GG Maint (807421) - 5

Pratt & Whitney Power Systems, Inc.
GG8 MAINTENANCE MANUAL (PN 807421)

GG8-2 GAS GENERATOR - REMOVAL/INSTALLATION-08
Air Starter
Figure 8
MAINTENANCE
REM/INST-08
PAGE 6-14
01-00 DEC 20/12
© Pratt & Whitney Power Systems, Inc
Homepage Previous Document

EAR Export Classification: ECCN EAR99 - Subject to the export control restrictions on the title page of this document.
Gas Starter
Figure 9
MAINTENANCE
REM/INST-08
PAGE 6-15
01-00 DEC 20/12

Natural Gas (Front View)

Figure 10
MAINTENANCE
REM/INST-08
PAGE 6-16
01-00 DEC 20/12

GAS GENERATOR - REMOVAL/INSTALLATION-09
1. Gas Generator Storage, Preservation and Depreservation
SEE SECTION 17
MAINTENANCE
REM/INST-09
PAGE 6-1
01-00 DEC 20/12

BELLMOUTH - REMOVAL/INSTALLATION-01
1. Bellmouth Removal
A. Illustrated Parts Catalog Section Reference: 01-18
B. Prerequisites: None
C. Tools: PWA 77356 Enclosure Trolley

PWA 77387 Hoist
D. Procedure
See Figure 1.
CAUTION: MAKE SURE THAT YOU DO NOT HIT THE VIBRATION PICKUP
(LOCATED AT THE 11 O’CLOCK POSITION ON THE INLET
CASE) WHEN YOU REMOVE THE BELLMOUTH.
(1) Put a mark on the bellmouth, plate, and inlet case to

be used for alignment at installation. The bellmouth
and inlet case offset hole is located at the bottom of
the gas generator.
(2) Install a nylon strap to the lifting lug at the

12 o’clock location on the bellmouth.
(3) Attach the nylon strap to the PWA 77387 Hoist which is
connected to the PWA 77356 Trolley. Put the weight of
the bellmouth on the hoist.
(4) Remove the nuts, plates, and bolts that hold the
bellmouth to the inlet case. Note the offset hole
location on the plate at the 6 o’clock position.
(5) Move the bellmouth forward into the inlet plenum and
put it against the wall. Release the nylon strap from
the hoist.
MAINTENANCE
REM/INST-01
PAGE 6-1
01-18 DEC 20/12

Bellmouth Removal/Installation
Figure 1
MAINTENANCE
REM/INST-01
PAGE 6-2
01-18 DEC 20/12

2. Bellmouth Installation
B. Tools: PWA 77356 Enclosure Trolley

PWA 77387 Bellmouth Hoist
C. Consumables: PWA 521 Oil
D. Expendables: None
E. Procedure
See Figure 1.
CAUTION: MAKE SURE THAT YOU DO NOT HIT THE ACCELEROMETER

(VIBRATION) SENSOR (LOCATED AT THE ELEVEN O’CLOCK
POSITION ON THE INLET CASE) WHEN YOU INSTALL THE
BELLMOUTH.
(1) Install the nylon strap on the bellmouth lifting lug.
(2) Attach the nylon strap to the PWA 77387 Hoist which is
connected to the PWA 77356 Trolley.
(3) Lift the bellmouth into position against the inlet case
flange (Flange A). Align the offset hole in the
bellmouth and the inlet case. Use the alignment marks
made on the cases at removal as a guide.
(4) Loosely install the plates, nuts and bolts lubricated

with PWA 521 Oil, on the flange.
(5) Torque the bolts to 180 - 200 lb-in. (20.337 –

22.597 N.m).
F. Postrequisites: None
MAINTENANCE
REM/INST-01
PAGE 6-3
01-18 DEC 20/12

1. Nose Cone Removal
B. Prerequisites
(1) Remove the bellmouth. Refer to Maintenance Section 01-

18, Removal/Installation-01.
C. Tools: None
D. Procedure
See Figure 1.
(1) Bend the key washer tabs away from the bolts that hold
the nose cone to the compressor inlet adapter.
(2) Remove the bolts and discard the key washers.
(3) Remove the nose cone.
(4) Remove the inlet adapter as follows:
(a) Remove the bolt and nut that holds the NL (N1)
transducer wire loop clamp to the bracket at the
bottom of the inlet adapter.
(b) Remove the five nuts and three washers that hold
the inlet adapter to the No. 1 bearing support
cover.
(c) Remove the bracket from the inlet adapter.
(d) Remove the inlet adapter from the No. 1 bearing

support cover.
MAINTENANCE
REM/INST-02
PAGE 6-1
01-18 DEC 20/12

Nose Cone Removal/Installation

Figure 1
MAINTENANCE
REM/INST-02
PAGE 6-2
01-18 DEC 20/12

2. Nose Cone Installation
B. Tools: None
D. Expendables:
PARTS CATALOG REFERENCE

PART NAME QUANTITY SECTION FIGURE ITEM
Key Washer 6 01-18 1 30
E. Procedure
See Figure 1.
(1) Install the inlet adapter as follows:
(a) Lightly lubricate studs with PWA 521 Oil and

install the inlet adapter on the studs that are
located on the No. 1 bearing support cover.
(b) Install the bracket over the bottom two studs.

Install washers on the other three studs.
(c) Install the nuts that hold the inlet adapter to

the No. 1 bearing support cover. Torque the nuts
to 150 - 170 lb-in. (16.948 - 19.207 N.m).
(d) Position the loop clamp on the bracket that holds

the NL (N1) transducer wire and install the bolt,
lubricated with PWA 521 Oil, and nut to hold the
loop clamp to the bracket. Torque the loop clamp
bolt to 32 - 36 lb-in. (3.616 - 4.067 N.m).
(2) Install the nose cone on the inlet adapter and hold it
in position with loosely installed bolts, lubricated
with PWA 521 Oil, and key washers.
MAINTENANCE
REM/INST-02
PAGE 6-3
01-18 DEC 20/12

(3) Cast Aluminum, Nose Cone (Pre SB 06B01) – Torque bolts

to 150 - 170 lb-in. (16.948 – 19.207 N.m) and bend the
key washer tabs to hold bolts in place.
(4) Fiberglass, Nose Cone (Post SB 06B01) – Torque bolts to

95 – 105 lb-in. (10.734 – 1.863 N.m) and bend the key
washer tabs to hold bolts in place.
F. Postrequisites
(1) Install the bellmouth. Refer to Maintenance

Section 01-18, Removal/Installation-01.
MAINTENANCE
REM/INST-02
PAGE 6-4
01-18 DEC 20/12

NL (N1) TACHOMETER DRIVE OIL SEAL RETAINER AND SEAL ASSEMBLY -
REMOVAL/INSTALLATION - 01
1. NL (N1) Tachometer Drive Oil Seal Retainer And Seal Assembly

Removal
B. Prerequisites
(1) Remove the nose cone. Refer to Maintenance Section

01-18, Removal/Installation-02.
C. Tools: PWA 77062 Holder, NL (N1) Transducer Wheel

PWA 77063 Knocker/Puller
D. Procedure
See Figure 1.
(1) Remove the NL (N1) transducer electrical connectors

from the motional pickup transducers.
(2) Remove the four nuts and washers that hold the
transducer housing cover to the motional transducer
housing assembly.
(3) Remove the cover and gasket.
NOTE: The loop clamp bracket mounted on the lower two

studs is also removed when removing the cover.
(4) Remove the cotter pin from the nut that holds the
motional pickup transducer wheel.
(5) Use a PWA 77062 Holder to hold the transducer wheel.

Loosen and remove the nut that holds the transducer
wheel on the gearshaft.
(6) Remove the motional pickup transducer wheel.
(7) Remove the woodruff key from the gearshaft.
(8) Remove the motional pickup transducer housing assembly

and gasket.
(9) Remove the two machine screws that hold the oil seal
retainer on the support assembly.
MAINTENANCE
REM/INST-01
PAGE 6-1
01-21 DEC 20/12

NL (N1) Tachometer Drive Oil Seal Retainer and Seal Assembly

Figure 1
MAINTENANCE
REM/INST-01
PAGE 6-2
01-21
DEC 20/12

(10) Use a PWA 77063 Knocker/Puller to remove the oil seal

retainer from the support assembly. Remove the packing
from the oil seal retainer and discard.
2. NL (N1) Tachometer Drive Oil Seal Retainer And Seal Assembly

Installation
B. Tools: PWA 77062 Holder, NL (N1) Transducer Wheel
C. Consumables: PWA 36500 Assembly Fluid

PWA 521 Oil
D. Expendables:

Packing 1 01-21 1 180

Gasket 1 01-21 2 140
Cotter Pin 1 01-21 2 190
Gasket 1 01-21 2 200
Wire, Safety As Req’d
E. Procedure
See Figure 1.
(1) Install a new preformed packing (lubricated with

PWA 36500 Assembly Fluid or PWA 521 Oil) into the ring
groove at the outer diameter of the oil seal retainer.
(2) Install the assembled oil seal retainer into the

support assembly. Align the two holes on the retainer
front flange to make installation of the machine screws
possible.
(3) Install the two machine screws, lubricated with PWA 521
Oil, to hold the oil seal retainer to the support
assembly.
(4) Torque the screws to 20 - 22 lb-in. (2.260 - 2.486

N.m).
MAINTENANCE
REM/INST-01
PAGE 6-3
01-21 DEC 20/12

(5) Install the woodruff key into the slot in the

gearshaft, flat edge out. Drift the key to seat in the
slot.
(6) Install a new gasket over studs to seat against the oil
seal retainer.
(7) Install the motional pickup transducer housing

assembly.
(8) Install the motional pickup transducer wheel, aligning

the slot in the wheel with the woodruff key in the
gearshaft.
(9) Use a PWA 77062 Holder to hold the transducer wheel

stationary. Lubricate the gearshaft nut with PWA 521
Oil and install.
(10) Torque the gearshaft nut to 225 - 300 lb-in. (25.422 -

33.895 N.m), aligning the slots in the nut with the
hole in the shaft within the torque range.
(11) Install and bend a new cotter pin to safety the nut.
(12) Set the gap between the transducer and the motional
pickup transducer wheel.
(a) Measure the gap between the transducers and the

motional pickup transducer wheel. If the gap is
0.020 inch (0.051 mm) the gap is serviceable and
needs no adjustment. Continue with Step (13). If
the gap is not 0.020 inch (0.051 mm), adjust it
with the method in Steps (13) and (14).
(13) Loosen the jamnut on the transducer that is to be

adjusted. Turn the transducer into the bushing until
it lightly touches the motional pickup transducer
wheel.
(14) Turn the transducer out 120-140 degrees to set the

0.020 inch (0.051 mm) gap. Use the jamnut to lock the
transducer in position. Torque the jamnut to 95 -
105 lb-in. (10.734 - 11.863 N.m).
(15) Install a new gasket and the cover.
MAINTENANCE
REM/INST-01
PAGE 6-4
01-21 DEC 20/12

(16) Lightly lubricate studs with PWA 521 Oil and install
two washers and nuts at the outer studs (from center of
support assembly) to hold the cover.
(17) Install bracket to remaining studs (29° angle end to

raised center of support assembly) with two washers and
nuts.
(18) Torque the nuts to 65 - 85 lb-in. (7.344 - 9.604 N.m).
(19) Use wire to safety the cover nuts as follows:
(a) Use one piece of wire to safety the lower left

cover nut to the left jamnut.
(b) Use another piece of wire to safety the lower

right cover nut to the right jamnut.
(c) Use another piece of wire to safety the two upper

cover nuts together.
(20) Install the NL (N1) transducer electrical connectors on

the motional pickup transducers.
F. Postrequisites
(1) Install the nose cone. Refer to Maintenance Section

MAINTENANCE
REM/INST-01
PAGE 6-5
01-21 DEC 20/12

NL (N1) TACHOMETER DRIVE OIL SEAL -
REMOVAL/INSTALLATION-02
1. NL (N1) Tachometer Drive Oil Seal Removal
B. Prerequisites
(1) Remove the oil seal retainer and seal assembly. Refer
to Maintenance Section 01-21, Removal/Installation-01.
C. Tools: PWA 12547 Drift
D. Procedure
See Figure 1
(1) Put the oil seal retainer on a bench with the rear face
(seal side) down.
(2) Use a PWA 12547 Drift to carefully remove the oil seal
from the retainer.
2. NL (N1) Tachometer Drive Oil Seal Installation
B. Tools: PWA 12540 Base

