a700 tech manual

TECHNICAL MANUAL

AVIATION UNITAND

AVIATION INTERMEDIATEMAINTENANCE MANUAL

ENGINEASSEMBLY

MODE L T63-A-5A

NSN 2840-00-923-6023

MODEL T63-A-700

NSN 2840-00-179-5536

TM 55-2840-231-23

HEADQUARTERSDEPARTMENT OF THE ARMY

27 FEBRUARY 1981 T h i s c o p y i s a r e p r i n t w h i c h i n c l u d e s c u r r e n t

p a g e s f r o m C h a n g e 1 t h r o u g h 6 , 7 , 8 , 9 , 1 0 , 1 1

TM 55-2840-231-23c 13

CHANGE

NO. 13} HEADQUARTERS

DEPARTMENT OF THE ARMYWASHINGTON, D.C., 31 July 1995

Aviation Unit and Aviation IntermediateMaintenance Manual

ENGINE ASSEMBLY

MODEL T63-A-700NSN 2840-00-179-5536

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

TM 55-2840-231-23, 27 February 1981, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical barin the margin. An illustration change is indicated by a miniature pointing hand.

Remove pagesi and ii1-49 and 1-501-57 and 1-581-61 and 1-62

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1-63 through 1-66- - -

1-93 and 1-941-129 and 1-130

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1-131 and 1-1321-137 and 1-138

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1-139 and 1-1401-148.1/(1-148.2 blank)1-149 and 1-1501-157 and 1-1581-159 and 1-1601-161 and 1-1622-13 and 2-142-23 through 2-26

Insert pagesi and ii1-49 and 1-501-57 and 1-581-61 and 1-621-62.1/1-62.2 blank)1-63 through 1-661-66.1/(1-66.2 blank)1-93 and 1-941-129 and 1-1301-130.1 and 1-130.21-131/(1-132 blank)1-137 and 1-1381-138.1 and 1-138.21-139 and 1-1401-148.1/(1-148.2 blank)1-149 and 1-1501-157 and 1-1581-159 and 1-160

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TM 55-2840-231-23c 13

Remove pages2-33 through 2-362-63 and 2-642-64.3/(2-64.4 blank)3-1 and 3-23-7 through 3-123-21 and 3-224-1 and 4-25-7 through 5-106-1 and 6-26-53 through 6-606-68.1 through 6-68.46-68.5/(6-68.6 blank)

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9-5 and 9-69-7 through 9-10B-7 and B-8B-11 and B-12G-25 through G-28H-5 and H-6Glossary-1 and Glossary-2Index-11 and Index-12

Insert pages2-33 through 2-362-63 and 2-642-64.3 and 2-64.43-1 and 3-23-7 through 3-123-21 and 3-224-1 and 4-25-7 through 5-106-1 and 6-26-53 through 6-606-68.1 through 6-68.46-68.5 and 6-68.66-68.7 through 6-68.9/(6-68.10 blank)6-69 and 6-707-9 and 7-108-15 and 8-168-16.1 and 8-16.28-17 and 8-189-5 and 9-69-7 through 9-10B-7 and B-8B-11 and B-12G-25 through G-28H-5 and H-6Glossary-1 and Glossary-2Index-11 and Index-12

2. Retain this sheet in front of manual for reference purposes.

TM 55-2840-231-23C 13

By Order of the Secretaty of the Army

DISTRIBUTION:To be distributed in accordance with DA Form 12-25-E, block no. 0750, requirements for

TM 55-2840-231-23.

TM 55-2840-231-23

Page 2-8.1 Page 2-8.2

Page 2-9 Page 2-10

Page 2-48

Page 2-48.1 Page 2-48.2

Page D-5 Page D-6

TM 55-2840-231-23

WARNING AND FIRST AID DATA PAGE

For artificial respiration and other first aid data, referto FM21-11.

Personnel performing instructions involvingoperations, procedures, and practices which areincluded or implied in this technical manual shallobserve the following instructions. Disregard of thesewarnings and precautionary information can causeserious injury, illness, death or an aborted mission.

An operating procedure, practice, etc., whichif not correctly followed, could result inpersonal injury or loss of life.

An operating procedure, practice, etc., which,if not strictly observed, could result in damageto or destruction of equipment.

NOTE

An operating procedure, condition, etc., whichit is essential to highlight.

Compressed Air

● Compressed air used for cleaning purposeswill not exceed 30 psi.

● Use only with effective chipguarding andpersonal-protective equipment (goggles,shields, gloves, etc.).

● Personnel should stand clear of air valvewhen loosening to prevent personal injury.

Change 11 a

TM 55-2840-231-23

WARNING AND FIRST AID DATA PAGE — Continued

W A R N I N G

Calibrating FluidMIL-C-7024

● Combustible — do not use near openflames, near welding areas, or on hotsurfaces.

● Prolonged contact with skin may causeirritation. Prolonged inhalation of vapor cancause dizziness, headache, and intoxication.

● If there is any prolonged contact with skin,wash affected area with soap and water. Ifliquid contacts eyes, flush eyes thoroughlywith water. Remove solvent-saturatedclothing. If vapors cause Iight-headedness,go to fresh air. If liquid is swallowed, do nottry to vomit. Get medical attention.

● When handling or when applying liquid atan air-exhausted workbench, wear approvedgloves.

● When handling or when applying liquid atan unexhausted workbench, wear approvedgloves and goggles.

● Dispose of liquid-soaked rags in approvedmetal container.

Radioactive Material

The Scroll assembly, NSN 2840-00-244-1774,contains thorium, a radioactive material.Maintenance of this engine part is limited toreplacement unless other maintenance isspecifically authorized and is covered by avalid US Nuclear Regulatory Commissionlicense. Nonrepairable Scroll assemblies mustbe disposed of as radioactive waste inaccordance with AR 385-11.

b Change 11

TM 55-2840-231-23


DRY CLEANING SOLVENT, P-D-680

used to clean parts is potentially dangerous topersonnel and property. Avoid repeated andprolonged skin contact. Avoid prolonged or repeatedbreathing of vapors. Do not use near open flame orexcessive heat. Flash point of solvent is 100°F - 138°F(38°C-59°C).

I WARNING ICLEANING SOLVENTS

Cleaning solvents may be toxic. Use in well ventilatedareas. Avoid prolonged inhalation of fumes or directcontact with skin. Do not use solvents near open flameor in areas where very high temperatures prevail.Solvent flash point must not be less than 100°F.

DANGEROUS CHEMiCALS

are used in this equipment. Skin rash may result fromcontact with lubricating fluids. Provide adequateventilation when using solvent, fuels, or lubricating oilin a closed area.

W A R N I N G

HIGH VOLTAGE

may be present in the igniter lead. Insure that theignition system has been off for at least five minutesbefore disconnecting the lead. Ground the lead to theengine using an insulated screwdriver to dissipate anyenergy stored in the exciter.

c


TM 55-2840-231-23

Prolonged contact with lubricating oil (item 5,Appendix D) may cause a skin rash. Those areas ofskin and clothing that come in contact with lubricatingoil should be thoroughly washed immediately.Enclosed areas where lubricating oil is used should beadequately ventilated to keep mist and fumes to aminimum.

SEVERE BURNS

may result from contact with the engine hot section.Insure that the engine has had sufficient time to coolbefore attempting to perform maintenance on the hotsection.

If a magnetic plug warning light comes on duringflight, land and inspect the magnetic plugs as soon aspossible. This light is an indication of conditions whichcould cause engine failure.

Prolonged contact with lubricating oil may cause askin rash. Those areas of skin and clothing that comein contact with lubricating oil should be thoroughlywashed immediately. Enclosed areas where lubricatingoil is used should be adequately ventilated to keepmist and fumes to a minimum.

Methanol is flammable; it should not be used if theambient temperature is above 4°C (40°F), its vapor isharmful; it could be fatal or cause blindness ifswallowed. Keep it away from open flame and avoidprolonged breathing of the vapor.

To prevent injury to personnel, the fuel system of allengines that are to be placed in containers (lessaccident-involved engines) will be thoroughly drained,purged, and preserved. All disconnected lines will becapped or plugged. Tape will not be used in place ofcaps or plugs.

Make certain that all air pressure has been releasedbefore loosening nuts and bolts. If nuts are removedbefore pressure is released, internal pressure couldblow off cover. lnjury to personnel could occur.

d Change 11

WARNING AND FIRST AID DATA PAGE - Continued

When handling combustion chamber internal partsthat have been exposed to fuels containing tetraethyllead, insure that the byproduct (poisonous lead oxide)is not inhaled or taken into the body through cuts orother external openings. If accidental exposureoccurs, drench affected area with large amounts ofclean water and obtain immediate medical attention.

Prior to removing engine from container, make sureboth sections are grounded and the container isopened in a well ventilated area. Explosion couldcause injury to personnel.

To avoid electrical shock, insure ignition system hasbeen off for at least five minutes before disconnectingany leads. Ground leads to engine using an insulatedscrewdriver.

Personnel should stand clear of air valve whenloosening to prevent personal injury.

Failure to properly install, align and torque fuel, oil,and air fittings and tubes could result in an enginefailure.

TM 55-2840-231-23

Change 11 e/f blank

TM 55-2840-231-23

TECHNICAL MANUAL

NO. 55-2840-231-23

HEADQUARTERSDEPARTMENT OF THE ARMY

WASHINGTON, D.C., 27 February 1981

Aviation Unit and Intermediate Maintenance ManualEngine AssemblyModel T63-A-700

NSN 2840-00-179-5536

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improvethe procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changesto Publications and Blank Forms), or DA Form 2028-2 located in the back of this manualdirectly to Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300Goodfellow Blvd., St. Louis, MO 63120-1798. A reply will be furnished directly to you.

Distribution Statement A: Approved for public release, distribution is unlimited.

CHAPTER 1Section ISection IISect ion I I ISection IVS e c t i o n VSection VISect ion VI ISection VIIICHAPTER 2CHAPTER 3CHAPTER 4CHAPTER 5CHAPTER 6CHAPTER 7CHAPTER 8CHAPTER 9APPENDIX A.APPENDIX B.APPENDIX C.APPENDIX D.APPENDIX E.APPENDIX F.APPENDIX G.

APPENDIX H.GLOSSARY . . . . . . .

PAGEENGINE - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-1General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Equipment Descrption ad Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Repair Parts; Special Tools. Measurement; TMDE and Support Equipment . . . . . . 1-23Service Upon Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23Preventive Maintenance Inspections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1-52Troubleshootin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-66General Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1-132.2Engine Testing In Mobile or Fixed Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142COMPRESSOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-1COMBUSTION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1POWER TURBINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-1ACCESSORY GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-1FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-1ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .7-1OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1MISCELLANEOUS EQUIPMENT/AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . ...9-1REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..A-lMAINTENANCE ALLOCATION CHART... . . . . . . . . . . . . . . . . . . . . . . . . . . . .. B-1SPECIAL TOOLS AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. C-lEXPENDABLE SUPPLIES ANDMATERIALS LIST . . . . . . . . . . . . . . . . . . . . . . . D-1SCHEMATIC DIAGRAMS (Not Applicable)ILLUSTARATED LIST OF MANUFACTURED ITEMS (Not Applicable)TORQUE VALUES AND DIMENSIONAL LIMITS, OVERHAUL ANDRETIREMENT SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1GENERAL MAINTENANCE PRACTICES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. H-1. . . . . . . .< . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GLOSSARY 1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..INDEX 1

*This manual supersedes TM 55-2840-231-24, 3 March 1972, including all changes.

Change 13 i

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List of Illustrations

1-11-21-31-41-51-61-71-81-91-91-101-111-121-131-141-151-161-171-18

1-18.11-191-20

1-11-21-31-41-51-61-71-81-91-101-11

T63-A-700 Turboshaft Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Engine Fuel and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Fuel ControlSystemSchematic (Sheet l of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8CompressorAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-10PowerTurbine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-11Combustion Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12Power and AccesoryGearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-13FuelPump and FilterAssembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-15Engine Lubrication Schematic (Sheet l of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16Engine Lubrication Schematic (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17Oil Pump Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-19Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-19Anti-Icing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Compressor Bleed Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-21Compressor Bleed Control Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21Engine Shipping Container Stenciling and Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51Compressor Shipping Container Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52Universal Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-136Pressure Oil Tube and Pressure Oil Filtering Screen, . . . . . . . . . . . . . . . . . . . . . . . . 1-139Bleed Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-153Idle and Flight Autorotation GFTOT Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-155

1-3

1-221-221-541-561-571-67

1-148.11-1511-153

ii Change 13

1.1

TM 55-2840-231-23

CHAPTER 1

ENGINE - GENERAL

This chapter contains information and descriptions pertaining to the T63-A-700 engine system,system components, major assemblies, leading particulars and operation. General maintenance and -

support information is also provided for inspection, servicing, maintenance, troubleshooting and testingof the complete engine.

Page

Section I.II.III.

IV.V.VI.VII.VIII .

General InformationEquipment Description and DataRepair Parts, Special Tools, Test Measurement and

Diagnostic Equipment (TMDE) and SupportEquipment

Service Upon ReceiptPreventive Maintenance InspectionTroubleshootingGeneral Maintenance ProceduresEngine Testing in Mobile or Fixed Facilities

1-11-4

1-231-231-521-661-132.21-142

Section I. GENERAL INFORMATION

ScopeModificationsMaintenance Forms, Records and ReportsDestruction of Army Material to Prevent Enemy UseAdministrative StorageQuality Assurance/Quality Control (QA/QC)

1-11-31-41-41-41-4

Type of Manual: Aviation Unit Maintenance (AVUM) and AviationIntermediate Maintenance (AVIM)

Model Number and Equipment Name: T63-A-700 Turboshaft Engine(See figure 1-1. )

Purpose of Equipment: To supply engine power requirements for various helicopteraircraft which have been designed to accept the turboshaftengine contained in this manual. External view of theengine is given below.

Change 11 1 -1

TM 55-2840-231-23

a. GENERAL

b.

Figure 1-1. T63-A-700 Turboshaft Engine

DESCRIPTION. Consists of:

(1) Engine

(2) Systems

(3) Components

(4) Accessories

MAINTENANCE PROCEDURES. Consists of:

(1) Removal

(2) Disassembly

(3) Cleaning

(4) Repair and Replacement

(5) Assembly

(6) Installation

(7) Preservation

(8) Storage

(9) Activation of Uninstalled Engine

1-2 Change 11

TM 55-2840-231-23

c. PROCEDURES. Contained in the airframe Organizational Maintenance Manual consist of:

(1) Preservation

(2) Storage

(3) Activation of installed engines

Applicable Airframe Organizational Manuals

Airframe Manual Title

TM 55-1520-214-23 AVUM and AVIM MaintenanceManual Helicopter, ObservationOH-6A (Hughes)

TM 55-1520-228-23 AVUM and AVIM MaintenanceManual Army Model OH-58AHelicopter

1.2 MODIFICATIONS: The following modification directives (table 1-1) have been incorporated in themanual. If the time compliance period for the modification directive has not been reached, bothconfigurations are included in the manual. If the time compliance period has expired, only the currentconfiguration is shown.

Table 1-1. Modification Directives

*MWO 55-2840-231-30/2 Modification to Install a Pc Air FilterKit (T63-A-700)

MWO 55-2840-231-3014 Modification to Install a CompressorBleed Valve Orifice Engine to be modified at nextoverhaul.

* Cancelled.

Change 11 1-3

TM 55-2840-231-23

1-3. MAINTENANCE FORMS, RECORDS AND REPORTS. Department of the Army forms and proceduresused for equipment maintenance will be those prescribed by DA Pamphlet 738-751, Functional Users/Manual for the Army Maintenance Management System - Aviation (TAMMS-A).

1-4. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE. Destroy engine when evacuation tosafety is not possible to prevent use by enemy. Refer to TM 750-244-1-5.

a. Demolition of Engine by Explosives. Use explosives to destroy engine. Place explosives, wheneverpossible in inlet and exhaust opening of engine. Detonate when personnel have withdrawn to a safedistance or cover. Explosives may also be detonated under an engine stored in a shipping container.

b. Demolition of Engine Using Mechanical Means. Smash all cast parts to destroy enginemechanically. A smashed compressor housing will cause engine to become inoperable. Other parts andaccessories may be smashed or crushed as time permits. When more than one engine is to be destroyedmechanically, insure similiar parts on each engine are destroyed.

c. Demolition of Engine by Fire. An incendiary grenade or any other source of intense and sustainedcombustion may be used to destroy the engine by fire.

1.5. ADMINISTRATIVE STORAGE. Requirements are part of maintenance instructions. Refer to SectionVII.

1.6. QUALITY ASSURANCE/QUALITY CONTROL (QA/QC). Refer to TM 55-0411 for information aboutQuality Assurance/Quality Control (QA/QC).

Section II. EQUIPMENT DESCRIPTION AND DATA

Page

Equipment Purpose, Capabilities and FeaturesDescription of Engine Operation

Fuel and Control SystemCompressorTurbineCombustion SectionPower and Accessory GearboxGas Producer Fuel ControlPower Turbine GovernorFuel Pump and Filter AssemblyLubrication SystemFuel NozzleIgnition SystemTemperature Measurement SystemAnti-Icing SystemAcceleration Bleed Air SystemAir Bleed Extraction

Engine Leading Particulars

1-51-71-71-101-101-121-121-131-141-141-151-181-181-201-201-201-211-21

1-4 Change 11

1-7

TM 55-2840-231-23

a. Purpose of Engine, Shaft Turbine. The T63 Series engines are designed for use on the OH-6A andOH-58A helicopters.

b. Capabilities and Features.

Ž Major Sections:

1. Combustion Section

2. Turbine Section

3. Compressor Section

4. Power and Accessories Gearbox

Ž Major Engine Systems:

1.

2.

3.

4.

5.

6.

Fuel and Control

Lubrication

Ignition

Anti-icing air

Temperature Measurement

Compressor acceleration bleed air

All components are covered separately in this manual.

1-8. Deleted.

Change 11 1-5

Figure 1-2.

TM 55-2840-231-23

1 - 6 Change 7

TM 55-2840-231-23

1-9. DESCRIPTION OF ENGINE OPERATION. The engine is a free turbine engine (no mechanicalconnection between the gas producer turbine and the power turbine). The power turbine is gas coupledto the gas producer turbine by the combustion gases.

The helicopter uses a conventional control system. The collective pitch of the helicopter rotorestablishes the power output demand on the engine. For all practical purposes, helicopter rotor speed isheld constant by the engine and its control system.

The fuel control is connected to the twist grip on the pilot’s and copilot’s collective pitch sticks. Thepower turbine governor is interconnected to the collective-pitch sticks through a coordinated system ofbellcranks and linkages. Any change in collective pitch resets the-governor to a new power demand. Thisdemand is transmitted to the gas producer fuel control, which resets and varies the N1 speed of the gasproducer turbine accordingly.

A motor-actuated speed trimming device is installed in the linkage between the collective pitch sticks andthe power turbine governor lever. It is operated by a trim switch on each collective pitch stick, andallows engine output speed to be varied over a normal range of approximately 98 to 103 percent (5880 to6180 rpm).

1-10. Fuel and Control System. The gas producer fuel control (figs. 1-2 and 1-3) is locatedschematically in the fuel system between the fuel pump assembly and the fuel nozzle. A power turbinegovernor, also apart of the control system, provides control intelligence to the gas producer fuel system.

The system controls engine power output by controlling gas producer speed. Gas producer speed levelsare established by the action of the power turbine governor which senses power turbine speed. Powerturbine speed is selected by the operator. The power required to maintain this speed is automatically main-tained by power turbine governor action on the gas fuel control.

The power turbine governor lever schedules the governor requirements. The power turbine governor inturn, schedules the gas producer speed to a changed power output to maintain output shaft speed.

Fuel flow for engine control depends on compressor discharge pressure (Pc), engine speed (gas producer -N1 and/or power turbine - N2), and lever angle. Fuel flow is a function of Pc as sensed in the fuel control.Variations of fuel flow schedules are obtained by modulating the Pc to Px and Py pressures in the controlthrough the action of a bleeddown circuit actuated by the governors.

Change 7 1-7

Figure 1-3.

TM 55-2840-231-23

1-8 Change 7

TM 55-2840-231-23

1-9

Figure 1-4.

TM 55-2840-231-23

1-11. Compressor. The compressor assembly (fig. 1-4) consists of a compressor front support, caseassembly with stator vanes, rotor assembly with blades, centrifugal impeller, front diffuser assembly, reardiffuser assembly, and diffuser scroll. Air enters the compressor through the front support. Struts in thesupport guide the air and direct it in the proper direction into the first stage of the compressor rotor. Theair is then compressed by the six axial compressor stages and one centrifugal stage. As the air passesthrough the axial stages, it is alternately accelerated by the rotor blade and decelerated by the statorvanes. At the same time, it is compressed into an ever decreasing space. This results in an increaseof both air pressure and temperature. The sixth-stage compressor vanes direct the compressed air into theimpeller. The impeller vanes centrifugally accelerate the air through an ever decreasing space to furtherincrease the air pressure and temperature. It is then discharged across the diffuser vanes and directedinto the diffuser scroll. The diffuser scroll collects the compressor discharge flow at a constant velocityand directs it rearward through two ports to the combustion section.

1-12. Turbine. The turbine (fig. 1-5) consists of a gas producer turbine, a power turbine support, a tur-bine and exhaust collector support, a two-stage gas producer turbine, and a two-stage power turbine. Theturbine is mounted between the combustion section and the power and accessory gearbox. The two-stagegas producer turbine drives the compressor and accessory gear train. The two-stage power turbinefurnishes the output power of the engine.

1-10

TM 55-2840-231-23

Figure 1-5. Power Turbine Section

1-11

Figure 1-6.

TM 55-2840-231-23

1-13. Combustion Section. combustion section (fig. 1-6) consists of two compressor dischargeair tubes (one on each side of engine), a combustion outer case, and a combustion liner. A spark igniterand fuel nozzle are installed in the rear of the outer combustion case. Compressor discharge air isducted from the diffuser scroll to the combustion outer case by the two compressor discharge air tubes.Air enters the single combustion liner at the rear through holes in the liner. The air is mixed with fuelsprayed from the fuel nozzle and combustion gases move forward out of the combustion liner to theturbine.

1-14. Power and Accessory Gearbox. The main power and accessory drive gear trains (fig. 1-7) areenclosed in a single gear case. The gear case serves as the structural support of the engine. All enginecomponents, including the engine-mounted accessories, are attached to the case. The reduction gearingreduces power turbine speed from 35,000 to 6000 rpm at the output drive pads.

1-12

Figure 1-7.

TM 55-2840-231-23

1-15. Gas Producer Fuel Control. The gas producer fuel control has a bypass valve, metering valve,acceleration bellows, governing and enrichment bellows, manually operated cutoff valve, maximumpressure relief valve, torque tube seal and lever assembly, and a start derichment valve. The maximumpressure relief valve protects the system from excessive fuel pressure.

Fuel enters the control from the engine fuel pump and filter assembly and is delivered to the meteringvalve. The bypass valve maintains a constant pressure differential across the metering valve. Also, excessfuel is bypassed to the fuel pump and filter assembly through an external line connecting the pumpbypass inlet to the bypass outlet port of the gas producer fuel control.

The metering valve is operated by lever action through movement of the governor and accelerationbellows. Metering valve area depends on valve travel. Before light-off and acceleration, the meteringvalve is set at a predetermined open position by the acceleration bellows under the influence of ambientpressure (Pc at zero rpm ).

Change 8 1-13

TM 55-2840-231-23

The start derichment valve is open during light-off and acceleration to a set Pc. The open derichmentvalve vents Py pressure to atmosphere. Venting Py allows the governor bellows to move the meteringvalve against the minimum flow stop. At minimum flow the metering valve provides the required leanfuel schedule after light-off. As compressor rpm increases, the derich-ment valve is closed by Pc acting onthe derichment bellows. When the derichment valve is closed, control of the metering valve is returned tothe normal operating schedule.

During acceleration, the Px and Pv pressures are equal to the modified compressor discharge pressure(Pc) up to the point where the speed enrichment orifice is opened by flyweight action. Opening thespeed enrichment orifice bleeds Px pressure while Py remains at a value equal to Pc. Under the influenceof the Py minus Px pressure drop across the governor bellows, the metering valve moves toward themaximum flow stop where it increases fuel flow.

Gas producer speed is controlled by the gas producer fuel control governor. A set of flyweights operate.

the governor lever which controls the governor bellows (Py ) bleed at the governing orifice. Flyweightoperation of the governor lever is opposed by a variable spring load. The spring force is established by thethrottle lever acting on a spring scheduling cam. Opening the governing orifice bleeds Py pressure andallows Px pressure to control the governor bellows. The Px influence on the bellows moves the meteringvalve toward minimum flow and at a position where metered flow is at steady state requirements.

The governor reset assembly in the gas producer fuel control limits or governs power turbine speed.Control of the reset assembly is derived from the power turbine governor. The power turbine governoralso provides quick responding overspeed protection by bleeding governor servo (Py) pressure from thegas producer fuel control.

1-16. Power Turbine Governor. Power turbine speed is scheduled by the power turbine governor leverand the power turbine speed scheduling cam. The cam sets a governor spring load which opposes a fly-weight output. As the desired speed is approached, the flyweights operating against the governor springmove a link to open the power turbine governor orifice. The flyweights also open the overspeed bleed(Py) orifice but at a higher speed than the regular governor (Pg) orifice.

The governor orifice is downstream of a bleed supplied by a regulated air pressure (P r). Opening theorifice results in a reduced pressure downstream of the bleed (Pg) as an inverse function of increasingspeed. Regulated pressure (Pr) and governing pressure (Pg) are applied to opposite sides of a diaphragm inthe governor reset section of the gas producer fuel control. The force generated by Pr minus Pg acrossthe diaphragm acts on the gas producer power output link through the governor reset rod. This forcesupplements the weight force in the gas producer fuel governor to reset (reduce) the gas producer speed.

Gas producer speed cannot exceed the gas producer fuel governor setting. The P r minus Pg diaphragm ispreloaded for establishing the active Pr minus Pg range. Pr pressure is supplied from engine Pc pressure byan air regulator valve.

The overspeed orifice bleeds Py pressure from the governing system of the gas producer fuel control.Bleeding Py pressure at the power turbine governor gives the fuel control system a rapid response tooverspeed conditions.

1-17. Fuel Pump and Filter Assembly. The fuel pump and filter assembly (fig. 1-8) has two gear-typepumping elements arranged in tandem and driven by a common drive shaft. Fuel enters the engine fuelsystem at the inlet port of the pump and passes through a low pressure filter before entering the gearelements. The gear elements are in parallel. Each pumping element has sufficient capacity to permittakeoff power operation if the other pumping element fails. Two discharge check valves are in the assem-bly to prevent reverse flow if one gear pumping element fails. A bypass valve in the pump assembly by-passes fuel if the filter element becomes clogged.

1-14

Figure 1-8.

TM 55-2840-231-23

The bypass return flow from the fuel control is passed back to the inlet of the gear elements through apressure regulating valve which maintains the bypass flow pressure above inlet pressure. By means ofpassages, leading to auxiliary filling ports on the periphery of the gear elements, a portion of the bypassflow is used to fill the gear teeth when vapor-liquid conditions exist at the inlet to the gear elements.

A 5-micron paper filter is located inside the fuel pump assembly upstream of the gear elements. It isretained by a threaded cover, distinguished by a hex, which can be found on the lower side of the pumpassembly. A container should be used to catch undrained fuel when the filter cover is removed.

1-17.1 PC Air Filter. The Pc air filter is a 10 micron filter located in the Pc air supply line leadingfrom the diffuser scroll to the power turbine governor. It incorporates a permanent type, wire mesh,cleanable element and prevents the governor and fuel control pneumatic components from being con-taminated with foreign particles by filtering Pc air flow to the governor and control.

1-18. Lubrication System. The lubrication system (fig. 1-9) is a dry sump type with an external reser-voir and heat exchanger. A gear type pressure and scavenge pump assembly is mounted within the Power andaccessory gearbox. oil fiter, bypass valve (fig. 1.9), and pressure regulating valve are in a unitwhich is located in the upper right-hand side of the power and accessory gearbox housing and are accessiblefrom the top of the engine. A check valve is located between the housing and the filter unit. Indicatingtype magnetic chip detectors are installed at the bottom of the power and accessory gearbox, snd at theengine oil outlet connection. All engine oil system lines and connections are internal with the exceptionof pressure and scavenge lines to the front compressor support, the gas producer turbine support, and thepower turbine support.

Change 7 1-15

Figure 1.9.

TM 55-2840-231-23

1 -16

TM 55-2840-231-23

Figure 1-9. Engine Lubrication Schematic (Sheet 2 of 2)1-17

Figure 1-10.

TM 55-2840-231-23

1-19. Fuel Nozzle. Fuel nozzle (fig. 1-11) is a single-entry, duual-otifice type unit. It contains anintegral valve for dividing primary and secondary flow. This same valve acts as a fuel shutoff valve whenfuel manifold pressure falls below a predetermined pressure, and keeps fuel out of the combustion chamberat shutdown.

1-20. Ignition System. The engine ignition system (fig. 1-12) consists of a low tension capacitor dischargeignition exciter, a spark igniter lead, and a shunted-surface gap spark igniter. The system receives itsinput power from a 14- to 29-volt dc power source.

