GG Maint (807421) - 8

Pratt & Whitney Power Systems, Inc.
GG8 MAINTENANCE MANUAL (PN 807421)
BLEED VALVE MANIFOLD AND PRESSURE TUBES -

REMOVAL/INSTALLATION-08
LEFT SIDE (POST SB 08B08)
(GG8-1, Post SB 98B27) and (GG8-3) Bleed Valve Manifold

and Pressure Tubes
Figure 1, Sheet 2
AIR SYSTEM III
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PAGE 7-5
01-17 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.

LEFT SIDE (PRE SB 08B08)
(GG8-2, Post SB 98B27) Bleed Valve Manifold and Pressure Tubes

Figure 2, Sheet 1
AIR SYSTEM III

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01-17 DEC 20/12


LEFT SIDE (POST SB 08B08)
(GG8-2, Post SB 98B27) Bleed Valve Manifold and Pressure Tubes

Figure 2, Sheet 2
AIR SYSTEM III
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01-17 DEC 20/12

SOLENOID AND VARIABLE VANE ACTUATOR WIRING HARNESS

- REMOVAL/INSTALLATION-09
1. Solenoid And Variable Vane Actuator Wiring Harness (Right)

Removal
A. Illustrated Parts Catalog Section Reference: 01-14
B. Prerequisites: None
C. Tools: None
D. Procedure
See Figure 1 and 2.
(1) (GG8-1 and GG8-2, Pre SB 98B27) Disconnect wiring

harness connectors located below the three bleed valve
solenoids. See Figure 1.
(2) (GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Disconnect

wiring harness connectors located above the three bleed
valve solenoids, at the vane actuators and gearbox.
See Figure 2, Sheet 1.
(3) Mark location of loop clamps and remove attaching bolts

and nuts at brackets and tubes. Remove harness.
2. Solenoid And Variable Vane Actuator Wiring Harness (Left)

Removal
C. Tools: None
D. Procedure
See Figure 1 and 2.
(1) (GG8-1 and GG8-2, Pre SB 98B27) Disconnect wiring

harness connectors located below the four bleed
solenoids and at the vane actuators. See Figure 1.
(2) (GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Disconnect

wiring harness connectors located above the four bleed
valve solenoids, at sensor, exciter, junction box and
gearbox. See Figure 2, Sheet 2.
AIR SYSTEM III

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01-17 DEC 20/12


(3) Mark location of loop clamps and remove attaching bolts

and nuts at brackets and tubes. Remove harness.
3. Solenoid And Variable Vane Actuator Wiring Harness (Right)

Installation
B. Tools: None
C. Consumables: PWA 521 Oil
D. Expendables: None
E. Procedure
See Figure 1 and 2.
(1) Lubricate bolts with PWA 521 Oil. Install clamps on

harness and attach with bolts and nuts to brackets and
tubes at the positions marked during removal.
(2) (GG8-1 and GG8-2, Pre SB 98B27) Install wiring harness

connectors to connectors located below the three bleed
valve solenoids. Tighten connectors hand tight.
See Figure 1.
(3) (GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Install

wiring harness connectors to connectors located above
the three bleed valve solenoids, at the vane actuators
and gearbox. Tighten connectors hand tight.
(4) Torque bolts at clamps to 36 - 40 lb-in. (4.067 -

4.519 N.m).
F. Postrequisites: None
4. Solenoid And Variable Vane Actuator Wiring Harness (Left)

Installation
A. Illustrated Parts Catalog: 01-14
B. Tools: None
AIR SYSTEM III

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01-17 DEC 20/12


E. Procedure
See Figure 1 and 2.
(1) Lubricate bolts with PWA 521 Oil. Install clamps on

harness and attach with bolts and nuts to brackets and
tubes at the positions marked during removal.
(2) (GG8-1 and GG8-2, Pre SB 98B27) Install wiring harness

connectors to connectors located below the four bleed
valve solenoids and at vane actuators. Tighten
connectors hand tight. See Figure 1.
(3) (GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Install

wiring harness connectors to connectors above the four
bleed valve solenoids, at sensor, exciter, junction box
and gearbox. Tighten connectors hand tight.
(4) Torque bolts at clamps to 36 - 40 lb-in. (4.067 -

4.519 N.m).
AIR SYSTEM III

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01-17 DEC 20/12


(GG8-1 and GG8-2, Pre SB 98B27) Solenoid and Variable Vane Actuator
Wiring Harnesses
Figure 1
AIR SYSTEM III
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01-17
DEC 20/12


(GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Solenoid and Variable
Vane Actuator Wiring Harness
Figure 2, Sheet 1
AIR SYSTEM III
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PAGE 7-5
01-17 DEC 20/12


(GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Solenoid and Variable
Vane Actuator Wiring Harness
Figure 2, Sheet 2
AIR SYSTEM III
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01-17
DEC 20/12

TURBINE COOLING AIR TUBES – REMOVAL/INSTALLATION-10
1. (GG8-1, GG8-2) Turbine Cooling Air Tubes Removal
B. Tools: None
C. Consumables: None
E. Procedure
See Figures 1 and 2.
(1) (GG8-1, Pre SB 00B06) Remove turbine cooling tube

assemblies. See Figure 1 and as follows:
(a) Mark the location of loop-clamp segments, and

remove the bolts and nuts that attach them to
brackets on Flange K, L and N.
(b) Remove bolts and nuts attaching tube assemblies

together, forward of Flange J.
(c) Remove tube assembly from gas generator.

Discard gasket.
(d) Remove lockwire from the four bolts attaching tube

assembly on high compressor just forward of
Flange H. Discard lockwire.
(e) Remove bolts and tube assembly from gas generator.

Discard gasket.
(2) (GG8-2, Post SB 00B04 and Pre SB 01B01) Remove turbine

cooling tube assembly. See Figure 2 and as follows:
(a) Mark the location of loop-clamp segments and tube

clamp assembly (if applicable) between Flange J
and N.
(b) Remove bolts and nuts attaching clamps to

brackets.
(c) Remove lockwire from four bolts that attach tube

assembly on high compressor just forward of
Flange H. Discard lockwire.
AIR SYSTEM III

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©
01-17 DEC 20/12

(d) Remove bolts and tube assembly from gas generator.

Discard gasket.
2. (GG8-1, GG8-2) Turbine Cooling Air Tubes Installation
A. Illustrated Parts Catalog Reference: 01-17
B. Tools: None
C. Consumables: PMC 9462 Paraffin Wax

PWA 521 Oil
D. Expendables:
PARTS CATALOG REFERENCE

PART NAME QUANTITY SECTION FIGURE ITEM
Gasket 1 01-17 10 1
Gasket 1 01-17 10 50
Gasket 1 01-17 5 430
Lockwire As Req’d
E. Procedure
(1) (GG8-1, Pre SB 00B06) Install turbine cooling tube

assemblies. See Figure 401 and as follows:
(a) Install a new gasket into the groove of the four

hole pad on the tube assembly and six hole pad on
tube assembly. Use PMC 9462 Paraffin Wax to hold
gasket in groove.
NOTE: Apply a small quantity of paraffin wax to

gasket.
CAUTION: BE CAREFUL NOT TO DISTURB GASKET IN GROOVE.
(b) Lubricate bolts with PWA 521 Oil. Install forward

tube assembly to four hole pad on high compressor
case at the one o’clock position with four bolts.
Tube to extend rearward.
AIR SYSTEM III

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©
01-17 DEC 20/12

(c) Lubricate bolts with PWA 521 Oil. Install the

rearward tube assembly to the forward tube
assembly with six bolts (heads forward) and nuts.
(d) Install the clamps (as marked during removal) to

brackets on Flange K, L and N with bolts,
lubricated with PWA 521 Oil, and nuts.
(e) Torque the four bolts at the high compressor case

to 85 - 95 lb-in. (9.604 - 10.734 N.m).
Lockwire bolts.
(f) Torque the six bolts and nuts attaching both tube
flanges together to 75 - 85 lb-in. (8.474 -
9.604 N.m).
(g) Torque the clamp bolts to 36 - 40 lb-in. (4.067 -

4.519 N.m).
(2) (GG8-2, Post SB 00B04 and Pre SB 00B06) Install turbine

cooling tube. See Figure 2 and as follows:
(a) Install a new gasket into the groove of four hole

pad on tube assembly. Use PMC 9462 Paraffin Wax
to hold gasket in place.

gasket.
(b) Lubricate bolts with PWA 521 Oil. Install tube

assembly to four hole pad on high compressor case
at the one o’clock position with four bolts.
Tube to extend rearward.
(c) Install the clamps (as marked during removal) to

brackets between Flange J and N with bolts,
(d) Torque the four bolts at the high compressor case

to 85 - 95 lb-in. (9.604 - 10.734 N.m). Lockwire
bolts.
(e) Torque the clamp bolts to 36 - 40 lb-in. (4.067 -

4.519 N.m).
AIR SYSTEM III

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PAGE 7-3
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01-17 DEC 20/12

(GG8-1, Pre SB 00B06) Turbine Cooling Air Tubes

Figure 1
AIR SYSTEM III
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01-17
DEC 20/12

(GG8-2, Post SB 00B04 and Pre SB 01B01) Turbine Cooling Air Tube
Figure 2
AIR SYSTEM III
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01-17 DEC 20/12

POWER TURBINE COOLING AIR TUBES - REMOVAL/INSTALLATION-11
1. (GG8-1) Power Turbine Cooling Air Tubes Removal
B. Tools: None
E. Procedure
(1) Mark the location of loop-type clamps and remove the

bolts and nuts that attach them to brackets between
Flange K and N.
(2) Phase I - Loosen the four bolts and nuts attaching

flanges of the cooling air tubes together at Flange K.
See Figure 1.
(3) Phase II - Loosen the four bolts and nuts attaching

flanges of the cooling air tubes together at Flange L.
See Figure 2.
(4) Loosen two bolts and nuts at bracket on Flange N.
(5) Remove the bolts, nuts and cooling air tube from gas
generator. Remove the gasket between flanges and
discard.
(6) Remove lockwire from the four bolts that attach the
forward cooling air tube on the high compressor case.
Discard lockwire.
(7) Remove the four bolts and the cooling air tube from the
gas generator. Remove gasket from tube and discard.
AIR SYSTEM III

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PAGE 7-1
01-17 DEC 20/12

2. (GG8-1) Power Turbine Cooling Air Tubes Installation
B. Tools: None

PWA 521 Oil
D. Expendables:

Gasket 1 01-17 10 110

Gasket 1 01-17 10 140
Gasket 1 01-17 10 390
Gasket 1 01-17 10 460
Lockwire As Req’d
E. Procedure
(1) Use PMC 9462 Paraffin Wax to hold gaskets in place.
NOTE: Apply a small quantity of paraffin wax to gasket.
(2) Lubricate bolts with PWA 521 Oil. Install tube

assembly with a new gasket and four bolts to the high
compressor case at approximately the four o’clock
position. Tube to extend rearward.
(3) Phase II - Install the clamps (as marked during

removal) to brackets with bolts, lubricated with
PWA 521 Oil.
(4) Torque the four bolts at the high compressor case to

75 - 85 lb-in. (8.474 - 9.604 N.m). Lockwire bolts.
(5) Torque the clamp bolts to 36 - 40 lb-in. (4.067 -

4.519 N.m).
AIR SYSTEM III

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PAGE 7-2
01-17 DEC 20/12

(6) Lubricate bolts with PWA 521 Oil. Install the cooling
air tube assembly to last installed tube with a new
gasket, four bolts and nuts. Tube to extend rearward
and upward to bracket on Flange N.
(7) Lubricate bolts with PWA 521 Oil. Attach tube assembly
to bracket on Flange N with two bolts and nuts.
(8) Phase I - Install the clamps (as marked during removal)

to brackets between Flanges K and N with bolts,
lubricated with PWA 521 Oil, and nuts (if applicable).
(9) Phase II - Install the clamps (as marked during

removal) to brackets on Flange M with bolts, lubricated
with PWA 521 Oil.
(10) Torque the four bolts at tube flanges to 85 - 95 lb-in.