PWA 12547 Drift

PWA 521 Oil
D. Expendables:

Seal 1 01-21 1 190
MAINTENANCE
REM/INST-02
PAGE 6-1
01-21 DEC 20/12

Oil Seal Retainer and Seal

Figure 1
MAINTENANCE
REM/INST-02
PAGE 6-2
01-21 DEC 20/12

E. Procedure
See Figure 1.
(1) Put the oil seal retainer, with square flanged end
down, on a PWA 12540 Base.
(2) Apply a light coat of PWA 36500 Assembly fluid or

PWA 521 Oil to the OD of the seal.
(3) Install the seal, spring side up on the PWA 12547

Drift, then guide the pilot of the drift into the hole
in the base.
(4) Using a suitable arbor press, seat the seal into the
retainer.
(5) Remove the assembled seal and retainer from the base.
F. Postrequisites
(1) Install the oil seal retainer and seal assembly. Refer
MAINTENANCE
REM/INST-02
PAGE 6-3
01-21 DEC 20/12

FRONT ACCESSORY DRIVE GROUP - REMOVAL/

INSTALLATION-03
1. Front Accessory Drive Group Removal
B. Prerequisites
(1) Remove the nose cone. Refer to Maintenance Section

C. Tools: PWA 45222 Knocker/Puller, No. 1 Bearing

Support
D. Procedure
See Figure 1.
(1) Disconnect the NL (N1) leads from the NL (N1)

transducers.
(2) Disconnect the five loop clamps that hold the NL (N1)
leads, from the bracket.
(3) Remove the two nuts and washers that hold the loop
clamp bracket to the NL (N1) transducer housing and the
two nuts that hold the outer loop clamp bracket to the
No. 1 bearing support cover. Remove the NL (N1) leads,
loop clamps and brackets, as an assembly, from the
group.
(4) Remove all but three equally spaced bolts that hold the
No. 1 bearing support cover to the compressor inlet
group. Loosen the three remaining bolts.
NOTE: The loose bolts are used to make sure that the
No. 1 bearing support cover will not fall during
the removal operation.
(5) Use the procedure that follows to remove the front

accessory drive group from the compressor inlet group:
MAINTENANCE
REM/INST-03
PAGE 6-1
01-21 DEC 20/12


INSTALLATION-03
Front Accessory Drive Group Removal/Installation

Figure 1
MAINTENANCE
REM/INST-03
PAGE 6-2
01-21 DEC 20/12


INSTALLATION-03
(a) Install two PWA 45222 Knocker/Pullers on the

threaded studs that are at locations approximately
opposite each other on the front face of the No. 1
bearing support cover.
(b) Operate the two slide hammers at the same time to

disengage the No. 1 bearing support cover from the
compressor inlet group.
(c) Remove the PWA 45222 Knocker/Pullers.
(d) Remove the three loosened bolts from the No. 1

bearing support cover.
(6) Put the No. 1 bearing support cover, rear side up on a

workbench.
(7) Remove the four transfer tubes. It is possible for the

tubes to stay either in the No. 1 bearing support cover
or in the compressor inlet group when the two groups
are divided.
(8) Remove and discard the packings that are located on the
transfer tubes and on the No. 1 bearing housing mating
diameter.
2. Front Accessory Drive Group Installation
B. Tools: F42774 Vacuum Cart (or equivalent)

PN 85866 Cox Airflow Kit (or equivalent)
Standard Connectors
PWA 12935 Cap

PWA 9609 Petrolatum
PWA 521 Oil
MAINTENANCE
REM/INST-03
PAGE 6-3
01-21 DEC 20/12


INSTALLATION-03
D. Expendables

Packing 12 01-21 3 10
Packing 4 01-21 3 30
Packing 1 01-21 3 40
Wire, Safety As Reqd
E. Procedure
See Figure 1.
(1) Install four new preformed packings (lubricated with

PWA 36500 Assembly Fluid or PWA 521 Oil) on each of the
four transfer tubes.
(2) Install the four transfer tubes into the oil ports in
the No. 1 bearing housing assembly.
CAUTION: IF YOU APPLY PETROLATUM TO THE PACKING, USE ONLY A

SMALL QUANTITY ON THE PACKING TO PREVENT POSSIBLE
CONTAMINATION OF THE OIL SYSTEM.
(3) Install a new preformed packing (lubricated with

PWA 36500 Assembly Fluid or petrolatum) into the ring
groove on the mating diameter of the No. 1 bearing
housing assembly.
NOTE: It is optional to use petrolatum as a replacement for

PWA 36500 Assembly Fluid, but it is better to use the
assembly fluid. Use petrolatum only if assembly
fluid is not available.
(4) Use the procedure that follows to install the front

accessory drive group:
(a) Make sure that the gears and the transfer tubes
are correctly aligned before installing the front
accessory drive group on the compressor inlet
group.
CAUTION: DO NOT USE THE BOLTS TO PULL THE FRONT

ACCESSORY DRIVE GROUP INTO POSITION. DAMAGE
TO THE PACKINGS WILL OCCUR IF THE FRONT
ACCESSORY DRIVE GROUP IS INSTALLED USING
THIS METHOD.
MAINTENANCE
REM/INST-03
PAGE 6-4
01-21 DEC 20/12


INSTALLATION-03
(b) Lightly hit the No. 1 bearing support cover with a

dead blow mallet to fully engage the No. 1 bearing
support cover. Do not hit the bolt lugs or the NL
(N1) transducer.
CAUTION: TORQUE THE BOLTS WITH THE PROCEDURE GIVEN. NOT

FOLLOWING THIS PROCEDURE, CAN CAUSE A FRONT
ACCESSORY DRIVE GROUP TO BE MISALIGNED.
(5) Install bolts, lubricated with PWA 521 Oil, and washers
by the sequence specified to hold the No. 1 bearing
support cover tight. Torque the bolts to 75 - 85 lb-
in. (8.474 - 9.604 N.m) in the sequence that follows:
(a) Torque two bolts that are approximately 180

degrees apart.
(b) Torque a second pair of bolts approximately 90

degrees from the first pair.
(c) Torque a third pair approximately 45 degrees from

the second pair.
(d) Continue to torque bolts in pairs that are located

approximately 45 degrees from the last pair until
only one bolt is loose.
(e) Torque the last loose bolt to complete the

sequence.
(6) Do an oil flow test to check the flow through the

nozzle and a vacuum test to check for leakage into the
No. 1 bearing compartment, as follows:
(a) Disconnect the No. 1 bearing oil pressure supply,

breather, and scavenge tubes at the bottom of the
gas generator at Flange B.
(b) Install PWA 12935 Cap on the end of the oil

pressure supply tube. Leave the breather and
scavenge lines open. Connect air and gage lines
from the airflow kit and do the following:
1 Set the air pressure to 10 psi (68.9 kPa).
MAINTENANCE
REM/INST-03
PAGE 6-5
01-21 DEC 20/12


INSTALLATION-03
2 Measure the rate of airflow through the No. 1

bearing oil nozzles.
3 The airflow value must be 7.5 - 12.5 lb/hr

(3.40 - 5.67 kg/hr).
(c) Remove the connector from the oil pressure supply

tube and the airflow kit.
(d) Install a suitable connector on the breather tube.

Cap the oil pressure and scavenge tubes.
(e) Attach the vacuum source and gages to the

connector and do the following:
1 Set the vacuum to -20 in.(-508 mm) Hg.
2 Measure the rate of airflow (this is leakage

into the No. 1 bearing compartment).
3 The airflow value shall be three lb/hr

(1.36 kg/hr) maximum.
(f) Remove the test equipment.
(7) Connect the oil supply, breather, and scavenge tubes to

the appropriate tubes at the bottom of the gas
generator at Flange B.
(8) Torque the No. 1 bearing breather tube connections at

the bottom of the gas generator at Flange B to 475 -
525 lb-in. (53.668 - 59.317 N.m).
(9) Torque the remaining oil supply and oil scavenge

connectors to 200 - 225 lb-in. (22.597 - 25.422 N.m).
(10) Safety all the tube connections with wire.
(11) Install the NL (N1) leads, loop clamps and bracket on

the group.
(a) Connect the NL (N1) leads on the NL (N1)

transducers.
(b) Install the bracket on the two outer bosses and

hold the bracket in place with two nuts.
MAINTENANCE
REM/INST-03
PAGE 6-6
01-21 DEC 20/12


INSTALLATION-03
(c) Torque the nuts to 150 - 170 lb-in. (16.948 -

19.207 N.m).
(d) Install the five loop clamps. Torque the bolts to

32 - 36 lb-in. (3.616 - 4.067 N.m).
F. Postrequisites
(1) Install the nose cone. Refer to Maintenance Section

MAINTENANCE
REM/INST-03
PAGE 6-7
01-21 DEC 20/12

NO. 1 BEARING OIL SCAVENGE PUMP - REMOVAL/
INSTALLATION-04
1. No. 1 Bearing Oil Scavenge Pump Removal
B. Prerequisites
(1) Remove the front accessory drive group. Refer to

Maintenance Section 01-21, Removal/Installation-03.
C. Tools: None
D. Procedure
See Figure 1.
(1) Remove the wire and four nuts and washers that hold the
pump to the No. 1 bearing support cover.
(2) Lift the pump assembly away from the No. 1 bearing
support cover.
2. No. 1 Bearing Oil Scavenge Pump Installation
B. Tools: None
D. Expendables:

Lockwire As Req’d
E. Procedure
See Figure 1.
MAINTENANCE
REM/INST-04
PAGE 6-1
01-21 DEC 20/12

INSTALLATION-04
No. 1 Bearing Oil Scavenge Pump Removal/Installation

Figure 1
MAINTENANCE
REM/INST-04
PAGE 6-2
01-21 DEC 20/12

INSTALLATION-04
(1) Put the No. 1 bearing support cover, front side down,
on a clean surface.
(2) Install the scavenge pump on the four studs.
(3) Lightly lubricate studs with PWA 521 Oil, and install
the four washers and nuts to hold the pump.
(4) Torque the nuts to 65 - 85 lb-in. (7.344 - 9.604 N.m).
CAUTION: MAKE SURE THAT THE WIRE IN THE STEP THAT FOLLOWS
DOES NOT TOUCH AND DAMAGE THE PUMP DRIVEGEAR WHEN
IT IS INSTALLED.
(5) Lockwire the four nuts.
F. Postrequisites
(1) Install the front accessory drive group. Refer to

MAINTENANCE
REM/INST-04
PAGE 6-3
01-21 DEC 20/12

NO. 1 BEARING OIL SCAVENGE PUMP SPUR IDLER GEAR AND

DRIVE GEARSHAFT - REMOVAL/INSTALLATION-05
1. No. 1 Bearing Oil Scavenge Pump Spur Idler Gear And Drive
Gearshaft Removal
B. Prerequisites
(1) Remove the No. 1 Bearing Oil Scavenge Pump. Refer to

C. Tools: PWA 12286 Holder
D. Consumables: None
E. Procedure
See Figure 1.
(1) Remove the cotter pin from the front accessory spur
gear nut.
(2) Install PWA 12286 Holder on the spur gear and remove
nut.
(3) Remove the spur gear.
(4) Hold the pump with the gearshaft down.
(5) Remove the screws that attach the pump cover and remove
cover.
(6) Remove the drive gearshaft from the pump body.
(7) Remove the spur idler gear from the shaft.
2. No. 1 Bearing Oil Scavenge Pump Spur Idler Gear And Drive
Gearshaft Installation
B. Tools: PWA 12286 Holder
MAINTENANCE
REM/INST-05
PAGE 6-1
01-21 DEC 20/12