Some T63-A-700 engines have an auto reignition system installed to automatically relight the enginein the event of an inflight flame-out. The system senses compressor discharge pressure and automaticallyturns on the ignition system when the rate of decay of compressor discharge pressure exceeds a predeter-mined rate. When an automatic reignition is initiated, the auto reignition light illuminates and the ignitionsystem is energized. After approximately 2.8 seconds, the ignition system deenergizes; however, the autoreignition light remains illuminated until it is manually turned off (reset).

1-18

TM 55-2840-231-23

Figure 1-11. Fuel Nozzle

‘ION

Figure 1-12. Ignition System

1-19

TM 55-2640-231-23

1-21. Temperature Measurement System. The temperature measurement system has four chromel-alumel single junction thermocouples in the gas producer turbine outlet (TOT) and an associated integralharness. The voltages of the four thermocouples are electrically averaged in the assembly and deliveredby the assembly lead to an engine terminal block for attachment to the airframe temperature indicatingsystem.

1-22. Anti-Icing System. Anti-icing (fig. 1-13) is provided for the compressor inlet guide vanes andfront support hub by the use of compressor discharge air. The air is taken from a port at the twelveo’clock position on the front face of the diffuser scroll. An anti-icing air shutoff valve is installed in theport and is manually operated from the flight deck to control anti-icing air flow. Anti-icing air tubesdirect the flow of air from the valve to fittings on each side of the compressor front support. The air isthen routed through an annuris around the OD of the front support and through the inlet guide vanesand is discharged into the inlet air stream.

Figure 1-13. Anti-Icing System

1-23. Acceleration Bleed Air System. The compressor bleed air system permits rapid engine response.The system has a compressor discharge pressure sensing port on the scroll, tubing from the sensing portto the bleed valve, a compressor bleed control valve (fig. 1-14) and a bleed air manifold on thecompressor case.

Elongated slots between every other vane at the compressor fifth stage bleeds compressor air into amanifold, which is an integral part of the compressor case. The manifold forms the mounting flange forthe compressor bleed control valve when the compressor case halves are assembled.

Compressor discharge air pressure sensing, for bleed control valve operation, is obtained at a sensingport on the compressor scroll. The bleed control valve is normally open; it is closed by compressor dis-charge pressure.

1-20 Change 6

TM 55-2840-231-23

.

Figure 1-14. Compressor Bleed Control Valve

Figure 1-15. Compressor Bleed Control Valve Operation

1-24. Air Bleed Extraction. Two parts are provided on the diffuser scroll to supply compressor bleed airfor aircraft systems. Bleed airflow is limited to four percent of total engine airflow.

1-25. ENGINE LEADING PARTICULARS. Engine leading particulars and performance rating are as givenin tables 1-3 and 1-4.

Change 11 1-21

TM 55-2840-231-23

Table 1-3. Leading Particulars

DimensionsLength 40.4 inches (1.03 m)Height 22.5 inches (0.57 m)Width 19.0 inches (0.48 m)

Maximum oil consumption 0.05 gal/hr (6.5 oz/hr)

Lubricating oil specifications MIL-L-23699 or MIL-L-7808

Fuel specifications:Primary MIL-T-5624 (JP-4)Alternate MIL-T-5624 (JP-5) (JP-8) (JET-A) (JETA-1 )Emergency MIL-G-5572

Design power output 317 shpRam power rating 335 shp

Design speeds:Gas producer (Nl ) 100% (51,120 rpm)Power turbine (N2) 100% (35,000 rpm)Power output shaft 100% (6,000 rpm)

Table 1-4. Performance Ratings (Standard Sea Level Static Conditions)

Ram powerGas Specific fuel rating Measured

Net jet producer consumption torque at rated gasShaft HP thrust lb speed rpm output lb/SHP-hr output shaft temp /260F (°C)

Rating (rnin) (rein) (%) (est) shaft rpm (max) ft-lb (max) (max)

Takeoff 317 33 51600 (100.9) 6000 0.697 293 1380 (749}

Normal 270 28 49760 (97.3) 6000 0.706 249 1280 (693)

90% normal 243 26 48650 (95.2 ) 6000 0.725 249 1226 (663)

75% normal 203 21 46950 (91.8) 6000 0.762 249 1148 (620)

Start and idle 35 max 10 max 32000 (62.6) 4500-6300 61 lb/hr — 750±100(399± 56)

Flight auto- 0 max 10 max 32000 (62.6) 5900-6480 61 lb/hr — 725±100ration (385±56)

NOTE: Specific fuel consumption = fuel flow/SHP.

1-22 Change 11

TM 55-2840-231-23

Section III. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

1-26. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.

Refer to Appendix C for special tools, support equipment, and test, measurement and diagnosticequipment (TMDE).

Section IV. SERVICE UPON RECEIPT

Page

Service Upon ReceiptShipping Container Dimensions and WeightEngine - Removal From Shipping ContainerEngine - Installation Into Reusable Metal Shipping and Storage

ContainerInspection of Engine Dropped During HandlingInstalling Engine In Turnover StandDismantling Engine Into Major Functional AssembliesPreservation MaintenanceEngine - DepreservationEngine - PreservationAccident Engine - PreservationDamaged, Cannibalized, or Failed Engine PreservationForms, Records, Tags and Stenciling

1-231-231-24

1-281-371-381-401-401-411-431-491-501-50

1-27. SERVICE UPON RECEIPT.

This section provides complete instructions and procedures for the inspection, preservation, storage,and activation of a complete engine assembly. Procedures for installing and removing the engine frommetal shipping and storage and marking of containers are also included in this section.

1-28. Shipping Container Dimensions and Weight. The following lists the size, weight, and cubic dis-placement of the engine, compressor, fuel pump, gas producer fuel control, and the power turbinegovernor shipping and storage containers.

a. Engine Container

Length 57 in. (1.45 m)Width 34 in. (0.86 m)Height 39 in. (0.99 m)Weight (with engine ) 600 lb (272 kgr)Cubic Displacement 45 cu ft (1.27 cu/m)

1-23

TM 55-2840-231-23

b. Compressor Container (Metal)

HeightDiameterWeight (with compressor)Cubic Displacement

c. Fuel Pump and Filter Assembly Container

HeightDiameterWeight (with fuel pump)Cubic Displacement

d. Gas Producer Fuel Control Container

HeightDiameterWeight (with fuel control)Cubic Displacement

e. Power Turbine Governor Container

HeightDiameterWeight (with governor)Cubic Displacement

24 in. (0.61 m)23 in. (0.58 m)85 lb. (38.6 kgr)5.7 cu ft (0.16 cu/m)

15 in. (0.38 m)14 in. (0.36 m)24 lb (10.9 kgr)1.15 cu ft (0.03 cu/m)

12¾ in. (0.32 m)10½ in. (0.27 m)16 lb (7.26 kgr)0.99 cu ft (0.028 cu/m)

12¾ in. (0.32 m)10½ in. (0.27 m)13 lb (5.9 kgr)0.6 cu ft (0.007 cu/m)

1-29. ENGINE - REMOVAL FROM SHIPPING CONTAINER.

INTIAL SETUP

Applicable Configuration Consumable MaterialsAll Corrosion Preventive Compound (item 9,

Appendix D)Special Tools

Engine Assembly Lift, Tool No.6796963

Engine Turnover Stand, Tool No.6795579

LOCATION/ITEM REMARKS ACTION

Prior to removing engine fromcontainer, make sure both sections ofcontainer are grounded and thecontainer is opened in a wellventilated area. Explosion couldcause injury to personnel.

1 - 2 4 Change 8

1-29

TM 55-2840-231-23

TM 55-2640-231-23

1-29. Engine - Removal From Shipping Container - Continued

LOCATION/lTEM REMARKS ACTIONI

1. Engine ShippingContainer




5. Engine

6. Engine Side Mounts

7. Engine Side Mounts

Make certain that all air pressure hasbeen released before loosening nutsand bolts (1 and 25). If nuts are re-moved before pressure is released, in-ternal pressure could blow off cover.Injury to personnel could occur.

Insure upper half of shipping con-tainer does not strike engine whenremoving cover. Damage to enginecould occur.

Use Engine Assembly Lift, Tool No. 6796963.

Loosen nut (15) andwasher (16). Removeengine records fromrecord receptacle (18).

Loosen nuts (21 ) andwashers (22). Opencover (23).

Loosen air valve (24).Allow container todepressurize.

Remove nuts (1) andbolts (25). Removecover (2).

Install engine assemblylift on gearbox mountingpad. Attach hoist. Raiseengine only enough totake the strain off themounts.

Remove four nuts (7),washers (6), and bolts (4).

Remove two cotter pins(8), pins (9), and adapters(5).

1 - 2 6

TM 55-2840-231-23


LOCATION/lTEM REMARKS



10. Engine Assembly

11. Engine Brackets removed during this action are toremain with the shipping container.

12. Engine Mounting brackets installed in this action aresupplied with Engine Turnover Stand, Tool No.6795579.

Do not use the shipping containermounting brackets in lieu of theturnover stand mounting brackets.Damage to engine could occur.


14. Desiccant

15. Container BaseAssembly (19)

16. Cover Assembly (2)

17. Cover Assembly (2)

ACTION I

Remove cotter pin (14)and pull out on pin as-sembly (13) until it dis-engages from the enginebottom mount.

Remove bolt (10) andwasher (11).

Lift out of shipping con-tainer.

Remove three enginemounting brackets (12).

Install three mountingbrackets on engine.Install engine in turnoverstand.

Place all loose shippingcontainer hardware incloth bag supplied withcontainer. Place bag inbottom of container.

Remove from desiccantbasket (20).

Install gasket (3) oncontainer base assembly(19).

Lower into place.

Engage forward end ofcover with guide pin inclosure flange of baseassembly (19) thenlower aft end.Insure gasket (3) isproperly seated.

1-27

TM 55-2840-231-23


LOCATION/lTEM REMARKS ACTION

18. Closure flange Bolts (25) shall be inserted from the bottom Install bolts (25)side of the closure flange. Use corrosion pre- and nuts (1).ventive compound (item 9, Appendix D). Tighten nuts (1)

finger tight. Applypreservative to boltthreads.

1-30. Engine - Installation Into Reusable Metal Shipping and Storage Container.

INITIAL SETUP

Applicable ConfigurationAll

Special ToolsEngine Assembly Lift, Tool No.

6796963

Consumable MaterialsLockwire (item 7, Appendix D)Desiccant (item 8, Appendix D)Liquid Soap (item 45, Appendix D)Corrosion Preventive Compound (item 9,Appendix D)

ReferencesPara 1-39


SHIPPING OR STORAGECONTAINER/Engine

1. Preparation ofContainer

All engines which are prepared for storageor shipment will be preserved and packed ina metal reusable shipping and storage con-tainer, PN 8145-CON-001, NSN 8145-00-034-1063, in accordance with the followingprocedure.

a. Loosen two nuts (26)and pivot cover (31)around to expose airvalve (32).

Personnel should stand clear of airvalve when loosening to preventpersonal injury

b. Slowly loosen airvalve (32) to relieve pres-sure in the container.

1-28

TM 55-2840-231-23

1 -29

TM 55-2840-231-23

1-30. Engine - Installation Into Reusable Metal Shipping and Storage Container - Continued


SHIPPING OR STORAGECONTAINER/ - Continued

c. Remove thirty-twonuts (1) and bolts (37)from the closure flangeand remove cover as-SEMBLY (2).

d. Remove two cotterpins (8) and pins (9)and remove engine sidemounting brackets (12).

e. Remove cotter pin (14)and pull out pin assembly(13) until it disengagesfrom the engine lowermounting bracket (12).Remove the mountingbracket.

f. Remove four nuts (7),washers (6), and bolts(4) and remove engineside mounting adapter(5).

g. Inspect container todetermine that it iscomplete and service-able. Particular atten-tion should be givento mounting brackets,bolts, nuts, pins andcotter pins in enginesuspension system.Replace parts whichshow signs of wearand/or darnage.

2. Installation ofEngine in Container

To prevent injury to personnel, thefuel system of all engines that areto be placed in containers (lessaccident-involved engines) will bethoroughly drained, purged, andpreserved. All disconnected lineswill be capped or plugged. Tape willnot be used in place of caps or plugs.

1-30

TM 55-2840-231-23


I LOCATION/ITEM REMARKS ACTION

SHIPPING OR STORAGE Engine Assembly Lift, Tool No. 6796963 a. Suspend engine fromCONTAINER/-Continued a hoist in upright posi-

tion (exhaust ducts up)using engine assemblylift.

Lockwire (item 7, Appendix D) b. Remove three turn-over stand mountingbrackets and assemblethree engine mountingbrackets (12) on theengine using nine bolts(10) and washers (11).Tighten bolts to 85-110 in. lb (1.0-1.3kg/m) and Iockwire.

Do not use the engine turnover standmounting brackets in lieu of enginemounting brackets (12). Damage toengine could occur.

c. Lower engine into con-tainer until the bottommounting bracket (12)engages with bottommounting adapter.

d. Aline pin holes andengage pin assembly(13). Secure withone cotter pin (14).

e. Insert two side mount-ing adapters (5) throughthe locating holes inyoke assembly (15) andengage with two sidemounting brackets (12).Secure with two pins(9) and cotter pins (8).

f. Secure two side mount-ing adapters (5) to yokeassembly (15) with fourbolts (4), washers (6)and nuts (7). Tightennuts (7) firmly thenloosen one completeturn.

1-31

TM 55-2840-231-23

1-30. Eng ine - Installation Into Reusable Metal Shipping and Storage Container - Continued

REMARKS ACTION

SHIPPING OR STORAGE Engine Assembly Lift, Tool No. 6796963 g. Release engine weightCONTAINER/ - Continued from the hoist and

remove engine assemblylift from engine.

h. Tighten four nuts (7)at engine side mountsto 40-50 in. lb (0.5-0.6 kg/m).

i. Tie the cloth bag, usedto store engine mount-ing bolts (10) andwashers (11), to desic-cant basket (25) forfuture use.

Desiccant (item 8, Appendix D) j. Place two bags of desic-cant into desiccantbasket (25).

k. Install gasket (3) oncontainer base assem-bly (24).

1. Lower cover assembly(2) into place overengine. Engage theforward end of coverwith guide pin in closureflange of base assem-bly (24); then lowerthe aft end. Insure thatgasket (3) is properlyseated.

m. I nsta II thirty-two bolts(37) and nuts (1) inclosure flange. Bolts(37) shall be insertedfrom bottom side ofclosure flange. Tightennuts (1) finger tight.

n. Tighten one nut (1)on each side of con-tainer at center and ateach of four corners toapproximately 75 in.lb (0.9 kg/m).

1-32

TM 55-2840-231-23




o. Starting at guide pinin forward end of theclosure flange andmoving in a clockwisedirection, fina1-tightennuts (1) to 150-165 in.lb (1.7-1.9 kg/m).

3. ContainerPressurization

Container Air Pressure vs AmbientTemperature

a. Tighten air valve (32).

b. Using a source offiltered, dry, compress-ed air, pressurize thecontainer to the valueshown in the followingtabular listing.

Temper- Temper-ature Pressure ature Pressure(°C) (°F) (psig) (°C) (°F) (psig)

60 140 7.6 4 4054 130 7.3 -1 3049 120 6.9 -7 2043 110 6.5 -12 1038 100 6.1 -18 032 90 5.8 -23 -1027 80 5.4 -29 -2021 70 5.0 -34 -3016 60 4.6 -40 -4010 50 4.3

3.93.53.22.82.42.01.71.30.9

Liquid Soap Solution (item 45, AppendixD)

c. Check gasket (3),humidity indicator(36), preformed pack-ing (28), drain plug (35),air valve (32), and reliefvalve (34) for leaks bybrushing a liquid soapsolution on all seamsand closure points.

d. If leaks are found,check torque on nuts(1) and (26).gasket (3) and packing(28) if necessary.

1-33

TM 55-2840-231-23



SHIPPING OR STORAGE Preformed packing (28)CONTAINER/ - Continued is removed by removing

four nuts (26), washers(27), three bolts (33) andbolt (30).

Do not attempt to stop leaks by over-torquing nuts. Damage to containercould occur.

4. Engine RecordsReceptacle

e. Repeat steps b and cas required.

f. Wipe off or flush awaysoap solution.

g. Install cover (31) onbolts (30) and tightennuts (26) to 15-25in. lb (0.2-0.3 kg/m).

a. Loosen two nuts (17)and swing stud as-sembly (22) out ofthe slot in cover(19). Pivot the coverout of the way.

b. Insert applicable en-gine records in envel-ope (21 ) and placein the engine recordsreceptacle.

c. Pivot cover (19) withgasket (20) into placeover the receptacleopening and swingstud assembly (22)into the cover (19)slot.

d. Secure the cover inplace by” tighteningtwo nuts (17) to30-45 in. lb (0.3-0.5kg/m). ‘

1-34

TM 55-2840-231-23




5. Tamper-Roof Container tamper-proof security is providedsecurity by five lead seals; two in the container closure

flange, two in the records receptacle cover,and one in the service receptacle cover.

a. Thread seal (16) wirethrough sealing holes-

in cover (31) and servicereceptacle (29). Sealends of wire togetherwith attached lead seal.

b. Seal both ends ofrecords receptaclecover (19) bythreading seal wire(16) through sealingholes in cover (19)and receptacle (23).Seal ends of wirestogether with attachedlead seals.

c. Thread seal wire (16)through each set ofsealing holes in closureflange of base assembly(24) and cover assem-bly (2). Thread wiredown through one holeand up through theother hole. Secureends of wires togetherwith attached leadseals. Sealing holes arelocated at left frontand right rear of con-tainer closure flange.

Corrosion Preventive Compound (item 9, d. Coat exposed threadsAppendix D). of bolts (30 and 37)

and stud assembly (22)with corrosion preven-tive compound.

6. Container Stenciling Stenciling of the engine shipping container willbe in accordance with paragraph 1-39 and thefollowing figure.

1-35

TM 55-2840-231-23

1-36

TM 55-2840-231-23

1-31. Inspection of Engine Dropped During Handling

INITIAL SETUP

Applicable Configuration ReferencesAll Para 1-30,1-38,1-39 and

1-63 thru 1-71


NOTE

If engine is dropped during handling,perform inspection and tests containedwithin this paragraph.

1. Accessory DriveGearbox

2. Governor andTachometer Drive

3. Oil Filter

4. Fuel ControlAssembly

5. Engine MountingPads

6. Air, Oil, and FuelHose Connections

7. Accessories

8. Engine If no visual damage is apparent, engine maybe operationally checked either in airframeor in mobile engine test unit. (Refer toparagraphs 1-63 thru 1-71.) Minimum testtime is 30 minutes and shall include vibrationcheck, coastdown noise check, and post-testinspection of oil filter and chip detectorsfor metal, lint, or other foreign material.Vibration levels must be within establishedlimits. If no defects are noted, engine isconsidered serviceable.

Inspect for crackedflanges.

Inspect for cracks, dis-tortion, and bentshafts.

Inspect for damage.

Inspect for crackedflanges.

Inspect for cracks.

Check to insure theyare secure.

Check for loose bolts,nuts, and connections.

Perform operationalchecks.

1-37

TM 55-2840-231-23

1-31. Inspection of Engine Dropped During Handling - Continued


NOTE

Action for items 9 thru 11 are to beperformed if engine is unserviceable.

9. Engine

10. Engine

11. Engine

Refer to paragraph 1-38 and 1-30.

Refer to paragraph 1-39.

Preserve if unserviceable.Pack in a metal reusableshipping and storage con-tainer.

Return to Depotfacility.

Complete and attachnecessary tags. Preparenecessary forms andrecords. Place recordsin receptacle.

1-32. Installing Engine In Turnover Stand.

INITIAL SETUP

Applicable ConfigurationAl l

Special ToolsEngine Assembly Lift, Tool No. 6796963Turnover Stand Mounting Brackets, Tool

No. 6795579


TEST STAND/

1. Engine Engine Assembly Lift, Tool No. 6796963 a. Install engine assemblylift on the gearbox topmounting pad andsuspend the enginefrom the hoist.

NOTE

1-38

Do not use the shipping container orairframe mounting brackets in lieuof the turnover stand mounting brackets.

TM 55-2840-231-23

1-32. Installing Engine In Turnover Stand - Continued


TEST STAND/ - Turnover Stand Mounting Brackets, Tool No.Continued

b. Install three turnover6795579 stand mounting brackets

on the gearbox sideand bottom pads.

c. Lower engine intothe turnover stand.Insure that the threemounting bracketsinstalled on the gear-box engage themounting bosseson the turnover stand.

d. Slide two clamps atthe gearbox sidemounts in to engagethe mounting bracketsand tighten the handknobs.

e. Remove hoist andlifting tool.

1-39

TM 55-2840-231-23

1-33. Dismantling Engine Into Major Functional Assemblies.

a. During dismantling, examine all major functional assemblies for serviceability. The condition of anassembly can often be better determined by examination during dismantling. Signs of scoring, burning, andexcessive wear or the presence of metal particles are danger signals. Thorough inspection should be madeimmediately. Look for any indications of work incorrectly performed during previous maintenance or over-haul. Report any such indications to the local maintenance officer.

b. Care must be exercised to prevent the entrance of dirt and other foreign material into the engine.Whenever practical, temporary covers shouldbe used to seal all openings in the dismantled engine. Allthreads, splines, and pilot diameters should be protected against damage. Protective covers should be of ashape that prohibits assembly with mating parts without removing the covers.

c. Unless parts of a particular engine are to be held for a special inspection, discard all gaskets, lock-washers, preformed packings, O-rings, diaphragms, and cotter pins as they are removed. These parts mustnot be mixed with new parts of similar type and must not be used again. Arrangement of self-locking nutsshall be determined in accordance with minimum prevailing torque at reassembly. Self-locking nutsshall be tested for reuse in accordance with TM 55-1500-204-25/1.

Prolonged contact with lubricating oil (item 5,Appendix D) may cause a skin rash. Those areasof skin and clothing that come in contact withlubricating oil should be thoroughly washedimmediately. Enclosed areas where lubricatingoil is used should be adequately ventilated to keepmist and fumes to a minimum.

Lubricating oil may soften paint upon contact. Iflubricating oil is spilled on painted surfaces, thesesurfaces should be thoroughly washed.

d. Remove the magnetic drain plug from the bottom of the gearbox and allow oil to drain before theengine is rotated in the turnover stand.

1-34. Preservation Maintenance. Preservationtion and replacement of the dehydrating agent.fied shipping container as long as possible.

maintenance is not represervation,Allow engine awaiting installation

but is the regular inspec-to remain in the dehumidi-

1-40

TM 55-2840-231-23

1-35. Engine - Depreservation.

INITIAL SETUP


Consumable MaterialsDrycleaning Solvent P-D-680 (item 1, Appendix D)

ReferencesPara 2-11, 2-17 and 5-6

I LOCATION/ITEM REMARKS ACTION

1. Engine Remove all shipping caps,plugs, and covers fromengine as required.

2. Engine Remove lockwire fromfuel control and governorstops and anti-icing airvalve lever.

Drycleaning solvent, P-D-680, used toclean parts is potentially dangerousto personnel and property. Avoid re-peated and prolonged skin contact.Avoid prolonged or repeated breathingof vapors. Do not use near open flameor excessive heat. Flash point of solventis 100° F - 138°F (38°C - 59°C).

3. Engine

4. Engine

Use drycleaning solvent P-D-680 (item 1,Appendix D).

Refer to paragraphs 2-11, 2-17 and 5-6.

Remove all barriermaterial and tape.Remove tape residuewith solvent.

Remove any corrosionfrom the exterior sur-faces. Touch up paintas required.

NOTE

Flushing of engine with fuel is notrequired.

1-41

TM 55-2840-231-23

1-42

TM 55-2840-231-23

1-36. Engine - Preservation.

INITIAL SETUP


Consumable MaterialsDrycleaning Solvent (item 1, Appendix D)Lubricating Oil (item 5, Appendix D)Lubricating Oil (item 4, Appendix D)Barrier Material (item 2, Appendix D)Tape (item 3, Appendix D)Methylethylketone (item 32, Appendix D)LockWire (item 7, Appendix D)

ReferencesTM 55-1500-333-24TM 55-1520-214-23TM 55-1520-228-23Para 2-11, 2-17 and 5-6


NOTE

A serviceable engine that is being re-moved from an aircraft for the pur-pose of storage or return to the over-haul facility will be preserved priorto removal from the aircraft.

Drycleaning solvent, P-D-680, used toclean parts is potentially dangerousto personnel and property. Avoid re-peated and prolonged skin contact.Avoid prolonged or repeated breathingof vapors. Do not use near open flameor excessive heat. Flash point of solventis 100°F - 138°F (38°C - 59°C).

1. Engine, Accessories, When external cleaning is necessary, cleanInlet Duct, Plenum with solvent (item 1, Appendix D). ReferChamber, and InletScreens

to TM 55-1500-333-24.

Insure these items areclean and free from cor-rosion and foreignmaterial.

Do not use contact preservatives ofany kind either internally or externallyon the compressor section. Damageto compressor could occur.

Change 1 1-43

TM 55-2840-231-23

1-36. ENGINE - PERSERVATION - Cont.

LOCATION/ITEM REMARKS

2. Engine Oil Tank

3. Engine

4. Engine

5. Engine

6. Power Input Lead

Prolonged contact with lubricating oil(item 5, Appendix D) may cause askin rash. Those areas of skin andclothing that come in contact withlubricating oil should be thoroughlywashed immediately. Enclosed areaswhere lubricating oil is used shouldbe adequately ventilated to keep mistand fumes to a minimum.

Use lubricating oil (item 5, Appendix D).If available, use external auxiliary power unit(APU).

Cranking engine with fuel pumpcircuit breaker on may cause fuel tospray past the cap on disconnectedfuel line.

NOTE

Perform action for items 6 thru 11 topreserve engine fuel system.

ACTION

Fill as necessary to normaloperating level withlubricating oil.Start engine.

Run at idle to insuresatisfactory operation.Operate engine for fiveminutes or until oiltemperature reaches 191oF(88°C), whichever comesfirst.

Idle for two minutes, priorto shutting down engine.

Allow to cool sufficiently toprevent auto ignition.

Pull fuel pump circuitbreaker to OFF beforecranking engine.

Disconnect at ignitionexciter or pull IGN ENGcircuit breaker.

1-44 Change 8

TM 55-2840-231-23

1-36. ENGINE – PRESERVATION – Cont.


7. Fuel Line Use lubricating oil (item 4, Appendix D).

8. Engine

Observe starter time restriction–35 seconds maximum whentemperature is 90°F (32°C) or above.Damage to starter could occur.

9. Engine

10. Engine

11. Power Lead

Disconnect at the fuelpump inlet port. Connect asource of lubricating oil Capdisconnected fuel line.

Move the twist grip toIDLE detent and motorengine with the starter (useAPU, if available).

Discontinue motoringwhen fuel-free oil flowsfrom the combustion burnerdrain valve hose.

Disconnect source oflubricating oil. Cap inletport of fuel pump.

Reconnect power lead toignition exciter orreset IGN ENG circuitbreaker. Reset boostpump circuitbreaker.

Change 8 1 - 4 5

TM 55-2840-231-23

1-36. Engine - Preservation - Continued

LOCATION/lTEM REMARKS

12. Engine Inlet and If covers are not available, seal openings withExhaust Protective barrier material (item 2, Appendix D) andCovers secure with tape (item 3, Appendix D).

13. Engine Use DA Form 2408-13.

14. Engine Accessories Refer to TM 55-1520-214-23 or TM 55-1520-228-23.

15. Starter-Generator Use methylethylketone (item 32, AppendixDrive D) as cleaning agent.

Prolonged contact with lubricatingoil (item 5, Appendix D) may causea skin rash. Those areas of skin andclothing that come in contact withlubricating oil should be thoroughlywashed immediately. Enclosed areaswhere lubricating oil is used shouldbe adequately ventilated to keepmist and fumes to a minimum.

16. Engine Use lubricating oil (item 5, Appendix D).

Prolonged contact with lubricatingoil (item 5, Appendix D) may causea skin rash. Those areas of skin andclothing that come in contact withlubricating oil should be thoroughlywashed immediately, Enclosed areaswhere lubricating oil is used shouldbe adequately ventilated to keepmist and fumes to a minimum.

1-46

ACTION

Install.

Make all necessary entriesto include date and ex-tent of engine preserva-tion on engine historicalform.

Remove.

Clean splines when nec-essary to remove pre-viously applied lubricant.

Coat all accessory, drivesplines and pads whichdo not have accessoriesinstalled on them andengine oil shippingplugs (6, 7, and 8) withlubricating oil.

TM 55-2840-231-23


LOCATION/lTEM REMARKS I IACTION

I

17. Fuel Inlet ShippingPlug (2)

Use lubricating oil (item 5, Appendix D). Coat with lubricatingoil.

18. Engine Shipping Install shipping plugs,Container covers, gaskets, washers,

and nuts.

1-47

TM 55-2840-231-23



19. Gas Producer FuelControl Stop

20. Power Turbine Lockwire (item 7, Appendix D) shall be usedGovernor Stop and to secure stops and lever.Anti-Icing ValveLever

21. Engine The following information shall appear ontag attached to fuel inlet shipping plug:

22. Engine

23. Engine

24. All Threaded Parts

25. Engine

THIS FUEL SYSTEM HAS BEEN PRE-PARED FOR STORAGE BY FLUSHINGWITH OIL CONFORMING TO SPECIFICA-TION MIL-L-6081, GRADE 1010.

