure 2 (9) Temperature correction calculation. The following formila and steps are a typical example for correcting actual bleed-air temperature to the value for a NACA STD DL Day, Tray NOTE Refer to table 3 for symbol definitions Formula: Ty w= Ty+ Delta T, (a) Assume actual bleed-air tomperature, T,is 430°F (b) Assune compressor inlet air temperature, +. is 81°F. Find this value in table 4, then read over to fourth column afid Find value for Delta Ty, which is (-24) (c) Add 430°F obtained in step (a) to Delta T,(-24) obtained in step (b) to obtain T,std 406°F, This is the actual bieed-air temperature corrected to the value for e 59°F (15°C), 29.92 inches Hg NACA STD SL Day, Tew: (d) Substituting al! preceding ing: 406 = 430 + (-24) igures in the formula results in the fol low- (e) Record bleed-air temperature on figure 2 367.0. 2G-GTC85-31 WP 005 00 (10) Pneumatic (acceleration control) thermostat adjustment. NOTE Ensure control air line (9, figure 1) is disconnected from fitting (10) and fitting is capped. (a) Actuate switches to start engine and supply electrical power and fuel to engine. (bo) (GTC85-56/-70A/-71A/-116)) Accelerate engine to no-load governed speed, 42,100 to 42,300 rpm, (GTC85-72) Accelerate engine to no-load governed speed, 42,500 to 42,700 rpm. Do not exceed Limits given in table 1 as engine damage may occur. (Actuate test cell switch to open load control valve (8). (@ While monitoring engine fuel flow, rpm and turbine discharge temperature, slowly open test cell bleed-air control valve until engine fuel flow and rpm start dropping. (©) Note turbine discharge temperature at this point. (The noted turbine discharge temperature is the pneumatic (acceleration control) thermostat (18) cracking temperature. (@ Record cracking temperature on figure 2. (h) The cracking temperature must be within 1250 to 1270°F (677 to 688°C). () Recheck cracking temperature two more successive times and compare cracking temperatures. ‘The cracking temperatures shall be within +15°F (+8°C) of recorded cracking temperature. {) Ieracking temperature is not within limits, adjust pneumatic (acceleration control) thermostat (18, figure 1) as outlined in steps (k) through (Ww) for shim type thermostats and step (x) for I adjustable collar type thermostats. (k) Close load control valve (8) and test cell bleed-air control valve. Failure to hold valve assembly of pneumatic (acceleration control) thermo- stat (18 figure 1 continued) when removing or connecting control air line (17) may result in a calibration shift andlor damage. (ni) Hold pneumatic (acceleration control) thermostat (18) with a wrench and remove control air line (17). Damage to the ball and seat in valve assembly (1, figure 5) ball valve itioner assembly is not used when remaving valve assembly (1) from iy assembly (3). (nr) Loosen middle locknut and small adjustment screw on 281421-1 ball valve positioner assembly and install on pneumatic (acceleration control) thermostat (18, figure 1). (0) Tighten small adjustment screw on 281421-1 ball valve positioner assembly until it contacts the bail in the valve assembly (I, figure 5), then tighten two full turns clockwise to offset the ball. Tighten middle locknut. {) Shut down engine. Change 7 37