D. Expendables:

Cotter Pin 1 01-21 2 1

Lockwire As Req’d
E. Procedure
See Figure 1.
(1) Before installing the spur idler gear and drive

gearshaft into rear housing assembly, do the following:
(a) Examine condition of gear teeth and splines,

including the front accessory spur gear.
NOTE: If either spur idler gear or drive gearshaft is

replaced with a new part, it is recommended that
both gears be replaced and installed as a set.
(b) Check condition of idler shaft, rear housing and

cover.
(c) Check screen strainer element for foreign

material. Clean as required
(2) Hold the pump rear housing with the gear recess up.
(3) Lightly lubricate both gears and inner side of rear

housing with PWA 521 Oil. Install the spur idler gear
on the shaft in the pump housing and the drive
gearshaft in the adjacent recess in the housing, spline
end down. Mesh gears when installing.
(4) Check gear backlash, 0.0045 inch (0.1143 mm) minimum,

0.0195 inch (0.4953 mm) maximum).
(5) Put the pump cover over the gears, aligning dowel pins,
and install on rear housing with two screws, lubricated
with PWA 521 Oil.
(6) Torque screws to 22 – 30 lb-in. (2.486 – 3.390 N.m).
MAINTENANCE
REM/INST-05
PAGE 6-2
01-21 DEC 20/12


(7) Install screen strainer element, if removed, on the

rectangular boss on the bottom of the pump rear housing
and attach with lockwire.
NOTE: Tails of twisted lockwire should be on housing

side.
(8) Install the front accessory spur gear on the gearshaft

spline. Tap lightly with a soft mallet to install it
tightly against the mating surface.
NOTE: If scavenge pump is to be immediately installed

in the No. 1 bearing support cover, Steps (8)
through (12) should be accomplished after to ease
installation. Refer to No. 1 Bearing Oil
Scavenge Pump – Removal/Installation-04.
(9) Install spur gear nut and hold the gear with a
PWA 12286 Holder.
(10) Torque the nut to 150 – 250 lb-in. (15.948 –

28.246 N.m). Remove the holder.
(11) Install and bend cotter pin.
(12) Check and make sure the pump gears rotate freely.
F. Postrequisites
(1) Install the No. 1 Bearing Oil Scavenge Pump. Refer to

MAINTENANCE
REM/INST-05
PAGE 6-3
01-21 DEC 20/12


1. Machine Screw
2. Pump Cover
3. Drive Gearshaft
4. Spur Idler Gear
5. Pump Housing
6. Spur Gear
7. Pump Gear Retaining Nut
8. Cotter Pin
9. Screen Strainer Element
No. 1 Bearing Oil Scavenge Pump Spur Idler Gear and Drive Gearshaft
Removal/Installation
│ Figure 1
MAINTENANCE
REM/INST-05
PAGE 6-4
01-21 DEC 20/12

NO. 1 BEARING AND SPUR GEAR ASSEMBLY - REMOVAL/
INSTALLATION-01
1. No. 1 Bearing And Spur Gear Assembly Removal
B. Prerequisites
(1) Remove the front accessory drive group. Refer to

C. Tools: PWA 29389 Hydraulic Pump

PWA 32766 Remover
PWA 45009 Puller
PWA 45023 Wrench
PWA 45024 Adapter
PWA 45232 Adapter
PWA 45233 Adapter
PWA 77036 Puller (Hydraulic)
PWA 77039 Puller (Mechanical)
PWA 80187 Torque Multiplier (Mechanical)
PWA 80651 Torque Multiplier (Pneumatic)
D. Procedure
See Figures 1, 2, and 3.
(1) Remove the retaining ring that holds the spur gear
assembly in the front hub (Figure 1). Attach a
PWA 45009 Puller behind the gearshaft gear teeth and
use the slide action to carefully remove the spur gear
assembly.
(2) Remove and discard the packing from the spur gear.
CAUTION: IF NEEDLE NOSE PLIERS OR EQUIVALENT TOOLS ARE

USED TO REMOVE THE NO. 1 BEARING INNER RACE
RETAINING NUT RIVET, BE CAREFUL TO PREVENT DAMAGE
TO THE HUB OR BEARING.
(3) Using PWA 32766 Remover, remove the rivet from the
No. 1 bearing inner race retaining nut.
MAINTENANCE
REM/INST-01
PAGE 6-1
01-23 DEC 20/12

INSTALLATION-01
No. 1 Bearing and Spur Gear Assembly

Figure 1
MAINTENANCE
REM/INST-01
PAGE 6-2
01-23 DEC 20/12

INSTALLATION-01
1. No. 1 Bearing Housing

2. Bolt
3. No. 1 Bearing Retaining Plate
4. Stop
5. Spur Gear Assembly
6. Retaining Ring
7. Rivet
8. Retaining Nut
9. No. 1 Bearing Inner Race
10. No. 1 Bearing Outer Race and Rollers
11. Seal Rings
12. First Stage Compressor Hub
13. Seal Seat
14. Packing
Key to Figure 1
(4) Remove the No. 1 bearing inner race retaining nut.
(a) Install the PWA 45023 Wrench on the nut and then
install the PWA 45024 Adapter through the wrench
and in the hub inner diameter spline.
(b) Put a PWA 45232 Adapter against the holding pins

on the PWA 80187 Torque Multiplier and secure it
with thumbscrews.
NOTE: PWA 80651 Torque Multiplier is installed over

the drive mechanism on PWA 80187 to provide
rapid rotation of nut.
(c) Install a PWA 45233 Adapter, from the opposite

side, in the splines located in the PWA 80187
Torque Multiplier.
(d) Put the PWA 80187 Torque Multiplier against the

slot in the PWA 45023 Wrench and engage the
splines with the PWA 45024 Adapter.
(e) Loosen and remove the No. 1 bearing inner race

retaining nut.
MAINTENANCE
REM/INST-01
PAGE 6-3
01-23 DEC 20/12

INSTALLATION-01
(5) Put shims at the 1st stage compressor blade tips to

keep the rotor position.
CAUTION: MAKE SURE THAT THE CENTER PUCK DETAIL OF THE

PULLER IS CORRECTLY INSTALLED ON THE HUB. A PUCK
THAT IS NOT CORRECTLY INSTALLED WILL CAUSE DAMAGE
TO THE HUB WHEN THE OUTER RACE AND ROLLERS ARE
REMOVED.
(6) Remove bolts then remove the No. 1 bearing retaining

plate and stop from the No. 1 bearing housing.
(7) Put the center puck detail of PWA 77039 Puller in the
hub (Figure 2). Engage and lock the puller jaws in the
mating groove on the No. 1 bearing outer race.
(8) Turn the jackscrew on the puller and remove the bearing
outer race and rollers.
(9) Remove the seal rings from the outer race.
CAUTION: MAKE SURE THAT THE CENTER PUCK DETAIL OF THE

PULLER IS CORRECTLY INSTALLED ON THE HUB. A PUCK
THAT IS NOT CORRECTLY INSTALLED WILL CAUSE DAMAGE
TO THE HUB WHEN THE PUMP IS PRESSURIZED TO REMOVE
THE BEARING INNER RACE AND SEAL SEAT.
(10) Put the center puck detail of PWA 77036 Puller in the
hub (Figure 3). Engage the puller jaws in the seal
seat groove located directly behind the bearing inner
race.
(11) Use a PWA 29389 Hydraulic Pump to operate the puller

and remove the bearing inner race and seal seat.
MAINTENANCE
REM/INST-01
PAGE 6-4
01-23 DEC 20/12

INSTALLATION-01
No. 1 Bearing Outer Race and Rollers Removal

Figure 2
MAINTENANCE
REM/INST-01
PAGE 6-5
01-23 DEC 20/12

INSTALLATION-01
No. 1 Bearing Inner Race and Seal Seat Removal

Figure 3
MAINTENANCE
REM/INST-01
PAGE 6-6
01-23 DEC 20/12

INSTALLATION-01
2. No. 1 Bearing And Spur Gear Assembly Installation
B. Tools: PWA 21598 Riveter

PWA 29389 Hydraulic Pump
PWA 45023 Wrench
PWA 45024 Adapter
PWA 45232 Adapter
PWA 45233 Adapter
PWA 45234 Compressor
PWA 46296 Pusher
PWA 75028 Gage
PWA 77038 Guide
PWA 80187 Torque Multiplier (Mechanical)
PWA 80651 Torque Multiplier (Pneumatic)

PMC 9934 Lubricant, Dry Film (dgf 123)
PMC 36500 Assembly Fluid
PMC 9630 Grease (Lubriplate)
D. Expendables:

Packing 1 01-23 4 160

Rivet 1 01-23 3 10
Lockwire As Req’d
E. Procedure
See Figures 1, 4 and 5.
(1) Use a PWA 45234 Compressor (Figure 4) as follows to

compress the No. 1 bearing carbon seal element:
(a) Install the compressor in the inner diameter of

the No. 1 bearing housing.
(b) Align four holes in the compressor with four

threaded holes in the housing.
(c) Install and equally tighten four thumbscrews until

the carbon seal element is fully compressed.
MAINTENANCE
REM/INST-01
PAGE 6-7
01-23 DEC 20/12

INSTALLATION-01
(2) Lightly spray front hub bearing journal with PMC 9934,
Dry Film Lubricant. Install the No. 1 bearing seal
seat on the 1st stage compressor hub. Correct
installation of the seat is with the puller groove in
front. Use a plastic drift if necessary to seat the
seal seat on the hub.
(3) Install the No. 1 bearing inner race as follows:
(a) Put the draw bar detail of the PWA 46296 Pusher,
with clamps retracted, in the inner diameter of
the 1st stage compressor hub.
(b) Pull the draw bar to the front to extend the

clamps against the hub.
(c) Put the No. 1 bearing inner race on the hub

journal with tapered O.D. end out and assemble the
ram and locator on the draw bar of the pusher.
(d) Connect a PWA 75028 Gage, or a pressure gage which

can show 10000 psi (68947.6 kPa) pump pressure,
between the PWA 29389 Hydraulic Pump and PWA 46296
Pusher.
(e) Use 5870 psi (40472.2 kPa) maximum pump pressure

to push the bearing inner race into position.
(4) Remove the PWA 46296 Pusher.
(5) Remove the PWA 45234 Compressor from the No. 1 bearing
housing.
MAINTENANCE
REM/INST-01
PAGE 6-8
01-23 DEC 20/12

INSTALLATION-01
No. 1 Bearing Seal Assembly Compressor Tool

Figure 4
MAINTENANCE
REM/INST-01
PAGE 6-9
01-23 DEC 20/12

INSTALLATION-01
No. 1 Bearing Outer Race End Clearance Measurement

Figure 5
MAINTENANCE
REM/INST-01
PAGE 6-10
01-23 DEC 20/12

INSTALLATION-01
(6) Examine the seal rings that will be installed on the

No. 1 bearing outer race to make sure they have 0.032 -
0.042 inch (0.813 - 1.067 mm) end gap.
NOTE: Seal ring end gap at 7.484 inch (190.094 mm) diameter
is 0.032 - 0.042 inch (0.813 - 1.067 mm).
(7) Install seal rings, with part numbers facing each

other, in the grooves of the No. 1 bearing outer race.
Stagger the ring gaps 180 degrees apart.
(8) Do an inspection to make sure the seal ring side

clearance is 0.001 - 0.007 inch (0.025 - 0.178 mm).
(9) Locate the threaded offset hole on the inner hole

flange of the bearing housing and make a temporary mark
at that location.
(10) Install a PWA 77038 Guide on the hub.
(11) Install the outer race in the bearing housing with the
antirotation slots pointed out, aligning one slot with
the threaded offset bolthole on the inner bolthole
flange of the bearing housing. If it is necessary, use
a drift to push the outer bearing race down until it
touches.
(12) Install the stop, aligning the offset hole in the stop
with the offset hole in the housing and the two I.D.
tabs in the stop with the slots in the bearing.
(13) Install the retaining plate, aligning the offset hole

in the plate with the offset hole in the bearing
housing. Secure the stop and plate with bolts. Torque
the bolts to 65 - 85 lb-in. (7.344 - 9.604 N.m) and
safety them with wire.
(14) Do an inspection to make sure the end clearance between

the No. 1 bearing outer ring to housing and retaining
plate is 0.002 - 0.006 inch (0.508 - 0.152 mm).
See Figure 5.
(15) Remove the shims from the 1st stage compressor blade
tips.
MAINTENANCE
REM/INST-01
PAGE 6-11
01-23 DEC 20/12

INSTALLATION-01
(16) Lubricate the inner race retaining nut threads with

PWA 521 Oil, then install the nut, hand tight, on the
hub.
(17) Install the tools to torque the No. 1 bearing inner

race retaining nut as follows:
(a) Install a PWA 45023 Wrench on the nut then install

a PWA 45024 Adapter through the wrench and into
the hub inner diameter spline.
(b) Put a PWA 45232 Adapter against the holding pins

on the PWA 80187 Torque Multiplier and secure it
with thumbscrews.
NOTE: PWA 80651 Torque Multiplier is installed over

the drive mechanism on PWA 80187 to provide
rapid rotation of nut prior to torque.
(c) Install a PWA 45233 Adapter, from the opposite

side, in the splines located in the PWA 80187
Torque Multiplier.
(d) Put the PWA 80187 Torque Multiplier against the

slot in the PWA 45023 Wrench and engage the
splines with the PWA 45024 Adapter.
(e) Turn the retaining nut until it touches the No. 1

bearing inner race.
(18) Torque the No. 1 bearing inner race retaining nut as

follows:
(a) Tighten the nut to 20000 - 24000 lb-in.