Refer to paragraphs 2-11, 2-17, and 5-6. Donot expose touchup areas to engine fluidsor cleaning solvents for a minimum periodof 72 hours after application.

This action does not apply to caps (1 and 5)on the combustor drain valve and exhaustcollector drain. Caps (1 and 5) are to betightened to bottom of cap, then twistedan additional 90-120 degrees.

Secure in cut-off posi-tion.

Secure tight enough toprevent movement.

Attach tag (3) to fuelinlet shipping plug (2).

Touch up paint wheredamaged.

Tighten aluminum andplastic shipping capsand plugs finger tight.

Tighten to standardtorques.

Tighten nuts whichsecure plastic acces-sory covers as requiredto obtain a snug fitwithout excessive coverindentation. Coverthe compressor bleedvalve with cover (4).

1-48

TM 55-2840-231-23

1-37. Accident Engine - Preservation

INITIAL SETUPApplicable Configuration

All

Consumable Materials

Barrier Material (item 2, Appendix D)Tape (item 3, Appendix D)

References

Para 1-30

1. Engine

2. Engine

3. Engine

4. Engine

NOTE

Do not treat an engine for corrosion thathas been involved in an accident whereengine failure or malfunction is knownor suspected to have been a factor. Thisengine must be held for shipment to anoverhaul depot or designated investiga-tion area and should not be treated forcorrosion prevention.

Perform this action without disconnecting lines orfittings.

If covers are not available, seal with barrier mate-rial (item 2, Appendix D) and secure with tape(item 3, Appendix D).


Prevent remaining fuel andoil in engine from leakingout.

Seal all openings with cov-ers.

Plug all ports and cap allfittings.Install in bottom half ofmetal reusable shipping andstorage container.

Ground engine to container to preventa possible explosion of dangerous va-pors which may be ignited by staticelectricity or a spark. Secure all loosemetal components to container withtape PPP-T-60 to prevent possiblespark during shipment.

1-49

TM 55-2840-231-23

1-38. Damaged, Cannibalized, or Failed Engine Preservation. Inoperable engines that are idle because they requireparts or maintenance shall be preserved in accordance with paragraph 1-37 and stored in a shipping container or ina clean, dry, area where the engine will be adequately protected from dirt, corrosion, and physical damage.

Do not use contact preservatives of any kind, either internally orexternally, on the compressor section. Damage to compressorcould occur.

1-39. Forms, Records, Tags and Stenciling.

a. The forms, records, and reports that are to be used by maintenance personnel when preparing an engine or enginecomponent for storage or shipment are listed in and prescribed by DA Pamphlet 738-751.

b. Authorized tags and published procedure for their completion is prescribed in TB 750-126. Additional pressur-ization tags may be applied to assist the maintenance officer in depreservation.

c. Stenciling, labeling and marking of containers for storage and shipment are shown in figures 1-16 and 1-17.Obliterate old markings that do not apply. Letters and numerals of stencils shall be in block letters 1/2 inch high. Usewhite stencil ink (item 10, Appendix D). For additional information on marking and stenciling refer to MIL-STD- 129.

1-50 Change 13

Figure 1-16.

TM 55-2840-231-23

1-51

Figure 1-17.

TM 55-2840-231-23

Section V. PREVENTIVE MAINTENANCE INSPECTIONS

P a g e

Pressurized Container - InspectionEngine Container - Internal Pressure and Humidity CheckSpecial Inspections

Turbine Overtemperature - InspectionCompressor - Special InspectionAbnormal Flight Maneuver InspectionInspection After Inflight Auto Reignition Operation

1-521-551-561-571-591-631-65

1-40. Pressurized Container - Inspection

INITIAL SETUP

Applicable Configuration ReferencesAll TB 55-8100-200-25

Para 1-36Table 1-5


ENGINE CONTAINER/ Immediately upon receipt of an engineat an activity and every 90 days (or morefrequently) thereafter, check the relativehumidity indicator and the internal pres-sure of the container in accordance withtable 1-5.

1-52

TM 55-2840-231-23

1-40. Pressurized Container - Inspection - Continued


ENGINE CONTAINER/ - NOTEContinued

An all blue in the humidity indicatorindicates a safe condition. As moisturecontent inside the container increases,the indicator color will change fromblue to pink. An all pink condition isconsidered unsafe and indicates thatthe desiccant must be changed and thecontainer repressurized.

1. Humidity Indicator If the humidity indicator indicates that therelative humidity is less than 40 percent andthe internal pressure is more than 1 psig,no maintenance is necessary until the nextregular inspection.

2. Humidity Indicator If the humidity indicator indicates that therelative humidity is less than 40 percent butthe internal pressure is less than 1 psig, thecontainer shall be checked for leakage, usinga soap solution at all closures. (Refer toTB 55-8100-200-25.) When leakage hasbeen corrected, the container shall be repres-surized to the value stated in table 1-5. Useclean dry compressed air. Record date ofrepressurization and name of activity in ap-propriate section of engine historical record.

3. Humidity Indicator If the humidity indicator indicates the rela-tive humidity to be 40 percent or more, anunsafe or corrosive condition exists. Correctas follows:

a. Depressurize shippingcontainer by openingair filling valve at frontof container.

1-53

TM 55-2840-231-23

1-40. Pressurized Container - Inspection - Continued

LOCATION/lTEM REMARKS ACTIONI

ENGINE CONTAINER/ -Continued

b. Allow air pressureto return to zero.

c. Remove capscrewsand nuts that securecontainer halves together,

d. Remove cover fromcontainer and inspectengine to determine itsserviceability. Anypresense of corrosion onthe inlet, or compressorhousing, or on othervisible exterior surfaces,or on the compressoror turbine blades or vanesis cause to render theengine as unserviceable.

Table 1-5. Container Air Pressure vs. Ambient Temperature

Temperature Pressure Temperature Pressure( ° C ) ( ° F ) (psig) ( ° C ) ( ° F ) (psig)

60 14054 13049 12043 11038 10032 9027 8021 7016 6010 50

7.67.36.96.56.15.85.45.04.64.3

4 40-1 30-7 20

-12 10-18 0-23 -10-29 -20-34 -30-40 -40

3.93.53.22.82.42.01.71.30.9

If the engine is found to be serviceable, re-move it from container and preserve it asoutlined in paragraph 1-36 or place it inservice.

If unserviceable, inspect and repair to a like-new corrosion-free condition per applicableparagraphs within this manual as authorizedby Maintenance Allocation Chart. If not re-pairable, ship engine to Depot.

1-54

TM 55-2840-231-23

1-41. Engine Container - Internal Pressure and Humidity Check

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Desiccant (item 8, Appendix D)

ReferencesPara 1-30,1-43Table 1-5Procedure 7, Troubleshooting Chart


ENGINE CONTAINER/ Check the internal pressure and humidity within24 hours after the container is pressurized.Check the pressure and humidity immediatelyprior to shipment if the engine is to be shipped.

If the internal pressure is not within 0.5 psig ofthe value shown in table 1-5, repeat proceduresin paragraph 1-30, item 3, steps b and c.

The humidity indicator (see figure) is normallylight blue in color. At 40 + or -3 percentrelative humidity; the color will change to light

1. Internal PressureCheck

2. Humidity IndicatorCheck

lavender or lavender pink.a. The humidity indicatormay be light lavenderor lavender pink whenthe container is pres-surized and shouldchange to light bluewithin one to twohours. If it does notchange to light blue,replace the indicator.

1-55

TM 55-2840-231-23

1-41. ENGINE CONTAINER – INTERNAL PRESSURE AND HUMIDITY CHECK – Cont.

ACTION

ENGINE CONTAINER/- NOTEContinued The humidity indicator should change

to light blue in an atmosphere of lessthan 37 percent relative humidityunless it has absorbed sufficientmoisture to wash away or destroy itschemical properties.

Refer to paragraph 1-40 (item 3). b. If humidity indicatorchanges to light lavender orlavender pink aftercontainer has beenpressurized, open thecontainer and inspect theengine for corrosion.Replace the desiccant (item8, Appendix D).

1-42. SPECIAL INSPECTIONS.

This section provides special inspections to be performed on the turbine when the engine has experiencedoperation beyond allowable temperature limits. Tables 1-6 and 1-7 list the various overtemperature conditionsfor starting and power transients and the maintenance action required for each.

Table 1-6. Overtemperature During Start

Temperature Range Time Maintenance Action

1380°F-1700°F (749°C-927°C) Over 10 seconds Inspect turbine. *1700°F-1830°F (928°C-999°C) Anytime Inspect turbine. *Over 1830°F (999°C) Anytime Remove engine for depot

maintenance or overhaul.

NOTE

1. Refer to Procedure 7,Troubleshooting Chart whentemperature consistently exceeds1550°F (843°C).

2. The time-at-temperature limitsare not additive and may be repeatedwithout restrictions.

*Refer to Turbine Overtemperature Inspection paragraph 1-43.

1-56 Change 8

TM 55-2840-231-23

Table 1-7. Overtemperature During Power Transients

Temperature Range Time Maintenance Action

1380° F- 1550° F Over 6 Seconds Inspect turbine.*(749° C- 843° C)

1550° F- 1700° F Anytime Inspect turbine.*(843° C- 927° C)

over 1700° F (927° C) Anytime Remove engine fordepot maintenanceor overhaul.

Note

The time-at-temperature limitsare not additive and may be re-peated without restrictions.

*Refer to turbine overtemperature inspection paragraph 1-43.

143. TURBINE OVERTEMPERATURE - INSPECTION.

INITIAL SETUP

Applicable Configuration ReferencesAll Para 3-2, 3-4, 3-6, 3-8 and 3-10

ENGINE/ NOTE

1. Combustion Section

The following inspection may beperformed with the engine in-stalled in the airframe.


NOTE

Removal of the first-stage nozzlefrom the turbine is not authorized.

Remove the combustionsection.

First stage turbine nozzle and shield. Replace Inspect the first stageengine if serviceable limits are exceeded on the turbine nozzle and shieldfirst stage turbine nozzle, Replace shield if as outlined in the followingserviceable limits are exceeded on the shield. tabular listing and figure.

Visually inspect blades offirst-stage N1 turbine forpossible damage.

Change 13 1-57

TM 55-2840-231-23

First-Stage Turbine Nozzle and Shield Inspection

Item condition Serviceable Limits

First Stage Nozzle

1 Axial cracks in vane airfoil.

2

3

4

Nicked or dented leadingand trailing edge. Warped orburned trailing edge only.

Fillet cracks-inner and outerband.

Outer band cracks-leadingand trailing edges.

5 Inner band cracks-leadingand trailing edges.

First Stage Nozzle Shield

6 Cracks around spotwelds onheat shield.

Combustion Section Components

Leading edge 1/4 in. (6.4 mm) maximum; trailing edge5/16 in. (7.9 mm) maximum.

a. No two cracks in same plane.

b. Adjacent cracks 1/4 in. (6.4 mm) apart.

c. Adjacent cracks not progressing toward each other.

Leading edge 1/16 in. (1.6 mm) maximum; trailing edge1/8 in. (3.2 mm) maximum.

Leading edge 1/4 in. (6.4 mm) maximum; trailing edge 1/8in. (3.2 mm) maximum.

Leading edge-visible portion of crack extends 3/8 in. (9.5mm) maximum axially into the band.Trailing edge-crack extends 1/2 in. maximum axially intothe band.Cracks on leading edge must not be in line with cracks ontrailing edge.

Leading edge-visible portions of crack extends 1/16 in.(1.6 mm) maximum axially into the band. Trailing edge-none permitted.

Cracks are acceptable provided the length of the crack isnot greater than 50 percent of the distance around the weld.

7 (Refer to paragraphs 3-2,3-4, 3-8 and 3-10.)

1-58

TM 55-2840-231-23

1-43. Turbine Overtemperature - Inspection - Continued


ENGINE/ - Continued

1-44. Compressor - Special Inspection. This paragraph presents special inspections to be performed onthe engine when damage has been sustained due to operation under abnormal conditions or operation insevere climatic conditions.

INITIAL SETUP

Applicable Configuration ReferencesAll Para 2-9, 2-10, 2-14, 2-21, 2-19, and

3-6Special Tools TM 55-4920-243-15

Vibration Mounting Kit, Tool No.171170-0104

LOCATION/lTEM

ENGINE/

1. Compressor Snowand Ice IngestionInspection

I REMARKS ACTION

This inspection must be performed follow-ing an in-flight flameout in ice-producingweather or anytime snow and ice ingestionis suspected. Inspect the compressorfor snow, ice, or water damage as follows:

a. Obtain access to thecompressor inlet butdo not disassembleany engine parts.

1-59

TM 55-2840-231-23

1-44. Compressor - Special Inspection - Continued


ENGINE/ - Continued b. Inspect compressorfront support vanesand first-stage rotorblades. Replacecompressor if anydamage, bending ordistortion is detected.

2. Compressor InletBlockage Inspection

a. Replace compressorassembly if enginehas been operatedwith inlet air restricteddue to foreign objectsor materials which havebecome lodged in thecompressor inlet.

b. Tag the replacedcompressor to showthat the cause ofremoval was inlet airblockage.

Conditions which constitute blockage are asfollows:

a. Foreign objects or materials found in theinlet during inspection of the aircraft whennot in operation. If it can be determined thatthe blockage was not there during the lastoperation of the engine, remove the foreignobject or material and leave the compressorin service.

b. Power loss encountered following a re-striction at the compressor inlet area whilethe engine is in operation. Blockage in flightcan usually be verified by inspection afterlanding (blockage still exists). However, someblockage may be followed by ingestion beforeinspection can take place. Objects or materialswhich were large enough to have stopped atthe inlet guide vanes before ingestion shouldbe considered to have caused compressorinlet blockage.

3. Compressor Foreign Power loss associated with an increase in en- s. Obtain access to com-Object Damage (FOD) gine vibration can often be attributed to pressor inlet but doInspection foreign object damage. Inspect for foreign not disassemble any

object damage as follows: engine parts.

1-60

TM 55-2840-231-23

1-44 Compressor - Special lnspection - Continued

ENGINE/ - Continued

If this inspection is inconclusive, remove one b. Inspect compressorcompressor case half and check for FOD front support vanes and(refer to paragraph 2-9). first-stage rotor blades

and vanes for FOD.

c. If compressor FOD isdetected, remove thecombustion section (referto paragraph 3-6) endcheck the turbinefirst-stage vanes andblades for FOD.

If turbine FOD is detected, replace theengine. If only the compressor has sustainedFOD, replace the compressor.

4. Compressor Erosion If the engine is frequently subjected to sandInspection and dust, ingestion causing reduced engine

performance (evidenced by high TOT and lowtorque), compressor erosion inspection isrecommended. (Refer to paragraphs 2-14 end2-19).

5. Compressor Vibration If engine vibration is encountered orInspection compressor replacement was made, perform

vibration test as follows and repair or replacethe engine as applicable.

Vibration Monitoring Kit, Tool No.171170-0104

a. Install vibrationmonitoring kit inaccordance with TM55-4920-243-15.

b. Run engine andcheck for vibration inexcess of the limitsspecified in the followingtabular listing. Note theorigin of the vibration.

Change 13 1-61

TM 55-2840-231-23

144. Compressor - Special Inspection - Continued

ENGINE/ - Continued

NOTEPerform engine vibration test after initialinstallation of engine in aircraft, afterremoval of combustion case, when excessiveengine vibration is suspected; or when anymaintenance has been performed that mayaffect engine to transmission alignment. Theengine vibration test requirement shall applyto all engines installed, reinstalled, new,overhauled, same or different.

Compressor Case Refer to paragraph 2-9.

Blades and Vanes If blade and vane conditions are not withinthe limits of paragraph 2-14 and 2-19, replacethe compressor assembly.


Damage is indicative of impeller vane tip orshroud failure; replace the compressorassembly.


1-62 Change 13

TM 55-2840-231-23

1-44.1 Time and Calendar Inspection.

Remove and inspect in accordance with Remove the compressorparagraph 2-43, 2-9, 2-10.1, 2-10.2, and 2-14. case.

Inspection shall be accomplished every 24months or 300 hours after installation,whichever occurs first.

Change 13 1-62.1/(1-62.2 blank)

TM 55-2840-231-23

1-45. Abnormal Flight Maneuver Inspection.

INITIAL SETUP

Applicable Configuration

AU

References

171170-0104

References

TM 55-4920-243-15Para 1-42

1-63

TM 55-2940-231-23

1-45. Abnormal Flight Maneuver Inspection - Continued

9. Vibration Test

9.1. Magnetic chip Detector

Vibration monitoring kit, tool no. 171170-0104 Install vibration monitoring kitin accordance with TM55-4920-243-15 and operatethe engine on the ground for 30minutes. Check for vibration inexcess of the limits specified inpara 1-44. action item 5 (Vibra-tion Limits).

12. Magnetic Chip Detectors

13. Engine Inlet

14. ENGINE/

15. Vibration Test

10. Sudden Stoppage Inspection The following inspections must be accomplishedwhenever the main rotor or tail rotor strikes a sta-tionary object.

11. Engine Mounts

Inspect magnetic chip detectorfor metal particle accumulation.

Inspect the engine mounts forcracks and security. If stoppagewas severe enough to fracture anengine mount, send the engine tooverhaul.

Check the magnetic chip detec-tors for metal particles.

Inspect the engine inlet for for-eign objects.

Motor the engine and check forunusual noise.

Install vibration monitoring kitin accordance with TM55-4920-243-15 and operatethe engine on the ground for 30minutes. Check that vibration iswithin limits specified in para1-44, action item 5 (VibrationLimits).

1-64 Change 13

TM 55-2840-231-23

1-45. Abnormal Flight Maneuver Inspection - Continued

16. Magnetic Chip Detectors a. Shut down and check themagnetic chip detectors for met-al particles.

b. Recheck the magnetic chipdetectors after eight hours of en-gine operation.

1-46. Inspection After lnflight Auto Reignition Operation.

References

Para 1-44

Perform inspections specified in paragraph 1-44and location/Items 1, 2 and 3.

Change 13 1-65

TM 55-2840-231-23

1-46.1. Inspections For Engines Operated In Volcanic Ash

Compressor wash in accordancewith paragraph 2-4.

a. Wash compressor in accor-dance with paragraph 2-4.

b. Flush the engine oil system inaccordance with TM55-1520-228-23, paragraph1-8.

c. Clean/replace egine oil filterin accordance with paragraph8-3 through 8-5.

d. Clean/replace engine oil falterin accordance with paragraphs6-27.1 through 6-27.3.

e. Clean the bleed valve air sys-tem and poppet seat area of ashdeposits in accordance with para-graph 2-4.1.

f. Perform compressor erosioninspection in accordance withparagraph 2-14.

g. Replace engine low pressurefuel falter in accordance withparagraph 6-27.

1-66 Change 13

TM 55-2840-231-23

Section VI. TROUBLESHOOTING

1-66

Troubleshooting procedures 1-67

1-47. GENERAL.

The troubleshooting procedures in this section are presented as a guide for locating and correcting malfunc-tions. Use of these procedures will reduce delays and maintenance down-time and will minimize unnecessary re-placement of engine components. Two basic assumptions have been made in preparing these procedures;(1) thecorrect operating procedures have been followed and (2) the problem is caused by a single failure or malfunction.

The trouble as reported by the flight crew is the main point of the problem. Obtain as much information aspossible from the flight crew and their report. In many cases. this information will define the problem completely;however, the malfunction should be confirmed by a ground run, providing there is no danger of possible enginedamage occuring.

The probable cause lists the components which might cause the malfunction. The cockpit indications canoften give a clue as to which of these components is causing the problem.

Caution must be exercised to avoid troubleshooting difficulties caused by false cockpit indications. In mostcases, a false indication can be detected by checking it against other indications. For example, a TOT indicationsystem malfunction should be suspected if TOT is high, low, or fluctuating with no change in fuel flow or torque.

It is not possible to list troubleshooting difficulties caused by false cockpit indications. In most cases, a falseindication can be detected by checking it against other indications. For example, a TOT indication system mal-function should be suspected if TOT is high, low, or fluctuating with no change in fuel flow or torque.

The troubleshooting procedures are given in logic diagrams. The logic diagrams are organized by specificsymptoms and contain the steps required to locate the fault.

The logic diagram lists the action to be taken to correct the fault.

Preserve the engine before removing it from aircraft.

The following is an outline of procedures to follow when troubleshooting.

If possible, confirm the reported fault with a ground test run.

Troubleshoot according to the symptoms listed in the Symptom Index. Table 1-8.

Confirm fault has been fixed with a maintenance operation check.

Change 13 1-66.1/(1-66.2 blank)

TM 55-2840-231-23

Table 1-8. Sympton Index (METS)

TroubleshootingProcedure

ANTI-ICING SYSTEM

Lack of Anti-Icing Air

ENGINE

Afterfire

Acceleration Temperature Too High During Start

Acceleration Temperature Too Low During Starting

Compressor Rear Bearing Labyrinth Seal Vent Smoking

Continuous Exhaust Smoking

Engine Fails to Light Off - Fuel Vapor Coming Out of Exhaust and No Audible

39

47

7

8

41

40

Ignition Operation

Engine Fails To Light Off - No Fuel Vapor Coming Out Of Exhaust

Engine Fails to Light Off - Vapor Coming Out of Exhaust and IgnitionAudible

Engine Fails to Reach Light Off Cranking Speed

2

4

Operation3

1

Engine Lights Off But Will Not Accelerate to Ground Idle Speed Due to Lackof Secondary Fuel

Engine Lights Off But Will Not Accelerate to Idle Speed in 45 Seconds

Engine N1 Overspeed Above Maximum Limits

Engine N2 Overspeeds

Engine Power Reset to the Takeoff Setting

Engine Tubing Cracked or Broken At the Flare

Excessive Exhaust Torching During Start and Transients

Excessive Fuel Leaking From Drains or Weep Holes

Exhaust Duct Emitting Sparks

Exhaust Smoking on Shutdown or Engine Start

Faulty Torquemeter Indication

High Health Indicator Test (HIT) Check

5

6

27

28

33

56

29

37

44

42

38

59

Change 11 1-67

TM 55-2840-231-23

Table 1-8. Symptom Index (METS) - Continued


High Temperature During Shutdown (Indicatd By Sudden and ConsiderableRise in TOT During N1 Deceleration)

Low Measured TOT at Normal or High Power

Low Power With High TOT

Low Power With TOT Below Maximum Limit

Main Rotor Does Not Rotate By 30% N1 Speed During Start

Engine Power Loss, N2 Droop or Flameout

OIL SYSTEM

Engine Oil Temperature Exceeds 225°F (107°C) But Remains Less Than248°F (120°C) For a Period Not Exceeding Ten Minutes Without AnyChange in Normal Oil Pressure

Engine Oil Temperature Exceeds 225°F(107°C) But Remains Less Than248°F (120°C) For a Period Not Exceeding 10 Minutes With a Change inNormal Oil Pressure

Excessive Oil Pressure Fluctuation

High Oil Pressure

Low Oil Pressure

No Response to Oil pressure Adjustment

Oil Consumption Exceeds 0.05 Gallons (6.5 Ounces) Per Hour

Oil Leakage at Compressor Attachment Insert in the Gearbox Housing(At Insert Adjacent to Compressor Oil Supply Fitting)

Oil Leakage During Shutdown Periods (Smoking on Shutdown)

Oil Leaking From Weep Holes at Ges Producer Fuel Control and/or PowerTurbine Fuel Governor

Oil Pressure Drops Off Severely

Oil Spewing From Diffuser Vent Orifice

Oil Temperature Exceeds 248°F(120°C) Momentarily on 225°F(107°C) Fora Period Exceeding 10 Minutes

Static Oil Leakage From Burner Drain Valve

Static Oil Leakage From Power and Accessory Gearbox Breather

48

26

24

25

54

58

18

19

15

17

16

21

22

50

49

52

14

23

20

43

51

1-68 Change 4

TM 55-2840-231-23

Table 1-8. Sympton Index (METS) - Continued


Starting

Starter Unable to Rotate Engine Immediately After Shutdown

Slow Engine Response While in Flight

Slow to Accelerate From Idle to Power Speed

Speed

Engine Instability Above Idle Speed

Engine Speed Cycles at Idle

Idle Speed Too High

Idle Speed too Low

Stalls

Compressor Stall During Acceleration

Compressor Stall During Low Power Operation

Compressor Stall During Starting or Near Idle Speed (Refer to TM 55-1520-214-10 or TM 55-1520-228-10 For Stall Definition)

TOT Approximately 30°C Lower Than Normal at Idle

Unable to Stop Engine

Unable to Obtain Maximum N2 RPM

Uncontrollable Acceleration Above Idle Speed During or Immediately Followinga Cold Engine Start - Ambient Temperature Below 41°F(5°C).

VIBRATION

Excessive Vibration

Powerturbine Governor and Gas Producer Fuel Control ThrottleShaft Binding.

53

31

30

11

10

13

12

35

36

34

32

46

55

9

45

57

Change 11 1-69

Troubleshooting Procedure 1.

TM 55-2840-231-23

1 - 7 0 Change 8


TM 55-2840-231-23

1-71


PARA 3-7

TM 55-2840-231-23

1-72


PARA 6-16

PARA 6-35

TM 55-2840-231-23

1-73


PARA 6-27

PARA 6-31

TM 55-2840-231-23

1-74


PARA 6-22

PARA 6-23

TM 55-2840-231-23

1-75


PARA 6-10

PARA 6-10

TM 55-2840-231-23

1-76 Change 11


PARA 6-12

PARA 6-9

PARA 6-11

PARAS 6-12

PARA 6-31

PARA 6-2

PARA 2-4

PARA 2-4.1

PARA 2-14 PARA 2-19

PARA 6-29

TM 55-2840-231-23

Change 11 1 - 7 7


TM 55-2840-231-23

1-78 Change 11


PARA 2-4

PARA 2-4.1

PARA 6-31

PARAS 6-12

PARA 6-12

TM 55-2840-231-23

.

Change 11 1 - 7 9


PARA 6-12

PARA 6-12

PARA 6-12.1

TM 55-2840-231-23

.

1 - 8 0 Change 11


TM 55-2840-231-23

Change 11 1 - 8 1


PARA 6-5

PARAS 6-5

PARA 6-10

PARA 6-11

TM 55-2840-231-23

1-82 Change 8


PARA 6-23

PARA 6-26

PARA 6-11

PARA 6-10

PARA 6-27

PARA 6-15

PARA 6-8

PARA 6-3

TM 55-2840-231-23

Change 11 1 - 8 3


PARA 2-4

PARA 6-5

PARA 6-3

PARA 6-30

TM 55-2840-231-23

.

1-84 Change 8


TM 55-1520-228-23 TM 55-1520-214-23

PARA 6-5

PARA 6-11

TM 55-2840-231-23

.

1-85


TM 55-1520-228-23

TM 55-1520-214-23

PARA 8-6

TM 55-1520-228-23

TM 55-1520-214-23

TM 55-1520-228-23

TM 55-1520-214-23

TM 55-2840-231-23

1-86 Change 11


TM 55-1520-214-23

TM 15-1520-228-23

TM 55-1520-214-23

TM 55-1520-228-23

PARA 8-6

PARA 8-5

PARA 5-5

TM 55-1520-228-23

PARAS 8-2

TM 55-2840-231-23

Change 11 1-87


TM 55-1520-214-23

TM 55-1520-228-23 PARA 8-4

TM 55-1520-214-23

T M 55-1520-228-23

TM 55-1520-228-23

TM 55-1520-214-23

PARA 8-5

PARA 5-5

PARA 8-6

TM 55-1520-228-23

TM 55-1520-214-23

TM 55-2840-231-23

1-88 Change 11


TM 55-1520-228-23

TM 55-1520-214-23 TM 55-1520-228-23 TM 55-1520-214-23

PARA 8-6

page 1-89

TM 55-2840-231-23

(1-89) blank)/1-90 Change 11


PARA 8-3

PARA 8-9

TM 55-2840-231-23

Change 11 1-91


PARA 8-2

PARA 8-3

PARA 8-9

TM 55-18520-228-23 TM 55-1520-214-23

TM 55-2840-231-23

1 - 9 2 Change 11

TM 55-2840-231-23

1-93

TM 55-2840-231-23

1-94 Change 13

REPLACE OIL FILTER HOUSING AS-SEMBLY (PARA 8-2)

NOTE

A FLOW OF LESS THAN 90CC (3COUNCES) INDICATES A SIGNIFI-CANT RESTRICTION OF THE OILNOZZLE AND/OR PASSAGES. lN-SPECT EXTERNAL CHECK VALVEFOR PROPER OPERATION IN ACCOR-DANCE WITH PARA 8-8, STEP 3. IN-SPECTION PRIOR TO ENGINE RE-MOVAL.


PARA 5-3

TM 55-2840-231-23

1-95


PARA 2-18

PARA 2-18

TM 55-2840-231-23

1-96


PARA 2-14

PARA 2-4

PARA 2-4.1

TM 55-1520-228-23

TM 55-1520-214-23

TM 55-1520-228-23

TM 55-1520-214-23

TM 55-1520-214-23

TM 55-1520-228-23

TM 55-2840-231-23

.