(9.604 - 10.734 N.m). Lockwire bolts.
(11) Torque the two bolts at Flange N to 180 - 200 lb-in.

(20.337 - 22.597 N.m).
(12) Torque the clamp bolts to 36 - 40 lb-in. (4.067 -

4.519 N.m).
(13) Lubricate threads with PWA 521 Oil. Install a new

gasket to flat threaded end of adapter (if removed) and
install same end to threaded opening at upper end of
last installed tube assembly.
(14) Torque the adapter to 110 - 120 lb-in. (12.428 -

13.558 N.m).
(15) Install cap assembly to the adapter and torque to 270 -

300 lb-in. (30.506 - 33.895 N.m).
AIR SYSTEM III

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01-17 DEC 20/12

(GG8-1) Phase I - Power Turbine Cooling Air Tubes

Figure 1
AIR SYSTEM III

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01-17 DEC 20/12

(GG8-1) Phase II - Power Turbine Cooling Air Tubes

Figure 2
AIR SYSTEM III

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PAGE 7-5
01-17 DEC 20/12

(GG8-3) COOLER RETURN AIR MANIFOLD - REMOVAL/INSTALLATION-12
1. Cooler Return Air Manifold Removal
B. Tools: None
E. Procedure
See Figure 1
(1) Remove lockwire from manifold bolts on diffuser case.

Discard lockwire.
(2) Remove manifold bolts and the bolts and nuts attaching
large adapter end to bracket on Flange K.
(3) Mark locations of loop-type clamps and remove the bolts

and nuts that attach them to the brackets.
(4) Remove manifold and discard gaskets.
2. Cooler Return Air Manifold Installation
B. Tools: None
D. Expendables:

Gasket 2 01-17 4 480

Lockwire As Req’d
E. Procedure
See Figure 1
(1) Install gaskets (Post SB 07B04) to the two small ends

of manifold assembly.
AIR SYSTEM III

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PAGE 7-1
01-17 DEC 20/12

(2) Install manifold to outer face of Flange K bracket,

threaded end with large adapter, with two bolts (heads
outward) and nuts, lubricated with PWA 521 Oil.
NOTE: Manifold to extend to the two parts on diffuser case.
(3) Attach manifold and gaskets to diffuser case ports with

four bolts, lubricated with PWA 521 Oil.
(4) Locate the three brackets on Flange K (as marked during

removal) and install manifold clamps to the brackets
with bolts (head outward) and nuts, lubricated with
PWA 521 Oil.
(5) Torque the four bolts that attach manifold to diffuser

case to 85 – 95 lb-in. (9.604 – 10.734 N.m).
Lockwire bolts.
(6) Torque the two bolts/nuts at large threaded adapter end

to bracket on Flange K to 62 – 72 lb-in. (7.005 –
8.135 N.m).
(7) Torque the three bolts/nuts at each clamp that attach

manifold to brackets to 27 – 30 lb-in. (3.051 –
3.390 N.m).
AIR SYSTEM III

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01-17 DEC 20/12

(GG8-3) Cooler Return Air Manifold Assembly

Figure 1
AIR SYSTEM III

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01-17 DEC 20/12

AIR SUPPLY AND COOLING AIR TUBES - REMOVAL/INSTALLATION-13
1. (GG8-1, GG8-3) Heat Exchanger Air Supply And (GG8-1) No. 4 And 5
Bearing Cooling Air Tubes Removal
B. Tools: None
E. Procedure
See Figure 1
(1) (GG8-1, GG8-3) Remove the heat exchanger air supply

tube assembly as follows:
(a) Mark the location of the loop-type clamps, and

remove the bolts and nuts that attach them to
brackets on Flange K.
NOTE: (GG8-3) Bracket at Location 29, 30 and 31 has

rear clamp bolt installed inward next to
bracket.
(b) Remove the bolts and nuts attaching the tube to

bracket at the six o’clock position.
(c) Remove lockwire and four bolts that attach the

tube to the diffuser case square boss. Remove the
tube assembly and discard lockwire.
(d) Remove gasket from tube assembly. Discard gasket.
(2) (GG8-1) Remove No. 4 and 5 bearing cooling air tube

assembly as follows:
(a) Remove two bolts and nuts attaching the tube to

bracket at the six o’clock position on Flange K.
(b) Remove lockwire and two bolts that attach the tube
to diffuser case. Remove the tube assembly and
discard lockwire.
(c) Remove gasket from tube assembly. Discard gasket.
AIR SYSTEM III

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PAGE 7-1
01-17 DEC 20/12

2. (GG8-2) No. 4 And 5 Buffer/Cooling Air Tubes Removal
B. Tools: None
E. Procedure
See Figure 2
(1) Remove the No. 4 and 5 bearing cooling air tube

assembly as follows:
(a) Remove lockwire from the tube nut on the tube just
rearward of Flange J at the five o’clock position.
Discard lockwire.
(b) Remove the two bolts and nuts that attach opposite
end of tube to bracket on Flange J at the five
thirty o’clock position.
(c) Remove tube assembly from gas generator.
(2) Remove No. 4 and 5 buffer air supply tube assembly as

follows:
(a) Remove the two bolts and nuts attaching tube to

bracket on Flange J at the five thirty o’clock
position.
(b) Remove lockwire from four bolts that attach

opposite and to diffuser case just rearward of
Flange J at the four thirty o’clock position.
(c) Remove bolts and tube assembly from gas generator.

Discard gasket.
AIR SYSTEM III

REM/INST-13
PAGE 7-2
01-17 DEC 20/12

3. (GG8-1, GG8-3) Heat Exchanger Air Supply And (GG8-1) No. 4 And 5
Bearing Cooling Air Tubes Installation
B. Tools: None

PWA 521 Oil
D. Expendables:

Gasket 1 01-17 4 450

Gasket 1 01-17 4 473
Lockwire As Req’d
E. Procedure
See Figure 1
(1) (GG8-1, GG8-3) Install the heat exchanger air supply

(a) Install a new gasket into the groove of the square

pad on the tube assembly. Use PMC 9462 Paraffin
Wax to hold gasket in groove.

gasket.

assembly to the diffuser case with four bolts.
Tube to extend downward to the large hole in
bracket on Flange K at the six o’clock position.
(c) Lubricate bolts with PWA 521 Oil. Attach the tube
assembly to the bracket on Flange K with two bolts
and nuts.
(d) Install clamps (as marked during removal) to

bracket on Flange K with bolts (heads outward),
AIR SYSTEM III

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PAGE 7-3
01-17 DEC 20/12

NOTE: (GG8-3) Install rear clamp bolt on upper

bracket, location 29, 30 and 31, head inward
next to bracket.
(e) Torque the four bolts at the diffuser case to 85 –

95 lb-in. (9.604 – 10.734 N.m). Lockwire bolts.
(f) Torque the two bolts and nuts attaching the tube
to Flange K bracket to 62 – 72 lb-in. (7.005 –
8.135 N.m).
(g) Torque the bolts to 27 – 30 lb-in. (3.051 –

3.390 N.m).
(2) (GG8-1) Install the No. 4 and 5 bearing cooling air

(a) Install a new gasket to small end of the tube

assembly.
(b) Lubricate the bolts with PWA 521 Oil. Install the
tube assembly on the diffuser case with two bolts.
Opposite end of tube to extend downward to the
small hole in bracket on Flange K at the six
o’clock position.
assembly to bracket on Flange K with two bolts and
nuts.
(d) Torque the two bolts at the diffuser case to 85 –

(e) Torque the two bolts attaching the tube to

Flange K bracket to 62 – 72 lb-in. (7.005 –
8.135 N.m).
AIR SYSTEM III

REM/INST-13
PAGE 7-4
01-17 DEC 20/12

4. (GG8-2) No. 4 And 5 Buffer/Cooling Air Tubes Installation
B. Tools: None

PWA 521 Oil
D. Expendables:

Gasket 1 01-17 5 680

Lockwire As Req’d
E. Procedure
See Figure 2.
(1) Install No. 4 and 5 buffer air supply tube assembly as

follows:
(a) Install a new gasket into the groove of the square

pad on the tube assembly. Use PMC 9462 Paraffin
Wax to hold gasket in groove.

gasket.

assembly to the diffuser case with four bolts.
Tube to extend downward to the large hole in
bracket on Flange J at approximately five thirty
o’clock position.
assembly to the bracket on Flange J with two bolts
and nuts.
(d) Torque the four bolts at the diffuser case to 85 –

AIR SYSTEM III

REM/INST-13
PAGE 7-5
01-17 DEC 20/12

(e) Torque the two bolts and nuts attaching the tube
to bracket on Flange J to 62 – 72 lb-in. (7.005 –
8.135 N.m).
(2) Install the No. 4 and 5 bearing cooling air tube

assembly as follow:
(a) Lubricate bolts with PWA 521 Oil. Install flange

end of tube to small hole in bracket on Flange J
at approximately the five thirty o’clock position
with two bolts and nuts.
(b) Attach reducer end of tube to tube nut on diffuser

case at the five o’clock position.
(c) Torque tube nut at diffuser case to 575 –

675 lb-in. (64.966 – 76.265 N.m). Lockwire tube
nut.
AIR SYSTEM III

REM/INST-13
PAGE 7-6
01-17 DEC 20/12

(GG8-1, GG8-3) Heat Exchanger Air Supply and

(GG8-1) No. 4 and 5 Bearing Tubes
Figure 1
AIR SYSTEM III

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PAGE 7-7
01-17 DEC 20/12

(GG8-2) No. 4 and 5 Buffer/Cooling Air Tubes

Figure 2
AIR SYSTEM III

REM/INST-13
PAGE 7-8
01-17 DEC 20/12

BLEED SOLENOID VALVE - CLEANING-01
1. Bleed Solenoid Valve (PN 801942)
B. Tools: None
C. Consumables: PMC 9001 Solvent
D. Expendables:

Seal 2 01-17
Seal 1 01-17
E. Procedure
See Figure 1
CAUTION: SOME DETAILS ARE A MATCHED SET. DETAILS MUST BE

KEPT TOGETHER FOR A GIVEN VALVE.
(1) Remove solenoid from valve body by removing four

machine screws.
NOTE: Mark position of all details when disassembling.
(2) Remove seals and discard.
(3) Clean all parts with PMC 9001 Solvent and inspect for
corrosion or other damage.
(4) Dry all parts with compressed air. Clean parts again,
if necessary.
(5) Replace any solenoid that has damage or internal

corrosion which will not clean up.
(6) Assemble solenoid valve with new seals.
(7) Install four machine screws and torque 30 - 35 lb-in.