(2259.696 - 2711.520 N.m).
(b) Make a mark on the nut and hub for reference.
(c) Loosen the nut to 0 lb-in. and tighten the nut

again to 20000 - 24000 lb-in. (2259.696 –
2711.520 N.m).
MAINTENANCE
REM/INST-01
PAGE 6-12
01-23 DEC 20/12

INSTALLATION-01
(d) If the reference marks are in line, or the nut

mark is beyond the hub mark within 0° 30’ maximum,
loosen the nut to 0 lb-in. and torque it to
4000 lb-in. (451.939 N.m) then turn through an
angle of 5° - 8° to satisfy rivet installation.
Refer to Step (19).
(e) If the reference marks are not within limits in

step (d), loosen the nut to 0 lb-in. and do steps
(a), (b) and (c) again until the marks are within
limits of step (d). If within limits, loosen to
0 lb-in. and torque it to 4000 lb-in. 451.939 N.m)
then turn through an angle of 5° - 8° to satisfy
rivet installation. Refer to Step (19).
(19) Install the retaining nut rivet from the inner diameter
through the nut and hub. Use a PWA 21598 Riveter to
flare the rivet.
(20) Install a new preformed packing, lubricated with

PWA 36500 Assembly Fluid or PWA 521 Oil, on the OD of
larger end of spur gear assembly.
(21) Apply PMC 9630 Grease to splines on No. 1 hub and OD

splines of spur gear.
(22) Install large OD end of gear assembly inside No. 1 hub,

align the splines of gear with splines of hub and seat
gear against shoulder of hub.
(23) Install the retaining ring to hold the spur gear

assembly in position.
F. Postrequisites:
(1) Install the front accessory drive group. Refer to

MAINTENANCE
REM/INST-01
PAGE 6-13
01-23 DEC 20/12

INLET CASE - REMOVAL/INSTALLATION-02
1. Inlet Case Removal
A. Illustrated Parts Catalog, Section Reference: 01-23
B. Prerequisites
(1) Remove the No. 1 bearing and spur gear assembly. Refer
(2) Remove the inlet guide vane variable stator and support
assembly. Refer to Hydraulic System, Removal/
Installation-04.
C. Tools: PWA 45130 Protector

PWA 75135 Safety Hook
PWA 77231 Lifting Eye
PWA 77356 Enclosure Trolley
PWA 77387 Hoist, Lift
D. Procedure
(1) Remove the four nuts and bolts that hold the cover to
the terminal board bracket. The cover is located at
the 4 o’clock position on the inlet case.
(2) Remove the external wiring harness from the terminal

board.
(3) Remove the lockwire and four screws then remove the
accelerometer from its mounting bracket on the inlet
case front flange. Discard lockwire.
(4) Mark the positions of the brackets that are attached to

the inlet case rear flange (Flange B).
(5) Install a PWA 77231 Lifting Eye at the 12 o’clock

position on the inlet case front flange (Flange A).
Attach a PWA 75135 Safety Hook to the lifting eye.
Attach the PWA 77387 Hoist to the safety hook and the
PWA 77356 Enclosure Trolley. Use the hoist to take up
slack.
CAUTION: BE SURE THE REAR ACTUATOR IS STILL BEING HELD.

THE ACTUATOR ASSEMBLY IS HEAVY AND CAN CAUSE
DAMAGE IF THE SUPPORT IS NOT INSTALLED.
MAINTENANCE
REM/INST-02
PAGE 6-1
01-23 DEC 20/12

(6) Remove the bolts and nuts from Flange B.
(7) Use jackscrews to remove the inlet case from the

compressor case.
(8) Carefully move the inlet case to the enclosure access

door.
(9) Trunnion the inlet case front flange down on a pallet.
(10) Remove the hoist, safety hook, and lifting eye from the
inlet case.
(11) Install a PWA 45130 Protector on the No. 1 bearing

sealing ring.
(12) Install work bolts through Flange B and the support

bracket to hold the remaining actuator assembly.
2. Inlet Case Installation
B. Tools: PWA 75135 Safety Hook

PWA 77231 Lifting Eye
PWA 77387 Hoist, Lift
D. Expendables

Lockwire As Req’d
E. Procedure
CAUTION: BE SURE THE REAR ACTUATOR ASSEMBLY (USED TO

ACTIVATE STAGES 1.1 AND 1.3) THAT IS INSTALLED ON
THE COMPRESSOR CASE IS STILL BEING SUPPORTED.
THE ACTUATOR ASSEMBLY IS VERY HEAVY AND CAN CAUSE
DAMAGE IF NOT PROPERLY SUPPORTED.
MAINTENANCE
REM/INST-02
PAGE 6-2
01-23 DEC 20/12

(1) With the inlet case front flange down on a pallet,

install a PWA 77231 Lifting Eye at the 12 o’clock
position on the front flange (Flange A). Attach the
PWA 77387 Hoist, located on the overhead rails, and a
PWA 75135 Safety Hook to the lifting eye.
(2) Remove the workbolts that are installed through

Flange B and the support brackets. These bolts were
used to temporarily hold the actuator assembly to the
front compressor case.
(3) Put the inlet case in position so that the alignment

pin and hole, located near the 6 o’clock position, are
in line. Remove the No. 1 bearing sealing ring
protector if it is installed.
(4) Carefully engage the inlet case to the compressor case.
(5) Lubricate bolts with PWA 521 Oil (SB 02B05, SB 03B01)
and install with nuts and brackets on Flange B.
Torque the nuts and bolts to 150 - 170 lb-in. (16.948 -
19.207 N.m.).
(6) Remove the lifting eye, safety hook, and hoist.
(7) Connect the external wiring harness at the inlet case.
(a) Remove the four nuts and bolts that hold the cover
to the terminal board bracket. The cover is
located at the 4 o’clock position on the inlet
case.
(b) Install the external wiring harness on the

terminal board.
(8) Install the accelerometer on its mounting bracket on

the inlet case front flange and install the four
screws. Torque the screws 12 - 14 lb-in. (1.356 -
1.582 N.m). Lockwire screws.
(9) Attach clamps on accelerometer cable to brackets on

Flange A with bolts and nuts. Torque nuts to 36 -
40 lb-in. (4.067 - 4.519 N.m).
MAINTENANCE
REM/INST-02
PAGE 6-3
01-23 DEC 20/12

F. Postrequisites
(1) Install the inlet guide vane actuator support.

Refer to Hydraulic System, Removal/Installation-04.
(2) Install the No. 1 bearing and spur gear assembly.

Refer to Maintenance Section 01-23, Removal/
Installation-01.
MAINTENANCE
REM/INST-02
PAGE 6-4
01-23 DEC 20/12

NO. 1 BEARING SEALING RING - REMOVAL/
INSTALLATION-03
1. No. 1 Bearing Sealing Ring Removal
A. Illustrated Parts Catalog Reference: 01-23
B. Prerequisites
(1) Remove the inlet case. Refer to Maintenance Section

01-23 Removal/Installation-02.
C. Tools: PWA 45106 Puller
D. Procedure
See Figure 1.
(1) Remove the bolts that hold the No. 1 bearing sealing
ring to the No. 1 bearing seal assembly and the No. 1
bearing housing assembly.
(2) Use a PWA 45106 Puller to remove the No. 1 bearing

sealing ring.
(a) Engage the locator detail of the puller into the

inner diameter of the sealing ring.
(b) Position the puller jaws behind the sealing ring

scallops and tighten.
(c) Use the jackscrew to remove the sealing ring.
(d) Remove the packing from the ring groove that is on

the outer diameter of the No. 1 bearing housing
assembly.
MAINTENANCE
REM/INST-03
PAGE 6-1
01-23 DEC 20/12

INSTALLATION-03
2. No. 1 Bearing Sealing Ring Installation
B. Tools: PWA 45130 Protector

PWA 45551 Aligning Pin (2 Reqd)

PMC 9609 Petrolatum
D. Expendables

Packing 1 01-23 3 150
E. Procedure
(1) Install the No. 1 bearing sealing ring.
(a) Install two PWA 45551 Aligning Pins 180 degrees

apart in the inner diameter rear flange of the
No. 1 bearing housing assembly.
(b) Put the No. 1 bearing sealing ring in an oven that

is at 250°F (121°C) for ten minutes.
CAUTION: IF YOU APPLY PETROLATUM TO THE PACKING, USE

ONLY A SMALL QUANTITY ON THE PACKING TO
PREVENT POSSIBLE CONTAMINATION OF THE OIL
SYSTEM.
(c) Install a new packing (lubricated with PWA 36500

Assembly Fluid or petrolatum) into the ring groove
at the outer diameter of the No. 1 bearing housing
assembly.
MAINTENANCE
REM/INST-03
PAGE 6-2
01-23 DEC 20/12

INSTALLATION-03
No. 1 Bearing Sealing Ring Removal

Figure 1
MAINTENANCE
REM/INST-03
PAGE 6-3
01-23 DEC 20/12

INSTALLATION-03
NOTE: It is optional to use petrolatum as a

replacement for PWA 36500 Assembly Fluid, but it
is better to use the assembly fluid. Use
petrolatum only if assembly fluid is not
available.
(d) Install the hot No. 1 bearing sealing ring flange

end down on the No. 1 bearing seal assembly. Use
the aligning pins to align the offset hole in the
sealing ring with the offset hole in the housing.
(e) Tap the sealing ring lightly to fully engage it

with the No. 1 bearing housing assembly.
(f) Use a 3/16 inch (5 mm) wrench to remove the

PWA 45551 Aligning Pins.
(g) Install the bolts and torque them to 75 -

85 lb-in. (8.474 - 9.604 N.m).
(h) Install a PWA 45130 Protector on the No. 1 bearing

sealing ring.
F. Postrequisites
(1) Install the inlet case. Refer to Maintenance Section

MAINTENANCE
REM/INST-03
PAGE 6-4
01-23 DEC 20/12

NO. 1 BEARING SEAL ASSEMBLY - REMOVAL/
INSTALLATION-04
1. No. 1 Bearing Seal Assembly Removal
B. Prerequisites
(1) Remove the No. 1 bearing sealing ring. Refer to

Maintenance Section, 01-23 Removal/Installation-03.
C. Tools: PWA 45109 Puller
D. Consumables: None
E. Expendables: None
F. Procedure
See Figure 1.
(1) Remove the No. 1 bearing seal assembly (Figure 1).
(a) Put the plate assembly (plate detail assembled

with clamps, knurled nuts and studs) of PWA 45109
Puller in the inner diameter and against the rear
face of the No. 1 bearing seal assembly.
NOTE: Make sure the clamp details do not touch the

seal assembly during installation.
(b) Turn the clamps to the engaged position. Tighten

the knurled nuts to hold the clamps and plate
assembly in position.
(c) Install the fixture body on the No. 1 bearing

housing.
(d) Move the swing washer to the engaged position on

the stud.
(e) Tighten the nut against the swing nut and lift the
seal assembly off the No. 1 bearing housing.
(2) Remove the packing from the ring groove that is on the
outer diameter of the No. 1 bearing seal assembly.
MAINTENANCE
REM/INST-04
PAGE 6-1
01-23 DEC 20/12