Change 11 1 - 9 7


TM 55-2840-231-23

1-98 Change 11


TM 55-1520-228-23 TM 55-1520-214-23

PARA 6-3

PARA 6-14

PARA 6-14

TM 55-2840-231-23

1-99

Troubleshooting Procedure 26. TM 55-1520-228-23 TM 55-1520-214-23

TM 55-1520-228-23 TM 55-1520-214-23

TM 55-2840-231-23

1-100


TM 55-1520-228-23 TM 55-1520-214-23

PARA 6-8

TM 55-2840-231-23

1-101


PARA 6-6

PARA 6-8

TM 55-1520-228-23 TM 55-1520-214-23

TM 55-2840-231-23

1-102


PARA 6-31

PARAS 6-12

TM 55-2840-231-23

Change 11 1-103


PARA 2-4

PARA 2-4.1

PARA 2-14 PARA 2-2

PARA 9-6

PARA 6-11

PARAS 6-12

TM 55-2840-231-23

1 - 1 0 4 Change 11


PARA 2-4

PARA 2-4.1

PARA 2-14

PARA 2-2

PARA 6-11

PARAS 6-12

TM 55-2840-231-23

Change 11 1-105


TM 55-1520-228-23 TM 55-1520-214-23

PARA 2-4.1

TM 55-2840-231-23

.

1-106 Change 11


TM 55-1520-228-23 TM 55-1520-214-23

TM 55-2840-231-23

1-107

TM 55-1520-214-10 TM 55-1520-228-10

TM 55-1520-214-10

TM 55-1520-228-10

PARA 2-4

PARA 2-4.1

PARA 6-11

PARAS 6-12

TM 55-2840-231-23

1-108 Change 11


PARA 2-4.1

PARA 6-11

PARAS 6-12

PARA 9-8

TM 55-2840-231-23

Change 11 1-109


PARA 2-4.1

TM 55-2840-231-23

1-110 Change 11


PARA 6-15

PARA 6-8

TM 55-2840-231-23

1-111


TM 55-1520-228-23 TM 55-1520-214-23

TM 55-1520-214-23 TM 55-1520- 214-23

TM 55-2840-231-23

1-112


PARA 9-4

TM 55-2840-231-23

1-113


PARA 2-2

TM 55-1520-214-23 TM 55-1520-228-23

TM 55-2840-231-23

1-114


PARA 2-18

PARA 2-2 PARA 2-18

TM 55-2840-231-23

Change 11 1 - 1 1 5


TM 55-1520-214-23 TM 55-1520- 228-23

PARA 8-8

TM 55-2840-231-23

1-116

.


TM 55-1520-214-23 TM 55-1520-228-23

TM 55-1520-214-23 TM 55-1520-228-23

TM 55-2840-231-23

1-117


PARA 3-4

PARA 2-2

TM 55-1520-214-23 TM 55-1520-228-23

TM 55-2840-231-23

1-118


para 1-45

PARA 5-5

TM 55-1520-214-23 TM 55-1520-228-23

TM 55-2840-231-23

Change 11 1-119


PARA 2-2

TM 55-2840-231-23

1 - 2 0 Change 11


PARA 6-5

TM 55-2840-231-23

1-121


PARA 3-11

PARA 6-28

PARA 6-5

TM 55-2840-231-23

1-122


TM 55-2840-231-23

1-123


PARA 2-2

PARA 8-8

TM 55-2840-231-23

1-124


TM 55-1520-214-23 TM 55-1520-228-23

TM 55-2840-231-23

.

1-125


PARA 8-7

PARA 8-2

TM 55-1520-214-23

TM 55-1520-228-23

TM 55-2840-231-23

1 - 1 2 6 Change 11


PARA 8-2

PARA 5-3

TM 55-2840-231-23

1-127


TM 55-1520-214-23 TM 55-1520-228-23

TM 55-2840-231-23

1-128

TM 55-2840-231-23

MAIN ROTOR DOES NOT ROTATE BY30% N1 SPEED DURING START

SHUT DOWN, ENSURE THAT THE OILBEING USED IS MIL-L-7808F OR G,OR MIL-L-12699. REPEAT STARTPROCEDURE. IF NOT ROTATING AF-TER SECOND ATTEMPT, SUSPECTDIRT OR SAND BETWEEN FOURTHSTAGE TURBINE WHEEL ANDSHROUD.

BLOW OUT THROUGH EXHAUSTSTACK WITH COMPRESSED AIR.MAKE THIRD START ATTEMPT TOVERIFY CORRECTIVE ACTION.

NO

v

AIRCRAFT POWER TRAIN SEIZURETM 55-1520-228-23

NO

+

REPLACE ENGINETM 55-1520-214-23/TM 55-1520-228-23

Change 13 1-129

TM 55-2840-231-23

● CHECK AND CORRECT RIGGING

● CHECK FUEL CONTROL MAXSPEED STOP (PARA 6-14)

● ADJUST GOVERNOR RIGGING

● REPLACE GOVERNOR (PARA6-18, 6-20)

1-44)

1-130 Change 11

TM 55-2840-231-23

Troubleshooting Procedure No. 57. Powerturbine Governor and Gas Producer Fuel ControlThrottle Shaft Binding

POWER TURBINE GOVERNOR ANDGAS PRODUCER FUEL CONTROLTHROTTLE SHAFT BINDING

APPLY ITEM 49 APPENDIX D TO THEAREA SHOWN IN ILLUSTRATION. AONE SECOND SPRAY SHOULD BESUFFICIENT. ROTATE SHAFT BACKAND FORTH FOLLOWING SPRAY TOASSURE PENETRATION. REPEATSPRAY IF NECESSARY.

Change 13 1-130.1

TM 55-2840-231-23

Troubleshooting Procedure 58. Engine Power Loss, N2 Droop or Flameout

TM 55-1520-228-23-1

1-130.2 Change 13

TM 55-2840-231-23

Troubleshooting Procedure No. 59. High Health Indicator Test (HIT) Check

CHECK FOR AIR LEAKS CLEAN COMPRESSOR (PARA 2-4AND 2-5) OR CLEAN BLEED VALVE(PARA 2-4.1)

CHECK BLEED AIR LINES AND AIRDISCHARGE TUBES FOR AIR LEAKS.REPAIR AS NECESSARY

CHECK F.A.T. GAGE REFER TO TM 55-1520-228-23 (PARA(THERMOMETER) 8-238).) REPLACE THERMOMETER IFFOR ERROR NECESSARY

NO

CHECK TURBINE OUTLET REFER TO TM 55-1520-228-23 (PARATEMPERATURE INDICATOR 8-108). REPAIR, ADJUST, ORAND SYSTEM FOR ERROR REPLACE AS NECESSARY

NO

CHECK GAS PRODUCER REFER TO TM 55-1520-228-23 (PARA(N1) TACHOMETER AND 8-58 THRU 8-74) REPAIR, ADJUSTORGENERATOR FOR ERROR REPLACE AS NECESSARY

Change 13 1-131/(1-132 blank)

TM 55-2840-231-23

Change 8 1-132.1

CAUTION

TM 55-2840-231-23

Section VII. GENERAL MAINTENANCE PROCEDURES

Page

General Maintenance InformationGeneral Maintenance PracticesCleanlinessHardwareUniversal FittingsRigid Tube InstallationFuel RequirementsLubricating Oil RequirementsElectrical Supply RequirementsDrainage RequirementsPreservation RequirementsUse of OilsOil Change ProcedureOil Changeover ProcedureEngine Exterior Surface - Cleaning

1-1321-1321-1341-1351-1351-1371-1371-1371-1371-1371-1371-1381-1381-1391-141

1-48. GENERAL MAINTENANCE INFORMATION.

This section contains general information and practices that maintenance personnel will become familiarwith before attempting work on the engine. Refer to Appendix G for torque values for bolts, nuts, andconnectors used on the engine.

1-49. General Maintenance Practices.

Engines removed for unscheduled repair, require only that work necessary to return the engine to service.

During disassembly, examine all parts and assemblies for serviceability. Look for indications of workdone incorrectly during previous maintenance or overhaul. Report any such indications.

Prolonged contact with lubricating oil (item 5, Appendix D) may cause a skinrash. Those areas of skin and clothing that come in contact with lubricatingoil should be thoroughly washed immediately. Areas in which lubricating oilis used should be adequately ventilated to keep mist and fumes to a minimum.

Never allow fuel or oil to contact electrical connectors. Do not use pliers totighten connectors. Use only specified solvent to clean connectors. Othersolvents might damage connectors.

NOTE

Lubricating oil may soften paint upon contact. If lubricating oil is spilled onpainted surfaces, these surfaces should be thoroughly washed.

1-132.2

TM 55-2840-231-23

Protect engine from dust and inclement weather, When possible, perform maintenance in a shelteredarea.

On removal of engine components, exercise care to prevent dirt and other foreign matter from enteringthe engine. Caps, plugs, or temporary covers shall be used to close all openings. Do not use tape to coverfuel and oil openings. Tape adhesive is soluble in fuel or oil and can cause contamination.

When the gas producer fuel control, power turbine governor, check valve, or accumulator are re-moved from the engine, use extreme care to prevent foreign materials from entering the pneumatic lines orthe ports of the component.

Always use a backup wrench on fittings when removing or installing tubing.

Before removing ignition components, disconnect the input power lead at the ignition exciter.

Carefully inspect the condition of all replacement parts before installation.

Never attempt to rotate the gear trains and rotors using a speed wrench at the tachometer drive pads.Side loads on the speed wrench could crack the tachometer drive shaft. Rotate the gas producer gear trainand rotor using the 6799790 turning adapter at the fuel control, fuel pump, starter-generator, or spareaccessory drive pad. Rotate the power turbine gear train and rotor using the 6799790 turning adapter atthe power turbine governor drive pad.

Before disconnecting tubes and hoses, remove locknuts and bolts from cushion clamps. This preventsdamage to fittings. If the same lines are going to be reinstalled, reassembly will be easier if clamps are notremoved from lines. Remove locknut and bolt that secure the clamp, free the clamp, then reinstall bolt andlocknut loosely in the clamp.

When connecting or disconnecting tubes and hoses, use caution to prevent damage and twisting action.When possible, use a backup wrench on fitting. As tubes and hoses are disconnected, cap or cover openingsto prevent entrance of foreign material.

To aid in reassembly, keep bolts together as they are removed from each bolt circle.

Dispose of unserviceable parts in accordance with current regulations. Discard all preformed packingsand gaskets that are removed during disassembly. Do not discard adapter gasket (sheet metal platewith integral seals) used on sequence valve, on oil cooler, or on oil manifold unless sealing material is dam-aged.

Keywashers are not reusable. Once used, they must be replaced by new keywashers in all applications.

All used locknuts will be tried for self-locking capabilities before being reused. Manually thread usedlocknut onto bolt or stud until it stops turning. Replace locknut if bolt or stud threads go past end of lock-nut.

Use care when assembling bolts to shank-type locknuts. Aline the bolts and engage the first few threadsmanually to avoid dislodging the locknut from its seat.

During assembly, be careful not to drop nuts, washers, or other objects into the subassembly. If an objectis dropped, do not proceed further until it is removed,

Do not use excessive force to assemble mating parts. If excessive force appears necessary, inspect matingsurfaces for burrs or pickups. Remove any such defects and repair or replace defective parts.

1-133

TM 55-2840-231-23

The special tools identified in this manual are designed specifically for use on this engine. Avoid theuse of makeshift tools.

Do not use brass or lead tools when installing or disassembling hot sectionparts. Brass and lead contaminants can ultimately lead to part failure.

Before using tools, be sure that they are clean and free from nicks, dents, or burrs that could damageengine parts.

Do not use cadmium-plated tools on titanium parts. Doing so may causeparts to fail during subsequent use.

Titanium parts require special care. When cadmium-plated tools are used on titanium parts, it is possiblefor particles of cadmium to become embedded in the titanium. At temperatures above 600°F (316°C), thecadmium can cause the titanium to become brittle, resulting in overstressed areas and possible cracking.Therefore, cadmium-plated tools will not be used on titanium parts.

Do not use screwdrivers or sharp metal rods to separate engine parts. If engine parts are bound or seized,use wooden wedges to separate them.

Do not use hammers with metal heads to drive any tool on any part of the engine; instead use hammerswith plastic, nylon, or rawhide heads when driving is required.

Do not leave tools or parts on any part of the engine, particularly near inlet, during maintenance. Returneach tool to its proper place immediately after use.

Use approved thermally insulated gloves.

Lift all heavy parts with proper lifting devices to prevent damage to the part or injury to personnel. Donot use engine components as handles when moving the engine.

Never mark engine parts with a lead pencil. Such deposits can cause corrosionand burn-out of parts. Do not use either the electrolytic-etch or electric-arcscribe methods to mark engine parts.

Use dye or equivalent to temporarily mark engine parts (item 48, Appendix D).

1-50. Cleanliness.

Keep dirt and other foreign material out of the engine. Use the recommended covers to seal openings inthe dismantled engine and in disassembled parts.

Place each engine part on a clean surface as it is removed from the engine. Wrap small parts in barriermaterial (item 15, Appendix D), seal with tape (item 3, Appendix D) and tag (or otherwise identify) thepackage with engine and module serial number, part nomenclature, and part number.

1-134

TM 55-2840-231-23

Do not remove wrappings, protectors or covers until the part is ready to be installed.

1-51. Hardware.

Use 0.020 in. diameter stainless steel lockwire (item 7, Appendix D) where lockwire size is not specified.Double strand lockwire all drilled bolts, plugs, and screws, except those locked with self-locking nuts orlockwashers. Lockwire bolts in pairs where possible. When reassembling, be sure to safety wherever lock-wire was removed. Do not use zinc lockwire. Do not reuse lockwire, cotter pins, ring seals, lip seals, com-position gaskets, and split or tabwashers.

1-52. Universal Fittings.

a. Use this procedure to install universal fittings with backup rings. (See figure 1-18.)

(1) Install the nut on the fitting and run it back until the counterbore of the nut alines with theupper inner. corner of the seal groove.

(2) Lubricate seals used on oil, anti-icing, and bleed air tube fittings with lubricating oil (item 5,Appendix D). Lubricate seals used on fuel tube fittings with lubricating oil (item 4, Appendix D). DO NOTlubricate seals used on fuel system control air tube fittings. Install the seal on the fitting.

(3) Work the backup ring into the counterbore of the nut,

(4) Turn the nut down until the seal is pushed firmly against the lower threaded section of thefitting.

(5) Install the fitting into the boss, making certain the nut turns with the fitting, until the sealtouches the boss. Then tighten the fitting one and one-half turns more.

(6) Put a wrench on the nut to prevent its turning, and position the fitting by turning it not morethan one turn.

(7) Hold the fitting in its position and tighten the nut against the boss.

b. Use this procedure to install universal fittings without backup rings. (See figure 1-17.)

(1) Run the nut on the fitting end back until the washer face is alined with the upper innercorner of the seal groove.

(2) Lubricate seals used on oil, anti-icing, and bleed air tube fittings with lubricating oil (item 5,Appendix D). Lubricate seals used on fuel tube fittings with lubricating oil (item 4, Appendix D). DO NOTlubricate seals used on fuel system control air tube fittings. Place the seal in the seal groove.

(3) Screw the fitting into the boss until the seal barely touches the boss.

(4) Turn the fitting and nut together until the nut touches the boss.

(5) Put a wrench on the nut to prevent its turning, and position the fitting by turning it in up to270 degrees or unscrewing it up to 90 degrees.

(6) Hold the fitting in its proper position and tighten the nut against the boss.

1-135

Figure 1-18.

TM 55-2840-231-23

1-136

TM 55-2840-231-23

1-53. Rigid Tube Installation.

a. Tube assemblies must fit and align with the mating flare tube fittings to the degree that both ends of the assemblyflares shall uniformly seat in a free state on the cones of The mating fittings. The fit shall be without distortion or stretch-ing of the tube assembly and to the degree that the nuts can be fully engaged up to the final one-half turn with lightfinger pressure.

b. If proper alignment cannot be attained by repositioning mating flare tube fittings, bend the tube enough to pro-vide alignment in the free-state as specified. Accomplish all bending with the tube removed from the engine. Adjust-ment of the fit may be accomplished by bending by hand at principal bends. In the event the tube cannot be bent byhand, use a proper tube bending device. The flattened effect of the cross section of the tube as a result of the reformingoperation must not exceed 15 percent of the tube OD.

c. When proper free-state alignment is attained complete the tubing installation by securing both the coupling nutsand tightening them to proper torque. Always use a backup wrench on the tube fittings when tightening the tube cou-pling nuts.

d. When a component to which rigid tube assemblies are attached is replaced, remove all interfering tube assem-blies to permit easy removal and reinstallation of the component. This precaution will prevent later damage to the tubeassemblies.

1-54. Fuel Requirements. The fuel used for testing shall conform to item 43, Appendix D. The fuel supply systemshall be capable of supplying 250 pounds per hour (113.50 kg) flow over the range of 5 to 45 psig inlet pressure. Asufficient number of 10 micron (No. 200 mesh screen) filter elements shall be provided to adequately filter the fueland allow the required flow rate.

1-55. Lubricating Oil Requirements. The engine lubricating oil used for testing shall conform to item 5, AppendixD. The oil supply system shall be capable of maintaining oil inlet pressure within 0 to 1.8 psig and oil inlet temperaturewithin the range of 180° F to 225° F (82.2° C to 107.2° C). A sufficient number of 25 micron filters shall be providedto adequately filter the scavenge oil.

1-56. Electrical Supply Requirements.

a. The ignition exciter requires a dc power supply of 28 volts (4 amps minimum).

b. The starter requires a source of external power capable of 350 to 400 amperes, and 28 volts is recommendedfor starting the engine; however, limits of 300 to 750 amperes and 28 volts are allowable for starting the engine.

1-57. Drainage Requirements. When the engine is to be tested on the test stand, drain bottles shall be provided tocollect drainage from the burner drain valve, fuel pump seal drain, firewall shield drain and exhaust collector drain.Combined drainage shall not exceed 2 cc/minute, except fuel pump seal drainage shall not exceed 0.5 cc/minute, ofthis total.

1-58. Preservation Requirements. Engines which are not scheduled for immediate installation into the airframe shallbe preserved as outlined in paragraphs 1-35 thru 1-38.

1-137

TM 55-2840-231-23

1-59. Use of Oils.

NOTE

It is not advisable to mix MIL-L-7808 and ML-L-23699 oils except in cases of emer-gency. If it becomes necessary, the system must be flushed after 6 hours of operation.(Refer to paragraph 1-61.)

NOTE

Nearly all present day lube oils contain anti-foam additives which can settle to the bot-tom of the container. Thoroughly shake (agitate) the container prior to adding oil to thesystem either at an oil change or during routine servicing.

a. Use of ML-L-23699 oil is authorized and directed for ambient temperatures above minus 25°F (-31.7°C). Thisoil may also be used when MIL-L-7808 oil is not available.

b. Use of MIL-L-7808 oil is specified for operation in ambient temperatures below minus 25°F (-31.7°C). Thisoil may also be used when MIL–L-23699 oil is not available.

1-60. Oil Change Procedure.


Lubricating Oil (item 5, Appendix D)

References

Paras 5-5, 8-3, 8-4 and 8-5

a. Drain the oil system.

Refer to paragraph 5-5. b. Remove, inspect and cleanthe magnetic chip detectors.

1-138 Change 13

TM 55-2840-231-23

1-60. Oil Change Procedure - Continued

ENGINE/ - Continued c. Loosen the fittings and re-move the line going to the “T”fittings that feeds oil to the num-ber six and seven bearing, pres-sure oil tube, P6871470. Removethe small oil screen, P6840476(Pressure Oil Fitting Screen As-sembly). Motor the engine withthe starter and permit a smallamount of oil (1 or 2 ounces) tocome out the end of the oil tube.Clean and reinstall the screenand tube assembly. Tighten pres-sure oil tube coupling nuts to80-120 in-lb (9.0-13.6 Kg/m).Tighten clamp nuts to 35-40 in.lb (3.9-4.5 Kg/m). Refer to Fig-ure 1-18.1.

d. Remove and clean or replacethe oil filter.

Change 13 1-138.1

TM 55-2840-231-23

Figure 1-18.1 Pressure Oil Tube and Pressure Oil Filter Screen

138.2 Change 13

TM 55-2840-231-23

1-60. Oil Change Procedure - Continued


ENGINE/ - Continued

Lubricating Oil (item 5, Appendix D). e. Refill oil tank withlubricating oil,

f. Motor engine with thestarter until positive oilpressure indication isobtained. Do not exceedstarter limitations. (TM55-1520-228-23/TM55-1520-214-23)

g. closely monitorindicated oil pressure forthe first live minutes ofengine operation.

1-61. Oil Changeover Procedure

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Lubricating Oil (item 5, Appendix D)

ReferencesParas 8-3 thru 8-5

Oil System

Prolonged contact withlubricating oil (item 5, AppendixD) may cause a skin rash. Thoseareas of skin and clothing thatcome in contact with lubricatingoil should be thoroughly washedimmediately. Enclosed areaswhere lubricating oil is usedshould be adequately ventilatedto keep mist and fumes to aminimum.

Change 13 1-139

TM 55-2840-231-23


ENGINE/ - Continued a. Drain the oil tank, sys-tem components and pip-ing, and engine gearbox ascompletely as possible.

Refer to paragraphs 8-3 thru 8-5. b. Remove and clean or re-place the oil filter.

c. Remove, inspect andclean the magnetic chip de-tectors.

Lubricating oil (item 5, Appendix D)


d. Fill oil tank with desiredlubricating oil.

e. Motor engine to pumpoil through the system.Check tank oil level andadd oil as required. Repeatthe motoring cycle until thetank oil level does notchange.

f. Run engine for 30 min-utes to one hour and shutdown.

g. Inspect and clean or re-place the oil filter.

(1) If filter was heavilycontaminated, accomplishaction items h. through 1.

(2) If filter was notheavily contaminated, ac-complish action items j.through 1.

h. Drain oil from the en-gine oil system

i. Fill oil tank with the de-sired oil and release the en-gine for service.

1-140

TM 55-2840-231-23

1-61. OIL CHANGEOVER PROCEDURE - Continued

ENGINE/-Continued j. After five hoursoperation, inspect andclean or replace the oilfilter.

k. After 15 hours operation,inspect and clean orreplace the oil filter.

l. Revert to normalschedule of inspectionof oil filter.

1-62. ENGINE EXTERIOR SURFACE – CLEANING

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Drycleaning Solvent (item 1, Appendix D)

ENGINE/

Drycleaning solvent, P-D-680, type IIused to clean parts is potentiallydangerous to personnel andproperty. Avoid repeated andprolonged skin contact. Avoidprolonged or repeated breathing ofvapors. Do not use near open flameor excessive heat. Flash point ofsolvent is 138oF (59o C).

Engine Exterior Surface Flush or spray wash external surfaces withpetroleum solvent (item 1, Appendix D) toremove grease, oil, and dirt. Insure that allopenings are plugged or covered beforecleaning.

Change 8 1-141

TM 55-2840-231-23

Section VIII. ENGINE TESTING IN MOBILE OR FIXED FACILITIES

Page

1-142General

Preparation For TestInstrumentation Requirements

Engine TestingEngine Motoring ProcedureEngine Operating ProceduresOperating LimitsTest RequirementsFunctional Test ScheduleHealth Indicator Test (HIT)Engine Performance Check

1-1421-1421-1421-1421-1421-1431-1491-1511-1531-156

1-162.1

1-63. GENERAL.

This section provides instructions for conducting functional tests following repair or replacement of parts.

1-64. PREPARATION FOR TEST. Engine testing may be accomplished with the engine installed in theairframe AVUM or on a mobile engine test stand AVIM.

Engine Installation in Airframe. Install the engine in the airframe as outlined in the applicable aircraftmaintenance manual TM 55-1520-214-23 or TM 55-1520-228-23.

Engine Installation on Test Stand. Install the engine on the mobile engine test stand, part No. LTCT 10465-02(NSN 4920-00-167-9178), as outlined in TM55-4920-328-13.

1-65. INSTRUMENTATION REQUIREMENTS. Engine testing may be accomplished using no more thanstandard aircraft instrumentation to monitor the following parameters.

a. Turbine Outlet Temperature 0oC-1000 oC)

b. Output Shaft Torque (0-110 psi).

c. Oil Pressure (0-150 psi).

d. Gas Producer (Nl) Speed (0-110%).

e. Power Turbine (N2) Speed (0-120%).

1-66. ENGINE TESTING.

1-67. ENGINE MOTORING PROCEDURE.

a. Engine installed in airframe.

(1) Disconnect the power input lead from the ignition exciter or pull the IGN ENG circuit braker (refer toTM 55-1520-235-10).

(2) Insure that the throttle (twist grip) is in the FUEL CUTOFF position.

1-142 Change 8

(3)

(4)

TM 55-2840-231-23

Insure that the collective pitch control is at the minimum position.

Press and hold the starter - ignition button to motor the engine. Release the button to stopmotoring

b. Engine Installed on Test Stand.

(1) Prepare the test stand for operation as outlined in TM 55-4920-328-13.

(2) Place the N1 throttle lever to the zero degree position as indicated on the throttle positionindicator.

(3) Place the governor lever to the minimum position.

NOTE

Do not press the ignition switch.

Insure that lubrication oil is available at the engine oil inlet port

(4) TO motor engine, press and hold start switch. To stop motoring engine, release start switch.

1-68. Engine Operating Procedures

INITIAL SETUP

Applicable Configuration ReferencesAll TM 55-4920-328- 13

TM 55-1520-214-10Teat Equipment TM 56-1520-228-10

Test Stand


AIRFRAME/

1. Engine Operation NOTE

Refer to the applicable TM 55-1520-214-10 or TM 55-1520-228-10 forstarting, operating, and shutdownprocedures where the engine is to betested in the airframe.

Change 3 1-143

TM 55-2840-231-23

1-68. Engine Operating Procedure - Continued


2. TEST STAND/STARTING

The following operating procedures applywhen the engine is installed on the teststand.

Prepare the test stand foroperation as outlined inTM 55-4920-328-13.

Insure that fuel and lubricatingoil are available at the enginefuel and oil inlet ports.

Place N1 throttle lever tozero degree position asindicated on the throttleposition indicator.

Place governor lever tominimum position.

Abort the start if any of thefollowing conditions occur:

• Time from starter ON to idlespeed exceeds one minute.Investigate and correct causebefore attempting another start.

• Engine oil pressure does notstart to increase by the time gasproducer speed (Nl) reaches20%. speed. Investigate andcorrect cause before attemptinganother start.

• NO indication of power turbinerotor speed (N2) by the time gasproducer speed (N1) reaches30% speed. Investigate andcorrect cause if malfunction wasof test stand origin. Reject engineif malfunction was of engineorigin,

1-144 Change 11

TM 55-2840-231-23

1-68. Engine Operating Procedures - Continued


TEST STAND/- -ContinuedContinued

● Indicated TOT exceeds 1380°F(749°C) for more than 10 secondswith a momentary peak of one secondat 1700°F (9270C).

● Indicated TOT exceeds 1700°F(9270C) or remains at 1700°F(9270C) for more than one second.

Simultaneously pressthe start switch, ignitionswitch, timer start switch.

Do not advance the N1 throttlelever above the 0° position (fuelcutoff) until the proper crankingspeed is attained. An overtemper-ature start or an explosive Iightoffmay occur.

When N1 speed reachesvalue listed below ad-vance the N1 throttlelever to 30-degree posi-tion (idle). If there isno immediate TOT indi-cation, retard throttlelever to O-degree posi-tion (fuel cutoff).Investigate to determinethe cause for no lightoff.

Ambient Temperature N1 Speed

45°F to 130°F (7°C to 54°C) 15%0°F to 44°F (-18°C to 7°C) 13%-65°F to -1°F (-54°C to -18°C) 12%

At 58% N1 speed, releasestart switch, and ignitionswitch to cut off starterand ignition.

Change 3 1-145

TM 55-2840-231-23



TEST STAND/ -Continued

The engine should continue to accelerateand stabilize at 62-65% N1 speed (idle).

Oil pressure should beat least 50 psi (3.51kg/sq cm).

NOTE

3. TEST STAND/Operating Idle

4. TEST STAND/Flight Autorotation

During cold weather, oil pressureup to 150 psi (10.55 kg/sq cm) ispermissible. Operate at idleuntil normal pressure limits can bemaintained.

Idle is the same setting as for starting and isestablished with the governor lever at theminimum position and the N1 throttle leverat the idle (30°) position. Other determiningfactors are:

N1 speed =62 to 65%N2 speed = 75 to 105%GPTOT = Determine from the following

figureTorque pressure = O to 11 psi (O to 0.77

kg/sq cm)

Flight autorotation is established with thegovernor lever in the minimum positionand the N1 throttle lever at any positionbetween idle (30°) and maximum (900).Other determining factors are:

N1 speed= 63% (estimated)N2 speed =98 to 108% (normal, see

table 1-9 for exception)GPTOT = Determine from the preceding

figure.Torque pressure = O to 5 psi (O to

0.35 kg/sq cm)

1-146

TM 55-2840-231-23


Change 3 1 - 1 4 7

TM 55-2840-231-23

1-68. Engine Operating Procedures . Continued


5. TEST STAND/Take off

Takeoff is established with the N1 throttlelever at maximum (90o), the governor leverpositioned to produce 100% N2 and theengine loaded to produce 1380°F (749°C)GPTOT. Other determining factors are:

N1 speed = 104% maxTorque pressure = 100 psi (7.03 kg/sq

cm) max

6. TEST STAND/Normal Shutdown

7. TEST STAND/Emergency Shutdown

If time permits, position the test set switchesand controls as outlined in TM 55-4920-328-13.