(3.390 - 3.954 N.m).
AIR SYSTEM IV
CLEANING 01
PAGE 7-1
01-17 DEC 20/12

BLEED SOLENOID VALVE - CLEANING-01
Bleed Solenoid Valve

Figure 1
AIR SYSTEM IV
CLEANING 01
PAGE 7-2
01-17 DEC 20/12

COMPRESSOR BLEED SYSTEM TEST-01
1. Compressor Bleed System Test (With Components Installed

On Gas Generator)
C. Tools:
Aspirator or Vacuum Pump - 1 pph minimum air flow with

atmospheric pressure on suction side. Vacuum capability
minimum 9.7 psia with suction port capped.
Pressure Gage - 0-75 psia
Power Supply - Suitable to activate bleed solenoids
D. Test.
(1) Inspect all tube connections in the bleed system for

proper tightness. Correct any deficiencies found.
(2) Temporarily remove vent plug, PN 431775 from port 3 of

bleed valve solenoid, PN 801942 (8th and 13th stage
bleed valves only). Connect pump to port 3. The 6th
stage valves, PN 728244, do not require a vacuum to
test.
(3) Connect 0-75 psia pressure gauge to existing tee in the

individual bleed muscle line between solenoid valve and
its bleed valve.
(4) Perform this test on each bleed valve and solenoid, one
at a time. The vacuum pump and muscle air supply must
be installed for this test. 6th stage valves,
PN 728244, do not require vacuum.
(5) Energize individual solenoid to operate bleed valve to

be tested. Listen for valve seating noise “clunk” as
the solenoid is energized. De-energize the solenoid
and energize it three times while listening for the
seating “clunk”. Record the pressure from the pressure
gage connected to the bleed muscle line with the
solenoid energized and again with the solenoid
de-energized.
AIR SYSTEM V
TEST-01
PAGE 7-1
01-17 DEC 20/12

(6) For the 6th stage bleed valve with the Quick Exhaust
Valve (Q.E.V.), PN 53T586, listen for a large volume of
air discharging for the Q.E.V. gradually decreasing to
0 when the solenoid is de-energized. There should be
no indication of air discharging from the valve as the
solenoid is energized. If pressure is measured at the
pressure tap in the feed line to the valve and there is
no indication of air discharging from the Q.E.V. as the
solenoid is cycled, replace the Q.E.V. before
conducting the test for other components in the same
branch.
(7) Follow GG8 Bleed System Troubleshooting Guide in

TROUBLESHOOTING, Section 3, to check the rest of the
bleed components.
AIR SYSTEM V
TEST-01
PAGE 7-2
01-17 DEC 20/12

Bleed System Troubleshooting Guide

Figure 1
AIR SYSTEM V
TEST-01
PAGE 7-3
01-17 DEC 20/12

BLEED SOLENOID VALVE ELECTRICAL TEST-02
1. Bleed Solenoid Valve Electrical Test
C. Tools:
28 VDC power supply capable of 1.5 Amp or more.
25 psig clean pneumatic supply.
OHM meter capable of reading 20 - 35 ohms with 10 percent

accuracy.
D. Consumables: PMC 9001 Solvent
E. Test
See Figure 1
(1) Inspect the electrical connector for damage to pins or

shell.
(a) Bent pins may be carefully straightened.
(b) Contamination may be cleaned away from pins with

PMC 9001 Solvent.
(c) Damaged shell must be replaced.
(2) Measure the coil resistance and for shorting to ground:
(a) Resistance across pin A and B at room temperature

shall be 20 to 30 ohms.
(b) Resistance from A to B to solenoid shell shall be

100 Megaohms minimum.
(3) Inspect valve ports for evidence of damage or

contamination. Replace any damaged solenoid valves.
AIR SYSTEM V
TEST-02
PAGE 7-1
01-17 DEC 20/12

(4) Connect a 25 psig pneumatic supply to port 2, and

28 VDC to the electrical connector. Pin A = pos.,
Pin B = ground. With power on, air should flow through
port 1.
(5) Replace valves not meeting these requirements.
AIR SYSTEM V
TEST-02
PAGE 7-2
01-17 DEC 20/12

Bleed Solenoid Valve

Figure 1
AIR SYSTEM V
TEST-02
PAGE 7-3
01-17 DEC 20/12

LIST OF EFFECTIVE PAGES

This List of Effective Pages (LOEP) lists each current page by number
and date. Discard any page not in agreement with this list.
The Symbol ”R/”, ”A/”, or ”D/”, placed to the left of a listed page,
identifies a page that was Revised, Added, or Deleted in the revi-
sions whose date appears at the bottom of the LOEP page.
PAGE DATE PAGE DATE
Tab Separator R/8-3 DEC 20/12

D/8-4 DEC 20/12
LOEP
R/A DEC 20/12 Rem/Inst-03
R/8-1 DEC 20/12
CONTENTS R/8-2 DEC 20/12
R/1 DEC 20/12 R/8-3 DEC 20/12
R/2 DEC 20/12 R/8-4 DEC 20/12
Lubrication System I Rem/Inst-04

Description R/8-1 DEC 20/12
R/8-1 DEC 20/12 R/8-2 DEC 20/12
R/8-2 DEC 20/12 R/8-3 DEC 20/12
Lubrication System II Rem/Inst-05

Troubleshooting R/8-1 DEC 20/12
R/8-1 DEC 20/12 R/8-2 DEC 20/12
R/8-2 DEC 20/12 R/8-3 DEC 20/12
R/8-3 DEC 20/12
R/8-4 DEC 20/12 Rem/Inst-06
R/8-5 DEC 20/12 R/8-1 DEC 20/12
R/8-6 DEC 20/12 R/8-2 DEC 20/12
R/8-7 DEC 20/12 R/8-3 DEC 20/12
Lubrication System III Lubrication System IV

Rem/Inst-01 Cleaning-01
R/8-1 DEC 20/12 R/8-1 DEC 20/12
R/8-2 DEC 20/12 R/8-2 DEC 20/12
R/8-3 DEC 20/12 R/8-3 DEC 20/12
D/8-4 DEC 20/12 R/8-4 DEC 20/12
Rem/Inst-02 Lubrication System IV

R/8-1 DEC 20/12 Cleaning-02
R/8-2 DEC 20/12 R/8-1 DEC 20/12
LUBRICATION SYSTEM
PAGE A
DEC 20/12

TABLE OF CONTENTS
SUBJECT SECTION PAGE
LUBRICATION SYSTEM I
Description............................... 01-61 8-1
Description
LUBRICATION SYSTEM II
General................................... 01-61 8-1
Troubleshooting
No Oil Pressure Indication............... 01-61 8-1
Troubleshooting
Low Oil Pressure......................... 01-61 8-4
Troubleshooting
High Oil Pressure........................ 01-61 8-6
Troubleshooting
Fluctuating Oil Pressure................. 01-61 8-7
Troubleshooting
LUBRICATION SYSTEM III
Main Oil Pump Removal..................... 01-61 8-1
Rem/Inst-01
Main Oil Pump Installation................ 01-61 8-3
Rem/Inst-01
Main Oil Strainer Element Assembly
(Post SB 98B14/Pre SB 98B20) – Removal... 01-61 8-1
Rem/Inst-02
(Post SB 98B14/Pre SB 98B20) -
Installation............................. 01-61 8-1
Rem/Inst-02
(Post SB 98B14/Pre SB 98B20) -
Disassembly.............................. 01-61 8-1
Rem/Inst-03
(Post SB 98B14/Pre SB 98B20) – Assembly.. 01-61 8-3
Rem/Inst-03
Oil Pressure Relief Valve Assembly
Removal.................................. 01-61 8-1
Rem/Inst-04
Oil Pressure Relief Valve Assembly
Installation............................. 01-61 8-1
Rem/Inst-04
LUBRICATION SYSTEM
CONTENTS
PAGE 1
DEC 20/12

TABLE OF CONTENTS
Main Oil Filter Element (Pre SB 98B14/

Post SB 98B20) – Removal................. 01-61 8-1
Rem/Inst-05
Main Oil Filer Element (Pre SB 98B14/
Post SB 98B20) – Installation............ 01-61 8-2
Rem/Inst-05
Oil Filter Pressure Relief Valve
Removal.................................. 01-61 8-1
Rem/Inst-06
Oil Filter Pressure Relief Valve
Installation............................. 01-61 8-1
Rem/Inst-06
LUBRICATION SYSTEM IV
Main Bearing Breather Tubes (No. 4 And 5
Bearing)................................. 01-61 8-1
Cleaning-01
Main Oil Strainer Element (Post SB 98B14/
Pre SB 98B20) -.......................... 01-61 8-1
Cleaning-02
LUBRICATION SYSTEM
CONTENTS
PAGE 2
DEC 20/12

LUBRICATION SYSTEM - DESCRIPTION
1. Description
A. The gas generator lubrication system consists of a

pressurized oil supply system, an oil and air scavenge
system and an oil compartment venting or breather system.
B. A single stage engine driven positive displacement gear type

pump, located in the main gearbox, draws conditioned oil
from a site mounted oil tank. Discharge oil from the pump
passes through a cleanable filter and is then regulated by
an adjustable pressure regulating valve, which, along with
the filter, is located in the main gearbox. The pressure
regulating valve is biased to gearbox cavity breather
pressure to maintain the required pressure differential
across the various oil jets in the gas generator regardless
of actual breather pressure levels. The regulated oil is
then directed both externally and internally to the No. 1,
No. 2 and 3, No. 4 and 5, and No. 6 and 4-1/2 bearing
compartment areas for lubrication and cooling of the
bearings and seals. There are last chance strainers in
each compartment to prevent blockage of the oil jets.
Pressure oil for the No. 4-1/2 bearing and seals enters the
gas generator at the No. 6 compartment and is transmitted to
the bearing and seals through the rotating No. 4-1/2 and
6 bearing tube assembly.
Some of the regulated oil from the main pump discharge is

diverted for use in the liquid fuel pump clutch and in the
gas generator hydraulic system.
The oil supply for the gas generator lubrication system is

shared with the independent power turbine oil system.
DESCRIPTION
PAGE 8-1
01-61 DEC 20/12