INSTALLATION-04
No. 1 Bearing Seal Assembly Removal

Figure 1
MAINTENANCE
REM/INST-04
PAGE 6-2
01-23 DEC 20/12

INSTALLATION-04
2. No. 1 Bearing Seal Assembly Installation
B. Tools: PWA 45551 Aligning Pin (2 Reqd)

PWA 521 Oil
D. Expendables:

Packing 1 01-23 4 130
E. Procedure
(1) Install the No. 1 bearing seal assembly.
(a) Install two PWA 45551 Aligning Pins 180 degrees

apart in the inner diameter rear flange of the
No. 1 bearing housing assembly.
(b) Install a new packing (lubricated with PWA 36500

Assembly Fluid or PWA 521 Oil) into the ring
groove on the outer diameter of the No. 1 bearing
seal assembly.
(c) Put the No. 1 bearing seal assembly in a freezer

(or equivalent) to lower the part temperature.
(d) While the part is cold, install it with the carbon

face down in the housing assembly. Use the
aligning pins to align the offset hole in the seal
assembly with the offset hole in the housing.
(e) To fully engage the seal, lightly tap the seal

flange with a drift then install and tighten work
bolts.
(f) Remove the work bolts.
NOTE: Do not remove PWA 45551 Aligning Pins at this

time. Aligning pins are used to install the
No. 1 bearing sealing ring.
MAINTENANCE
REM/INST-04
PAGE 6-3
01-23 DEC 20/12

INSTALLATION-04
F. Postrequisites
(1) Install the No. 1 bearing sealing ring. Refer to

MAINTENANCE
REM/INST-04
PAGE 6-4
01-23 DEC 20/12

N1 SENSOR WIRING HARNESS - REMOVAL/
INSTALLATION-05
1. N1 Sensor Wiring Harness Removal
B. Tools: None
C. Consumables: None
E. Procedure
(1) Locate the bracket on the outside cover, located at the

8 o’clock position.
(2) Remove the four nuts and bolts that attach the cover to
the bracket. Retain nuts and bolts for reassembly.
(3) Remove the four screws that attach the wires from the
cover to the electrical terminal board. Retain the
screws for reassembly.
(4) Remove the four screws that attach the wires from the
N1 Sensor wiring harness to the electrical thermal
board. Retain the screws for reassembly.
(5) Cut the four terminals off of the wires and dispose of
them properly.
(6) Tape the four wires together. Attach a string to the

end of the harness with the four taped wires. String
will be used to pull the new harness in place after the
old harness is removed.
(7) Remove the red sealant from both areas with a soft
material scraper so the inlet case will not be damaged.
(8) Pull old harness out of case from the center of the
case. Make sure that there is enough string left out
of case on both openings so the new harness can be
attached and pulled thru. Cut string and dispose of
old harness properly.
MAINTENANCE
REM/INST-05
PAGE 6-1
01-23 DEC 20/12

INSTALLATION-05
2. N1 Sensor Wiring Harness Installation
B. Tools: WT111M Pliers, STA-KON
C. Consumables: PWA 36003-1 Sealant-Red (RTV159)

PMC 9016 Alcohol, Isopropyl
E. Procedure
(1) Tape the four wires of the new harness (PN 1081873) to
prevent damage. Tape the string to the four wires.
(2) Start the new harness from the center of the inlet
case. While supporting the harness at the center of
case pull the string on the other end slowly. Pull
harness until the taped end with the four wires passes
thru the case at the electrical terminal board.
(3) Remove tape and string from the four wires.
(4) Connect one terminal to each of the four wires and

crimp as follows:
(a) Place terminal over bare wire.
(b) The distance between end of the terminal and

beginning of wire insulation must not be bigger
than the diameter size of the wire.
(c) Holding terminal in this position, crimp terminal

using WT111M STA-KON pliers.
(d) Test the connection by holding terminal with one

hand and wire with the other hand. Lightly pull
in opposite directions, terminal must not move.
(e) Install the remaining terminals per above

directions.
MAINTENANCE
REM/INST-05
PAGE 6-2
01-23 DEC 20/12

INSTALLATION-05
(5) Connect the orange wire to the upper left hand screw on
the electrical terminal board. Continue to the right
and use screws to connect the remaining wires, brown,
red and black, in that order.
(6) Remove the slack in the harness in the strut by

adjusting the length of the inboard boss.
(7) Tighten and torque screws 8 to 10 lb-in. (0.90 -

1.13 N.m).
(8) Install the wires from cover to connector as follows:
(a) Take the orange wire and connect it to the lower

left hand screw on the electrical terminal board.
Continue to the right and connect the remaining
wires, brown, red and black, in that order.
(b) Tighten and torque the four screws 8 to 10 lb-in.

(0.90 - 1.13 N.m).
(c) Bend connectors up 90 degrees; this will allow

cover to fit over connectors and posts.
NOTE: Verify that the wires are installed correctly.

All connections are torqued and connections are
made to upper and lower rows of screws in the
following order, starting at the left hand
screw, orange, brown, red and black.
WARNING: ISOPROPYL ALCOHOL IS FLAMMABLE AND HARMFUL TO THE

EYES, SKIN, AND BREATHING PASSAGES. KEEP FLOW
SOURCES AWAY AND PROVIDE ADEQUATE VENTILATION.
WEAR EYE PROTECTION AND PROTECTIVE CLOTHING.
(9) Clean the area where the harness passes thru the boss
adjacent to the No. 1 bearing housing and at the
electrical terminal bracket located on the outside
diameter of the inlet case with PMC 9016 Isopropyl
Alcohol. Area must be dry for a minimum of 10 minutes.
MAINTENANCE
REM/INST-05
PAGE 6-3
01-23 DEC 20/12

INSTALLATION-05
(10) Locate harness in the center of oblong hole. With
harness positioned in the center of the oblong hole,
apply PWA 36003-1 Sealant to the oblong hole on the
electrical terminal bracket. Sealant must fill hole
and to be flush with inlet case surface. Remove any
excess sealant.
(11) Locate hole adjacent to the No. 1 bearing housing.

Hole is located at approximately the 5 o’clock
position.
(12) With the harness positioned in the center of the hole,

apply PWA 36003-1 Sealant to hole. Sealant must fill
hole and be flush with the surface of the case.
Remove excess sealant.
(13) Secure the harness to case, without disturbing the

sealant, with tape. Harness must not move during
curing period of eight hours.
(14) Install cover to terminal bracket located on the

outside diameter at the 8 o’clock position. Threaded
boss in cover to be on assemblers left. Use the bolts
and nuts that were previously removed.
(15) Tighten and torque the four nuts 36 to 40 lb-in.

(4.07 - 4.52 N.m).
MAINTENANCE
REM/INST-05
PAGE 6-4
01-23 DEC 20/12

(GG8-1, GG8-3) FUEL NOZZLE AND SUPPORT ASSEMBLY - REMOVAL/
INSTALLATION-01
1. (GG8-1, GG8-3) Fuel Nozzle And Support Assembly Removal
A. Illustrated Parts Catalog Section Reference: 01-11, 01-37
B. Prerequisites
(1) Combustion chambers must be moved rearward as far as

possible to provide clearance for fuel nozzle removal.
All combustion chambers may be moved rearward as a
unit. Refer to combustion chamber removal, Maintenance
Section 01-41, Removal/Installation-01 for removal of
the combustion chamber outer rear case and removal of
the combustion chambers from the diffuser case and
combustion chamber duct.
C. Tools: PWA 77420 Adapter, Torque (Liquid Fuel)

PWA 77442 Adapter, Torque (Gaseous Fuel)
D. Procedure
NOTE: The fuel system for the gas generator can be

either liquid fuel or gaseous fuel or both. The
small supply tubes are for liquid fuel and the
large tubes are for gaseous fuel. The same fuel
nozzle and support assembly is used for both
fuels.
(1) Remove the combustion chamber outer rear case and move
the combustion chambers rearward as a unit as far as
possible to provide clearance before attempting to
remove the fuel nozzle and support assembly.
(2) Use the PWA 77420 Torque Adapter and disconnect the
liquid fuel supply tube from the connector on the fuel
nozzle and support assembly.
(3) Remove the transfer tube from the liquid fuel

connector. Discard the two packings from the transfer
tube.
(4) For the gas generator that uses gaseous fuel, remove
lockwire from manifold tube coupling nut on fuel nozzle
and support assembly.
MAINTENANCE
REM/INST-01
PAGE 6-1
01-37 DEC 20/12

INSTALLATION-01
CAUTION: BEFORE ANY ATTEMPT IS MADE TO LOOSEN OR TORQUE A

GAS FUEL SUPPLY MANIFOLD TUBE COUPLING NUT OR CAP
ASSEMBLY AT THE FUEL NOZZLE AND SUPPORT, MAKE
SURE AN OPEN END WRENCH IS PLACED ON THE
WRENCHING FLATS OF THE GAS FUEL NOZZLE, BEHIND
CONNECTOR, BY A SECOND PERSON TO HOLD THE
CONNECTOR AND PREVENT IT FROM TWISTING. DAMAGE
TO THE FUEL NOZZLE AND SUPPORT CAN OCCUR IF THIS
PROCEDURE IS NOT FOLLOWED.
(5) Use a PWA 77442 Torque Adapter and a 1-3/16 inch

(30.1625 mm) open end wrench. Place wrench on
wrenching flats behind gas fuel nozzle connector for
counter-torque and use adapter to disconnect the tube
coupling nut from the connector on the fuel nozzle and
support assembly. Remove and discard the gasket.
NOTE: Two persons are needed to accomplish this

procedure.
(6) Remove the lockwire from the fuel nozzle support bolts.
(7) Remove the bolts that attach the fuel nozzle and
support assembly to the diffuser case and remove the
fuel nozzle and support assembly. Discard the gasket
from the bottom of the support.
(8) Put the fuel nozzle and support assembly in a container

to prevent damage to the assembly.
2. (GG8-1, GG8-3) Fuel Nozzle And Support Assembly Installation
B. Tools: PWA 77180 Adapter, Flow-Divider Valve (Liquid

Fuel)
PWA 77234 Adapter (Gaseous Fuel)
PWA 77420 Adapter, Torque (Liquid Fuel)
PWA 77442 Adapter, Torque (Gaseous Fuel)
PWA 77457 Adapter (Supplemental Water System)

PWA 521 Oil
PMC 9609 Petrolatum
PMC 9569 Leak Detector Fluid
MAINTENANCE
REM/INST-01
PAGE 6-2
01-37 DEC 20/12

INSTALLATION-01
D. Expendables:
PARTS CATALOG
REFERENCE
Gasket 9 01-37 9 10
Packing 10 01-11 1 60
Packing 8 01-11 2 70
Gasket 9 01-11 5 410
Lockwire As Req’d
E. Procedure
(1) Fuel Nozzle and Support Assembly Installation:
(a) Put a new gasket on the flange of the fuel nozzle

and support assembly and install the fuel nozzle
and support assembly through the diffuser case.
(b) Attach the support to the diffuser case with four

bolts, lubricated with PWA 521 Oil. Tighten the
bolts by hand. Allow the fuel nozzles to remain
loose.
NOTE: To make sure of proper seating between fuel

nozzles and combustion chambers, the fuel
nozzles must remain loose until after completing
the installation of the combustion chambers.
(c) Move the combustion chambers forward as a unit and

install to the diffuser case and combustion
chamber duct. Refer to combustion chambers
installation, Maintenance Section 01-41,
Removal/Installation-01 for connecting combustion
chambers to the diffuser case and the combustion
chamber duct.
(d) Torque the fuel nozzle bolts to 65 - 85 lb-in.

(7.344 - 9.604 N.m).
(e) Do not loosen the bolts and do Step (d) again.