Place N1 throttle leverto ground idle (30°)position the governorlever to the minimumposition.

Stabilize at idle fortwo minutes.

Move N1 throttle leverto fuel cutoff (0°) posi-tion.

Shut down the test standas outlined in TM 55-4920-328-14.

Press instrument poweroff switch and moveN1 throttle lever to thefuel cutoff (0°) position.

1-148 Change 3

TM 55-2840-231-23

1-69. Operating Limits - Continued. Observe engine operating limits during all phases of engine testing.(Refer to table 1-9.)

Table 1-9. Operating limits

NOTE

Refer to figure 1-18.2.

NOTEIf temperature limits are exceeded,inspect the turbine as outlined inparagraph 1-43.

Change 13 1-148.1/(1-148.2 blank)

1-69. Operating Limits.

TM 55-2840-231-23

Figure 1-18.2. Maximum Allowable N2 Speed

Change 13 1-149

TM 55-2840-231-23

Table 1-9. Operating Limits - Continued

Vibration test required after initialinstallation of engine in aircraft orwhen excessive vibration issuspected. (Refer to para 1-44.)

1-150

TM 55-2840-231-23

1-70. Test Requirements.

a.Table 1-10 lists theaccessory. Parts removed

NOTE

During cold weather operation, 150 psig engineoil pressure is permitted following enginestart. When the 130 psig limit is exceeded,operate engine at idle RPM until normalengine oil pressure is obtained. When engineoil pressure is within normal limits, enginemay be operated within full range oftemperature limits – 54°C to 107OC ( – 65°F to224OF) without regard to engine oiltemperature markings.

test requirements following repair or replacement of an engine component orto gain access to other parts or areas shall invoke the same test requirements

in accordance with the table of test requirements, as parts repaired or replaced to correct deficiencies ormalfunctions. In the event that more than one test requirement is invoked, the most severe shall apply.

b. Setting numbers listed in the functional test column of table 1-10 refer to the setting numbers inthe functional test schedule (Table 1-11).

c. The following test points should be utilized for vibration testing of an engine when installed in anaircraft.

(1) Steady state data points:

(a) Throttle full open, 103 percent N2, flat pitch, stabilize for 30 seconds, record reading,

(b) Throttle full open, 103 percent N2, increase collective until skids are light, stabilizefor 30 seconds, record reading.

(2) Transient data points:

Item

1

2

(a) Throttle at idle, flat pitch, increase throttle to full open (103 percent N2 ) record thepeak reading.

(b) Throttle full open, 103 percent N2, flat pitch, increase collective until skids are light,record the peak reading.

Table 1-10. Test Requirements

Parts Replacedor Repaired

Gearbox seals

Oil pressure reducer

3Lube oil check valve

FunctionalTest

Settings3 thru 6

Settings1 thru 6

Settings1 thru 6

Remarks

Check for leaks.

Insure oil pressure is within limits of table 1-9.

Insure oil pressure is within limits of table 1-9.

Change 11 1-151

TM 55-2840-231-23

Table 1-10. Test Requirements - Continued

Item

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

1-152

Parts Replacedor Repaired

Oil filter housing andassociated valves

Spark igniter

Ignition exciter

Bleed valve

Fuel control

Governor

Fuel pump

Compressor

Compressor case

Combustion liner

Combustion outer case

Compressor dischargeair tube(s)

Double check valve

Fuel filter element

Oil filter element

Fuel, oil, and airpiping

Change 11

.

FunctionalTest

Settings3 thru 6

Settings1 and 2

Settings1 and 2

Settings3 thru 6

Settings1 thru 6

Settings1 thru 6

Settings1 thru 6

Settings1 thru 10

Settings1 thru 6

Settings3 thru 6

Settings3 thru 6

Settings3 thru 6

Settings3 thru 6

Settings1 and 2

Settings1 and 2

Settings1 and 2

Remarks

Adjust oil pressure regulating valve. (Refer toparagraph 8-6. ) Insure oil pressure is withinlimits of table 1-8.

Insure satisfactory start.

Insure satisfactory start.

Insure valve operates within limits of figure1-19 with a non-restricted fitting installed onBleed Valve Compressor discharge part.

Make fuel control adjustments as required.(Refer to paragraphs 6-5 thru 6-14. ) Insureengine operates within limits of table 1-8.

Insure engine operates within limits of table 1-9.







Check for leaks.

Check for leaks.

Check for leaks.

Check for leaks.

TM 55-2840-231-23

AMBIENT TEMPERATURE

Figure 1-19. Bleed Valve Operation

1-71. FUNCTIONAL TEST SCHEDULE.

Table 1-11 lists the power settings and sequence of events for performing an engine functional test run.Perform the applicable portions of the test as outlined in table 1-10. The engine must operate within thelimits specified in table 1-9.

Table 1-11. Functional Test Schedule

SettingNo.

1

2

3

4

5

Condition

Start engine (ac-celerate to idle)

Shut down

Start engine (ac-celerate to idle)

Takeoff

Idle

Time(minutes)

5max

2

2

N1 speed(%)

62 to 65

62 to 65

62 to 65

N2 speed(%)

75 to 105

75 to 105

100

75 to 105

GPTOT°F (°C)

See fig,1-20

See fig.1-20

1380(749)

See fig.1-20

Torque Press(psi )

0-11

0-11

100

0-11 D

Change 11 1-153

TM 55-2840-231-23

Table 1-11. Functional Test Schedule - Continued

SettingNo.

6

7

8

9

10

Condition

Shut down

Start engine (ac-celerate to idle:

Takeoff

Idle

Shut down

Time(minutes)

5

2

N1 speed(%)

62 to 65

62 to 65

N2 speed(%)

75 to 105

100

75 to 105

GPTOT‘F (°C)

See fig.1-20

1380(749)

See fig.1-20

Torque Press(psi)

0-11

100

0-11

NOTES

A Observe engine for abnormal conditions such as vibration, noise, or leakage. Lightoil vapor or spewing may occur at the diffuser vent orifice when a new compressorhas been installed. Leakage should cease after high power transients have permittedseal to wear in.

B

C

D

E

F

G

H

NoteRef

Make idle speed and start derichment adjustments if required. (Refer to paragraph 6-5,6-12.) Adjust oil pressure regulator if required, (Refer to paragraph 8-6. )

If the engine is being tested in the airframe, limit collective to just short of lift-off.

Check operation of the anti-icing valve..

Give the engine a thorough visual inspection after shutdown. Repeat the check run. .if any repairs are necessary as a result of the run or the inspection.

The check run is complete after setting No. 6 unless a new compressor has been in-stalled. To obtain seal wear-in on the new compressor, continue to the completionof the listed check run settings.

If the engine is being tested in the airframe, make a test flight IAW TM 55-1500-328-25and observe published operating limits.

Check the diffuser vent orifice. Repeat settings 7 through 10 until the proper orificesize is determined. (Refer to paragraph 2-18. )

E,F

G

H

1-154

Figure 1-20

TM 55-2840-231-23

Change 3 1 - 1 5 5

TM 55-2840-231-23

1-72. HEALTH INDICATOR TEST (HIT)

INITIAL SETUP

Applicable Configuration ReferencesAll

AIRFRAME/

1. Health Indicator Test(HIT)

TM 55-1520-214-10TM 55-1520-228-10

The HIT is the method by which a pilot, inday-to-day flying, monitors the aircraftengine condition. This is accomplished by thepilot selecting an N1 setting (%) based on theexisting outside air temperature (OAT)observed on the aircraft OAT gauge. The TOTindicated at that N1 setting must then relateto the predicted value (Baseline TOT Value)found on the HIT Log. TOT variations fromthe baseline values are logged by the pilot onthe appropriate HIT Log. This log, is thenused by maintenance personnel as an aid inmonitoring engine health trend data.

Several readings less than theestablished baseline value (minusindications) may be an indicationof inaccuracies in the TOT, N1, orOAT indicating systems or anerroneous baseline and shouldbe investigated and corrected.(Far example, a HIT indication of– 15 degrees could mean that theindicating systems may bedisplaying a lower value than theactual present value. Given thisexample, if the engine isoperated at or near an N1 orTOT limit, it may well beoperating beyond limitationswhile indicating to the pilotoperations within publishedlimits.)

1-156 Change 11

TM 55-2840-231-23

1-72. Health Indicator Test (HIT) - Continued

Change 11 1-157

TM 55-2340-231-23


1-158 Change 13

TM 55-2840-231-23

AIRFRAME/ Continued


g. Read TOT fromindicator. Record TOTbeside the circle OAT.

h. Apply the TOTCorrection Factor incolumn three adjacentthe circled OAT to

to

indicated TOT and recordthe result in the openspace in column four.

i. Apply the TOTB

Correction Factor incolumn five to the TOT incolumn four. Recordsresults of calculations foreach of the OAT/N 1combinations shown incolumn six.

j. Enter baselineinformation in therespective columns of theHIT TOT Log.

k. The HIT TOT Logshould be placed in thelog book where pilots canutilize it in accordancewith applicable – 10manual directions. TheHIT TOT Work Sheetshould be retained withthe engine HistoricalRecords and discardedonly after the completionof the next successive HITTOT Baseline. Thecurrent HIT TOT Log andWork Sheet shouldaccompany the HistoricalRecords when the engineis removed for any reason.

Change 11 1-158.1

TM 55-2840-231-23


AIRFRAME/-Continued

3. Adjust the HITBaseline TOT value.

Baseline TOT Values will be adjusted, rather a. Perform threethan establishing a new baseline, when successive Healthreverse flow fairings are removed/installed. Indicator Test (HIT)An engine performance check is not required Checks in accordancefor a baseline adjustment. with HIT TOT Log

instructions, immediatelyprior to and after reverseflow fairing inletinstallation/removal.

b. Adiust the baselineTOT values on the HITTOT Log to reflect thedifference in HIT.

c. Check readings. Forexample:

(1) The HIT Checkafter installation ofreverse flow fairings isthree degrees C TOThigher than before theinstallation. Add threedegrees to each of theBaseline TOT values ofthe original HIT Log andenter the adjusted TOTvalues on the ReverseFlow Inlet TOT BaselineWork Sheet.

(2) Transcribe the TOTvalues from the worksheet to the new HIT TOTLog (Reverse Flow InletsInstalled.) This HIT TOTLog now reflects TOTValues adjusted tocompensate for theinstallation of thefairings.

NOTE

The pilot will usewhichever HIT TOT Logis applicable at the time.

1-158.2 Change 11

TM 55-2840-231-23


AIRFRAME/Continued

4. Verify the HIT BaselineTOT values.

Verify Baseline HIT Values when correctiveaction is taken to bring the HIT TOT LogValue back in tolerance with Baseline TOTValues. [Refer to Troubleshooting ProcedureNo. 59. High Health Indicator Test (HIT)],verification of the Baseline TOT is required.

NOTE

If variations between actual TOT andBaseline TOT Values are withinacceptable tolerance, then theBaseline TOT Values are verified,

(3) Install both HITTOT Logs in the aircraftlogbook, and retain theAdjusted HIT TOT WorkSheet with the enginehistorical records. Discardonly after the completionof the next successive HITTOT Baseline.

a. Perform a normal HITcheck in accordance withinstructions on the HITLog.

b. Compare actual HITTOT Value with BaselineHIT TOT Value.

c. If variations are notacceptable, perform anEngine PerformanceCheck to ensure properengine operationlhealthand establish a new HITTOT Baseline.

Change 11 1-158.3/(1-158.4 blank)

TM

55-2840-231-23

Change 131-159

TM

55-2840-231-23

1-160C

hange 11

Pages 1-161 and 1-162 have been deleted.

TM 55-2840-231-23

1-73. ENGINE PERFORMANCE CHECK

See Applicable Aircraft Maintenance Test Flight Manual (MTF)

Change 6 1-162.1/(1-162.2 blank)

TM 55-2840-231-23

CHAPTER 2

COMPRESSOR SECTION

This chapter contains procedures for the maintenance and preservation of the Compressor Section.Paragraphs following outline disassembly, inspection, repair, and additional requirements needed tomaintain the compressor section and related parts. Procedures requiring maintenance on the AviationIntermediate Maintenance ( AVIM ) level are specified and must be performed as such. Paragraphs in whichthe maintenance level is not specified shall be considered Aviation Unit Maintenance (AVUM) and may beperformed at this level or a higher level of maintenance.

Compressor Maintenance ProceduresCompressor - RemovalCompressor Cleaning to Restore Lost PerformanceBleed Valve Cleaning to Restore Lost Compressor PerformanceCompressor Cleaning to Remove Salt Walter ContaminationCompressor - InstallationCompressor - Preparation for Storage and ShipmentCompressor Front Support - InspectionCompressor Case Half - RemovalCompressor Case Half - CleaningCompressor Plastic Coating - InspectionCompressor Stator Vane - InspectionCompressor Case - RepairCompressor Rotor Blades - CleaningCompressor Rotor and Blades - InspectionCompressor Rotor and Blades - RepairCompressor Case Half - InstallationDiffuser Scroll - InspectionDiffuser Scroll - RepairDiffuser Vent Orifice SelectionCompressor - Removing From Shipping ContainerAdapter Spur Gearshaft - Inspection

2-1. COMPRESSOR MAINTENANCE PROCEDURES.

Page

2-12-22-82-14.12-152-172-262-332-342-362-36.12-36.32-372-482-482-562-642-652-66.12-682-742-76

Visually inspect all subassemblies and accessories removed from the engine compressor section. Checkfor loose or missing parts. Note any damage or excessive wear. Repair damaged parts when possible. Replacedamaged parts that cannot be repaired. Disassembly procedures provided enable required cleaning, inspec-tion, repair or replacement of compressor subassemblies and accessories.

During reassembly of the engine subassemblies and accessories discard all of the following parts andreplace with new parts:

Seals LockpinsGaskets LockwashersCotter Pins LockwireTabwashers Preformed Packing

Change 11 2-1

TM 55-2840-231-23

2-2. Compressor - Removal.

INITIAL SETUP

Applicable ConfigurationAu

Special ToolsTurnover Stand, Tool No. 6795579

ReferencesPara 1-32

TURNOVERSTAND/

Install the engine in the turnover stand, Rotate the engine to atool no. 6795579. Refer to para 1-32. vertical position in the

stand with the compressorup.

ENGINE/

1. Oil Supply Tubeand Scavenge Tube(13 and 27)

2. Discharge PressureSensing Tube (35)

3. Lockwire onJam Nut (36)

4. Jam Nut (36)

6. Pressure ProbeElbow (34)

Remove compressor oilsupply tube (13 ) andscavenge tube (27) betweenthe compressor front supportand the gearbox.

Remove discharge pressuresensing tube (35) byremoving attaching clamp(39), bolt (40) and nut(38), and removing tubebetween the diffuserscroll and the tee at thepower turbine governor.

Remove.

Loosen.

Remove from diffuserscroll.

2-2

TM 55-2840-231-23

2-2. Compressor - Removal - Continued

ENGINE/-Continued

Change 11 2 - 3

TM 55-2840-231-23

2-2.Compressor - Removal - Continued

ENGINE/-Continued

1. Deleted2. Auto Reignition Tube3. Bolt (2)4. Washers (2)5. Nut (2)6. Bleed Valve7. Bolt8. Gasket9. Washer

10. Nut11. Nut12. RH Anti-Icing Tube

15. Clamp (2)16. Anti-Icing Valve17. Jam Nut18. Preformed Packing19. LH Anti-Icing Tube20. Deleted21. Deleted22. Jam Nut23. Preformed Packing24. Deleted25. Deleted26. Deleted

29. Bolt (5)30. Washer30A. Shim31. Preformed Packing32. Preformed Packing33. Turbine-to-Compressor

Coupling34. Pressure Probe Elbow35. Pressure Sensing Tube36. Jam Nut37. Preformed Packing38. Nut

13. Oil Supply Tube 27. Scavenge Oil Tube 39. Clamp (2)14. Bolt 28. Pressure Probe Elbow 40. Bolt

7. Lockwire and Jam Nut(22)

8. Pressure Probe Elbow(28)

9. Preformed Packing (23)

ENGINE

10. Air Tube (2) This step applies only if enginereignition system installed.

Remove and loosen jamnut (22).

Remove.

Remove and discard.

has an auto Disconnect air tube (2) atbleed valve (6).

11. Deleted

12. Deleted

2-4 Change 11

TM 55-2840-231-23

2-2. Compressor - Removal - Continued

ENGINE/-Continued

13. Bleed Valve (6)

14. Gasket (8)

15. Anti-Icing Air Tubes(12, 19)

16. Lockwire on Jam Nut(17)

17. Anti-Icing Valve (16)

18. Preformed Packing(18)

19. Lockwire on Bolts (29)

20. Bolts (29), Washer (30)and Shim (30A)

21. Turbine-to-CompressorCoupling (33)

22. Preformed Packing(31, 32)

Remove three nuts (5, 10),washers (4, 9), and bolts(3, 7) and remove bleedvalve (6).

Remove and discard,

Remove between thecompressor front supportand the anti-icing airvalve (16 ). Remove clamp(15), bolt (14) and nut(11).

Remove and loosen jamnut (17).

Remove from diffuserscroll.

Remove and discard.

Remove.

Remove five bolts and onewasher retaining thecompressor to thegearbox. Lift thecompressor off the engine.Save shims found at thecompressor mountingpads for possible reuse.

Remove from the adapterspacer gearshaft.

Remove and discard.

Change 11 2 -5

TM 55-2840-231-23

2-3. Deleted.

Page 2-7, 2-8 deleted.

2-6 Change 11

TM 55-2840-231-23

2-4. Compressor Cleaning to Restore Lost Performance. This paragraph contain cleaning instructions for thecompressor. Use care in separating metals for cleaning. Observe the following general cleaning precautions.

NOTEB&B 3100 (MIL-C-85704,Type I) is the primary-cleaner for Army turbine engines and remains an ap-proved cleaner for locales where environmental re-strictions permit. Egine cleaners that conform toMIL-C-85704, Type II and Type IIA are also accept-able engine cleaners and meet EPA environmentalrequirements. continue use B&B 3100 where notrestricted. Where restrictions apply useMIL-C-85704, Type II and Type IIA cleaners. Approved Type II andType IIA cleaners shall be used inaccordance with the existing washing procedure. TypeIIA cleaners do not require dilution with water. Bothtypes of cleaners are less effective than Type I clean-ers. Therefore more frequent engine washes mayberequired to achieve Satisfactory results.

Drycleaning solvent/P-D-680, used to clean partsis potentially dangerous to personnel and property.Avoid repeated and prolonged skin contact. Avoidprolonged or repeated breathing of vapors. Do notuse near open flame or excessive heat. Flash pointof solvent is 100oF-138oF(38oC-59oC).

Petroleum solvent (item 1, Appendix D) is the cleaning solvent recommended for nonferrous parts.

Cleaners for stel will damage nonferous parts. Donot use rust preventives on magnesium and alumi-num parts.

Clean aluminum-coated steel parts with carbon removal compound (item 22, Appendix D). Rinse the part with wa-ter and dry with an air blast.

Clean steel parts with cresol base cleaning compound (item 23, Appendix D). Rinse the part thoroughly with hotwater. Coat parts with a compound of one part rust preventive (item 24, Appendix D) and three parts oil (item 25, Ap-pendix D).INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Methanol (item 47, Appendix D)

Water Soluble Cleaner (item 26. Appendix D)Special Tools Antiseize Compound (item 6, Appendix D)

Compressor Protector Kit, Tool No. 6798861 Lockwire (item 17, Appendix D)Type II and Type IIA Cleaners (items 55.56.57.

58, Appendix D)

ENGINE/1. Compressor

Allow the engine to cool for a minimumof 45 minutes prior to spraying thecompressor. Mandatory cooling periodis required to prevent warpage to inter-nal engine components.

Change 12 2-8.1/(2-8.2 blank)

TM 55-2840-231-23

2-4. Compressor Cleaning to Restore Lost Performance - Continued

ENGINE/ - Continued

Buildup of dirt in the compressor can result in aserious loss of engine power and performanceLost performance may be restored by flushing theinstalled engine with a water/solvent solution asfollows

Methanol is flammable; it should not beused if the ambient temperature isabove 4°C (40°F), its vapor is harmful;it could be fatal or cause blindness ifswallowed. Keep it away from openflame and avoid prolonged breathing ofthe vapor.

NOTE

Once the cleaning procedure is started, itmust be carried through to completionwithout delay. At ambient temperaturesbelow 4°C (40oF) and above -29°C(-20°F), use a 40 percent Methanol (item47, Appendix D), 60 percent water mix-ture in place of fresh water. The tempera-ture of the wash solution should not bebelow 4°C (40°F); ideally it should bebetween 21°C-26oC (70°F-80oF). Toavoid spraying concentrated Methanol,which is flammable, mix the solutionthoroughly.

Water soluble cleaner (item 26, Appendix D). Prepare two to fourquarts of cleaning

Type II and Type IIA (items 55,56, consisting of one part57,58, Appendix D). Cleaning compound to

four parts of clean waterdisstilled if available).

Do not substitute petroleum base sol-vent or jet fuel for recommended clean-ing compound. Compressor plastic lin-ing could be damaged.

Change 12 2-9

TM 55-2840-231-23

2-4. Compressor Cleaning to Restore Lost Performance-Continued

ENGINE/ - Continued

2. Anti-Icing Air Valve

3. Control Air and Bleed ValvePressure Sensing Tubes

Compressor Protector Kit, tool no. 6798861

2-10 Change 6

Retain the anti-icing airvalve in the closed position.Disconnect control air andbleed valve pressure sensingtubes (1 and 35, fig. on page2-19) at diffuser scrollpressure probes. Cap bothpressure probes and plug allopen Sensing lines. closebleed valve by movingplunger down with a pieceof safety wire through holeabove plunger and seeminginclosed position with blockof Compressor Protector Kit,fig. C-7.

TM 55-2840-231-23


ENGINE/-Continued

4. Burner Drain Valve Remove burner drainvalve from the drain porton outer combustion case.

Change 11 2-11

TM 55-2840-231-23


ENGINE/-Continued

5. Deleted

ENGINE/

6. Ignition System Deactivate the ignitionsystem by disconnectingpower lead to ignitionexciter or pull the IGNENG circuit breaker.(Refer to TM55-1520-228-10).

Do not exceed 10% N1 motoringspeed during the cleaning andrinsing cycles to prevent possibleblade damage and assureadequate rinse/cleaning at thebase of the blades. Do not injecta solid stream of fluid into thecompressor. Damage tocompressor could occur.

7. Compressor

2-12 Change 11

a. Spray cleaningsolution into compressorinlet using a pressuretype sprayer equippedwith a quick openingvalve while motoringengine without ignition.Start injection 3 secondsprior to starterengagement and injectsolution at the rate of onequart in 9 to 11 secondsuntil 2 to 4 quarts (1.9-3.81 ) have been utilized.

TM 55-2840-231-23


Change 11 2-13

TM 55-2840-231-23

2-4.

2-14 Change 13

TM 55-2840-231-23

2-4.1 Bleed Valve Cleaning to Restore Lost Compressor Performance. This paragraph contains cleaninginstructions for the bleed valve.

INITIAL SET UP

Applicable Configuration Consumable MaterialsP/N 6874979 only Lockwire (item 17, Appendix D).

Ultrasonic Cleaner SolventSpecial Tools (item 52, Appendix D).

Ultrasonic Cleaning Equipment Mineral Spirits (item 53, Appendix D).(If available) Sewing Thread (item 54, Appendix D).

Lubricating Oil (item 5, Appendix D).

ENGINE/

1. Compressor Bleed Valve

Change 11 2-14.1

TM 55-2840-231-23

2-4.1 Bleed Valve Cleaning to Restore Lost Compressor Performance - Continued

ENGINE/-Continued

Clean the bleed valvenozzle, filter, and jet asfollows:

a. Remove the air sensingline (1) from the bleedvalve elbow (2).

b. Remove the elbow (2)from the bleed valve.Discard the O-ring (4).

c. Remove the internalretaining ring (5) andseparate the filter (6)from the bleed valve.Replace the retainingring before assembly if itis damaged during theremoval operation.

d. Using a screwdriver,remove the jet (7) fromthe bleed valve,

Do not blow the jet dry. The smalljet can be easily lost ordamaged.

Mineral Spirits (item 53, Appendix D).

e. Clip the lockwire thenremove the nozzle (8) fromthe bleed valve.

f. Clean the nozzle, filterand jet ultrasonically inmineral spirits ifequipment is available. Ifultrasonic equipment isnot available, agitate theparts in a clean containerof mineral spirits. Use asoft bristle brush to cleanexposed surfaces.

2-14.2 Change 11

TM 55-2840-231-23


ENGINE/-Continued Sewing Thread (item 54, Appendix D) Insert a sewing threadthrough the jet hole. Slidethe jet back and forth onthe thread to remove film.Clean the nozzle in thesame manner.

NOTE

If the jet must be replaced, return thebleed valve to overhaul for partreplacement and recalibration of thevalve assembly.

Do not use a probe to removeparticles lodged in the jet ornozzle.

g. Inspect the jet and thenozzle using a flashlight.Place the part on thecenter of the lens so thelight can be seen throughthe hole. Reclean the partif any particles or coatingcan be seen.

h. Install the jet in thebleed valve. Tighten to8-12 lb in.

i. Place the filter in thebleed valve (skirt endfirst ). Secure with aninternal retaining ring.

Lockwire (item 17, Appendix D) . j. Install the nozzle in thebleed valve. Tghten to50-60 lb in. and securewith lockwire.

Change 11 2-14.3

TM 55-2840-231-23


ENGINE/-Continued



2-14.4 Change 11

k. Lubricate the O-ringand install it with theelbow on the bleed valve.Do not tighten the elbowiam nut at this time.

Failure to properly install, alignand torque fuel, oil and airfittings and tubes could result inan engine failure.

1. Position the elbow asrequired and install airsensing line. Tighten thecoupling nut to 80-120 in.lbs. T i g h t e n the jam nut to 55-80 in. lbs.

INITIAL SETUP


Special ToolsCompressor Protector CleaningK i t , T o o l N o . 6 7 9 8 8 6 1

2-5. Compressor Rinsing to Remove Salt Water Contamination

ReferencesPara 2-4

ENGINE/

Allow the engine to cool for aminimum of 45 minutes prior tospraying the compressor.Mandatory cooling period isrequired to prevent warpage tointernal engine components.

The compressor shall be rinsed if operatedwithin 200 miles of volcanic activity oroperated within ten miles of salt water.Rinsing shall be according to the followingprocedure as soon as practical after shutdownfollowing the last flight of the day.

Compressor Protector Cleaning Kit, Tool No.6798861.

1. Bleed Valve

2. Anti-Icing Valve

Do not exceed 10% N1 motoringspeed during the cleaning andrinsing cycles to prevent possibleblade damage and assureadequate rinse/cleaning at thebase of the blades. Do not inJecta solid stream of fluid into thecompressor. Damage tocompressor could occur.

TM 55-2840-231-23

Block bleed valve inclosed position using thecompressor protectorcleaning kit as shown inparagraph 2-4, it is notnecessary to remove anylines.

Insure that anti-icingvalve is in the closedposition.

Change 11 2-15

TM 55-2840-231-23

2 -5 . C o m p r e s s o r R i n s i n g t o R e m o v e S a l t W a t e r C o n t a m i n a t i o n - C o n t i n u e d

ENGINE-Continued3. Compressor Spray one pint to one

quart of clean water(distilled preferred) intocompressor inlet whilemotoring engine withoutignition. Start injection 3seconds prior to starterengagement anddisengage starter at 10%N1 speed. The sprayerused to inject watershould have a quickopening valve and anozzle which flows onequart of water in 9 to 11seconds. This flow rateshould allow the desiredquantity of water to beinjected by the time 10%N1 speed is attained.

NOTE

A common garden sprayer can beused provided the spray orifice issized to give the desired flow.

4. Bleed Valve

5. AIRFRAME

Remove block from bleedvalve.

Start and operate theengine for a minimum offive minutes. Operateengine anti-icing systemto purge water from thecompressor front support.Also. operate any aircraftsystems which usecompressor bleed air. Thedrying run should beperformed within 15minutes after wash cycle.

2-16 Change 11

TM 55-2840-231-23

2-6. Compressor - Installation

INITIAL SETUP


Antiseize Compound (item 6, Appendix D)Special Tools Lockwire (item 7, Appendix D)

Turnover Stand, Tool No. 6795579Engine Turning Adapter, Tool No. References

6799790 Para 1-63 thru 1-71Bleed Valve Tube, P/N 6873354

E N G I N E /

Use only chrome plated steel or un-plated steel tools for the disassemblyor reassembly procedures describedin this manual. The use of cadmiumon zinc plated tools is not permittedsince these platings are prone tochipping and flaking. Should thesechips enter the engine, they maycontaminate the lubrication system,ultimately clogging the filters orproduce intergranular attack onnickel or titanium base alloys atelevated temperatures.

1. Engine Turnover Stand 6795579. a. Install engine assem-bly in the turnoverstand.

b. Rotate engine instand to a vertical posi-tion with combustionsection on the bottom.

NOTE

Check to insure that the compressorand gearbox mounting flanges areclean and free of foreign materialwhich could cause misalinement.

Change 6 2-17

TM 55-2840-231-23

2-6. COMPRESSOR - INSTALLATION - Cont.