LUBRICATION SYSTEM - DESCRIPTION
C. A gear driven pump in the No. 1 bearing compartment sump

scavenges oil externally to the main gearbox sump. This
oil, along with gravity oil drainage from the No. 2 and
3 compartment, is picked up by the gearbox mounted scavenge
pump, which is a separate unit attached to, and in line
with, the main pressure pump. A separate pump in the No. 6
bearing compartment scavenges oil from the compartment
internally through the rotating No. 4-1/2 and 6 bearing tube
assembly to the No. 4 and 5 bearing compartment. This oil,
along with No. 4 and 5 area scavenge oil is picked up by a
dual element scavenge pump and routed externally to the
gearbox. At the gearbox it joins the discharge from the
main gearbox scavenge pump and is routed for conditioning by
the site mounted system.
The site system provides for oil cooling, filtering and

heating, and includes a chip detecting system.
D. Each bearing compartment is vented, either internally or

externally, to the main gearbox case. A dual impeller
rotary separator (deoiler) in the gearbox separates oil
particles from the air. The relatively oil free air from
the deoiler is then vented overboard after passing through a
site mounted breather vent valve and an additional air/oil
separator unit.
DESCRIPTION
PAGE 8-2
01-61 DEC 20/12

LUBRICATION SYSTEM - TROUBLESHOOTING
1. General
A. The following troubleshooting tables list the probable cause

and any action necessary to correct the problem.
TABLE 1. NO OIL PRESSURE INDICATION

POSSIBLE CAUSE TEST PROCEDURE CORRECTIVE ACTION
1) Oil Level Low None Add Oil
2) Dirty Oil Strainer None Clean oil strainer
3) Black Oil Note: Black High oil temperature
discoloration of oil is
evidence of
overheating.
4) Malfunctioning Refer to applicable Replace systems
Systems Indication Systems Maintenance components, as
System Manual necessary. Refer to
Systems Maintenance
Note: Check oil Manual
pressure indicators,
transmitters,
and electrical
connections.
TROUBLESHOOTING
PAGE 8-1
01-61 DEC 20/12


5) Malfunctioning Main a. Connect 0-50 psig
Oil Pump (0-144 kPa) gage to
LP5 tap (before
strainer) on main
accessory gearbox
housing.
b. Motor gas generator If gage pressure

with starter to 1800 from LP5 is low,
- 2100 rpm. Normal remove and check
pressure from LP5 main oil pump and
tap at 1800 - 2100 pressure regulating
rpm should be 7.5 - valve. If gage
10.2 psig (51.7 - pressure at LP5 is
70.3 kPa) and 10.8 - not low, perform the
14.2 psig (74.5 - following procedures
97.9 kPa) in the following
sequence:
(a) Main Oil Pump.
See Section 8,
Rem/Inst-01
(b) Main Oil
Strainer. See
Section 8,
Rem/Inst-02.
(c) Check main oil
pressure line
for blockage
(d) Refill oil tank
TROUBLESHOOTING
PAGE 8-2
01-61 DEC 20/12


6) Defective Oil a. Remove oil pressure
Pressure Relief relief valve. See
Valve Section 8, Rem/Inst
-04.
b. Check preformed If packings are

packings for damage damaged, install
valve with new
packings.
Note: If packings are If packings are not

not damaged, inspect damaged, install new
valve for internal valve with new
binding. packings.
TROUBLESHOOTING
PAGE 8-3
01-61 DEC 20/12

TABLE 2. LOW OIL PRESSURE

1) Oil Level Low None Add oil
2) Dirty Oil Strainer None Clean Oil Strainer
3) Black Oil Note: Black High Oil Temperature
discoloration of oil
is evidence of
overheating or
contamination.
Systems Mainten-
Note: Check oil ance Manual
pressure indicator,
transmitters and
electrical
connectors
5) Defective Oil a. Remove oil
Pressure Relief Valve pressure relief
valve. See
Section 8,
Rem/Inst-04.

packings for damaged, install
damage valve with new
packings.
Note: If packings If packings are not
are not damaged, damaged, install new
inspect valve for valve with new
internal binding. packings.
TROUBLESHOOTING
PAGE 8-4
01-61 DEC 20/12


6) Malfunctioning Main a. Remove main oil
Oil Pump pump. See
Section 8,
Rem/Inst-01.
b. Inspect pump If packings are

packings for damaged, reinstall
damage pump with new
packings.
Note: Check pump If packings are not

cavity in gearbox damaged, install new
for scoring. pump with new
packings.
TROUBLESHOOTING
PAGE 8-5
01-61 DEC 20/12

TABLE 3. HIGH OIL PRESSURE

Systems Indica- Systems Maintenance components, as
ting System Manual necessary. Refer to
Systems Maintenance
Note: Check oil Manual
pressure indicators,
transmitters and
electrical connect-
ions.
2) Defective Oil a. Remove oil pres-
Pressure Relief sure relief valve.
Valve See Section 8, Rem/
Inst-04.

packings for damaged, install valve
damage. with new packings.
Note: If packings are If packings are not

not damaged, inspect damaged, install new
valve for internal valve with new
binding. packings.
TROUBLESHOOTING
PAGE 8-6
01-61 DEC 20/12

TABLE 4. FLUCTUATING OIL PRESSURE

Systems Maintenance
Note: Check oil Manual.
pressure sensors,
transmitters, and
electrical
connections.
2) Defective Oil a. Check oil quan-
Pressure Relief tity and main oil
Valve strainer
b. Remove oil pressure

relief valve. See
Section 8, Rem/
Inst-04.
c. Check preformed
packings for
damage.
Note: If packings are

not damaged, inspect
valve for internal
binding.
3) Low Oil Level Check oil level Add oil
TROUBLESHOOTING
PAGE 8-7
01-61 DEC 20/12

MAIN OIL PUMP - REMOVAL/INSTALLATION-01
1. Main Oil Pump Removal
C. Tools: None
D. Procedure
See Figure 1.
(1) Close oil supply valve on oil tank located on lube oil
skid and tag with warning not to operate valve until
re-installation of oil pump is completed.
(2) Remove and discard safety wire from the drain plug to
the gearbox.
(3) Remove the drain plug and drain the gearbox. Remove
the packing from the drain plug and discard the
packing.
WARNING: PREVENT OIL LEAKAGE ON PERSONS AND EQUIPMENT WHEN

THE OIL PUMP IS REMOVED, USE EXTRA CAUTION IF THE
OIL IS HOT. HOLD APPLICABLE CONTAINER BELOW THE
OIL PUMP WHEN THE OIL PUMP IS REMOVED FROM THE
GEARBOX.
CAUTION: IF THROUGH BOLTS ARE ACCIDENTALLY REMOVED, SAFETY

WIRE CAN FALL INTO THE GEARBOX HOUSING. REMOVE
ONLY THE BOLTS ON THE OUTER EDGE OF THE OIL PUMP
COVER.
(4) Remove and discard the safety wire from the four bolts
on the outer edge of the main pump. Remove the four
bolts and washers.
(5) Remove the oil pump from the gearbox with standard US
thread jackscrews.
(6) Remove the three packings from the oil pump and discard
the three packings.

REM/INST-01
PAGE 8-1
01-61 DEC 20/12

1. Packings (Three Reqd)

2. Main Oil Pump
3. Washer (Four Reqd)
4. Bolt (Four Reqd)
Main Oil Pump Replacement

Figure 1

REM/INST-01
PAGE 8-2
01-61 DEC 20/12

2. Main Oil Pump Installation
B. Tools: None
C. Consumables: PWA 36500 Assembly Fluid

PWA 521 Oil
D. Expendables:

Packing 3 01-61 4 200

Packing 1 01-61 3 30
Wire, Safety As Reqd
E. Procedure
See Figure 1.
(1) Install three new preformed packings, lubricated with a

thin layer of PWA 36500 Assembly Fluid or PWA 521 Oil,
in the three outer diameter grooves of the pump
assembly.
CAUTION: BE SURE THAT UPPER BEVEL GEAR OF MAIN OIL PUMP

ASSEMBLY MESHES CORRECTLY AT INSTALLATION.
(2) Install the main oil pump to the gearbox with four
bolts and washers. Torque the four bolts to 125 -
170 lb-in. (14.123 - 9.207 N.m) and safety with wire.
(3) Install the drain plug with a new preformed packing,

lubricated with a thin layer of PWA 36500 Assembly
Fluid or PWA 521 Oil, into the gearbox. Torque the
plug to 65 - 75 lb-in. (7.344 - 8.474 N.m) and safety
with wire.
(4) Remove the warning tag on the oil supply valve on the
oil tank located on the lube oil skid and open the
valve.
(5) Fill the oil system to correct level if necessary.

REM/INST-01
PAGE 8-3
01-61 DEC 20/12

MAIN OIL STRAINER ASSEMBLY - REMOVAL/INSTALLATION-02
1. Main Oil Strainer Element Assembly (Post SB 98B14/Pre SB 98B20)

Removal
C. Tools: None
D. Procedure
See Figure 1.
(1) Remove the drain plug from the main oil strainer cover
to drain oil from the cavity.
(2) Remove packing from the plug and discard the packing.
(3) Remove and discard the lockwire from the four nuts that
hold the main oil strainer cover. Loosen and remove
the four nuts and four washers.
CAUTION: HOLD THE COVER SO THAT THE SPRING PRESSURE WILL

NOT CAUSE THE COVER TO BE RELEASED TOO FAST.
(4) Remove the cover, spring, key washer and main oil
strainer assembly from the gearbox.
NOTE: The spring and retaining key washer are not normally
removed and should remain assembled to the cover.
(5) Remove the packing from the cover and discard the
packing.

Installation
B. Tools: None

PWA 521 Oil

REM/INST-02
PAGE 8-1
01-61 DEC 20/12

Main Oil Strainer Element Assembly Replacement

Figure 1

REM/INST-02
PAGE 8-2
01-61 DEC 20/12

D. Expendables:

Key Washer 1 01-61 2 60

Packing 1 01-61 2 50
Packing 1 01-61 2 10
Lockwire, As Req’d
E. Procedure
See Figure 1.
(1) If the spring is not attached to the cover, put the

inner diameter tabs of a new key washer in the circular
groove of the cover.
NOTE: Normally the spring and retaining key washer remain

assembled to the cover.
(a) Set the cover on a bench with the spring up.