Continue to do Step (d) until the 65 - 85 lb-in.
(7.344 - 9.604 N.m) torque is constant.
(f) Lockwire the bolts in pairs.
MAINTENANCE
REM/INST-01
PAGE 6-3
01-37 DEC 20/12

INSTALLATION-01
(g) Lubricate two new preformed packings with

PWA 36500 Assembly Fluid or petrolatum (do not
use oil) and put them on the transfer tube.
(h) Put a transfer tube in the small, threaded liquid

fuel connector on the fuel nozzle and support
assembly.
(i) Lubricate the liquid fuel supply coupling nut

threads with oil and then connect the tube to the
fuel nozzle.
(j) Tighten the coupling nut finger tight.
(k) If the gas generator uses gaseous fuel, put a

gasket on the fuel nozzle gaseous fuel connector.
(l) Lubricate the gaseous fuel supply coupling nut

threads with oil and then connect the tube to the
fuel nozzle.
(m) Tighten the coupling nut finger tight.
(n) Perform applicable leak test per Step (2), (3),

or (4).
NOTE: Leak test may be performed with or without the

combustion chamber outer rear case installed.
(2) Leak Test (Liquid Fuel) Without Supplemental Water

System:
CAUTION: MAKE SURE THAT ANY TUBE COUPLING NUTS THAT

HAVE BEEN LOOSENED OR REMOVED ARE INSTALLED
FINGER TIGHT AND NOT TORQUED UNTIL AFTER THE
LEAK TEST. THE LEAK TEST IS PERFORMED TO
CHECK THAT THE PACKINGS ON THE FITTINGS WHICH
ARE ENCLOSED BY THE COUPLING NUTS ARE NOT
LEAKING. TO MAKE SURE THAT THE NUTS ARE NOT
INSTALLED TOO TIGHT, NUTS SHOULD BE INSTALLED
ON THE FITTINGS FINGER TIGHT AND THEN BACKED
OFF 1/8 TURN.
(a) Install a PWA 77180 Adapter on the fuel inlet pad

of the flow divider valve.
MAINTENANCE
REM/INST-01
PAGE 6-4
01-37 DEC 20/12

INSTALLATION-01
(b) Connect a suitable air supply to the PWA 77180

Adapter.
(c) Pressurize the fuel system to 95 - 105 psig

(655.0 - 723.9 kPa).
(d) Keep the air pressure at 95 - 105 psig for five

minutes and examine the fuel nozzle connections
for leaks. Use the PMC 9569 Leak Detector Fluid
on the connections. Leakage from any connection
is not permitted.
(e) If there is a leak at any connection, decrease the

air pressure to zero psig.
(f) Repair and/or replace any part if necessary.
(g) Do the leak test again.
(h) If there is no leakage, remove the air supply and

the PWA 77180 Adapter.
(i) Use PWA 77420 Torque Adapter and torque the tube
coupling nuts at the fuel nozzles to 192 -
210 lb-in. (21.693 - 23.727 N.m).
(j) Do not loosen the tube nuts and do Step (i) again.
If a nut will not keep the torque after four
torque procedures, replace and/or repair the fuel
tube or gaskets.
(k) Lockwire the nuts.
(3) Leak Test (Liquid Fuel) With Supplemental Water System:
CAUTION: MAKE SURE THAT ANY FUEL TUBE COUPLING NUTS

THAT HAVE BEEN LOOSENED OR REMOVED ARE
INSTALLED FINGER TIGHT AND NOT TORQUED UNTIL
AFTER THE LEAK TEST. THE LEAK TEST IS
PERFORMED TO CHECK THAT THE PACKINGS ON THE
FITTINGS WHICH ARE ENCLOSED BY THE COUPLING
NUTS ARE NOT LEAKING. TO MAKE SURE THAT THE
NUTS ARE NOT INSTALLED TOO TIGHT, NUTS
SHOULD BE INSTALLED ON THE FITTINGS FINGER
TIGHT AND THEN BACKED OFF 1/8 TURN. THE
WATER MANIFOLD NUTS SHOULD BE TORQUED.
MAINTENANCE
REM/INST-01
PAGE 6-5
01-37 DEC 20/12

INSTALLATION-01
(a) Install a PWA 77180 Adapter on the fuel inlet pad

of the flow divider valve.
CAUTION: THE PURGE TUBE (TYPICAL PN 1081065) MUST BE

INSTALLED ON THE FLOW DIVIDER VALVE TO
PREVENT BACK PRESSURE DAMAGE TO THE FLOW
DIVIDER VALVE.

Adapter.
(c) Disconnect the water supply at the large threaded

connector at the bottom of the water manifold.
(d) Pressurize the fuel system to 95 - 105 psig

(655.0 - 723.9 kPa).
(e) Keep the air pressure at 95 -105 psig for five

minutes and examine the fuel nozzle connections
for leaks. Use the PMC 9569 Leak Detector Fluid
on the connections. Leakage from any connection
is not permitted.
(f) Inspect for any indication of air leaking from the

open threaded connector at the bottom of the water
manifold. Any air leakage indicates a faulty
water check valve. A faulty water check valve is
not permitted and must be replaced.
NOTE: It will be necessary to disconnect the water

manifold to remove and determine which of the
nine check valves is faulty.
(g) After a successful test, reduce the air pressure

to zero psig. Continue the test by checking for
leakage at the water manifold connections per
Step (i).
(h) If the test was not successful, reduce the air

pressure to zero psig. Repair and/or replace any
faulty part and do the leak check again. After a
successful test, continue the test by checking for
leakage at the water manifold connections per
Step (i).
MAINTENANCE
REM/INST-01
PAGE 6-6
01-37 DEC 20/12

INSTALLATION-01
(i) Install the plug (part of PWA 77457 Adapter) in

the PWA 77180 Adapter installed in the flow
divider valve. Install the PWA 77457 Adapter on
the open threaded connector at the bottom of the
water manifold. Pressurize the water manifold
with air to 95 - 105 psig (655.0 - 723.9 kPa) and
keep it pressurized for at least five minutes.
Use the PMC 9569 Leak Detector Fluid on each of
the nine connections. Leakage from any connection
is not permitted.
(j) After a successful test, reduce the air pressure

to zero psig. Remove the air supply, the
PWA 77457 Adapter, and plug.
(k) If there was a leak at any connection, reduce the

air pressure to zero psig. Repair and/or replace
the faulty part and repeat the leak test. Remove
the air supply, adapter, and plug after a
successful test.
(l) Use PWA 77420 Torque Adapter and torque the

coupling nuts at the fuel nozzles to 192 –
210 lb-in. (21.693 - 23.727 N.m).
(m) If removed or loosened, torque the nine water

manifold coupling nuts at the check valve tee
connections to 918 - 988 lb-in. (103.720 -
111.629 N.m) using PWA 77442 Torque Adapter.
(n) If removed or loosened, torque the manifold nut

that joins the two water manifolds to 591 -
635 lb-in. (66.774 - 71.745 N.m) using crowfoot.
(o) Do Steps (l), (m), or (n) again but do not loosen

the nuts. If a nut will not keep the torque after
four torque procedures, replace and/or repair the
tubes or manifolds.
(p) If wire was removed, lockwire the tube nuts.
MAINTENANCE
REM/INST-01
PAGE 6-7
01-37 DEC 20/12

INSTALLATION-01
(4) Leak Test (Gaseous Fuel):
(a) Install a PWA 77234 Adapter to the large diameter

connector on the gas manifold.

Adapter.
(c) Pressurize the system to 95 -105 psig (665.0 -

723.9 kPa).
(d) Keep the air pressure at 95 - 105 psig for five

minutes and examine the fuel nozzle connectors for
leaks. Use the PMC 9569 Leak Detector Fluid on
the connections. Leakage from any connection is
not permitted.
(e) If there is a leak at any connection, the air

pressure must be reduced to zero psig.
(f) Repair and/or replace any part, if necessary.
(g) Do the leak test again.
(h) If there is no leakage, remove the air supply and

the PWA 77234 Adapter.
CAUTION: BEFORE ANY ATTEMPT IS MADE TO LOOSEN OR

TORQUE A GAS FUEL SUPPLY MANIFOLD TUBE
COUPLING NUT OR CAP ASSEMBLY AT THE FUEL
NOZZLE AND SUPPORT, MAKE SURE AN OPEN END
WRENCH IS PLACED ON THE WRENCHING FLATS OF
THE GAS FUEL NOZZLE, BEHIND CONNECTOR, BY A
SECOND PERSON TO HOLD THE CONNECTOR AND
PREVENT IT FROM TWISTING. DAMAGE TO THE
FUEL NOZZLE AND SUPPORT CAN OCCUR IF THIS
PROCEDURE IS NOT FOLLOWED.
MAINTENANCE
REM/INST-01
PAGE 6-8
01-37 DEC 20/12

INSTALLATION-01
(i) Use a PWA 77442 Torque Adapter on the manifold

tube coupling nuts and a 1-3/16 inch (30.1625 mm)
open end wrench on wrenching flats behind gas fuel
nozzle connectors for counter-torque, then torque
the tube coupling nuts at the fuel nozzles to
662 - 728 lb-in. (74.796 - 82.253 N.m).
NOTE: Two persons are needed to accomplish this

procedure.
(j) Do Step (i) again but do not loosen the tube nuts.
If a nut will not hold the torque after four
torque procedures, replace and/or repair the fuel
tube or gaskets.
(k) Lockwire the tube nuts.
F. Postrequisites
(1) If not previously accomplished, install the combustion

chamber outer rear case. Refer to Maintenance Section
MAINTENANCE
REM/INST-01
PAGE 6-9
01-37 DEC 20/12

(GG8-2) FUEL NOZZLE SUPPORT ASSEMBLY - REMOVAL/
INSTALLATION-02
1. (GG8-2) Fuel Nozzle Support Assembly Removal
B. Prerequisites: None
C. Tools: PWA 77441 Handle, Anti-Torque

PWA 77442 Adapter, Torque
PWA 77598 Handle, Lifting (2 Req’d)
D. Procedure
See Figure 1.
NOTE: Removal of the fuel nozzles requires at least two

people.
CAUTION: MAKE SURE THE MAIN FUEL SUPPLY LINE IS CLOSED AND
THE LINES ARE PURGED OF RESIDUAL GAS PRIOR TO
REMOVING THE FUEL NOZZLES AND PLUMBING.
(1) Disconnect the (2) thermocouple connectors. It is not

necessary to remove the thermocouples from the fuel
nozzle support assembly. If necessary, the
thermocouples can be removed in a workbench operation.
(2) Disconnect the (2) gaseous fuel tubes from the

connectors on the fuel nozzle support assembly. Remove
and discard the packings. Use PWA 77442 Torque Adapter
and PWA 77441 Anti-Torque Handle on any tube manifold
coupling nut.
NOTE: Loosening fluid may be required.
(3) Unbend tab locks and remove bolts and brackets as

required. Remove all bolts and brackets as required.
Remove all bolts except one on each side of the fuel
nozzle. Discard tab locks.
(4) Attach two PWA 77598 Lifting Handles using workbolts.