TURNOVER STAND/

2. Preformed Packing(31 and 32)


Lubricate with oil andinstall new preformedpackings (31 and 32) onadapter spur gearshaft andon compressor reardiffuser.

1. Deleted2. Auto Reignition Tube3. Bolt (2)4. Washers (2)5. Nut (2)6. Bleed Valve7. Bolt8. Gasket9. Washer

10. Nut11. Nut12. RH Anti-Icing Tube13. Oil Supply Tube14, Bolt

Prolonged contact with lubricating oil(item 5, Appendix D) may cause askin rash. Those areas of skin andclothing that come in contact withlubricating oil should be thoroughlywashed immediately. Enclosed areaswhere lubricating oil is used should beadequately ventilated to keep mistand fumes to a minimum.

15. Clamp (2) 29. Bolt (5)16. Anti-icing Valve17. Jam Nut18. Preformed Packing19. LH Anti-Icing Tube20. Deleted21. Deleted22. Jam Nut23. Preformed Packing24. Deleted25. Deleted26. Deleted27. Scavenge Oil Tube28. Pressure Probe Elbow

30. Washer30A. Shim31. Preformed Packing32. Preformed Packing33. Turbine-to-Compressor Coupling34. Pressure Probe Elbow35. CDP Sensing Tube36. Jam Nut37. Preformed Packing38. Nut39. Clamp (2)40. Bolt

2-18 Change 8

2-6

T M 5 5 - 2 8 4 0 - 2 3 1 - 2 3

Change 8 2-19

TM 55-2840-231-23

2-6. Compressor - Installation - Continued

ENGINE - Continued

3. Turbine-to-CompressorCoupling (33)

4. Compressor, Shims(30A)

Lubricating oil (item 5, Appendix D)

Do not attempt to turn the gasproducer gear train using aspeed wrench at the tachometerdrive pad. Side loads on thespeed wrench could crack thetachometer drive shaft.

Engine Turning Adapter, 6799790.

Lubricate with oil, theadapter spur gearshaftand-splines at-both endsof turbine-to-compressorcoupling (33).

Position turbine-to-compressor coupling (33) on adapter spurgearshaft. Determine thenumber of shims requiredfor compressorinstallation. The numberof .002 inch thick shimsrequired at each bolt holeis marked on the reardiffuser adjacent to thehole (1 requires one .002inch shim, 2 require two.002 inch shims, etc.)Compressor assemblieswithout these numbersshall be installed withoutshims. Place thecompressor on thegearbox with the requiredshims in place at the boltpads. Use engine turningadapter at starter-generator pad to turn thegas producer gear trainuntil it meshes withadapter spur gearshaft.

2-20 Change 11

TM 55-2840-231-23


Be sure the adapter spurgearshaft is in mesh with thegearbox mating gear beforetightening the compressorretaining bolts.

5. Bolts (29), Washer (30) Antiseize Compound (item 6, Appendix D) Apply antiseize compoundto five compressorattaching bolts (29 ).Attach compressor topower and accessorygearbox with five bolts(29) and one washer (30).The long bolt (29) andwasher (30) are installedfrom the rear at the topattaching position.Tighten bolts.

Change 11 2-20.1/(2-20.2 blank)

TM 55-2840-231-23


ENGINE/ - Continued

Lockwire (item 7, Appendix D).

6. Anti-Icing AirValve (16)

7. Anti-Icing AirTubes (12 and 19)

8. Anti-Icing AirValve Poppet Guide

Antiseize Compound (item 6, Appendix D).Lubricating Oil (item 5, Appendix D).

AntiSeize Compound (item 6, Appendix D).

Lockwire (item 7, Appendix D)

(29) to 70-85 in. lb (0.8 -1.0 kg/m) and securewith lockwire.

Apply antiseize com-pound to threads ofanti-icing air valve (16)and lubricating oil to anew preformed packing(18). Screw anti-icingair valve (16), withbacked-off jam nut (17)and new preformedpacking (18) into thediffuser scroll. Do nottighten the jam nut (17)at this time.

Apply antiseize tothreads; then installanti-icing air tubes (12and 19) between anti-icing air valve (16) andcompressor frontsupport, Tightencoupling nuts of tubes(12 and 19) to 150-200in. lb (1.7 -2.3 kg/m).Tighten anti-icing valvejam nut (17) to 100-150in. lb (1.2 -1.7 kg/m)and secure with lockwire.

Loosen the anti-icingair valve poppet guideand position the anti-icing valve lever as fol-lows with respect to theengine.

a. On the OH-6 helicop-ter, the lever shall extendupright and be parallelto vertical centerline ofengine.

2-21

TM 55-2840-231-23


ENGINE/ - Continued b. On the OH-58 heli-copter, the lever shallextend to the left (whenviewed from rear ofengine) and shall beparallel to horizontalcenterline of engine.

9. Lever

10. Pressure ProbeElbows (28 and 34)


Prolonged contact with lubricatingoil (item 5, Appendix D) may causea skin rash. Those areas of skin andclothing that come in contact withlubricating oil should be thoroughlywashed immediately. Enclosedareas where lubricating oil is usedshould be adequately ventilated tokeep mist and fumes to a minimum.

Antiseize Compound (item 6, Appendix D).


When lever is properlypositioned, tightenpoppet guide to 65-75 in. lb (0.7 -0.9 kg/m)and secure with lock-wire.

Apply antiseize com-pound to threads ofpressure probe elbows(28 and 34) and lubri-cant to preformedpackings (23 and 37).Screw pressure probeelbows (28 and 34),with backed-off jamnut (22 and 36) andpreformed packings (23and 37) into diffuserscroll. Do not tightenjam nuts (22 and 36)at this time.

2 - 2 2 Change 6

TM 55-2840-231-23


Change 13 2-23

TM 55-2840-231-23


2-24 Change 11

TM 55-2840-231-23


1-63 thru 1-71.

1-44.

Change 13 2-25

TM 55-2840-231-23

2-7. Compressor - Preparation for Storage and Shipment

INITIAL SETUP


Lubricating Oil (item 5, Appendix D)Water-Vapor-Proof Bag (item 2, Appendix D)Desiccant (item 8, Appendix D)Barrier Material (item 2, Appendix D)Cushioning Material (item 12, Appendix D)Cleated Plywood Box (item 46, Appendix D)Dehydrating Agent (item 8, Appendix D)

ReferencesPara 1-39, 2-11, 2-17, 2-20

The compressor assembly will be preparedfor storage and shipment in accordance withthe following instructions. These instructionsare based on the assumption that the assemblywill be stored or in transit or both for anindefinite period. Compression assemblies

that are to be stored at an AVIM level forshort periods of time, and no metal shippingor storage container is available, will be pre-pared for storage in accordance with actionitem 1 below. The compressor will then bestored in a clean dry area.

STORAGE ANDSHIPMENT/

The procedure prescribed for theremoval of the compressor fromthe container is listed in paragraph2-20.

1. Preparation ofCompressor

Prepare the compressorassembly for installationin the metal shipping andstorage container, MS63054-3, as follows:

2-26

TM 55-2840-231-23

2-7. Compressor - Preparation for Storage and Shipment - Continued

STORAGE ANDSHIPMENT/ -Continued

Do not use any preservatives ofany kind internally within the com-pressor assembly. Compressorplastic liner muld be damaged.

Drycleaning solvent, P-D-680, usedto clean parts is potentially dangerousto personnel and property. Avoidrepeated and prolonged skin contact.Avoid prolonged or repeated breathingof vapors. Do not use near openflame or excessive heat. Flash pointof solvent is 100°F - 138°F (38°C -5 90C).

Drycleaning solvent (item 1, Appendix D). a. Clean exterior of com-pressor assembly asnecessary with solvent.Air dry or dry with aclean lint-free cloth.Blow out all creviceswith dry, filtered, low-pressure compressedair. Touch up paintedareas when damaged inaccordance with para-graphs 2-11 and 2-17.Do not expose touchupareas to oil or cleaningsolvent for a minimumof 72 hours after appli-cation.

2-27

TM 55-2840-231-23



2-28

e. Install cover (12) oncompressor bleed valveflange.

f. Install shipping capsand plugs at the follow-ing locations. Tightenthreaded caps andplugs fingertight.

g. Complete and attachnecessary tags to com-pressor. Prepare neces-sary forms and recordsin accordance with para-graph 1-39 and place ina greaseproof envelope.

Prolonged contact with lubricatingoil (item 5, Appendix D) may causea skin rash. Those areas of skin andclothing that come in contact withlubricating oil should be thoroughlywashed immediately. Enclosed areaswhere lubricating oil is used should beadequately ventilated to keep mist andfumes to a minimum.

Lubricating Oil (item 5, Appendix D). b. Coat splines of adap-ter spur gearshaft withoil. Place cap (19) onthe adapter spur gear-shaft and install cover(20) on rear diffuserpilot diameter.

c. Place plugs (17) incompressor dischargeair tube bosses.

d. Install cover (24) oncompressor air inlet.

TM 55-2840-231-23



1. Top Cushion 7. Nut 13. Plug2. Bottom Cushion 8. Wire Seal 14. Cap3. Humidity Indicator Card 9. Cover 15. Plug4 . B o d y5. Bolt6. Locking Ring

10. Gasket 16. Plug11. Plastic Bag 17. Plug12. Cover 18. Plug

19. Cap20. Cover21. Plug22. Plug23. Cap24. Cover

2-29

TM 55-2840-231-23



Water-vapor-proof bag (item 2, Appendix D).

.

Desiccant (item 8, Appendix D).

IndexNo. Location

Front Support

23 Anti-Icing AirTube Fittings

23 Scavenge OilTube Fitting

14 Oil PressureReducer

Diffuser Scroll15 Anti-Icing Air

Valve MountingBoss

13 Bleed Valve Con-trol Air Boss

21 Fuel ControlAir Boss

16 & Aircraft Bleed22 Air Bosses

Rear Diffuser18 Compressor Seal

Vent Orifice

h. Place the compressorassembly in plastic bag(11) and fold top.Ventilate bag to allowfor circulation of air.

i. If a metal shippingcontainer is not avail-able, place compressorassembly in a water-vapor-proof bag andinsert 32 units of freshdry desiccant. Insulatedesiccant from assemblyby use of barrier mater-ial and heat seal the bag.Place compressor in acleated plywood box in

2-30

TM 55-2840-231-23



accordance with para-graph 2-7, location/item 4.

2. Preparation ofMetal ShippingContainer

3. Installation ofCompressor IntoMetal ShippingContainer - -

a. Loosen nut (7) andremove ring (6), cover(9), gasket (10), andtop cushion (1) frombody (4).

b. Check gasket (10) fordamage or deteriorationand replace if necessary.

c. Check container forcleanliness and generalcondition.

a. Insert compressor as-sembly into container,aft end down. Insurethat it is properlyseated in the bottomcushion (2).

b. Install top cushion(1) in container. Insurethat it is properlyseated over the com-pressor.

Dehydrating Agent (item 8, Appendix D). c. Place two bags of de-hydrating agent in thevoids on each side oftop cushion (1) -- onebag per side.

d. Place compressor as-sembly records in oneof the voids at the sideof the top and bottomcushions. Tape thethree-spot humidity indi-cator card (3) on theside of top cushion.

2-31

TM 55-2840-231-23TM 55-2840-231-23

2-7. Compressor - Preparation for Shipping and Storage - Continued


e. Place gasket (10) oncover (9). Install coveron body (4) and securewith ring (6).

f. Slowly tighten nut(7) while tapping onlocking ring until 65-75 in. lb (0.7 -0.9kg/m) torque is ob-tained. Secure nut withwire seal (8).

4 . Instal lat ion of Cushioning Material (item 12, Appendix D). a. Insert two inches ofCompressor Into Cleated Plywood Box (item 46, Appendix cushioning materialCleated Plywood D). into the bottom of aContainer cleated plywood box.

Wrap compressor withapproximately two inchesof cushioning materialand carefully insertassembly into plywoodbox, aft end down.Make certain assemblyis held firmly by thecushioning material andthat all voids are filled.

b. Install a minimum oftwo inches of cushion-ing material on top ofthe assembly.

c. Insert the compressorrecord envelope andsecure lid of box.

5. ContainerStenciling

Stenciling of containerwill be in accordancewith paragraph 1-39 andthe following figure.

2-32

TM 55-2840-231-23



2-33

TM 55-2840-231-23

2-9. Compressor Case Half -Removal

INITIAL SETUP


ReferencesPara 2-8, 2-9, 2-10.1, 2-10.2, 2-12, 2-14, 9-4 thru 9-8

ENGINE/

Remove only one case half at atime. DO NOT remove both casehalves at the same time. Frontsupport could be misaligned.Insure that the removed case halfis properly reinstalled and thatthe bolts are tightened to therequired torque values before anyof the bolts on the other case halfare loosened. (Refer toparagraph 2-12.)

1, Compressor Case HalfRemoval

One compressor case half may be removed toinspect the rotor blades, stator vanes, plasticcoating, and front support welds. (Refer toparagraphs 2-8, 2-9, 2-10.1, 2-10.2, and 2-14. )Removal of compressor case half isauthorized only as a last resort to determinethe cause of low engine performance or whenforeign object damage (FOD) is suspected.Before removing the case half insure that lowengine performance is not caused by adefective bleed valve or anti-icing valve,leaking scroll-to-rear diffuser seal orcompressor discharge air tube seals, or adirty compressor. Removal of the compressorcase and inspection in accordance withparagraphs 2-8, 2-9, 2-10.1, 2-10.2 and 2-14,will be accomplished every 24 months or 300hours, whichever comes first.

a. Remove the compressorbleed valve. (Refer toparagraph 9-4 thru 9-8. )

b. Remove the anti-icingair tubes between theanti-icing air valve andthe compressor frontsupport. (Refer to para9-4.)

c. Mark the location ofnameplate (6) when theapplicable compressorcase half-to-front supportbolts (3) are to beremoved. This is to insurethat the nameplate willbe returned to the samelocation at assembly.

2-34 Change 11

TM 55-2840-231-23

2-9. Compressor Case Half - Removal - Continued

ENGINE/ - Continued

ANTI-ICINGAIR TUBE

d. Remove one compressorcase half (2) by removing16 horizontal splitline nuts(8) and bolts (1), five casehalf-to-front support nuts(5) and bolts (3), and eightcase half-to-front diffusernuts (7) and bolts (4). Liftthe case half straight out.

1. Bolt (16)2. Compressor Case Half (2)3. Bolt (10)4. Bolt (16)5. Nut (10)6. Nameplate7. Nut (16)8. Nut (16)

Change 11 2-35

TM 55-2840-231-23

2-9. Compressor Case Half - Cleaning

INITIAL SETUP


All

COMPRESSOR/

1. Compressor Case Half Drycleaning Solvent (item 1, Appendix D).

2-36

TM 55-2840-231-23

2-10.1 Compressor Plastic Coating - Inspection

INITIAL SETUP

Applicable Configuration ReferencesAll Para 2-9, 2-12

COMPRESSOR/

1. Compressor case

Remove only one case half at atime. DO NOT remove both casehalves at the same time. Frontsupport could be misaligned.Insure that the removed case halfis properly reinstalled and thatthe bolts are tightened to therequired torque values before anyof the bolts on the other case halfare loosened. (Refer toparagraph 2-12.)

NOTE

Visually inspect the plastic coating ofboth compressor case halves for thereasons stated in para 2-9.

Visually inspect the compressor caseplastic coating for the followingconditions. Loss of plastic can have anadverse effect on compressorperformance and is a justified reasonfor replacement of the case on lowperformance engines.

a. If any crack along thehorizontal splitline is inexcess of 1/2 inch, replacecompressor halves.

b. Cracks are acceptablewithout limitation as tolength, quantities, orareas provided the plasticis securely bonded to thecase.

Change 11 2-36.1

TM 55-2840-231-23

2-10.1 Compressor Plastic Coating - Inspection - Continued

COMPRESSOR/-Continued

c. If more than 50 percentof the plastic is missing/debonded betweenadjacent vanes in stagesfive and six, or if 25percent of the plastic ismissing/debondedbetween adjacent vanes in -

stages one thru four,replace compressor casehalves.

d. Debonding and/or lossof plastic in the bladepath areas is notacceptable. Replacecompressor case halves.

e. Evidence of heatdiscoloration on any rotorblade tip is not -

acceptable. Replacecompressor case assembly.

f. Erosion of the plasticcoating is acceptableunless any portion of anysingle half-case vaneband (metal) can be seen.Replace compressor casehalves if any portion ofany single half case vaneband (metal) can be seen.Erosion patterns areshown in the adjacentfigure.

2-36.2 Change 11

TM 55-2840-231-23

2-10.2 Compressor Stator Vane - Inspection

INITIAL SETUP

Applicable Configuration ReferencesAll Para 2-9 and 2-11

COMPRESSOR/

1. Stator Vanes Visually inspect compressor stator vanes for Replace compressorthe following conditions. assembly if any of the

stator vanes are missingor if a vane tip has

NOTE rubbed.

This inspection requires removal of acompressor case half and shall beperformed only for the reasons statedin paragraph 2-9.

NOTE

If FOD is detected refer to paragraph1-44.

2. Stator Vanes

3. Vane Tips

4. Vanes

5. Vanes (stages 3 through6)

Inspect for cracked ormissing stator vanes -none are permitted.

Rub is indicated by smeared metal on the Inspect vane tips forvane tip associated with a burr on the convex evidence of rub. None areside or by heat discoloration on the vane. permitted. Replace the

compressor if rub isindicated.

Refer to paragraph 2-11.Inspect for evidence ofcorrosion on the vanes.There must be noevidence of pitting onouter one-half of thevane. After polishing toremove corrosion, pittingin any area of the vanethat forms a definite lineis not acceptable.

Inspect for erosion on theairfoil surface in vanestages 3 through 6. Themajor thickness of theairfoil must not be lessthan 0.020 in. (0.051 cm).

Change 11 2-36.3

PARA 2-10.2

TM 55-2840-231-23

2-10.2 Compressor Stator Vane - Inspection - Continued


6. Vane Leading andTrailing Edges

Refer to paragraph 2-11. Inspect for nicks, dents,and erosion on the vaneleading and trailingedges. All damage andimperfections must beblended out. Blendedleading and trailingedges must not exceedlimits shown in thefollowing figures.

2 - 3 6 . 4 Change 11

TM 55-2840-231-23


SCALLOP BLENDING ON OUTER 1/2 OF VANE LE ANDTE IS NOT PERMITTED, ONLY ONE SCALLOP BLENDPER VANE IS PERMITTED,

TYPICAL SCALLOP BLENDING OF A NICK OR DENTON THE INNER 1/2 OF THE VANE LEADING EDGE ISSHOWN THIS IS ALSO APPLICABLE TO THE TE, BUTNOT BOTH LE AND TE.

AFTER STRAIGHT LINE BLENDING. SCALLOP BLENDLE AND TE AS SHOWN TO REMOVE MAJOR NICKSAND DENTS. USE A FINE STONE. LE AND TE RADIIMUST BE MAINTAINED. FINAL BLENDING ANDPOLISHING MUST BE IN A LONGITUDINAL DIRECTION.

Change 11 2-36.5

TM 55-2840-231-23



AIRFOIL SURFACE NICKS AND DENTS

OUTER 1/2 OF VANE

MAX DEPTH OF 1/4 AIRFOIL THICKNESS AFTERBLEND. MAINTAIN 3/64 IN. (1.2 MM) MIN BOTTOMRADIUS ON ALL BLENDING. MAX OF TWOBLENDS PER VANE AND BLENDS MUST NOTBE IN LINE PARALLEL WITH CASE CENTERLINE.

7. Vane Airfoil Surface Refer to paragraph 2-11.

8. Vanes

2-36.6 Change 11

INNER 1/2 OF VANE

MAX DEPTH OF 112 AIRFOIL THICKNESS AFTERBLENDING. MAINTAIN 3/64 IN. (1.2 MM) MINBOTTOM RADIUS ON ALL BLENDING. BLENDSMUST NOT BE IN LINE PARALLEL WITH CASECENTER LINE.

Inspect for nicks anddents on vane airfoilsurface. All damage andimperfections must beblended out. Blended areamust be within the limitsshown in figure above.

Inspect for bent vanes.Bent vanes are notacceptable. Replacecompressor case halvesand inspect rotor.

TM 55-2840-231-23

2-11. Compressor Case - Repair

INITIAL SETUP


Consumable MaterialsAbrasive Paper (item 27, Appendix D)Emery Cloth (item 28, Appendix D)Paint Thinner (item 29, Appendix D)Gray Corrosion Resistant Paint (item 30, Appendix D)Trichloroethylene (item 13, Appendix D)Methylethylketone (item 32, Appendix D)Acetone (item 39, Appendix D)Sermetal Paint (item 44, Appendix D)

ReferencesPara 2-10.2

COMPRESSOR/-

1. Case Repair of the compressor case consists ofblending and polishing to remove nicks,dents, corrosion, and erosion from the statorvanes. Where blending is recommended, usea medium grit stone. Where polishing isrecommended, use a fine grit stone orabrasive paper (item 27, Appendix D). Blendand polish vanes in a longitudinal directiononly with the repair forming a smooth blendwith the basic airfoil. No sharp edges, burrs,cracks, or tears are acceptable afterblending.

NOTE

It is impossible to fully describe alldamage conditions that can beencountered. If damage is within therepair limits of the following figuresbut there is reasonable doubt aboutthe strength of the blended vanes,replace the compressor case halves.Unlimited light polishing to removeminor damage, where vanedimensions are basically unchanged,is permissible on any part of thevane.

Change 11 2-37

TM 55-2840-231-23

2-11. Compressor Case - Repair - Continued


2. Corrosion Removal

3. Vane Surface BlendRepair

Abrasive Paper (item 27, Appendix D) Remove corrosion depositsfrom the stator vanes bypolishing with abrasivepaper. Polish vanes in alongitudinal directiononly. Blending to removecorrosion pitting is notrequired. Pitting must notexceed the limits ofparagraph 2-10.2.

Blend out nicks, dents,and scratches on theairfoil surface. Finalpolish to remove blendingmarks. Blended areasmust be within the limitsshown below. No vane

OUTER 1/2 OF VANE

AIRFOIL SURFACE NICKS AND DENTS

MAX DEPTH OF 1/4 AIRFOIL THICKNESS AFTERBLEND. MAINTAIN 3/64 IN. (1.2 MM) MIN BOTTOMRADIUS ON ALL BLENDING. MAX OF TWOBLENDS PER VANE AND BLENDS MUST NOTBE IN LINE PARALLEL WITH CASE CENTER

straightening allowed.

INNER 1/2 OF VANE

MAX DEPTH OF 1/2 AIRFOIL THICKNESS AFTER -

BLENDING. MAINTAIN 3/64 IN. (1.2 MM) MINBOTTOM RADIUS ON ALL BLENDING. BLENDSMUST NOT BE IN LINE PARALLEL WITH CASECENTER LINE.

LINE.

2-38 Change 11

PARA 2-10.2

Page 2-40

TM 55-2840-231-23



4. Vane Leading and a. Straight-line blend theTrailing Edges Blend leading and trailingRepair edges to remove minor

erosion, nicks, and dentson the outer one-half of the vane. (See thefollowing figure.)

b. The chordal width onstraight-line blendedvanes must be within thelimits specified.

Change 11 2-39/(2-40blank)

TM 55-2840-231-23



SCALLOP BLENDING ON OUTER 1/2 OF VANE LE AND

TE IS NOT PERMITTED. ONLY ONE SCALLOP BLEND

PER VANE IS PERMITTED.

TYPICAL SCALLOP BLENDING OF A NICK OR DENTON THE INNER 1/2 OF THE VANE LEADING EDGE IS SHOWN. THIS ALSO APPLICABLE TO THE TE, BUT N O T B O T H L E A N D T E .

AFTER STRAIGHT LINE BLENDING, SCALLOP BLENDLE AND TE AS SHOWN TO REMOVE MAJOR NICKSAND DENTS. USE A FINE STONE. LE AND TE RADIIMUST BE MAINTAINED. FINAL BLENDING AND POLISHING MUST BE IN A LONGITUDINAL DIRECTION.

Change 11 2-41

36.4

TM 55-2840-231-23



5. Vanes Two chordal width gagesnecessary to measurechordal width on straight-line blended vanes isshown in the followingfigure, and may be locallyfabricated to facilitatechecking chordal width.

2-42 Change 11

TM 55-2840-231-23


COMPRESSOR/ -Continued

6. Compressor Compressor cases which are painted withCase Painting gray corrosion resistant paint (item 30,

Appendix D) have a glossy, light gray finish.Compressor cases which are painted withSex’metal paint (item 44, Appendix D) havea dull, gray matte finish and appear to beunpainted.

Emery Cloth (item 28, Appendix D).

Paint Thinner (item 29, Appendix D).

Gray Corrosion Resistant Paint (item 30,Appendix D).

Trichloroethylene, Methylethylketone,or Acetone (items 13, 32, or 39, AppendixD).

Emery Cloth (item 28, Appendix D),

a. The compressor caseexternal surface may bepainted with eithergray, corrosion resistantpaint or Sermetal paint.

b. Repair damaged painton the external surfaceof the compressor caseas follows:

c. Gray, corrosion resis-tant paint.

(1) Abrade the damagedarea and localized sur-rounding area withemery cloth.

(2) Wipe abraded areawith paint thinner.

(3) Apply gray corrosionresistant paint to theabraded area.

(4) Air dry at least onehour before handling.

d. Sermetal paint.

(1)Thoroughly cleanthe damaged area witha clean cloth saturatedwith tnchloroethylene,methylethylketone, oracetone, or othersuitable solvent.

(2) Air dry for 5-10minutes.

(3) Using emery clothabrade an area slightlylarger than the damagedarea. Feather the edgesof the abraded area.

2-43

TM 55-2840-231-23


ContinuedCOMPRESSOR/-

Use approved personnel protective equipmentto protect eyes and face when usingcompressed air. Maximum allowable airpressure for cleaning operations is 30 psi. Donot direct air stream towords yourself ortoward another person.

(4) Clean the abradedarea as in step ( 1 ) and dryusing a blast of clean,compressed air.

Sermetal Point (item 44, Appendix D).

2-12. Deleted.

2-44 Change 11

Pages 2-45, 2-46 and 2-47 deleted.

(5) Apply Sermetal paintto the abraded area andair dry for at least onehour.

TM 55-2840-231-23

2-12. Compressor Case Half - Installation - Continued


The compressor case halves are amatched set and shall not be inter-mixed. If the removed case halfcannot be repaired to a serviceablecondition, replace the compressorassembly.

2-45

TM 55-2840-231-23

2-12. Compressor Case Half - Installation - Continued


1. CompressorCase Half (2)

a. Position compressorcase half in place onthe compressor.

b. Install eight bolts (l),and nuts (8) in eachhorizontal splitline.Bolt at positions twoand seven are pilotbolts. Tighten nutson the pilot bolts to10-15 in. lb (0.1 -0.2 kg/m) plus lock-nut drag; then tightenthe remaining nuts.

NOTE

To determine locknut drag, run the nutup snug; then back off one-half turn.The torque required to first turn theloosened nut is locknut drag.

c. Install eight case-to-front diffuser bolts (4)and nuts (7). Tightenthe nuts to 10-15 in. lb(0.1 -0.2 kg/m) pluslocknut drag.

d. Install nameplate (6)(if applicable) and fivecase-to-front supportbolts (3) and nuts (5).Tighten the nuts to10-15 in. lb (0.1 -0.2kg/m) plus locknut drag.

2-46

2-48

TM 55-2840-231-23

2-13. Compressor Rotor Blades - Cleaning.

INITIAL SETUP

Applicable ConjurationALL

Consumable MaterialsWater Soluble cleaner (item 26, Appendix D)Type II and Type IIA Cleaners (items 55, 56,

57, 58, AppendixD)

COMPRESSOR/-Rotor Blades Water Soluble Cleaner (item 26, Appendix D)

Type II and Type IIA Cleaners (items 55, 56, 57,58, App D).

NOTEB&B 3100 (ML-C-85704, Type I) is theprimary cleaner for Army turbine enginesand remains an approved cleaners for lo-cales where environmental restrictionspermit Engine cleaners that conform toMIL-C-85704, Type II and Type IIA arealso acceptable engine cleaners and meet

ue use of B&B 3100 where not restrictedWhere restrictions apply useMIL-C-85704,Type II and Type IIAcleaners. Approped Type II and type IIAcleaners shall be used in accordance withthe existing washing procedure. Type IIAcleaners do not require dilution with wa-ter. Both types of cleaners are lease effec-tive than Type I cleaners. Therefore morefrequent engine washes may be requiredto achieve satisfactory results.

Change 12

With one compessor casehalf rernoved, cleancontamination from theblades using a toothbrush and a solution ofone part cleaningcompound to four partsof clean water (distilledif possible).

EPA environmental requirements. Contin-

TM 55-2840-231-22

2-14. Compressor Rotor and Blades - InspectionINITIAL SETUP

Applicable Configuration Consumable MaterialsAll Paras 2-9 and 2-15

COMPRESSOR/

l. Rotor and Blades NOTE

If FOD is detected refer to paragraph1-44.

NOTE

This inspection requires removal of acompressor case half and shall be per-formed only for the reasons stated inparagraph 2-9.