Apply sufficient pressure down against the outer
diameter of the key washer, to bend the inner
diameter tabs into contact with the outer diameter
of the groove. It is not necessary to make the
tabs flat.
(b) Install the outer diameter tabs of the key washer

over the first coil of the spring. Bend the tabs
to hold the spring.
(2) Install a new preformed packing, lubricated with a thin

layer of PWA 36500 Assembly Fluid or PWA 521 Oil, on
the flange of the cover.
(3) Install the oil strainer element assembly and cover

assembly to the gearbox. Attach the cover with four
washers and four nuts. Torque the four nuts to 25 -
30 lb-in. (2.825 - 3.390 N.m).
(4) Install the drain plug in the main oil strainer cover
with a new preformed packing lubricated with a thin
layer of PWA 36500 Assembly Fluid or PWA 521 Oil.
Torque the plug to 200 - 225 lb-in. (22.597 -
25.422 N.m) and lockwire.

REM/INST-02
PAGE 8-3
01-61 DEC 20/12


Disassembly
B. Prerequisites
(1) Remove the main oil strainer element assembly. Refer

to Lubrication System III, Removal/Installation-02.
C. Tools: PWA 10014 Wrench

PWA 14406 Fixture
D. Procedure
See Figure 1.
(1) Put the main oil strainer element assembly into

PWA 14406 Fixture.
(2) Use PWA 10014 Wrench to loosen the retaining nut.

Remove the retaining nut.
(3) Lift out the bypass valve and the valve spring.
(4) Remove the seat assembly, screens, and spacers from the
strainer sleeve assembly.

REM/INST-03
PAGE 8-1
01-61 DEC 20/12


Figure 1

REM/INST-03
PAGE 8-2
01-61 DEC 20/12


Assembly
B. Tools: PWA 10014 Wrench

PWA 14406 Fixture
E. Procedure
See Figure 1.
(1) Put the strainer sleeve assembly into the base of

PWA 14406 Fixture.
(2) Install complete sets of spacers and screens on the

sleeve assembly (a set consists of two oil strainer
screens, one oil screen inlet spacer, and one oil
screen outlet spacer). Arrange set details in order:
outlet spacer, screen, inlet spacer, screen.
(3) Continue to add only complete sets of screens and

spacers until the length of the assembled stacked sets
is 3.160 inches (80.264 mm) when constrained between
the strainer sleeve assembly and the seat assembly.
(4) When length of the assembled stacked sets is correct,

add one more outlet spacer.
NOTE: The assembly length is satisfactory between 3.130

and 3.190 inches (79.50 and 81.03 mm) when all other
conditions are correct. Add or remove only complete
sets of parts to get the necessary dimension. When
properly assembled, an outlet spacer must be at each
end of the assembly and a screen must be between
each outlet spacer and an inlet spacer.

REM/INST-03
PAGE 8-3
01-61 DEC 20/12

(5) Install the seat assembly on the assembled spacers and

screens. Put the fixture plate detail on the seat
assembly and attach with wing nuts.
NOTE: Align the pin in the seat assembly with the slot in
the sleeve bushing.
(6) Install the spring and the bypass valve into the sleeve
assembly.
(7) Push in the bypass valve and install the retaining nut.
(8) Use PWA 10014 Wrench to torque the retaining nut

sufficiently to touch against the bushing when viewed
through the slots of the seat assembly.
NOTE: If screens and spacers can be turned by hand after

torque is applied, disassemble until another
complete set can be added to the assembly, and repeat
Steps (5) through (8).
F. Postrequisites
(1) Install the main oil strainer element assembly. Refer

to Lubrication System III, Removal/Installation-02.

REM/INST-03
PAGE 8-4
01-61 DEC 20/12

OIL PRESSURE RELIEF VALVE ASSEMBLY - REMOVAL/

INSTALLATION-04
1. Oil Pressure Relief Valve Assembly Removal
C. Tools: None
D. Procedure
See Figure 1.
(1) Remove and discard the lockwire from the pressure

relief valve assembly to the gearbox.
WARNING: PREVENT OIL LEAKAGE ON PERSONS AND EQUIPMENT

WHEN THE PRESSURE RELIEF VALVE ASSEMBLY IS
REMOVED; USE EXTRA CAUTION IF THE OIL IS HOT.
HOLD APPLICABLE CONTAINER BELOW THE PRESSURE
RELIEF VALVE ASSEMBLY WHEN THE PRESSURE RELIEF
VALVE ASSEMBLY IS REMOVED FROM THE GEARBOX.
(2) Loosen and remove the pressure relief valve assembly

from the gearbox.
(3) Remove the four packings from the pressure relief valve
assembly and discard the four packings.
2. Oil Pressure Relief Valve Assembly Installation
B. Tools: None

PWA 521 Oil

REM/INST-04
PAGE 8-1
01-61 DEC 20/12


INSTALLATION-04
1. Packings
2. Pressure Relief Valve Assembly
Oil Pressure Relief Valve Assembly Replacement

Figure 1

REM/INST-04
PAGE 8-2
01-61 DEC 20/12


INSTALLATION-04
D. Expendables:
Packing 1 01-61 5 130

Packing 1 01-61 5 140
Packing 1 01-61 5 150
Packing 1 01-61 5 160
Lockwire As Req’d
E. Procedure
See Figure 1.
(1) Install four new performed packings, lubricated with a

thin layer of PWA 36500 Assembly Fluid or PWA 521 Oil,
in each groove and adjacent to the largest outer
diameter flange of the pressure relief valve assembly.
(2) Install the pressure relief valve assembly to the

gearbox. Torque the valve to 550 - 650 lb-in. (62.142 -
73.440 N.m).
CAUTION: YOU MAY NOT USE SAFETY CABLE AS AN ALTERNATE TO

LOCKWIRE AT THIS LOCATION.
(3) Lockwire valve assembly.

REM/INST-04
PAGE 8-3
01-61 DEC 20/12

MAIN OIL FILTER ELEMENT ASSEMBLY - REMOVAL/

INSTALLATION-05
1. Main Oil Filter Element (Pre SB 98B14/Post SB 98B20) Removal
C. Tools: PWA 16477 Drift

PWA 33201 Base
D. Procedure
See Figure 1.
(1) Drain oil from main oil filter cavity.
(2) Remove locknuts and washers attaching main oil strainer

cover to main gearbox.
(3) Remove cover, oil filter pressure relief valve assembly

and main oil filter element.
(4) Remove main oil filter element from oil filter pressure
relief valve.
(5) If oil filter element is difficult to remove from

pressure relief valve, separate filter element and
valve as follows:
(a) Pull back key washer from slots in relief valve

and remove oil filter cover.
(b) Place filter element and relief valve on PWA 33201

Base, valve end up.
(c) Remove filter element from relief valve using

PWA 16477 Drift.
(6) Remove packing from oil filter pressure relief valve OD

and cover mount pad. Discard packings.

REM/INST-05
PAGE 8-1
01-61 DEC 20/12


INSTALLATION-05
2. Main Oil Filter Element (Pre SB 98B14/Post SB 98B20)

Installation
B. Tools: None

PWA 521 Oil
D. Expendables:
Key Washer 1 01-61 2 200

Packing 1 01-61 2 230
Packing 1 01-61 2 50
E. Procedure
See Figure 1
(1) Install a new packing, lubricated with a thin layer of

PWA 36500 Assembly Fluid or PWA 521 Oil, on the oil
filter pressure relief valve OD and cover mount pad.
(2) If it was necessary to remove oil filter pressure

relief valve from cover in order to remove oil filter
element, install relief valve on cover so that tabs of
cover key washer engage slots in valve.
(3) Install new main oil filter element on oil pressure

relief valve.
(4) Install main oil filter element, cover and oil pressure
relief valve assembly on main gearbox.
(5) Attach cover assembly to gearbox with washers and

locknuts. Torque locknuts to 25 - 30 lb-in.
(2.825 - 3.390 N.m) and lockwire.

REM/INST-05
PAGE 8-2
01-61 DEC 20/12


INSTALLATION-05
Main Oil Filter Element, Relief Valve and Cover Assembly

Figure 1

REM/INST-05
PAGE 8-3
01-61 DEC 20/12

OIL FILTER PRESSURE RELIEF VALVE - REMOVAL/

INSTALLATION-06
1. Oil Filter Pressure Relief Valve Removal
B. Prerequisites:
(1) Remove main oil filter element. Refer to Lubrication

System III, Removal/Installation-05.
C. Tools: PWA 16477 Drift

PWA 33201 Base
D. Procedure
See Figure 1.
(1) Pull back key washer from slots in bypass valve and
remove cover.
(2) Place element and bypass valve on PWA 33201 Base

(bypass valve end up). Remove element from valve
assembly using PWA 16477 Drift.
2. Oil Filter Pressure Relief Valve Installation
B. Tools: None

PWA 521 Oil
D. Expendables:
Key Washer 1 01-61 2 200

Packing 1 01-61 2 230
E. Procedure
See Figure 1

REM/INST-06
PAGE 8-1
01-61 DEC 20/12


INSTALLATION-06
(1) Install pressure relief valve over key washer. Make

sure that tabs of key washer engage slots in pressure
relief valve.
(2) Install a packing, lubricated with a thin layer of

PWA 36500 Assembly Fluid or PWA 521 Oil, in groove on
the outside of the pressure relief valve.
(3) Install strainer element in pressure relief valve with

larger OD flange away from valve.
F. Postrequisites:
(1) Install main oil filter element. Refer to Lubrication

System III, Removal/Installation-05.