Remove remaining two bolts. Discard tab locks.
(5) Remove fuel nozzle using handles. Remove gasket from

spacer plate and discard.
(6) Continue to remove all fuel nozzles per Step (1)

through (5) above.
MAINTENANCE
REM/INST-02
PAGE 6-1
01-37 DEC 20/12

INSTALLATION-02
(7) Put fuel nozzles in a safe area outside the enclosure

marked as to their position in the diffuser case.
Secure all fuel nozzles and diffuser openings with
protective covers to preclude F.O.D. contamination and
damage to fuel nozzles and fuel lines.
2. (GG8-2) Fuel Nozzle Support Assembly Installation
B. Tools: PWA 77441 Handle, Anti-Torque

PWA 77442 Adapter, Torque
PWA 77598 Handle (2 Req’d)
PWA 77617 Hydraulic Ram

PMC 9569 Leak Detector Fluid
PWA 36001 Compound, Anti-seize
PMC 9016 Alcohol
PWA 521 Oil
D. Expendables:

Gasket 16 01-37 9 90
Key Washer 224 01-37 9 470
E. Procedure
(1) Broken bolts can be removed from the diffuser/combustor

case inserts by drilling out the bolt and retapping the
existing threads or by replacing the pressed-in insert
in the diffuser/combustor case by one of the following
methods:
(a) Hammer Method - (ear plugs needed for this method)
1 Grind down remnant of broken bolt below insert

surface being very careful not to damage bore
wall surface of diffuser case - use of a drill
pilot is recommended. See Figure 1.
2 Obtain/make a drift slightly smaller than bore

diameter.
MAINTENANCE
REM/INST-02
PAGE 6-2
01-37 DEC 20/12

INSTALLATION-02
Using Pilot Bushing to either Remove Bolt or Bolt Section Above Insert
Figure 1
MAINTENANCE
REM/INST-02
PAGE 6-3
01-37 DEC 20/12

INSTALLATION-02
3 Use loosening fluid on old insert and drive old

insert out using a large hammer or mallet.
4 Butterfly polish insert bore to clean up

surface not more than .0003 inch.
(b) Hydraulic Ram Method
1 Grind down remnant of broken bolt below insert

surface being very careful not to damage bore
wall surface. Use of a drill pilot is
recommended. See Figure 1.
2 Use Hydraulic Ram Tool PWA 77617 to

hydraulically force out old insert.
3 Butterfly polish insert bore to clean up

surface not more than .0003 inch (.0076 mm).
(c) Insert Installation
1 Obtain new insert, lubricate I.D. threads

(sparingly) and O.D. surface with PWA 36001
Anti-seize Compound.
2 Using a longer work-bolt with same threads as

replacement bolt, pull new lubricated insert
into position using large washer on O.D. and
appropriate wrench for work-bolt. Pull insert
into case to seat only.
3 As an alternate to 2, use the hydraulic ram

with the appropriate adapters to pull in new
lubricated insert (see 2 above).
(2) Before installing fuel nozzles, ensure the Nozzle

Bracket, PN 1082096, is installed on the nozzle and all
protective covers have been removed.
NOTE: If thermocouples have been removed from the fuel

nozzles or new fuel nozzles are being installed,
install thermocouples before installing fuel nozzles.
See Section 13.
MAINTENANCE
REM/INST-02
PAGE 6-4
01-37 DEC 20/12

INSTALLATION-02
(3) Install a new gasket into grooves on inner surface of

each spacer. Hold gasket in place with a small amount
of wax. If new nozzles are being installed, install
spacer to each fuel nozzle with PWA 521 lubed screws.
Tighten screws to 85 - 95 lb-in. (9.604 - 10.734 N.m).
CAUTION: DO NOT USE OIL ON BOLT THREADS. APPLY PWA 36001

ANTI-SEIZE COMPOUND TO BOLT THREADS AFTER
REMOVING ALL TRACES OF PREVIOUS COATING ON
THREADS WITH A WIRE BRUSH. FOLLOW THE WIRE
BRUSHING WITH A CLEANING WITH ALCOHOL. ALLOW TO
DRY PRIOR TO COATING BOLT WITH ANTI-SEIZE
COMPOUND.
NOTE: Apply PWA 36001 Anti-seize Compound (sparingly) to

external threads only. Remove excess compound before
and after installation.
(4) Attach two PWA 77598 Handles to the nozzle, and using
two people, install nozzle onto its previous position
(if reinstalling old nozzles) in the diffuser case
using two PWA 36001 Anti-seize Compound lubricated
bolts on either side of the nozzle. Engage (2)
alignment pins at forward end of fuel nozzle into fuel
nozzle support prior to installing the two bolts.
Be sure to use new tab locks on all bolts. Align tab
locks and tighten bolts to seat.
(5) Remove handles and install all other fuel nozzles per
Step (4) above until all fuel nozzles are in place.

(6) Install appropriate brackets onto each fuel nozzle

using PWA 36001 Anti-seize Compound lubricated bolts
and new tab locks. Secure tab locks and tighten bolts
to seat.

MAINTENANCE
REM/INST-02
PAGE 6-5
01-37 DEC 20/12

INSTALLATION-02
(7) Install balance of tab locks and PWA 36001 Anti-seize

Compound lubricated bolts. Torque all bolts to 110 -
120 lb-in. (12.428 - 13.558 N.m). using an opposite
bolt sequence and the proper torque wrench. Torque
bolts until no loss of torque occurs.
(8) Bend all tab locks to secure nozzle bolts. Tab locks
are to be bent only once and cannot be reused.
(9) Reconnect all fuel lines using new lubricated gaskets.

Install all lines with fittings finger tight. Make
sure all protective closures have been removed prior to
installation.
(10) Leak check fuel lines per Section 01-37, Rem/Inst-01,

Leak Test (Gaseous Fuel).
(11) Reconnect harness leads to fuel nozzle (two

thermocouples). Secure with lockwashers and nuts.
Torque small nuts to 15 - 20 lb-in. (1.695 - 2.260
N.m). Torque large nuts to 24 - 40 lb-in. (2.712 -
4.519 N.m).
MAINTENANCE
REM/INST-02
PAGE 6-6
01-37 DEC 20/12

(GG8-2) FUEL NOZZLE ASSEMBLIES - REMOVAL/INSTALLATION-03
1. (GG8-2) Fuel Nozzle (Sidewall) Assembly - Removal
B. Prerequisites
(1) Remove gas manifolds and hoses. Refer to Fuel System

III, Removal/Installation-13.
C. Tools: None
D. Procedure
See Figure 1.
NOTE: For primary fuel nozzle removal, see 01-37, Removal/

Installation-02. For resonator removal, see 01-41,
Removal/Installation-02.
(1) Locate 15 fuel nozzle assemblies on the outside

diameter of the combustion chamber rear case.
(2) Remove bolts and key washers attaching the fuel nozzles
to the case. Discard key washers.
(3) Remove the fuel nozzles.
(4) Remove the gaskets and discard.
2. (GG8-2) Fuel Nozzle (Sidewall) Assembly - Installation
B. Tools: None
C. Consumables: PWA 36001 Compound, Anti-seize
D. Expendables:

Gasket 15 01-41 8 310
Key Washer 45 01-41 8 300
MAINTENANCE
REM/INST-03
PAGE 6-1
01-37 DEC 20/12

(GG8-2) Fuel Nozzle Assembly

Figure 1
MAINTENANCE
REM/INST-03
PAGE 6-2
01-37 DEC 20/12

E. Procedure
See Figure 1.
NOTE: For resonator installation, see 01-41, Removal/

Installation-02. For primary fuel nozzle
installation, see 01-37, Removal/Installation-02.
(1) Install a new gasket on the fuel nozzle until it seats

on the nozzle flange.
(2) Install fuel nozzle into combustion chamber rear case

with 90 degree fitting facing left (counterclockwise)
looking from rear.
(3) Attach fuel nozzles to pads with new key washers

(prebent tabs in small hole in flange nozzle) and bolts
lubricated with PWA 36001 Anti-seize Compound. Tighten
bolts fingertight.

(4) Torque the bolts 54 - 60 lb-in. (6.101 - 6.779 N.m).
(5) Bend the key washer tabs to the bolt heads.
F. Postrequisites
(1) Install gas manifolds and hoses. Refer to Fuel System

III, Removal/Installation-13.
MAINTENANCE
REM/INST-03
PAGE 6-3
01-37 DEC 20/12

(GG8-1, GG8-3) COMBUSTION CHAMBERS - REMOVAL/INSTALLATION-01
1. (GG8-1, GG8-3) Combustion Chambers Removal
B. Prerequisites
(1) Remove the two igniter plugs. Refer to Ignition

System, Removal/Installation-03.
C. Tools: PWA 77176 Collar, Combustion Chamber Outer

Rear Case
PWA 77451 Protector, Fuel Nozzle
TC383-002 Support, Stabilization
D. Procedure
See Figures 1 through 4.
(1) Remove the external tubes and hoses from the combustion
area. See Figure 1 for Phase I Gas Generator
(GG8-1) configuration and Figures 1A, 1B and 2 for Gas
Generator (GG8-1 [Phase II], GG8-3) configuration.
NOTE: Mark all bracket and clamp locations to make

sure of correct assembly.
(a) Turbine exhaust case cooling air sensing tube

assembly.
(b) Turbine cooling air tube assembly. Remove two

gaskets.
(c) Rear No. 6 bearing pressure tube assembly.
(d) Eighth stage low pressure turbine (LPT) cooling

air manifold (left side). Remove three gaskets.
(e) (GG8-1) Phase I. Ps3 pressure sensing tube

assembly.
(f) (GG8-1) Phase I. Pressure sensing tube assembly.
(g) External fuel drain hoses from the two finger-

valves at the bottom of the combustion chamber
outer rear case.
(h) Eighth stage low pressure turbine (LPT) cooling

air manifold (right side). Remove three gaskets.
MAINTENANCE
REM/INST-01
PAGE 6-1
01-41 DEC 20/12

(i) Burner pressure (Pb) sensing manifold.
(j) No. 6 Bearing Cooling Air tube assembly.
(k) Heat exchanger air supply tube.
(l) No. 4 and 5 bearing cooling air tube.
(2) Install a support under the power turbine. See

Figure 3.
(a) Attach a TC383-002 Support to the enclosure base

under Flange R on the power turbine.
(b) Turn the support nut until the saddle cushion

firmly touches the flange.
(3) Remove the combustion chamber outer rear case. See

Figures 4 and 5.
NOTE: Mark all bracket locations on Flanges K and L to

make sure of correct assembly.
NOTE: (GG8-3) Mark location of shorter bolts (POST

SB 11B05) on Flange K.
(a) Remove lockwire and four screws that attach

vibration accelerometer to bracket on Flange K,
disconnect cable clamps and related hardware
(Post SB 98B04). Discard lockwire.
(b) Remove the bolts, brackets and nuts that attach

the combustion chamber outer rear case to the
front case (Flange K).
(c) Remove the brackets and nuts that attach the

combustion chamber outer rear case to the turbine
case front flange (Flange L).
MAINTENANCE
REM/INST-01
PAGE 6-2
01-41 DEC 20/12

(GG8-1) Phase I. Gas Generator Tube Assemblies and Manifolds,

Left Side
Figure 1, Sheet 1
MAINTENANCE
REM/INST-01
PAGE 6-3
01-41 DEC 20/12

01-41
(GG8-1) Phase I. Gas Generator Tube Assemblies and Manifolds,

Right Side
Figure 1, Sheet 2
MAINTENANCE
REM/INST-01
PAGE 6-4
01-41 DEC 20/12

(GG8-1, GG8-3) Eighth Stage Low Pressure Turbine (LPT) Cooling Air
Manifold (Left Side) (Post IR 94C14)
Figure 1A
MAINTENANCE
REM/INST-01
PAGE 6-5
01-41 DEC 20/12

(GG8-1, GG8-3) Eighth Stage Low Pressure Turbine (LPT) Cooling Air
(Post IR 94C14) Manifold (Right Side)
Figure 1B
MAINTENANCE
REM/INST-01
PAGE 6-6
01-41 DEC 20/12

(GG8-1, GG8-3) Gas Generator Tube Assemblies and Manifolds,

Left Side
Figure 2 (Sheet 1)
MAINTENANCE
REM/INST-01
PAGE 6-7
01-41 DEC 20/12

(GG8-1, GG8-3) Gas Generator Tube Assemblies and Manifolds,

Right Side
Figure 2 (Sheet 2)
MAINTENANCE
REM/INST-01
PAGE 6-8
01-41 DEC 20/12

(d) Install PWA 77176 Collar around the middle of the

combustion chamber outer rear case with the hand
knob on top and the two dowel handles at the 3 and
9 o’clock positions. Tighten the hand knob to
secure the collar on the case.
(e) Install jackscrews in the tapped holes in front

and rear flanges of rear case (Flanges K and L,
respectively).
(f) Turn the jackscrews evenly until the case is

released from both flanges.
CAUTION: DO NOT LET THE CASE HIT THE COMBUSTION

CHAMBERS WHEN THE CASE IS RELEASED FROM BOTH
FLANGES.
(g) Using the dowel handles on the collar, move the

case to the rear until it touches the turbine
case.
(h) Remove the jackscrews from the front and rear

flanges.
(4) Remove and discard the lockwire from the following:
(a) Bolts retaining the combustion chamber guides.
(b) Bolts and nuts retaining the interconnector tubes

(Pre SB 97B12). See Figure 4, Sheet 1.
(c) Bolts retaining the combustion chamber pins

(Pre SB 97B12). See Figure 4, Sheet 1.
(d) Bolts attaching each fuel nozzle and support

assembly to the diffuser case.
(e) Fuel tube nuts attaching the fuel tubes to each of

the fuel nozzle and support assemblies.
MAINTENANCE
REM/INST-01
PAGE 6-9
01-41 DEC 20/12

(GG8-1, GG8-3) TC383-002 Support Installed Under Power Turbine

Figure 3
MAINTENANCE
REM/INST-01
PAGE 6-10
01-41 DEC 20/12

01-41
(GG8-1, GG8-3) Combustion Chamber Removal/Installation (Pre SB 97B12)

Figure 4, Sheet 1
MAINTENANCE
REM/INST-01
PAGE 6-11
01-41 DEC 20/12

01-41
(GG8-1, GG8-3) Combustion Chamber Removal/Installation (Post SB 97B12)

Figure 4, Sheet 2
MAINTENANCE
REM/INST-01
PAGE 6-12
01-41 DEC 20/12

(GG8-1, GG8-3) No. 4 Combustion Chamber in Removal/Installation

Position
Figure 5
MAINTENANCE
REM/INST-01
PAGE 6-13
01-41 DEC 20/12

(5) Bend tabs on key washers (Post SB 97B12) away from bolt
heads on the interconnector tubes and combustion
chamber pins. See Figure 4, Sheet 2.
CAUTION: PROVIDE ADEQUATE CLEARANCE BETWEEN THE COMBUSTION

CHAMBERS AND FUEL NOZZLES BEFORE ATTEMPTING TO
REMOVE THE COMBUSTION CHAMBERS. EACH FUEL NOZZLE
MUST BE LOOSENED SO THAT IT CAN BE MOVED FORWARD
TO PROVIDE CLEARANCE AND TO MAKE SURE THAT THE
FUEL NOZZLES ARE NOT DAMAGED DURING COMBUSTION
CHAMBER REMOVAL.
(6) Remove the combustion chambers. See Figure 5.
(a) Remove the bolts retaining the combustion chamber

guides and move the guides as far forward as
possible on the combustion chambers.
(b) Remove the interconnector tube bolts and nuts.