2. Blades

Visually inspect thecompressor and bladesfor the following connditions.Replace compressor assemblyif any of the limits areexceeded

Inspect for cracked or missingcompresstor blades -none arepermitted

Change 12 2-48.1/(2-48.2 blank)

TM 55-2840-231-23

2-14. Compressor Rotor and Blades - Inspection - Continued


3. Rotor Blades and Wheel a. Visually inspect theHubs compressor rotor and

blades. Replacecompressor assembly ifany of the followinglimits are exceeded.

b. Inspect for cracked ormissing compressorblades. None permitted.Replace engine if blade(s)is missing. Replacecompressor assembly ifblade is cracked.

c. Inspect compressorrotor blades and wheelhubs for evidence ofcorrosion. Corrosion onthe outer 2/3 of the blademust be removed byblending and polishing.

NOTE

Minor surface corrosion on the inner

Change 11 2-49

TM 55-2840-231-23


COMPRESSOR/- NOTEContinued Obvious heat discoloration is defined

as any shade of blueing which can notbe rubbed off with a pencil eraser.

4. Blade Tips

5. Rotor Blades and Wheel Refer to paragraph 2-15.Hubs

Change 11

Inspect blade tips for heatdiscoloration on one ormore blades. Heatdiscoloration is caused bysevere blade rub on thecompressor case plasticlining which occurs whenthe wheels shift off centerdue to an unbalancecondition. Replacecompressor assembly ifheat discoloration isdetected.

Inspect compressor rotorblades and wheel hubs fornicks, dents and scratchesin areas other than theblade leading and trailingedges. All damages andimperfections must beblended out. Blendedareas must not exceed thelimits shown in thefollowing figure.

2 - 5 0

TM 55-2840-231-23



2-51

TM 55-2840-231-23



6. Blade Leading and Refer to paragraph 2-16. Inspect for nicks, dentsTrailing Edges and erosion on the blade

leading and trailingedges and at the blade tip.All damage andimperfection must beblended out. Blendedleading and trailingedges and chamferedblade tips must not exceedthe limits shown in thefollowing figures.

2-52 Change 11

TM 55-2840-231-23


Change 11 2-53

TM 55-2840-231-23

2-14. Compressor Rotor and Blades -Inspection - Continued


2-54 Change 11

PARAS 2-2

TM 55-2840-231-23



Change 11 2-55

TM 55-2840-231-23



7. Blade Tips and LeadingE d g e s

2-15. Compressor

INITIAL SETUP

Loose plastic rub is a result of the compressorcase plastic lining coming loose anddisplacing inward wearing away portions ofall blades in a given stage. Loose plastic rubis evidenced as a chamfer at the leading edgeor trailing edge tip, or an undercut of theblade leading edge. See the following figure.

Rotor and Blades - Repair


2-56 Change 11

Inspect blade tips andleading edges for evidenceof loose plastic rub on allblades in a given stage.Replace compressorassembly if rub is severeenough to cause obviousheat discoloration.

Consumable MaterialsAbrasive Paper (item 27, Appendix D)

ReferencesPara 2-2, 2-6, 2-13, 2-14

TM 55-2840-231-23

2-15. Compressor Rotor and Blades - Repair - Continued

COMPRESSOR/

1. Rotor and Blades Repair of compressor rotor and blades con-sists of blending and polishing to removenicks, dents, scratches, corrosion, or erosionfrom blades, blade fillets and wheel hubs.Where blending is recommended, use a No.0 Swiss pattern file or a medium grit stone.Where polishing is recommended, use a finegrit stone or abrasive paper (item 27, Appen-dix D). Blend and polish blades in a longi-tudinal direction only with the repair forming a smooth blend with the basic airfoil.No sharp edges, burrs, cracks, or tears areacceptable after blending.

NOTE

It is impossible to fully describe alldarnage conditions that can be en-countered. If damage is within therepair limits shown in the followingfigures but there is reasonable doubtabout the strength of the blendedblade, replace the compressor as-sembly. Unlimited light polishingto remove minor damage, whereblade dimensions are basically un-changed, is permissible on any partof the blade.

2. Hub and FilletBlend Repair

3. Blade SurfaceBlend Repair

Blend out nicks, dentsand scratches on thecompressor wheel huband blade fillets. Finalpolish to removeblending marks. Blendedareas must be within thelimits shown in the fol-lowing figures.

Blend out nicks, dents,and scratches on theairfoil surface (surfaceB). Final polish toremove blending marks.Blended areas must bewithin the limits shownin the following figure.

2-57

TM 55-2840-231-23



2-58 Change 11

TM 55-2840-231-23



4. Blade Leading andTrailing Edges BlendRepair

The chordal width on straight-line and Blend-repair as follows:chamfer blended blades must be within thelimits specified in the following two figures. a. Straight-line blend

the leading and trailingedges to remove erosionand minor nicks anddents, Refer to thefollowrng figure forlimits.

b. Chamfer blend toremove any remainingdamage at the blade tip.Refer to the followingfigures for limits.

c. Scallop blend to removeany remaining damage onthe outer one-half of theblade leading and trailingedges. Refer to thefollowing figures forlimits.

Change 11 2-59

TM 55-2840-231-23



2-60 Change 11

TM 55-2840-231-23

2-15. Compressor Rotor and Blades - Repair -Continued


Change 11 2-61

PARAS 2-2

TM 55-2840-231-23


C O M P R E S S O R / -Continued

2-62 Change 11

TM 55-2840-231-23


b. Remove corrosion stainson the inner 1/3 of theblades by cleaning in ac-cordance with paragraph2-13. Do not remove orpolish metal on the inner1/3 of the blades. Pittingmust not exceed the limitsshown in paragraph 2-14,item 3.

6. Hub and Fillet Blend Repair

7. Blade Surface Blend Repair

8. Blade Leading and TrailingEdges Blend Repair

Blend out nicks, dents, andscratches on compressorwheel hub and plate filletsFinal polish to removeblending marks. Blendedareas must be within limitsshown in item 3 above.

Blend out nicks, dents, andscratches on the airfoil sur-face(surfsce B, item3above). Final polish to re-move blending marks.Blended areas must bewithin limits shown in item3, above.

Straight-line blend lead-ing and trailing edges to re-move erosion and minornicks and dents (see figurein item 4 above).

Change 11 2-63

TM 55-2840-231-23

2-15.1 Compressor Case Half - Installation.

COMPRESSOR/


Sealant (item 51, Appendix D)

References

Paras 9-6 thru 9-8

2-64 Change 13

TM 55-2840-231-23

2-15.1 Compresor Case Half - Installation - Continued


The compressor case halves are amatched set and shall not beintermixed, If any removed casehalf cannot be repaired to aserviceable condition, replaceboth compressor case halves.

Change 11 2-64.1

TM 55-2840-231-23

2-15.1 CompressorCase Half - Installation - Continued


1. Compressor Case Half(2)

a. Position compressorcase half in place on thecompressor.

b. Install eight bolts(l),and nuts (8) in eachhorizontal splitline. Boltat positions two and sevenare pilot bolts. Tightennuts on the pilot bolts to10-15 in. lb (0.1-0.2 kg/m)plus locknut drag; thentighten the remainingnuts.

NOTE

To determine locknut drag, run thenut up snug; then back off one-halfturn. The torque required to first turnthe loosened nut is locknut drag.

NOTE

When installing the first case half,apply a thin coat of sealant (item 51,Appendix D) to the vertical splitlines.When installing the second case half,apply a thin coat of sealant to thevertical and horizontal splitlines andimmediately proceed to securecompressor half before sealant cures.

c. Install eight case-to-front diffuser bolts (4)and nuts (7). Tighten thenuts to 10-15 in. lb (O.l-0.2 kg/m) plus locknutdrag.

d. Install nameplate (6) (ifapplicable ) and five case-to-front support bolts (3)and nuts (5). Tighten thenuts to 10-15 in. lb (0.1-0.2 kg/m) plus locknutdrag.

2 -64 .2 Change 11

TM 55-2840-231-23

2-15.1 Compressor Case Half - Installation - Continued


NOTE

NOTE

When installing the first casehalf, apply a thin coat of sealant(item 51, Appendix D)to the vertical splitlines. Wheninstalling the second case half,apply a thin coat of sealant tothe vertical and horizontalsplitlines and immediatelyproceed to secure compressorhalf before sealant cures.

c. Deleted

d. Deleted

.

To determine locknut drag, runthe nut up snug; then back offone-half turn. The torquerequired to first turn theloosened nut is locknut drag.

Change 13 2-64.3

TM 55-2840-231-23

2-15.1 Compressor Case Half - Installation - Continued

e. Turn compressor rotorusing engine turningadapter at the startergenerator pad. The rotorand gear train should turnfreely with no evidence ofinterference or blade tiprub (evidenced by feel ornoise).

f. Install compressorbleed valve. Refer toParagraphs 9-6 thru 9-8.

g. Install anti-icing airtubes. Tighten couplingnuts to 150-200 in. lb(1.7-2.3 kg/m).

2 - 6 4 . 4 Change 13

TM 55-2840-231-23

2-16. Diffuser Scroll - Inspection

INITIAL SETUP


ReferencesPara 2-17

ENGINE/

The Scroll assembly, NSN 2840-00-244-1774, contains thorium, aradioactive material.Maintenance of this engine part islimited to replacement unlessother maintenance is specificallyauthorized and is covered by avalid US Nuclear RegulatoryCommission license.Nonrepairable Scroll assembliesmust be disposed of asradioactive waste in accordancewith AR 385-11.

1. Diffuser Scroll Visually inspect the installed diffuser scrollfor the following conditions. Replace thecompressor assembly if the damage cannot berepaired.

a. Inspect for visiblecracks. Replace thecompressor if cracks arefound.

b. Inspect for corrosionand paint damage; repairin accordance withparagraph 2-17.

c. Check the turningvanes in the outlet portsfor evidence of damage.Damage is indicative ofimpeller vane tip orshroud failure. Replacethe compressor.

Change 11 2-65

TM 55-2840-231-23

2-16. Diffuser Scroll - Inspection - Continued

ENGINE/-Continued

d. Inspect the diffuserscroll discharge air tubeinserts for wear andlooseness. If wear in theID of the insert exceeds0.010 in. (0.025 cm) depthor there is evidence thatthe insert has been pulledout of the scroll, replacethe compressor assembly.If insert wear does notexceed 0.010 in. (0.025cm) depth, blend andpolish per paragraph2-17.

2. Diffuser Vent Tube If a 3/8 in. diameter rod can be inserted into Inspect diffuser vent tubetube, it is acceptable, A gap not exceeding for distortion, 0.010 in.0.010 in. (0.025 cm) is acceptable. No cracks (0.025 cm) gap whereare permitted. Remove the tube if tube enters passage, andreplacement is required and replace per cracks.paragraph 2-17.

2-66 Change 11

TM 55-2840-231-23

2-17. Diffuser Scroll-Repair

INITIAL SETUP


Consumable MaterialsEmery Cloth (item 31, Appendix D)Methylethylketone (item 32, Appendix D)Cres Paint (item 34, Appendix D)Lacquer Reducer (item 35, Appendix D)Abrasive Paper (item 36, Appendix D)Lockwire (item 7, Appendix D)Aluminum Paint (item 33, Appendix D)

DIFFUSER SCROLL/

The Scroll assembly, NSN 2840-00-244-1774, contains thorium, aradioactive material.Maintenance of this engine part islimited to replacement unlessother maintenance is specificallyauthorized and is covered by avalid US Nuclear RegulatoryCommission license.Nonrepairable Scroll assembliesmust be disposed of asradioactive waste in accordancewith AR 385-11.

1. Corrosion Removal and Emery Cloth (item 31, Appendix D) a. Remove corrosion withPaint Repair emery cloth.

b. Abrade damaged areaswith emery cloth.

Change 11 2-66.1/(2-66.2 blank)

TM 55-2840-231-23

2-17. Diffuser Scroll - Repair - Continued

DIFFUSER SCROLL/ -Continued

2. Air Tube InsertBlend Repair

Methylethylketone (item 32, Appendix D).

Heat Resistant Aluminum Paint (item 33,Appendix D).Cres Paint (item 34, Appendix D).Lacquer Reducer (item 35, Appendix D).

Abrasive Paper (item 36, Appendix D).


c. Touchup damagedbichromate coating(abraded areas) bychrome pickle perMIL-M-3171.

d. Clean surface withmethylethylketoneand air dry 5 to 10minutes.

e. Touchup aluminumpainted scrolls withheat resistant alumi-num paint. Touchupspray-painted scrollswith two parts grayCres paint to onepart lacquer reducer byvolume.

f. Air dry at least onehour. Localized heatcuring is permissible.

a. Using abrasive paperblend and polish wearin the OD of the airtube inserts which doesnot exceed 0.010 in.(0.025 cm) depth.Blend and polish wearstep as necessary toinsure freedom ofmovement of the airtube seals and to insurethat the sealing proper-ties will not be im-paired.

b. Install a new tubeand secure with clamp,washer and screw.Secure the screw withlockwire.

Change 5 2-67

2-68

TM 55-2840-231-23

2-17. Diffuser Scroll - Repair - Continued

2-18. Diffuser Vent Orifice Selection

INITIAL SETUP


Consumable MaterialsLockwire (item 17, Appendix D)

ReferencesTable 1-10

NOTE

Diffuser orifice may be safetiedeither by starting at the top andending around the tube andending at the top.

New compressors should have a -2size orifice installed on the diffuservent tube. If the compressor hasnot been replaced, use the orificethat is presently installed on thevent tube.

TM 55-2840-231-23

2-18. Diffuser Vent Orifice Selection - Continued

Clean area around orifice.

Perform settings 7 through10 of the test run schedulein table 1-10.

After the test run, inspectthe area around the orifice.If there is any evidence ofsmoking or spewing fromthe vent, reduce the orificesize by installing the nextlower dash number orifice.(See figure.) Secure theorifice with lockwire (item17, Appendix D),

Repeat the run, inspection,and orifice replacementuntil no evidence of spew-ing or smoking is present.

2-69

TM 55-2840-231-23

2-19. Deleted.

Pages 2-71 through 2-73 deleted.

2-70 Change 11

TM 55-2840-231-23

2-20. Compressor - Removing From Shipping Container

INITIAL SETUP


COMPRESSOR NOTESHIPPING CONTAINER/ Before removing the compressor from

the shipping container, inspect for. . -evidence of rough handling ortampering.

1. Compressor a. Remove wire seal (8),and loosen nut (7) andremove ring (6), cover (9),and gasket (10 ) and bolt(5).

b. Note the condition ofthe humidity indicator(3).

c. Remove compressorassembly records anddehydrating agent fromvoids on each side of thetop cushion (1).

d. Remove top cushion (1).

e. Remove compressorfrom the container body(4) and bottom cushion(2).

f. Remove the compressorfrom plastic bag (11 ).

g. Remove all shippingcaps, plugs, and coversfrom compressor asrequired.

(2-73 blank)/2-74 Change 11

TM 55-2840-231-23

2-20. Compressor - Removing From Shipping Container - Continued

COMPRESSORSHIPPINGCONTAINER/ -Continued

h. Place all shippingparts inside shippingcontainer (less desiccant)and replace the cover.

2-75

TM 55-2840-231-23

2-21. Adapter Spur Gearshaft - Inspection

INITIAL SETUP


Special ToolsWrench, Tool No. 6795588

COMPRESSOR/

1. Adapter Spur Visually inspect the adapter spur gearshaftGearshaft for excessive wear on the 17-tooth gear and

splines. Replace the compressor if excessivewear is noted.

The runout may be checked using a suitable Check the runout of theindicator in a magnetic holder mounted adapter spur gearshaft.anywhere on the compressor assembly. The gearshaft runout

must not exceed 0.003in. (0.0076 cm) TIR.

2. Nut Check nut (3) for tight-ness. The nut should betightened to 50-55 in.lb (0.6 -0.65 kg/m)plus locknut drag, usingwrench, tool no. 6795588.Replace nut if locknutdrag is less than 5 in. lb(0.1 kg/m) in the lasttwo turns. Recheckthe gearshaft runout. Ifnot within limits, re-place the compressorassembly.

2-76

TM 55-2840-231-23

CHAPTER 3

COMBUSTION SECTION

Combustion Maintenance Procedures and First-Stage Nozzle Shield InspectionOuter Combustion Case - InspectionOuter Combustion Case - Weld-Repair (AVIM)Combustion Liner - InspectionCombustion Liner - Weld-Repair (AVIM)Combustion Section - RemovalCombustion Section - InstallationCompressor Discharge Air Tube - InspectionCompressor Discharge Air Tube - Weld - Repair (AVIM)Compressor Discharge Air Tube Seal Ring - InspectionBurner Drain Valve - Removal, Cleaning, Testing, and Installation

3-13-13-43-63-103-133-163-233-243-253-26

3-1. COMBUSTION MAINTENANCE PROCEDURES AND FIRST-STAGENOZZLE SHIELD INSPECTION.

Visually inspect all subassemblies and accessories removed from the engines combustionsection. Check for loose or missing parts. Note any damage or excessive wear. Repairdamaged parts where possible. Replace damaged parts that cannot be repaired. Disassemblyprocedures provided enable required cleaning, inspection, repair or replacement.

3-2. Outer Combustion Case - Inspection.

INITIAL SETUP


ReferencesPara 3-3

Change 13 3-1

TM 55-2840-231-23

3-2. Outer Combustion Case - Inspection - Continued

ENGINE/

1. Outer Combustion Case Visually inspect for cracks and dents in sheet met-al surfaces and wear in the air tube bosses. Re-place the outer combustion case if the repairablelimits are exceeded.

Wear in air tube bosses.

Out of round at air tube bosses.

Check for cracks in theouter shell. Replace theouter comubustion case ifcracks exceed the limitsshown in figure. Weld allrepairable cracks. (Refer toparagraph 3-3.)

Check for cracks in the lin-er (inner basket). Weld-re-pair cracks three inches(71.2 mm) or less in lengthand a minimum of one inch(25.4 mm) apart. (Refer toparagraph 3-3.) Replacethe outer combustion caseif cracks are greater thanthree inches (71.2 mm) inlength cracks are less thanone inch (25.4 mm) apart,or there are more than twocracks.

Check for dents in outershell. Replace the outercombustion case if dentsare more than 1/8 inch (3.2mm) deep.

Check for wear in the airtube bosses. Replace outercombustion case if Stepwear is greater than 0.004inch (0.010 mm) (measuredfrom adjacent unwornarea).

Maximum of 0.004 in.(0.10 mm) out of round.

3-2 Change 11

TM 55-2840-231-23

3-2. Outer Combustion Case - Inspection - Continued

ENGINE/ - Continued

NOT ACCEPTABLE AND NOT REPAIRABLE

1. ARC STRIKES OR CRACKS IN SHEET METAL AREA WITHIN 2 IN. (50.8 MM) OF BUTT WELDS 1A & 1BIN LENGTH E.

2. CRACKS IN BUTT WELDS NO. 1A& 1B IN LENGTH E.3. CRACKS IN OR ADJACENT TO BUTT WELD NO. 4.

WELD REPAIR PERMITTED

1. CRACKS UP TO 1/16 IN. (1.6 MM) LENGTH IN BUTT WELDS 1A& 1B OUTSIDE OF LENGTH E.2. CRACKS UP TO 1 /2 IN. (12,7 MM) LENGTH OR SEPARATED CRACKS FOR AN ACCUMULATED LENGTH

OF 14/2 IN. (38.1 MM) TOTAL LENGTH IN BUTT WELDS 3 AND ADJACENT FLANGE.3. CRACKS UP TO 1/2 IN. (12.7 MM) LENGTH OR SEPARATED CRACKS FOR AN ACCUMULATED LENGTH OF

1/2 IN. (12.7 MM) LENGTH IN BUTT WELDS 2A & 2B AND ADJACENT FLANGE.4. CRACKS UP TO 1/2 IN. (12.7 MM) LENGTH IN SHEET METAL AREA WITHIN 2 IN. OF BUTT WELDS

2A& 2B IF AT LEAST 2 IN. (50.8 MM) FROM BUTT WELDS 1A& 1B IN LENGTH E.5. CRACKS UP TO 1/2 IN. (12.7 MM) LENGTH IN SHEET METAL AREA ADJACENT TO BUTT WELD 3.6. CRACKS UP TO 3/8 IN. (9.5 MM) LENGTH IN FILLET WELDS 5 AND 67. CRACKS IN AREAS OTHER THAN ABOVE UP TO 1 IN. (25.4 MM) LENGTH.

3-3

TM 55-2840-231-23

3-3. Outer Combustion Case - Weld-Repair (AVIM)

INITIAL SETUP

Applicable Configuration Consumable MaterialsAl l Acetone (item 39, Appendix D)

Class 6 Weld Rod (item 40, Appendix D)

COMBUSTIONSECTION/

1. Outer Combus- Weld-repair cracks intion Case the outer combustion

case as follows. (Seethe following figure.)

a. Remove surface con-tamination using astainless steel wirebrush.

Acetone (item 39, Appendix D). b. Clean the area withacetone using a cleancloth for the applica-tion.

Class 6 weld rod (item 40, Appendix D). c. Weld cracks usinginert gas arc and class6 weld rod. Apply1/8 inch (3.2 mm)wide stringer bead usingmedium heat input.Cool each bead withwet cloth immediately.Do not apply anotherbead until cool enoughto touch by hand.

d. To weld cracks inbutt weld areas (2A, 2Band 3) back up the areawith a copper block andargon gas back-up andbuild up the area 1/32inch (0.8 mm) minimum.e. Inspect the weld forundercut, cracking anddiscontinuities. Theremust be no evidence ofundercutting and crack-ing.

3-4

TM 55-2840-231-23

3-3. Outer Combustion Case - Weld-Repair (AVIM) - Continued

COMBUSTIONSECTION/ - Continued

NOT ACCEPTABLE AND NOT REPAIRABLE

1. ARC STRIKES OR CRACKS IN SHEET METAL AREA WITHIN 2 IN. (50.8 MM) OF BUTT WELDS 1A & 1BIN LENGTH E.

2. CRACKS IN BUTT WELDS NO. 1A&1B IN LENGTH E.3. CRACKS IN OR ADJACENT TO BUTT WELD NO. 4.

WELD REPAIR PERMITTED

1.2.

3.

4.

5.6.7.

CRACKS UP TO 1/16 IN. (1.6 MM) LENGTH IN BUTT WELDS 1A & 1B OUTSIDE OF LENGTH E.CRACKS UP TO 1/2 IN. (12.7 MM) LENGTH OR SEPARATED CRACKS FOR AN ACCUMULATED LENGTH

OF 1-1/2 IN. (38.1 MM) TOTAL LENGTH IN BUTT WELDS 3 AND ADJACENT FLANGE.CRACKS UP TO 1/2 IN. (12.7 MM) LENGTH OR SEPARATED CRACKS FOR AN ACCUMULATED LENGTH OF1/2 IN. (12.7 MM) LENGTH IN BUTT WELDS 2A & 2B AND ADJACENT FLANGE.CRACKS UP TO 1/2 IN. (12.7 MM) LENGTH IN SHEET METAL AREA WITHIN 2 IN. OF BUTT WELDS2A& 2B IF AT LEAST 2 IN. (50.8 MM) FROM BUTT WELDS 1A & 1B IN LENGTH E.CRACKS UP TO 1/2 IN. (12.7 MM) LENGTH IN SHEET METAL AREA ADJACENT TO BUTT WELD 3.CRACKS UP TO 3/6 IN. (9.5 MM) LENGTH IN FILLET WELDS 5 AND 6.CRACKS IN AREAS OTHER THAN ABOVE UP TO 1 IN. (25.4 MM) LENGTH.

3-5

TM 55-2840-231-23

3-4. Combustion Liner - Inspection

INITIAL SETUP

Applicable Configuration ReferencesAl l Para 3-5

ENGINE/

1. Combustion Liner Inspect the combustion liner as outlinedbelow.

Combustion Liner Inspection

Item

1

2

3

4

3-6

Inspection and Method

Pulled or broken spotweldsat liner step. (See precedingfigure.) (Visual)

Handling damage.preceding figure.)

(See

a. Mashed-out-of-round.(Visual)

b. Dented. (Visual)

Localized high tempera-ture distortion indicated bywarping or rippling of theliner surface and is nor-mally accompanied by dis-coloring (burning) of thearea. (Visual)

Burning in area of reliefslots. (See preceding fig-ure.) (Visual)

Serviceable Limits

None permitted.

None permitted.

None permitted.

Warpage less than 1/16inch (1.6 mm) deepover an area 1 inch(25.4 mm) in diameterand remaining withinthe area shown onfollowing figure.

Rear edge burned lessthan 1/16 inch (1.6mm) or both cornersburned less than 1/4inch (6.4 mm) alongrelief slot.

Repairable Limits

Not more than fouradjacent spotweldsor 40 percent oftotal per step.

Able to straighten toconcentricity limits.

Any dent that re-mains within thearea shown on pre-ceding figure anddoes not cause thin-out of metal.Straightened dentsmust meet concen-tricity limits.

Not repairable.

Not repairable.

Corrective Action

Weld-repair. (Referto paragraph 3-5.)

Straighten and re-form.

Straighten and re-form.

Replace liner.

Replace liner.

TM 55-2840-231-23

3-4 Combustion Liner - Inspection - Continued

C h a n g e 1 3 3 - 7

TM 55-2840-231-23

3-4. Combustion Liner - Inspection - Continued

ENGINE - Continued

Combustion Liner Inspection - Continued

Item

5

6

7

8

9

10

11

Inspection and Method

Check on outside of liner.(See preceding figure.)

Crack in tab end insideliner. (See preceding fig-ure.) (Visual)

Cracks at two adjacent re-lief slots progressing to-ward same hole. (See pre-ceding figure.) (Visual)

Crack in relief slots atcombustion liner steps.(See preceding figure.)(Visual)

Crack in double lip area.(See preceding figure.)(Visual)

Crack in igniter ferrule at-taching weld. (See preced-ing figure.) (Visual)

Roughened igniter ferruleID. (See preceding fig-ure.) (Visual)

Serviceable Limits

None permitted.

No cracks greater than1/4 inch (6.44 mm)long and no more thantwo cracks per tab.

Not permitted.

Any number 3/16 inch(4.8 mm) or less inlength.

None permitted.

None permitted.

None permitted.

Repairable Limits

Any number as longas crack length doesnot exceed limitsshown on precedingfigure. Not repairableif crack cannot becompletely weldedand/or weld obstructscooling air passage.

Not repairable.

Not repairable.

Any number 1/2 inch(12.7 mm) or less inlength.

Not more than 3 in-ches (76.2 mm) long.

Crack does not ex-ceed 1/4 inch (6.4mm) long.

ID does not exceed0.560 inch ( 1.422cm) after polishing.

Corrective Action


Replace liner.

Replace liner.




Polish ID. (Refer toparagraph 3-5.)

3-8

TM 55-2840-231-23

3-4. Combustion Liner - Inspection - Continued

Combustion Liner Inspection - Continued

Item Inspection and Method Serviceable Limits Repairable Limits Corrective Action

12 Worn or distorted (out- Wall thickness is not Not repairable. Replace liner.of-round) igniter ferrule. less than 0.020 inch(See preceding figure.) (0.05 1 cm) and/or(Visual) ID does not exceed

0.560 inch (1.422cm).

13 Crack in fuel nozzle fer- None permitted. Crack does not ex- Weld-repair. (Referrule attaching weld. (See teed 1/4 inch (6.4 to paragraph 3-5.)preceding figure.) (Visual) mm) long.

14 Roughened fuel nozzle None permitted. ID does not exceed Polish ID. (Refer toferrule ID. (See preceding 0.670 inch (1.702 pargraph 3-5.)figure.) (Visual) cm) after polishing.

15 Worn or distorted (out-of- ID does not exceed Not repairable. Replace liner.round) fuel nozzle ferrule. 0.670 inch (1.702(See preceding figure.) cm).(Visual)

16 Crack around spotwelds No cracks with a Not repairable. Replace shield.on heat shield. greater length of

50 percent of thedistance around theweld.

Change 13 3-9

TM 55-2840-231-23

3-5. Combustion Liner - Weld Repair (AVIM)


All


Acetone (item 39, Appendix D)Class 6 Weld Rod (item 40, Appendix D)Emery Cloth (item 28, Appendix D)Class 12 Weld Rod (item 40, Appendix D)

References

Para 3-4

COMBUSTION SECTION/

1. Combustion Liner, Pulled or Weld-repair pulled or bro-Broken, Spotweld ken spotwelds in the lines

as follows. (Refer to thefollowing figure.)

Acetone (item 39, Appendix D).

Class 6 Weld Rod (item 40, Appendix D).

3-10

TM 55-2840-231-23

3-5. Combustion Liner - Weld-Repair (AVIM) - Continued

Change 13 3-11

TM 55-2840-231-23

3-5. Combustion Liner - Weld Repair (AVIM) - Continued

3-12

TM 55-2840-231-23

3-5. COMBUSTION LINER - WELD REPAIR (AVIM) - Cont.

COMBUSTIONSECTION/– Continued

4. Fuel Nozzle and Igniter Emery Cloth (item 28, Appendix D).Ferrule ID Roughness

Remove roughened orgalled surfaced in the ID ofthe fuel nozzle and igniterferrules by polishing withemery cloth. Polish asrequired to remove allsurface roughness. Checkto insure that the ID, afterpolishing, does not exceedthe limit specified inparagraph 3-4.

3-6. COMBUSTION SECTION - REMOVAL.