REM/INST-06
PAGE 8-2
01-61 DEC 20/12


INSTALLATION-06
Main Oil Filter Pressure Relief Valve

Figure 1

REM/INST-06
PAGE 8-3
01-61 DEC 20/12

(GG8-1, GG8-3) MAIN BEARING BREATHER TUBES (NO. 4

AND 5 BEARING) - CLEANING-01
1. Main Bearing Breather Tubes (No. 4 And 5 Bearing)
B. Tools: PWA 77520 Reamer
D. Expendables:

Gasket 1 01-09 4 10
E. Procedure
See Figure 1.
(1) Mark the location of the loop-type clamps, and remove

the bolts securing them to the brackets.
(2) Loosen the tube coupling nut at the junction of the two
breather tubes. Loosen the tube nut on the forward
breather tube at the elbow on the gearbox. Loosen and
remove the two bolts that attach the rear tube to the
pad just forward of Flange J.
(3) Remove the two tubes from the gas generator.
(4) Clean the two tubes as follows:
(a) Pyrolytically clean using SPOP 201, Standard

Practices, as a guide at 900°F (482°C) for 1 to
2 hours.
(b) Blow clean with shop air.
CLEANING-01
PAGE 8-1
01-61 DEC 20/12


(GG8-1, GG8-3) Main Bearing Breather Tube

Figure 1
CLEANING-01
PAGE 8-2
01-61 DEC 20/12


(c) Check that the tubes are open by rolling a ball

(largest size possible) through the ID of the
tubes.
(5) Clean the installed diffuser to No. 4 bearing housing

tube and boss as follows:
(a) Check the passage way using the PWA 77520 GO-NO-GO
combination gage and coke reamer.
NOTE: The PWA 77520 Reamer is of specific diameter

with preset length and positive stop to aid in
demonstrating passageway openness with or
without using the integral cleaning form of the
tool.
(b) Slowly insert PWA 77520 Reamer into the breather

tube. If resistance is felt, lightly tap the end
of the tool with a mallet to dislodge (by shearing
impact) and coke accumulation on the interior of
the tube.
NOTE: Do not force the tool to the point of binding.
(c) Frequently check for freedom of movement of the

tool by turning. Clear the tube by tool insertion
and turning to the point of the positive stop on
the tool.
(d) After reaching full open gage point for the tube
(as indicated on the tool) remove the tool and
follow-up with an air purge using shop air.
(6) Install new gasket, and connect the rear of main

bearing breather tube to the pad just forward of
Flange J. Secure the tube to the pad with two bolts
lubricated with PWA 521 Oil.
CLEANING-01
PAGE 8-3
01-61 DEC 20/12


(7) Install sleeves and loop clamps and secure with bolts
(8) Torque the bolts on the tube flange to 85 - 95 lb-in.

(9.604 - 10.734 N.m).
(9) Torque the tube nut connecting the two tubes to 675 -
750 lb-in. (76.265 - 84.739 N.m).
(10) Torque the tube nut at the gearbox elbow to 200 -

220 lb-in. (22.597 - 24.857 N.m).
(11) Torque the clamp retaining bolts to 36 - 40 lb-in.

4.067 - 4.519 N.m).
(12) Safety the tube nuts and flange bolts with wire.
CLEANING-01
PAGE 8-4
01-61 DEC 20/12

MAIN OIL STRAINER ASSEMBLY - CLEANING-02
1. Main Oil Strainer Element (Post SB 98B14/Pre SB 98B20)
B. Prerequisites
(1) Disassemble main oil strainer element assembly. Refer

to Lubrication System III, Removal/Installation-03
C. Tools: None
D. Consumables: PMC 9001 Solvent
E. Procedure
(1) Slide screens and spacers on a suitable rod provided

with stops to prevent screens and spacers from sliding
off during cleaning.
(2) Loosen screens from spacers by sliding parts along rod.
(3) Rinse parts in a petroleum solvent such as PMC 9001.
(4) Dry with low pressure compressed air.
NOTE: Inspect the assembly and detail parts for metal

particles that could indicate possible component
failure.
CLEANING-02
PAGE 8-1
01-61 DEC 20/12

LIST OF EFFECTIVE PAGES
This List of Effective Pages (LOEP) lists each current page by number
and date. Discard any page not in agreement with this list.
The Symbol ”R/”, ”A/”, or ”D/”, placed to the left of a listed page,
identifies a page that was Revised, Added, or Deleted in the
revisions whose date appears at the bottom of the LOEP page.
PAGE DATE PAGE DATE PAGE DATE
Tab Separator Rem/Inst-04

R/9-1 DEC 20/12 R/9-6 DEC 20/12
LOEP R/9-2 DEC 20/12 R/9-7 DEC 20/12
R/A DEC 20/12 R/9-3 DEC 20/12 R/9-8 DEC 20/12
R/9-4 DEC 20/12 R/9-9 DEC 20/12
CONTENTS R/9-5 DEC 20/12 D/9-10 DEC 20/12
R/1 DEC 20/12 R/9-6 DEC 20/12
R/2 DEC 20/12 R/9-7 DEC 20/12 Rem/Inst-07
R/9-8 DEC 20/12 R/9-1 DEC 20/12
Hydraulic System I R/9-9 DEC 20/12 R/9-2 DEC 20/12
Description R/9-10 DEC 20/12 R/9-3 DEC 20/12
R/9-1 DEC 20/12 R/9-11 DEC 20/12 R/9-4 DEC 20/12
R/9-12 DEC 20/12 R/9-5 DEC 20/12
Hydraulic System II R/9-13 DEC 20/12 R/9-6 DEC 20/12
Troubleshooting R/9-14 DEC 20/12 R/9-7 DEC 20/12
R/9-1 DEC 20/12 R/9-8 DEC 20/12
Rem/Inst-05 R/9-9 DEC 20/12
Hydraulic System III R/9-1 DEC 20/12 R/9-10 DEC 20/12
Rem/Inst-01 R/9-2 DEC 20/12 R/9-11 DEC 20/12
R/9-1 DEC 20/12 R/9-3 DEC 20/12 R/9-12 DEC 20/12
R/9-2 DEC 20/12 R/9-4 DEC 20/12 R/9-13 DEC 20/12
R/9-3 DEC 20/12 R/9-5 DEC 20/12 R/9-14 DEC 20/12
R/9-4 DEC 20/12 R/9-6 DEC 20/12 R/9-15 DEC 20/12
R/9-5 DEC 20/12 R/9-7 DEC 20/12 R/9-16 DEC 20/12
R/9-8 DEC 20/12
Rem/Inst-02 D/9-9 DEC 20/12 Hydraulic System IV
R/9-1 DEC 20/12 Calibration-01
R/9-2 DEC 20/12 Rem/Inst-06 R/9-1 DEC 20/12
R/9-1 DEC 20/12 R/9-2 DEC 20/12
Rem/Inst-03 R/9-2 DEC 20/12 R/9-3 DEC 20/12
R/9-1 DEC 20/12 R/9-3 DEC 20/12 R/9-4 DEC 20/12
R/9-2 DEC 20/12 R/9-4 DEC 20/12 R/9-5 DEC 20/12
R/9-3 DEC 20/12 R/9-5 DEC 20/12 R/9-6 DEC 20/12
HYDRAULIC SYSTEM
PAGE A
DEC 20/12

TABLE OF CONTENTS
HYDRAULIC SYSTEM I
Description.............................. 01-10 9-1
Description
HYDRAULIC SYSTEM II
General.................................. 01-10 9-1
Troubleshooting
High Hydraulic Differential Pressure
Alarm................................. 01-10 9-1
Troubleshooting
Low Hydraulic Pressure Alarm............ 01-10 9-1
Troubleshooting
IGV or VSV Actuator Not Positioning
Correctly.............................. 01-10 9-1
Troubleshooting
HYDRAULIC SYSTEM III
Hydraulic Oil Pump And Hydraulic Oil
(Servo) Valve Package Removal.......... 01-10 9-1
Rem/Inst-01
Hydraulic Oil Pump And Hydraulic Oil
(Servo) Valve Package Installation..... 01-10 9-3
Rem/Inst-01
Hydraulic Oil Pump Filter Removal........ 01-10 9-1
Rem/Inst-02
Hydraulic Oil Pump Filter Installation... 01-10 9-1
Rem/Inst-02
Hydraulic Oil Valve (Servo) Removal...... 01-10 9-1
Rem/Inst-03
Hydraulic Oil Valve (Servo) Installation. 01-10 9-1
Rem/Inst-03
Inlet Guide Vane Variable Stator Actuator
And Support Assembly Removal............ 01-10 9-1
Rem/Inst-04
Inlet Guide Vane Variable Stator Actuator
And Support Assembly Installation....... 01-10 9-3
Rem/Inst-04
HYDRAULIC SYSTEM
CONTENTS
PAGE 1
DEC 20/12

TABLE OF CONTENTS
Inlet Guide Vane Variable Stator

Actuator Removal........................ 01-10 9-1
Rem/Inst-05
Inlet Guide Vane Variable Stator
Actuator Installation................... 01-10 9-3
Rem/Inst-05
Variable Stator (1.1 And 1.3 Stage Vanes)
Actuator Removal........................ 01-10 9-1
Rem/Inst-06
Actuator Installation................... 01-10 9-3
Rem/Inst-06
Actuator And Support Assembly Removal... 01-10 9-1
Rem/Inst-07
Actuator And Support Assembly
Installation............................ 01-10 9-4
Rem/Inst-07
HYDRAULIC SYSTEM IV
Inlet Guide Vane And Variable Stator Vane
Actuators - Field Calibration.......... 01-10 9-1
Calibration-01
HYDRAULIC SYSTEM
CONTENTS
PAGE 2
DEC 20/12

HYDRAULIC SYSTEM - DESCRIPTION
1. Description
A. The gas generator hydraulic system consists of a pump, a

dual servovalve assembly and two actuators that adjust the
variable inlet guide vanes and the variable compressor
stator vanes for stages 1.1 and 1.3. In addition, the
system also provides hydraulic pressure for operation of the
electrohydraulic actuators in the site mounted engine fuel
and water metering systems. The hydraulic system uses the
same oil supply that is used for lubrication and cooling of
the gas generator and power turbine bearings and seals.
B. Filtered and regulated oil from the gas generator main oil
pressure pump is routed externally to the hydraulic pump
that is mounted on the rear right drive pad of the main
gearbox. The hydraulic pump discharge oil is filtered and
regulated to 750 psig and is then supplied internally to the
dual servovalve that is attached to the hydraulic pump. The
filter element is replaceable and is integral with the
hydraulic pump.
Metered fluid from the two servovalves is routed to the two

actuators through either of two external tubes connected to
each of the actuators. A drain line is also connected to
each actuator. The vanes in both stator stages 1.1 and 1.3
are controlled by one of the two actuators. The other
actuator controls the inlet guide vanes.
The system also incorporates flow check valves and a site

mounted accumulator. This is to assure that sufficient
pressure will be available for the required actuator
function should hydraulic pump discharge pressure be lost.
HYDRAULIC SYSTEM I
DESCRIPTION
PAGE 9-1
01-10 DEC 20/12

HYDRAULIC SYSTEM - TROUBLESHOOTING
1. General
A. The following troubleshooting tables list the probable cause

and any action necessary to correct the problem.
TABLE 1. HIGH HYDRAULIC DIFFERENTIAL PRESSURE ALARM
PROBABLE CAUSE TEST PROCEDURE CORRECTIVE ACTION

1) Dirty or Plugged None Replace Filter
Hydraulic Pump
Filter
TABLE 2. LOW HYDRAULIC PRESSURE ALARM