Discard key washers (Post SB 97B12). See
Figure 4, Sheet 2.
NOTE: If all combustion chambers are to be moved

rearward as a unit for removal of the fuel
nozzles, do not loosen or remove the
interconnector tubes.
(c) Remove the combustion chamber pin bolts. Discard

key washers (Post SB 97B12). See Figure 4,
Sheet 2.
NOTE: To provide clearance for bolt removal, move the

combustion chambers rearward as far as possible
while unthreading the bolts.
(d) Loosen but do not remove the external fuel tube

nuts attached to the fuel nozzles. Loosen and/or
remove any clamps to allow tube movement.
(e) Remove the four bolts attaching each fuel nozzle

to the diffuser case.
(f) Move the fuel nozzles forward and remove the

combustion chambers.
(g) Remove the interconnector tubes.
MAINTENANCE
REM/INST-01
PAGE 6-14
01-41 DEC 20/12

(h) Remove the combustion chamber guides from each

combustion chamber.
(i) Remove each fuel nozzle.
(j) Remove the gasket from each fuel nozzle. Discard

the gaskets.
(k) Remove any packings from the fuel tubes and

discard.
(l) Install a PWA 77451 Protector on each fuel nozzle.
2. (GG8-1, GG8-3) Combustion Chambers - Installation
B. Tools: PWA 77176 Collar, Combustion Chamber Outer Case
C. Consumables: PMC 9462 Paraffin Wax

PWA 521 Oil
D. Expendables:

Gasket 2 01-17 9 140

Gasket 2 01-17 9 170
Gasket 2 01-17 5 170
Gasket 1 01-17 5 160
Gasket 1 01-17 10 140
Gasket 2 01-17 10 50
Gasket 2 01-17 5 70
Gasket 1 01-17 5 60
Gasket 2 01-17 9 60
Gasket 2 01-17 9 30
Key Washer 9 01-41 3 15
Key Washer 9 01-41 3 18
Lockwire As Req’d
MAINTENANCE
REM/INST-01
PAGE 6-15
01-41 DEC 20/12

E. Procedure
See Figures 1 through 7.
(1) Install the combustion chambers.
NOTE: The fuel nozzles were removed during removal of the

combustion chambers and must be reinstalled at this
time.
(a) Remove the PWA 77451 Protectors, if installed,

from the fuel nozzle and support assemblies.
(b) Put a new gasket on the flange of each fuel nozzle

and support assembly and install the fuel nozzle
and support assemblies into the diffuser case.
(c) Install four bolts (lubricated with PWA 521 Oil)

to attach each nozzle to the diffuser case.
Tighten bolts by hand but allow the nozzles to
remain loose.
(d) Install any required packings on fuel tubes and/or

transfer tubes (depending upon type of fuel used).
Lubricate the tube nut threads with PWA 521 Oil
and connect the tubes to the fuel nozzles. Thread
the nuts on the nozzles but allow nuts to remain
loose. Install any brackets and/or clamps on
tubes that were removed during removal. Allow
brackets or clamps to remain loose so that tubes
are not rigid and able to move.
NOTE: Fuel nozzles should be loose and able to move

forward to facilitate combustion chamber
installation.
(e) Install a combustion chamber guide on each

combustion chamber. Move it forward on the
combustion chamber.
MAINTENANCE
REM/INST-01
PAGE 6-16
01-41 DEC 20/12

CAUTION: INSTALLATION OF DOUBLE KEYWASHERS (POST

SB 97B12) IS THE PREFERRED METHOD TO SECURE
THE BOLTS. BROKEN LOCKWIRE HAS LET BOLTS
RELEASE AND DAMAGE THE GAS PATH.
(f) Install an interconnector tube on each combustion

chamber and attach each tube with two bolts and
two nuts (Pre SB 97B12). See Figure 4, Sheet 1.
Tighten the nuts by hand but allow tubes to remain
loose.
1 Gas generators which include Post SB 97B12,

install one key washer between bolt heads and
each interconnector flange. See Figure 4,
Sheet 2.
(g) Install a combustion chamber, positioning the rear

of the combustion chamber into the opening in the
combustion chamber duct. See Figure 5. Hold
(support) the combustion chamber in position.
(h) Install the other combustion chambers and

carefully rotate to engage the interconnector
tubes.
CAUTION: MAKE SURE THE FUEL NOZZLES ARE LOOSE AND

POSITIONED FORWARD SO THAT THE FRONT OF THE
COMBUSTION CHAMBERS CLEAR THE NOZZLES AND DO
NOT SCRAPE THE CERAMIC COATING ON THE
NOZZLE.
CAUTION: INSTALLATION OF DOUBLE KEYWASHERS (POST

SB 97B12) IS THE PREFERRED METHOD TO SECURE
THE BOLTS. BROKEN LOCKWIRE HAS LET BOLTS
RELEASE AND DAMAGE THE GAS PATH.
(i) Move the combustion chambers forward and install

the combustion chamber pins with the pin shank
angled rearward. Attach the pins to the lug in
the diffuser case with bolts (Pre SB 97B12).
Tighten the bolts finger tight. See Figure 4,
Sheet 1.
1 Gas generators which include Post SB 97B12,

install key washers between bolt heads and
pins. See Figure 4, Sheet 2.
NOTE: The combustion chambers may have to be moved

rearward slightly so that the bolts can be
installed.
MAINTENANCE
REM/INST-01
PAGE 6-17
01-41 DEC 20/12

(j) Move each combustion chamber guide rearward to

seat against the combustion chamber duct. Attach
each guide to the duct with two bolts.
(k) Torque the bolts attaching the combustion chamber

guides to the duct to 85 - 95 lb-in. (9.604 -
10.734 N.m).
CAUTION: YOU MAY NOT USE SAFETY CABLE AS AN ALTERNATE

TO LOCKWIRE AT THIS LOCATION.
(l) Lockwire the bolts to the holes in the combustion

chamber duct.
(m) Tighten the interconnector tube nuts and torque

the nuts to 36 - 40 lb-in. (4.067 - 4.519 N.m).
Lockwire the nuts together (Pre SB 97B12).
See Figure 6, Sheet 1.
1 Post SB 97B12: Bend tabs on key washers.

(n) Torque the combustion chamber pin bolts to 150 -

170 lb-in. (16.948 - 19.207 N.m). Lockwire the
bolts (Pre SB 97B12). See Figure 7, Sheet 1.
1 Post SB 97B12: Bend tabs on keywashers.

(o) Torque the four bolts on each fuel nozzle 65 -

85 lb-in. (7.344 - 9.604 N.m).
(p) Do not loosen the bolts but do step (n) again.

Continue to do step (n) until the 65 - 85 lb-in.
(7.344 - 9.604 N.m) torque is constant.
(q) Lockwire the bolts in pairs.
(r) Tighten all fuel tube nuts on the fuel nozzle.

Attach any brackets or clamps to the fuel tubes.
NOTE: Fuel tube nuts are torqued and lockwired during

postrequisite leakage check operations.
MAINTENANCE
REM/INST-01
PAGE 6-18
01-41 DEC 20/12

(GG8-1) Lockwire on Combustion Chamber Interconnector Tube

(Pre SB 97B12)
Figure 6, Sheet 1
MAINTENANCE
REM/INST-01
PAGE 6-19
01-41 DEC 20/12

(GG8-1, GG8-3) Combustion Chamber Interconnector Tube

(Post SB 97B12)
Figure 6, Sheet 2
MAINTENANCE
REM/INST-01
PAGE 6-20
01-41 DEC 20/12


GG Maint (807421) - 5

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

GG Maint (807421) - 5

Uploaded by

Copyright:

Available Formats

Pratt & Whitney Power Systems, Inc.

GG8 MAINTENANCE MANUAL (PN 807421)

Homepage Previous Document

Homepage Previous Document

Natural Gas (Front View)

Homepage Previous Document

1. Gas Generator Storage, Preservation and Depreservation

Homepage Previous Document

A. Illustrated Parts Catalog Section Reference: 01-18

C. Tools: PWA 77356 Enclosure Trolley

(1) Put a mark on the bellmouth, plate, and inlet case to

(2) Install a nylon strap to the lifting lug at the

Homepage Previous Document

Homepage Previous Document

A. Illustrated Parts Catalog Section Reference: 01-18

B. Tools: PWA 77356 Enclosure Trolley

C. Consumables: PWA 521 Oil

CAUTION: MAKE SURE THAT YOU DO NOT HIT THE ACCELEROMETER

(1) Install the nylon strap on the bellmouth lifting lug.

(4) Loosely install the plates, nuts and bolts lubricated

(5) Torque the bolts to 180 - 200 lb-in. (20.337 –

Homepage Previous Document

1. Nose Cone Removal

A. Illustrated Parts Catalog Section Reference: 01-18

(1) Remove the bellmouth. Refer to Maintenance Section 01-

(2) Remove the bolts and discard the key washers.

(3) Remove the nose cone.

(4) Remove the inlet adapter as follows:

(c) Remove the bracket from the inlet adapter.

(d) Remove the inlet adapter from the No. 1 bearing

Homepage Previous Document

Nose Cone Removal/Installation

Homepage Previous Document

2. Nose Cone Installation

A. Illustrated Parts Catalog Section Reference: 01-18

C. Consumables: PWA 521 Oil

PARTS CATALOG REFERENCE

Key Washer 6 01-18 1 30

(1) Install the inlet adapter as follows:

(a) Lightly lubricate studs with PWA 521 Oil and

(b) Install the bracket over the bottom two studs.

(c) Install the nuts that hold the inlet adapter to

(d) Position the loop clamp on the bracket that holds

Homepage Previous Document

(3) Cast Aluminum, Nose Cone (Pre SB 06B01) – Torque bolts

(4) Fiberglass, Nose Cone (Post SB 06B01) – Torque bolts to

(1) Install the bellmouth. Refer to Maintenance

Homepage Previous Document

1. NL (N1) Tachometer Drive Oil Seal Retainer And Seal Assembly

A. Illustrated Parts Catalog Section Reference: 01-21

(1) Remove the nose cone. Refer to Maintenance Section

C. Tools: PWA 77062 Holder, NL (N1) Transducer Wheel

(1) Remove the NL (N1) transducer electrical connectors

(3) Remove the cover and gasket.

NOTE: The loop clamp bracket mounted on the lower two

(5) Use a PWA 77062 Holder to hold the transducer wheel.

(6) Remove the motional pickup transducer wheel.

(7) Remove the woodruff key from the gearshaft.

(8) Remove the motional pickup transducer housing assembly

Homepage Previous Document

NL (N1) Tachometer Drive Oil Seal Retainer and Seal Assembly

Homepage Previous Document