1) Low Oil Level in Check Lube Level in Add Lube Oil as
Lube Oil Tank Tank Required
2) Plumbing Leaks None Repair Leaks as
Necessary
3) Hydraulic Pump Not None Remove and Replace
Operating Properly Hydraulic Pump
TABLE 3. IGV OR VSV ACTUATOR NOT POSITIONING CORRECTLY

1) Leaks in Actuator None Repair Leaks as
Plumbing Necessary.
2) Incorrect Linkage Check Actuator Rigging Correct Rigging as
Rigging Necessary.
3) Malfunctioning Dual None Refer to Systems
Servo Valve or Maintenance Manual
Valve Control
System
HYDRAULIC SYSTEM II
TROUBLESHOOTING
PAGE 9-1
01-10 DEC 20/12

HYDRAULIC OIL PUMP AND HYDRAULIC OIL (SERVO) VALVE

PACKAGE - REMOVAL/INSTALLATION-01
1. Hydraulic Oil Pump And Hydraulic Oil (Servo) Valve Package

Removal
C. Tools: None
D. Procedure
See Figure 1.
(1) Disconnect the electrical connector on the hydraulic

oil valve housing.
(2) Loosen the clamps on the NH (N2) transducer cover that

hold the main hydraulic oil pump supply tube.
(3) Disconnect the coupling nut at the hydraulic oil pump

housing.
(4) Loosen the clamp that holds:
(a) Inlet guide vane hydraulic tube
(b) Variable stator vane hydraulic tube
(c) Inlet guide vane return tube
(d) Variable stator vane return tube
(5) Loosen the clamp at Flange G.
(6) Disconnect the coupling nuts that hold the two inlet
guide vane hydraulic tubes to the hydraulic oil valve
housing.

REM/INST-01
PAGE 9-1
01-10 DEC 20/12


Hydraulic Oil Pump and Hydraulic Oil Valve Removal/Installation

Figure 1

REM/INST-01
PAGE 9-2
01-10 DEC 20/12


(7) Disconnect the coupling nuts that holds the two

variable stator hydraulic tubes to the hydraulic oil
valve
housing.
(8) Disconnect three hoses that connect the hydraulic oil

pump and valve to the accumulator, and to and from the
fuel modulating valves on the base plate.
(9) Remove the nuts that hold the hydraulic oil pump to the
hydraulic pump drive pad on the gearbox.
CAUTION: DO NOT LET THE WEIGHT OF THE HYDRAULIC PUMP BE

TRANSMITTED TO THE GEARBOX HYDRAULIC SPLINES AT
REMOVAL.
(10) Support the hydraulic oil pump and oil valve housing
and carefully remove the hydraulic oil pump and oil
valve from the gearbox.
(11) Discard the gasket on the hydraulic oil pump drive pad
of the gearbox housing group.
2. Hydraulic Oil Pump And Hydraulic Oil (Servo) Valve Package

Installation
B. Tools: PWA 77447 Torque Adapter
D. Expendables:

Gasket 1 01-61 17 1

REM/INST-01
PAGE 9-3
01-10 DEC 20/12


E. Procedure
See Figure 1.
(1) Install a gasket around the studs at the hydraulic oil

pump drive pad on the gearbox housing group.
CAUTION: DO NOT LET THE WEIGHT OF THE HYDRAULIC PUMP BE

TRANSMITTED TO THE GEARBOX HYDRAULIC SPLINES AT
ATTACHMENT.
NOTE: Lightly lubricate studs, coupling nuts and clamp

bolts with PWA 521 Oil.
(2) Support the hydraulic oil pump and hydraulic oil valve
and carefully attach the pump and valve on the pad of
the gearbox with nuts. Use a PWA 77447 Torque Adapter
with a standard wrench and torque the nuts to 290 -
325 lb-in. (32.766 - 36.720 N.m).
(3) Install the main hydraulic oil pump supply tube to the
hydraulic oil pump housing. Tighten the coupling nut
hand tight. Torque the nut to 270 - 300 lb-in.
(30.506 - 33.895 N.m). Safety the nut with wire.
(4) Connect three hoses to the accumulator, and to and from

the fuel modulating valves on the base plate to the
hydraulic oil pump and hydraulic oil valve.
(5) Install the inlet guide vane hydraulic tube on the

hydraulic oil valve housing. Tighten the coupling nut
(22.597 - 25.422 N.m). Safety the nut with wire.
(6) Install the variable stator hydraulic tube on the

(22.597 – 25.422 N.m). Safety the nut with wire.

REM/INST-01
PAGE 9-4
01-10 DEC 20/12


(7) Install the inlet guide vane return tube to the

(8) Install the variable stator vane return tube to the

(9) Tighten the clamp at Flange G hand tight. Torque the

bolt to 32 - 36 lb-in. (3.616 - 4.067 N.m).
(10) Tighten the position clamp below the hydraulic oil pump
hand tight. Torque the bolts to 32 - 36 lb-in.
(3.616 - 4.067 N.m).
(11) Attach the electrical cable to the connector on the

hydraulic oil valve.

REM/INST-01
PAGE 9-5
01-10 DEC 20/12

HYDRAULIC OIL PUMP FILTER - REMOVAL/

INSTALLATION-02
1. Hydraulic Oil Pump Filter Removal
C. Tools: None
D. Procedure
See Figure 1.
(1) Remove the oil filter assembly by unscrewing the filter

housing from the hydraulic oil pump.
(2) Remove the filter element from the filter housing.
2. Hydraulic Oil Pump Filter Installation
B. Tools: None
E. Procedure
See Figure 1.
(1) Install a new filter element into the filter housing.
(2) Install the filter housing into the hydraulic oil

pump. Continue to turn the housing until it is hand
tight.

REM/INST-02
PAGE 9-1
01-10 DEC 20/12

HYDRAULIC OIL PUMP FILTER - REMOVAL/

INSTALLATION-02
Hydraulic Oil Pump Filter Removal/Installation

Figure 1

REM/INST-02
PAGE 9-2
01-10 DEC 20/12

HYDRAULIC OIL VALVE (SERVO) - REMOVAL/

INSTALLATION-03
1. Hydraulic Oil Valve (Servo) Removal
C. Tools: None
D. Procedure
See Figure 1.
(1) Disconnect the electrical cable from the connector on

the oil valve.
(2) Disconnect the coupling nuts that hold the two inlet
guide vane hydraulic tubes to the hydraulic oil valve
housing.
(3) Disconnect the coupling nuts that holds the variable

stator vane hydraulic tubes to the hydraulic oil valve
housing.
(4) Remove the bolts and washers that hold the hydraulic
oil valve to the hydraulic oil pump.
(5) Carefully remove the hydraulic oil valve from the

hydraulic oil pump.
(6) Remove the packings from the oil supply and drain
bosses in the pump housing mating flange.
2. Hydraulic Oil Valve (Servo) Installation
B. Tools: None

REM/INST-03
PAGE 9-1
01-10 DEC 20/12


INSTALLATION-03
Hydraulic Oil Valve (Servo) Removal/Installation

Figure 1
REM/INST-03
PAGE 9-2
01-10 DEC 20/12


INSTALLATION-03
D. Expendables:

Wire,Safety As Reqd
Packing (Kit No. 8924-874)
NOTE: Kit No. 8924-874 may be obtained from Woodward

Governor Co., Engine and Turbine Controls Division,
P.O. Box 1519 Fort Collins, CO 80522.
E. Procedure
See Figure 1.
NOTE: Lightly lubricate packings, bolts and coupling nuts

with PWA 521 Oil.
(1) Install the packings supplied in Kit No. 8924-874 in

the grooves in the hydraulic oil pump housing.
(2) Align the locating pins and the bolt hole pattern in
the hydraulic oil pump flange with the holes in the oil
valve flange.
(3) Install the oil valve on the pump.
(4) Attach the oil valve to the pump with washers and
bolts. Torque the bolts to 250 - 270 lb-in. (28.246 -
30.506 N.m.).
(5) Install the two variable stator vane hydraulic tubes to

the oil valve housing. Tighten the coupling nuts hand
tight, then torque the nuts to 200 - 225 lb-in.
(22.597 – 25.422 N.m). Safety the nuts with wire.
(6) Install the two inlet guide vane hydraulic tubes to the
oil valve housing. Tighten the coupling nuts hand
tight, then torque the nuts to 200 - 225 lb-in.
(22.597 – 25.422 N.m). Safety the nuts with wire.
(7) Attach the electrical cable to the connector on the oil

valve.

REM/INST-03
PAGE 9-3
01-10 DEC 20/12

INLET GUIDE VANE VARIABLE STATOR ACTUATOR AND

SUPPORT ASSEMBLY - REMOVAL/INSTALLATION-04
1. Inlet Guide Vane Variable Stator Actuator And Support Assembly

Removal
C. Tools: None
D. Procedure
See Figure 1.
(1) Disconnect the lead from the electrical connector on

the variable stator actuator.
(2) Disconnect the flexible hoses from the DRAIN, ROD, and
HEAD ports which are marked on the variable stator
actuator.
NOTE: To maintain original vane rigging and facilitate

reinstallation, do not change the length of the
adjuster.
(3) Remove the cotter pin, nut, washer, and bolt that holds
the adjuster rod end bearing to the synchronizing ring.
(4) Install a web belt and hoist to support the weight of

the inlet guide vane actuator and support assembly.
(5) Install another web belt and hoist to support the

weight
of the 1.1 and 1.3 stage vanes compressor stator
cylinder support assembly that is located next to the
inlet guide vane actuator support assembly.
(6) Remove four cotter pins, washers, spacers, and bolts

that hold the support assembly to the brackets on the
inlet case flange (Flange A) and to the brackets on
Flange B.

REM/INST-04
PAGE 9-1
01-10 DEC 20/12


Inlet Guide Vane Variable Stator Actuator and Support Assembly

Figure 1

REM/INST-04
PAGE 9-2
01-10 DEC 20/12


CAUTION: BE SURE THE ADJACENT 1.1 AND 1.3 STAGE VANES

COMPRESSOR STATOR CYLINDER SUPPORT ASSEMBLY IS
STILL BEING HELD BY THE WEB BELT. THE SUPPORT
ASSEMBLY IS VERY HEAVY AND CAN CAUSE DAMAGE IF THE
WEB BELT IS NOT INSTALLED.
(7) Use the hoist and web belt and lift the inlet guide
vane
actuator and support assembly from the inlet case. Put
it on a suitable clean surface and remove the web belt.
(8) Install workbolts to temporarily hold the adjacent 1.1

and 1.3 stage vanes support assembly to the brackets at
Flange B.
2. Inlet Guide Vane Variable Stator Actuator And Support Assembly

Installation
B. Tools: PWA 77041 Rigging Pin

PWA 77082 Rigging Bracket
PWA 77266 Rigging Pin
PWA 77267 Rigging Bracket
PWA 77345 Hydraulic Pump
PWA 77455 Alignment Bolt
D. Expendables:
Cotter Pin 2 01-10 2 30

Cotter Pin 1 01-10 2 170
Cotter Pin 1 01-10 2 210
Cotter Pin 2 01-10 2 340
Key Washer 1 01-10 2 290
Key Washer 1 01-10 2 330
Shim As Req’d
Lockwire As Req’d

REM/INST-04
PAGE 9-3
01-10 DEC 20/12


E. Procedure
See Figures 1 through 5.
CAUTION: MAKE SURE THAT A WEB BELT IS INSTALLED TO SUPPORT

THE 1.1 AND 1.3 STAGE COMPRESSOR STATOR CYLINDER
SUPPORT ASSEMBLY. THE ASSEMBLY IS VERY HEAVY AND
CAN CAUSE DAMAGE IF IT IS NOT PROPERLY SUPPORTED.
(1) If not previously installed, install a web belt and

hoist to hold the weight of the of the adjacent 1.1 and
1.3 stage vane support assembly.
(2) Remove the workbolts that were installed through

Flange B and the support brackets to temporarily hold
the adjacent 1.1 and 1.3 support assembly to the front
compressor.
(3) Check the fit between the brackets on Flanges A and B

and the support assembly by measuring the distance
between the inner surfaces of the brackets on Flanges A
and B and the outer surfaces of the support assembly.
See Figure 2. Subtract the support dimension from the
bracket dimension. The fit should be 0.005 in.
(0.127 mm) loose to 0.005 in. (0.127 mm) tight.
NOTE: Shims are used as required between the bracket and

the support assembly at Flange A boltholes to obtain
this fit.
(4) Use another web belt and hoist and lift the inlet guide
vane actuator and support assembly to the compressor
inlet case. Position it between the brackets on
Flanges A and B.
(5) Install shims (as required) between the brackets and

support assembly at Flange A.
NOTE: Shims are classified as:
Class No. 1 = 0.0025 to 0.0035 inch

Class No. 2 = 0.0045 to 0.0055 inch
Class No. 3 = 0.0095 to 0.0105 inch
Class No. 4 = 0.0145 to 0.0155 inch

REM/INST-04
PAGE 9-4
01-10 DEC 20/12


(6) Use the PWA 77455 Alignment Bolt to align the shims
(if used), then install the bolts, spacers, and nuts
to secure the support assembly to the brackets.
Install bolts, washers, and nuts to secure the support
assembly to Flange B.
NOTE: On Flange A, install the spacers next to the bolt

head and the washers under the nut. On Flanges A
and B, a maximum of two washers may be used on any
one bolt to make sure that the nut is threaded on
the bolt so that the cotter pin head will seat in
the nut slot.
(7) Torque the bolts at Flanges A and B to 225 - 300 lb-in.

(25.442 - 33.895 N.m). Install and bend new cotter
pins to safety the nuts.
NOTE: The cotter pins are bent so that one prong is seated
firmly against the bolt and the other prong is seated
against the nut wrench flat.

REM/INST-04
PAGE 9-5
01-10 DEC 20/12


Support Assembly Fit Between Flange Brackets

Figure 2

REM/INST-04
PAGE 9-6
01-10 DEC 20/12


(8) Rig the inlet guide vane system as follows:
(a) Position the PWA 77082 Rigging Bracket to the two

hole pad on the vane actuator lever set.
Secure the bracket to the lever set with the tool
bolt. See Figure 3.
(b) Rotate the lever set to align the slot in the

PWA 77082 Rigging Bracket with the hole in the
support assembly.
(c) Install the PWA 77041 Rigging Pin through the slot
in the PWA 77082 Rigging Bracket and into the hole
in the support assembly.
(d) Remove the bolt and nut located to the left of the
vertical slot in Flange B and install the
PWA 77267 Rigging Bracket aligning the pin in the
bracket with the slot in the flange. See
Figure 4. Attach the bracket to the flange with
the tool bolt, washer, and nut. Retain the bolt
and nut for re-installation after rigging.
(e) Rotate the synchronizing ring to align the hole in

the clevis with the slot in the tool.
(f) Install the PWA 77266 Rigging Pin into the hole in
the clevis and through the slot in the tool.
NOTE: The inlet guide vanes are now rigged in the open
position.

REM/INST-04
PAGE 9-7
01-10 DEC 20/12


Lever Set Rigging Tools

Figure 3

REM/INST-04
PAGE 9-8
01-10 DEC 20/12


Flange B Rigging Tools

Figure 4

REM/INST-04
PAGE 9-9
01-10 DEC 20/12


(9) Position the adjuster to align the bolthole in the rod

end bearing with the synchronizing ring. The adjuster
bearing should align with the synchronizing ring if the
original adjuster is used. If the adjuster was removed
from both the synchronizing ring and the lever set,
align the bearings with the boltholes in both the
synchronizing ring and the lever set. If the bolt
holes do not align, the adjuster length must be
changed. Proceed to Step 10.
(10) The adjuster length is changed by rotating the rod end

bearings on the ends. Replace any used key washers.
Remove the rod end bearings from the adjuster and
remove the used key washers from the bearing threaded
ends. Reinstall the bearings on the adjuster using new
key washers. Turn the bearings so that the boltholes
in the bearings align with the boltholes in the
synchronization ring and the lever set (bellcrank).
Check for adequate thread engagement at each end by
inserting a piece of safety wire into the inspection
holes. If the wire passes through either hole, there
is not enough thread engagement and the adjuster is not
set properly. If the wire does not pass through, the
adjuster is set properly. Secure the jamnut against
the key washer at both ends. Torque the jamnuts on the
adjuster to 180 - 220 lb-in. (20.337 - 24.857 N.m).
Hold the adjuster while torquing. Bend the key washer
tabs. Bend one tab against the flat on the adjuster
and the other against the flat on the jamnut. Safety
the jamnuts with wire and install the lead seal to lock
the adjustment.
(11) Install the bolt, washer (washer next to nut), and nut
to secure the adjuster to the synchronizing ring (and
the lever set if removed). Torque the bolts to
150 lb-in. (16.948 N.m). Continue to torque until the
slot in the nut aligns with the hole in the bolt, but
do not exceed 200 lb-in. (22.597 N.m). Install a new
cotter pin to safety the nut.

REM/INST-04
PAGE 9-10
01-10 DEC 20/12


(12) If the actuator rod bearing is connected to the lever

set, remove the cotter pin, nut, washer, and bolt
connecting the actuator rod bearing to the lever set
before activating the actuator using the PWA 77345
Hydraulic Pump.
NOTE: The PWA 77345 Hydraulic Pump is used to make sure

that the actuator piston is at full extension against
its internal stop and that the rod end bearing is at
the correct length to mate with the clevis in the
lever set.
(13) Use the PWA 77345 Hydraulic Pump to activate the

actuator as follows:
(a) Make sure the hydraulic pump has the correct level
of PWA 521 Oil.
(b) Put the control valve on the unit in neutral

position (center position).
(c) Connect shop air to the air inlet.
(d) Open the air supply valve and adjust the air
pressure to 30 psi (206.8 KPa).
(e) Connect the hose from the advance position on the

control valve to the port marked HEAD on the
actuator.
(f) Connect the hose from the retract position on the

control valve to the port marked ROD on the
actuator.
(g) Connect the hose from the top of the reservoir to

the port marked DRAIN on the actuator.

REM/INST-04
PAGE 9-11
01-10 DEC 20/12


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GG8 MAINTENANCE MANUAL (PN 807421)

BLEED VALVE MANIFOLD AND PRESSURE TUBES -

LEFT SIDE (POST SB 08B08)

(GG8-1, Post SB 98B27) and (GG8-3) Bleed Valve Manifold

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BLEED VALVE MANIFOLD AND PRESSURE TUBES -

LEFT SIDE (POST SB 08B08)

(GG8-2, Post SB 98B27) Bleed Valve Manifold and Pressure Tubes

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SOLENOID AND VARIABLE VANE ACTUATOR WIRING HARNESS

1. Solenoid And Variable Vane Actuator Wiring Harness (Right)

A. Illustrated Parts Catalog Section Reference: 01-14

(1) (GG8-1 and GG8-2, Pre SB 98B27) Disconnect wiring

(2) (GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Disconnect

(3) Mark location of loop clamps and remove attaching bolts

2. Solenoid And Variable Vane Actuator Wiring Harness (Left)

A. Illustrated Parts Catalog Section Reference: 01-14

(1) (GG8-1 and GG8-2, Pre SB 98B27) Disconnect wiring

(2) (GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Disconnect

AIR SYSTEM III

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SOLENOID AND VARIABLE VANE ACTUATOR WIRING HARNESS

(3) Mark location of loop clamps and remove attaching bolts

3. Solenoid And Variable Vane Actuator Wiring Harness (Right)

A. Illustrated Parts Catalog Section Reference: 01-14

C. Consumables: PWA 521 Oil

(1) Lubricate bolts with PWA 521 Oil. Install clamps on

(2) (GG8-1 and GG8-2, Pre SB 98B27) Install wiring harness

(3) (GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Install

(4) Torque bolts at clamps to 36 - 40 lb-in. (4.067 -

4. Solenoid And Variable Vane Actuator Wiring Harness (Left)

A. Illustrated Parts Catalog: 01-14

AIR SYSTEM III

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SOLENOID AND VARIABLE VANE ACTUATOR WIRING HARNESS

C. Consumables: PWA 521 Oil

(1) Lubricate bolts with PWA 521 Oil. Install clamps on

(2) (GG8-1 and GG8-2, Pre SB 98B27) Install wiring harness

(3) (GG8-1 and GG8-2, Post SB 98B27) and (GG8-3) Install

(4) Torque bolts at clamps to 36 - 40 lb-in. (4.067 -

AIR SYSTEM III

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SOLENOID AND VARIABLE VANE ACTUATOR WIRING HARNESS

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SOLENOID AND VARIABLE VANE ACTUATOR WIRING HARNESS

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SOLENOID AND VARIABLE VANE ACTUATOR WIRING HARNESS

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TURBINE COOLING AIR TUBES – REMOVAL/INSTALLATION-10

1. (GG8-1, GG8-2) Turbine Cooling Air Tubes Removal

A. Illustrated Parts Catalog Section Reference: 01-17

(1) (GG8-1, Pre SB 00B06) Remove turbine cooling tube

(a) Mark the location of loop-clamp segments, and

(b) Remove bolts and nuts attaching tube assemblies

(c) Remove tube assembly from gas generator.

(d) Remove lockwire from the four bolts attaching tube