INITIAL SETUP


ENGINE/

.

1. Drain Hose

2. Lockwire on Jamnut (16)

3. Jamnut (16)

4. Bracket (15)

Before removing combustion section,check engine historical log to see ifengine has used lead basedemergency fuels. Handling leadresidue coated parts with open cuts orscratches on hands is extremelydangerous. Always wear gloves whenchecking residue coated turbine orexhaust parts.

Disconnect drain hose fromthe burner drain valve (12or 14).

Remove.

Remove.

Disengage bracket (15)from engine.

Change 8 3-13

TM 55-2840-231-23

3-6. Combustion Section - Removal - Continued

ENGINE/-Continued

3-14 Change 11

TM 55-2840-231-23

3-6. Combustion Section - Removal - Continued

ENGINE/ - Continued

5. Igniter Lead (9)

6. Fuel Hose (8)

7. Fuel Nozzle (7),and Spark Igniter (10)

8. Drain Valve andPlugs (12 and 14)

9. RetainingRings (17)

10. Nuts (5), Clamp(4), and Bolts (1 and 2)

Insure ignition system has been offfor at least f ive minutes before dis-connecting the igniter lead. Electri-cal shock could occur. Ground thelead to the engine using an insulatedscrewdriver to dissipate any energystored in the exciter.

Disconnect from sparkigniter (10 ).

Remove fuel hose (8)between the firewallshield and fuel nozzle(7).

NOTE

If a new outer combustion case (6)is to be installed, proceed with thenext two items.

Remove from outercombustion case (6).

Remove from bottomof outer combustioncase (6). Discard pre-formed packings (11and 13).

Remove from outercombustion case (6)and slide them forwardon the discharge airtubes (18).

Remove 24 nuts(5),one clamp (4) and 24bolts (1 and 2) a.t thecombustion case split-line.

3-15

TM 55-2840-231-23

3-6. COMBUSTION SECTION - REMOVAL - Cont.

ENGINE/–Continued

11. Combustion Case (6),Air Tubes (18)

12. Combustion Liner (3)

13. Seal Rings (19)

14. Retaining Rings (17)and Seal Ring (20)

15. Lockwire andPositioning Plugs (22)

3-7. COMBUSTION SECTION – INSTALLATION

INITIAL SETUP


Special ToolsTurnover Stand, tool no. 6795579Installation Clamp, tool no. 6799953Installation Clamp, tool no. 6799952

3 - 1 6 Change 8

Separate the air tubesfrom the outer combustioncase.

Remove from the engine.

Remove from the smallends of the air tubes.

Remove from the largeends of the air tubes.

Remove and lift off firststage turbine nozzle shield(21).

Consumable MaterialsAntiseize Compound (item 6, Appendix D)Lockwire (item 7, Appendix D)Molykote (item 41, Appendix D)Lubricating Oil (item 5, Appendix D)Lockwire (item 7, Appendix D)

TM 55-2840-231-23

3-7. COMBUSTION SECTION – INSTALI.ATION - Cont.

ENGINE/

1. First StageNozzle Shield

2. Plugs (22)

3. CombustionLiner (3)

4. RetainingRings (17)

NOTE

This paragraph provides instructionfor installing the combustion sectionon the engine while the engine isinstalled in turnover stand (tool no6795579). If the turnover stand isused, rotate the engine in the standto a vertical position with thecompressor on the bottom.

Install first stage nozzleshield (21), if removed.

Antiseize Compound (item 6, Appendix D). Apply antiseize compoundLockWire (item 7, Appendix D). and install two positioning

plugs (22). Tighten to 100 to150 in.-lb. (1.15 to 1.7 kg/m) andsecure with lockwire.

Place combustion liner (3)over first stage turbinenozzle shield with igniterplug opening at the nineo’clock position (as viewedfrom rear of engine).

Slip retaining rings (17’)over the large ends ofcompressor discharge airtubes (18).

Change 8 3-17

TM 55-2840-231-23

3-7. Combustion Section - Installation - Continued

ENGINE/-Continued

1. Bolt2. Bolt (23)3. Combustion Liner4. Clamp5. Nut (24)6. Outer Combustion Case7. Fuel Nozzle8. Fuel Hose

3-18 Change 11

9. Igniter Lead10. Spark Igniter11. Preformed Packing 12. Drain Valve (OH-6)

Plug (OH-58)13. Preformed Packing14. Drain Valve (OH-58)

Plug (OH-6)

15. Bracket16. Jamnut17. Retaining Ring18. Compressor Discharge Air Tube19. Seal Ring (2 piece)20. Seal Ring (2 piece)21. Shield Assembly22. Plug Machine

TM 55-2840-231-23

3-7. Combustion Section - Installation-Continued

ENGINE/ - Continued

5. Seal Ring Assem- Molykote (item 41, Appendix D). Apply mol ykote to sealblies (19 and 20) ring assemblies (19 and

20) if they do not in-corporate a previouslyapplied bonded lubri-cant. Install the indivi-dual components of sealassemblies (19 and 20)and compressor dischargeair tubes (18). On thesmall end of air tubes(18), position ring gaps180 degrees apart withgap of seal rings to theoutboard side of tubes(18). On large end oftubes (18), positionring gaps 180 degreesapart with the gap ofseal rings to the inboardside of tubes (18).

6. Left-Hand Com-pressor DischargeAir Tube (18)

7. Right HandCompressor Dis-charge Air Tube (18)

Installation Clamp No. 6799953. Insert left-hand com-pressor discharge airtube (18 ) through fire-wall shield, Compressseal ring with the com-pressor discharge airtube-to-compressorscroll installation clamp.Mate air tube (18) withcompressor scroll, then,remove installationclamp .

Install in the samemanner used for in-stalling the left-handtube above.

Change 6 3-19

TM 55-2840-231-23


ENGINE/-Continued

8. Seal Rings (20) Installation Clamp No. 6799952. Compress seal rings atlarge end of air tube (18)with compressordischarge air tube toouter combustion caseinstallation clamps.Then, place outercombustion case (6) overcombustion liner (3)while mating the case (6)to compressor dischargeair tubes (18).

NOTE

9. Bolts (1 and 2)

3-20 Change 11

The case (6) is properly indexed whendrain port is at the bottom of engine.Also check to insure that igniter plughole in the outer combustion case (6)aligns with the igniter plug hole incombustion liner (3) before insertingattaching bolts.

NOTE

The mating notches on thecombustion air tubes and combustionsection must be aligned prior toinstalling retaining rings on the AFTend of the combustion tubes.

Antiseize Compound (item 6, Appendix D). Coat threads of the 24outer combustion caseattaching bolts ( 1 and 2 )lightly with antiseizecompound. Secure outercombustion case (6) to the

The half-inch length bolt is used to secure gas producer turbinethe thermocouple harness clamp (4) on the support with 24 bolts (1rear side of the splitline flange at bolt and 2 ) and nuts (5).position 6 (viewed from the rear of the engine Tighten nuts (5) to 20 towith 1 at top center). 30 in.lb (0.2-0.3 kg/m).

Remove the installationclamps. Secure thecompressor discharge airtubes (18) to the outercombustion case (6) withretaining rings ( 17).

TM 55-2840-231-23


Change 13 3-21

TM 55-2840-231-23


3-22 Change 13

TM 55-2840-231-23

3-8. Compressor Discharge Air Tube - Inspection

INITIAL SETUP

Applicable Configuration ReferencesAll Para 3-9

ENGINE/

1. Air Tubes Visually inspect for cracks or dents in thesheet metal surfaces and wear in the sealring grooves. Replace the air tube if repair-able limits are exceeded.

(Refer to paragraph 3-9.) Check for cracks insheet metal surface.Weld-repair cracks whichare three inches (7.6 cm)or less in length anddo not extend into brazedjoints at the end flanges.Replace the air tube ifcracks are longer thanthree inches (7,6 cm)or extend into thebrazed joint.

NOTE

Dents should be round with noevidence of a sharp bottom. Asa rule of thumb, a dent 1/8 in.(3.2 mm) deep should be a min-imum of 1/2 inch (12.7 mm) indiameter.

Check for dents in sheetmetal surfaces. Replaceair tube if:

a. Any dent is greaterthan 1/8 inch (3.2 mm).

b. There are more thantwo dents up to 1/8inch (3.2 mm) deep inor affecting the weldjoint (P/N 6850398 and6870748 tubes only).

3-23

TM 55-2840-231-23

3-8. Compressor Discharge Air Tube - Inspection - Continued

ENGINE/ - Continued c. There are more thanfour dents up to 1/8inch (3.2 mm) deep inareaa not affected byweld joints.

d. Any dent is greaterthan 11/2 inches (3.8cm) in diameter.

3-9. Compressor Discharge Air Tube - Weld-Repair (AVIM)

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Acetone (item 39, Appendix D)

Class 6 Weld Rod (item 40, Appendix D)

COMPRESSOR/

1. CompressorDischarge AirTube

Acetone (item 39, Appendix D).

Weld-repair cracks inthe compressor dis-charge air tubes asfollows:

a. Remove surface con-tamination using astainless steel brush.

b. Clean the area withacetone using a cleancloth for the applica-tion.

Class 6 Weld Rod (item 40, Appendix D). c. Weld cracks usinginert gas arc and class 6weld rod.

d. Do not grind weldunless weld material ex-tends into air path. Thinout of material fromwelding or grinding isnot permitted.

3-24

TM 55-2840-231-23

3-10. Compressor Discharge Air Tube Seal Ring - inspection

INITIAL SETUP


ENGINE/

Do not substitute standard rubber“O” rings for the Kalrez syntheticrubber. Due to the high tempera-ture restrictions and thermalgradients, only Kalrez syntheticrubber is authorized for use on thecompressor discharge tubes,

Compressor Discharge Air Replace compressor discharge air tube sealTube Seal Ring rings which exhibit fretting, excessive wear,

or distortion. Replace two-piece seals whenthe spherical radius on the OD is worn flatall the way across. Slight leakage aroundcompressor discharge air tube seal ring isallowed, provided it does not affect engineperformance.Some compressor discharge tubes utilize asynthetic rubber, trade name Kalrez, and asteel backup ring as the sealing arrange-ment. Inspect the synthetic rubber seals andreject any seals that exhibit any tears, cuts,or deformation. Use care in removal orinstallation of synthetic rubber to avoiddamage and make certain that the steelbackup ring is installed on the atmosphericside of the compressor discharge tube groove.

3-11. Burner Drain Valve - Removal, Cleaning, Testing and Installation

INITIAL SETUP


ENGINE/Burner DrainValve

1. Removal

Consumable MaterialsCarbon Removal Compound (item 22, Appendix D)Drycleaning Solvent (item 1, Appendix D)Antiseize Compound (item 6, Appendix D)Lockwire (item 17, Appendix D)Lubricating Oil (item 5, Appendix D)

Remove drain valve (1)from the outercombustion case anddiscard preformedpacking (2).

Change 11 3-25

TM 55-2840-231-23

3-11. Burner Drain Valve - Removal, Cleaning, Testing and Installation

ENGINE/Burner DrainValve - Continued

2. Removal

3. Cleaning

Remove lockwire andremove nut (3) from drainvalve (4). Disengagebracket (5) and removethe drain valve from theouter combustion case.Discard preformedpacking (6).

Solvent (item 22, Appendix D). Soak the valve in solvent.

3-26 Change 11

TM 55-2840-231-23

3-11. Burner Drain Valve - Removal, Testing and Installation - Continued

ENGINE/Burner DrainValve - Continued

4. Testing

Drycleaning solvent, P-D-680,used to clean parts is potentiallydangerous to personnel andproperty. Avoid repeated andprolonged skin contact, Avoidprolonged or repeated breathingof vapors. Do not use near openflame or excessive heat. Flashpoint of solvent is 100oF - 138oF( 3 8OC - 5 9OC ) .

Petroleum Solvent (item 1, Appendix D).

Use approved personnelprotective equipment to protecteyes and face when usingcompressed air. Maximumallowable air pressure forcleaning operations is 30 psi. Donot direct air stream towardsyourself or toward anotherperson.

Flush valve withpetroleum solvent. Passsolvent through the valveto insure that it is open.

Blow dry with cleancompressed air.

Test valve to insure that itcloses by applying airpressure of 8 psig (0.56 kgsq/cm) maximum to thevalve.

Change 11 3-27

TM 55-2840-231-23

3-11. Burner Drain Valve - Removal, Testing and Installation - Continued

ENGINE/Burner DrainValve-Continued

5. Deleted

6. Installation

Prolonged contact withlubricating oil (item 5, AppendixD) may cause o skin rash. Thoseareas of skin and clothing thatcome in contact with lubricatingoil should be thoroughly washedimmediately. Enclosed areaswhere lubricating oil is usedshould be adequately ventilatedto keep mist and fumes to aminimum.


Antiseize Compound (item 6, Appendix D).


3-28 Change 11

Lubricate new preformedpacking (6) and place ondrain valve (4). Applyantiseize compoundlightly to threads of drainvalve and install in outercombustion case. Tightento 120 to 140 in. lb(1.4 to 1.6 kg/m). Applyantiseize compound tothreads on the drainvalve and install bracket(5) and nut (3). Tightennut to 55 to 80 in. lb(0.6 to 0.9 kg/m) andlockwire drain valve toplug assembly. Startengine and check to insurethat the valve is closed.Replace the valve if itfails to close.

Attach the drain hose tothe valve.

TM 55-2840-231-23

CHAPTER 4

POWER TURBINE

O V E R V I E W

This chapter contains procedures for the maintenance and preservation of the power turbine. Paragraphs followingoutline disassembly, inspection, repair, and additional requirements needed to maintain the power turbine and relatedparts. Procedures requiring maintenance on the Aviation Intermediate Maintenance (AVIM) level are specified andmust be performed as such. Paragraphs in which the maintenance level is not specified shall be considered AviationUnit Maintenance (AVUM) and maybe performed at this level or a higher level of maintenance.

Page

Power Turbine Maintenance Procedures 4-1Exhaust Collector Support - Inspection 4-1Thermocouple Assembly - Inspection 4-2Thermocouple Terminal Assembly - Removal and Installation 4-3

4-1. POWER TURBINE MAINTENANCE PROCEDURES.

Visually inspect all subassemblies and accessories removed from the engines power turbine section. Check for looseor missing parts. Note any damage or excessive wear. Repair damaged parts where possible. Replace dmaaged partsthat cannot be repaired. Disassembly procedures provided enable required cleaning, inspection, repair or replacement.

4-2. EXHAUST COLLECTOR SUPPORT - INSPECTION.

3-5. Combustion Liner - Weld Repair (AVIM)

INITIAL SETUP


All

ENGINE/

Exhaust Collector Visually inspect the exhaust support for cracks.Cracks are not repairable, replace the engine. (Re-fer to paragraph 1-43 and 7-2.1).

Change 8 4-1

TM 55-2840-231-23

4-3. Thermocouple Assembly - Inspection

INITIAL SETUP

Applicable Configuration ReferencesAll TM 55-4920-244-14

ENGINE/

Themocouple When erroneous temperature inspections aresuspected, insure that the indicating systemis functioning properly. Perform a TOT gagecalibration check and a total TOT circuitresistance check. (Refer to TM55-4920-244-14 and applicable airflamemanuals.) If no discrepancies are noted,check the thermocouple system as follows. Donot remove the thermocouple assembly fromthe engine.

NOTE

A check of these limits can beperformed only by using testinstruments that offer usablesensitivity in this range (null-typeresistance bridge). lf suchinstrumentation is not available,an ohm meter (Simpson meter orequivalent) can be used to detectan open circuit. (An open circuitwiII cause a high resistance; ashort circuit wiII cause it to below).

a. Visually inspectthermocouple assembly forbroken leads, looseterminals and other visibledamage.

b. Disconnect plug P12from receptacle at theengine deck.

c. Measure the internalresistance of thethermocouple harness atthe terminal block on theright-hand side of theexhaust collector.Resistance shall be 0.55 to0.65 ohms.

d. Reconnect plug P12.Reconnect leads to theterminal assembly. Ensurethat the connector isproperly mated and secure.

4-2 Change 13

TM 55-2840-231-23

4-4. THERMOCOUPLE TERMINAL ASSEMBLY - REMOVAL AND INSTALLATION.

INITIAL SETUP


ENGINE/Thermcouple TerminalAssembly

1. Removal

2. Installation

Remove two nuts securingthe thermocouple leads tothe terminal assembly.

Remove two nuts and boltssecuring the terminalassembly to the exhaustcollector.

Position the terminalassembly on the exhaustcollector with the largeterminal to the top andsecure with two bolts andself-locking nuts. Tightenthe nuts to 35 to 40 in.-lb(0.4 to 0.5 kg/m).

Attach the alumel leads tothe top post on the terminalassembly and secure withthe no. 10-32 alumel nut.Tighten the nut to 17 to 25in.-lb (0.2 to 0.3 kg/m).

Attach chromel leads tobottom post on the terminalassembly and secure withthe no. 8-32 chrome] nut.Tighten the nut to 17 to 25in.-lb (0.2 to 0.3 kg/m).

Change 8 4-3

TM 55-2840-231-23

4-5. Power Turbine Outer Coupling Nut - Inspection

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll None

ENGINE/POWERTURBINE OUTERCOUPLING NUT

1. Inspection a. Engines identified by the suffix c after theEngine Serial Number do not needinspection. Examples: AE4081OOABC,AE402603BC. These engines will have hadthe new nut P/N 23001801 installed.

b. The OH-58A inspection requires removalof the engine cowling and exhaust stacks(Refer to TM 55-1520-228-23/1). The OH-6Ainspection requires removal of exhaust tail-pipes (Refer to TM 55-1520-214-23 ).

a. The nut is locatedapproximately one andone half inches forward ofthe fourth stage turbinewheel inside the Centersection of the exhaustcollector support. (Refer toillustration.)

b. The condition of thenut can be determinedwith the use of the mirroror polished metal and ahigh intensity lightsource.

c. Insert the mirror orpolished metal halfwayinside the exhaustcollector, holding the lightsource in a position suchthat the light falls uponthe nut.

d. Position the mirror orpolished metal until thenut is in view.

e. Insert the equipmentand slowly rotate thefourth stage turbinewheel by hand so that the

4-4 Change 11

full 360 degree area ofthe nut can be view-ed. Uncoated orcoated nuts will showa grainy textured sur-face created by thecorrosion attack.

f. Replace nut if thecorrosion is con-tinuous around thefull 360 degrees ofrotation, (Refer to il-lustration.)

g. If there are onlylocal, intermittentspots of corrosionaround the full 360degrees of rotation,the engine should becontinued in service.(Refer to illustration.)

h. Repetitive com-pliance is required at90 day intervals foreach engine in-corporating an accep-table uncoated orcoated coupling nut.

Change 8 4 -5/ (4-6 blank)

5-1

TM 55-2840-231-23

CHAPTER 5

ACCESSORY GEARBOX

This chapter contains procedures for the maintenance and preservation of the accessory gearbox. Para-graphs following outline disassembly, inspection, repair, and additional requirements needed to maintainthe accessory gearbox and related parts. Procedures requiring maintenance on the Aviation IntermediateMaintenance (AVIM) level are specified and must be performed as such. Paragraphs in which the mainte-nance level is not specified shall be considered Aviation Unit Maintenance (AVUM) and may be performedat this level or a higher level of maintenance.

Page

Accessory Gearbox Maintenance Procedures 5-1Gearbox - Inspection 5-2Gearbox External Seals - Replacement (AVIM) 5-3Gearbox External Stud - Replacement 5-6Magnetic Chip Detectors - Removal, Inspection, Cleaning, Installation, and

Testing 5-8Gearbox Housing and Cover - Painting 5-10

ACCESSORY GEARBOX MAINTENANCE PROCEDURES.

Visually inspect all subassemblies and accessories removed from the engines accessory gearbox. Checkfor loose or missing parts. Note any damage or excessive wear. Repair damaged parts where possible.Replace damaged parts that cannot be repaired. Disassembly procedures provided enable required cleaning,inspection, repair or replacement.

5-1

TM 55-2840-231-23

5-2. Gearbox - Inspection

INITIAL SETUP

Applicable Configuration ReferencesParas 5-3, 5-4 and 5-6

ENGINE/

1. Gearbox Housing Visually inspect the exterior of the gear-and Cover box for the following conditions.

Check for cracks in thegearbox housing andcover, especially instress areas, enginemounts, accessory pads,and at the splitline. Ifcracks are found, re-place the engine.

1. Gas Producer Tachometer- 4. Torquemeter Spanner Nut 9. Power TakeoffGenerator 5. Power Turbine Fuel Governor 10. Gas Producer Fuel

2. Power Takeoff 6. Spare (not used) Control3. Power Turbine Tachometer 7. Fuel Pump

Generator 8. Starter-Generator

5-2

TM 55-2840-231-23

5-2. Gearbox - Inspection - Continued

ENGINE/ - Continued

2. Seals and PowerTakeoff Pad

3.Gearbox Studs

4. PaintedSurfaces

Check for oil leaks. Ifarea below seal at anyaccessory or power take-off pad is dripping,replace the seal assem-bly. (Refer to para-graph 5-3.)

If any gearbox mountedaccessory is removed,visually inspect thegearbox studs for secur-ity, worn areas, anddamaged threads.Replace loose, damagedor worn studs. (Referto paragraph 5-4.)

Check for damagedpainted surface. (Referto paragraph 5-6.)

5-3. Gearbox External Seals - Replacement (AVIM)

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Grease (item 37, Appendix D)

Special ToolsSeal Puller Kit, Tool No. 6796941

GEARBOX/External seals

Do not pry between the seal cavity in the gearbox housing and theseal. Be careful not to contaminatethe shaft bearing or damage thegearshaft.

TM 55-2840-231-23

5-3. Gearbox External Seals - Replacement (AVIM) - Continued

GEARBOX/ -Continued

CAUTIONDo not use the double lip seal NSN5330-00-185-0341 on T63-A-700 enginesinstalled on OH-6A Helicopters.Damage to the gearbox could occur.

-20

-200

Seal Puller Kit, Tool No. 6796941.

-19 -17 -18 -16

-203

Remove accessory ordrive from the gearboxpad.

Remove defective sealsusing seal puller kit asfollows:

-15 -14 -13 -201 -12 -202

DETAIL NAME AND APPLICATION

6796941-200 PULLER-TACHOMETER-201 PULLER-FUEL PUMP ACCESSORY DRIVE,

FUEL CONTROL, GOVERNOR, AND STARTER-202 PULLER-POWER TAKEOFF-203 HANDLE ASSEMBLY-12 PULLER-IDLER GEARS-13 GUIDE-TACHOMETER-14 GUIDE-FUEL PUMP, ACCESSORY DRIVE;

FUEL CONTROL, GOVERNOR, AND STARTER.15 GUIDE-HELICAL POWER TRAIN DRIVE-16 INSTALLATION TOOL-TACHOMETER-17 INSTALLATION TOOL-FUEL PUMP, SPARE:

FUEL CONTROL AND GOVERNOR-18 INSTALLATION TOOL-STARTER-19 INSTALLATION TOOL-POWER TAKEOFF-20 INSTALLATION TOOL-GAS PRODUCER GEAR

TRAIN IDLER SPUR GEAR

a. Use -201 detail toremove seals (1) in thefollowing figures.

5 - 4 Change 3

TM 55-2840-231-23

5-3. Gearbox External Seals - Replacement (AVIM) - Continued

GEARBOX/ -Continued

b. Use -202 detail toremove seals (2).

c. Use -200 detail toremove seals (3).

Discard removed seals.

Apply grease (item 37,Appendix D) to theseal lip to aid installa-tion. Carefully drivethe new seal into placeusing seal kit as follows:

a. Use- 17 and -14 detail toinstall seals (1) at thefuel pump, space ac-cessory, fuel control,and governor pads.

b. Use- 18 and -14 detail toinstall seal (1) at thestarter-generator pad.

c. Use- 19 and -15 detail toinstall seals (2) at thepower takeoff pad.

d. Use -16 and -13 detail toinstall seals (3) at thetachometer pad.

Reinstall the accessoryor drive on the gearboxpad.

Change 8 5-5

TM 55-2840-231-23

5-4. Gearbox External Stud - Replacement

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Antiseize Compound

GEARBOX/

1. Stud

See following figures for details of threadsize, height and torque.

Oversize replacement studs may be usedwhen necessary.

2. Stud Antiseize Compound (item 38, Appendix D).

5-6

(item 38, Appendix D)

Remove and discarddamaged stud.

Clean and retap studhole threads only whencondition of hole threadsrestrains stud installation.Use the same size tap.

Apply antiseize com-pound to the studthreads and to the studhole threads.

Install the stud andtighten to obtain thetorque and settingheight specified inpreceding figure.

TM 55-2840-231-23

5-4. Gearbox External Stud - Replacement - Continued

Change 11 5-7

TM 55-2840-231-23

5-5. Magnetic Chip Detectors - Removal, Inspection, Cleaning, Installation and Testing

INITIAL SETUP

Applicable Configuration Consumable MaterialsA l l

ENGINE/Magnetic ChipDetectors

1. Removal

2. Inspection

Lubricating Oil (item 5, Appendix D)Lockwire (item 17, Appendix D)

Magnetic chip detectors are located at the oiloutlet port on the right front and on the bottom of theaccessory gearbox. Each chip detector consists ofa magnetic plug with a single pin electrical recep-tacle. The threaded plug portion of the chip detec-tor includes a terminal shaft and pole piece sepa-rated from a magnet in the plug body by insula-tors. When ferrous metal particles are sufficient insize or accumulation to bridge the gap between thepole piece and the magnet, an electrical (ground)circuit between the chip detector and the ENGCHIP DET indicator l ight is completed.

Remove electrical lead. Removelockwire and unscrew magneticchip detector. Same oil spillingis likely. Remove preformedpacking the plug and dis-card preformed packing

NOTE

When removing chip detector, careshould be taken not to contaminate detect o r .

a. Visually check eachplug for metal accumulation.

b. Flakes of magnetic material of1/16 in. (1.6 mm) or mom diam-eter are indications of an incipi-ent failure and are cause for en-gine removal.

ACCEPTABLE UNACCEPTABLE

5-8 Change 13

TM 55-2840-231-23

5-5. Magnetic Chip Detectors - Removal, Inspection, Cleaning, Installation and Testing - Continued

ENGINE/ - Continued

Prolonged contact with lubricatingoil (item 5, Appendix D) may cause askin rash. Those areas of skin andclothing that come in contact withlubricating oil should be thoroughlywashed immediately. Enclosed areaswhere lubricating oil is used shouldbe adequately ventilated to keepmist and fumes to a minimum.

c. Fuzz or hair-likemagnetic particles cannormally be found on themagnetic plug and are notcause for enginereplacement.

3. Cleaning

4. Installation

5. Testing Chip Detectorand Circuitry

Wipe chip detectors with aclean, lint-free cloth.

Lubricating Oil (item 5, Appendix D). Install a new preformedLockwire (item 7, Appendix D). packing lubricated with oil

on magnetic plug. Installmagnetic plug; tighten to60-80 in. lb (0.7-0.9 kg/m)and Iockwire. Connectelectrical lead.

a. Place BATT-OFFswitch to OFF and applyexternal power.

b. Remove chip detector.

c. Connect the electricallead to the chip detectorand ground the case ofthe chip detector to theengine.

Change 13 5-9

TM 55-2840-231-23

5-5. Magnetic Chip Detectors - Removal, Inspection, Cleaning, Installation and Testing -Continued

e. If ENG.CHIP DET indicatorlight does not illuminate, checkthat case is grounded to engine.If light is still not observed, re-move electrical connector fromchip detector and ground con-nector to engine. ENG.CHIPDET indicator light should illu-minate. If light does illuminate,replace chip detector; if lightdoes not illuminate, check com-ponents for continuity and re-place defective parts.

f. Reinstall chip detector.

g. Reinstall electrical connectorto chip detector.

h. With engine running, checkthe magnetic chip detector light;the light should be out.

5-10

TM 55-2840-231-23

5-6. Gearbox Housing and Cover - Painting

INITIAL SETUP

Applicable ConfigurationAl l

Consumable MaterialsDrycleaning Solvent (item 1, Appendix D)Emery Cloth (item 28, Appendix D)Paint Thinner (item 29, Appendix D)Medium Gray Corrosion Resistant Paint

(item 30, Appendix D)

GEARBOX/

Drycleaning solvent, P-D-680, usedto clean parts is potentially danger-ous to personnel and property.Avoid repeated and prolonged skincontact. Avoid prolonged or re-peated breathing of vapors. Do notuse near open flame or excessiveheat. Flash point of solvent is 100°F -1 3 8oF (380C-59°C) .

1. Gearbox Housingand Cover

Repair damaged painton the external surfacesof the gearbox housingand cover as follows:

Solvent (item 1, Appendix D). a. Clean darnaged areawith a clean cloth satu-rated with solvent.

Emery Cloth (item 28, Appendix D). b. Using emery clothabrade an area slightlylarger than the damagedarea. Feather the edgesof the abraded area.

c. Clean area as instep a. and dry using ablast of clean compressedair.

d. Chrome pickle thecleaned area perMIL-L-3171.

Paint Thinner (item 29, Appendix D). e. Wipe the abradedarea with paint thinner.

5-11

TM 55-2840-231-23

5-6. Gearbox Housing and Cover - Painting - Continued

GEARBOX/ - Medium Gray Corrosion Resistant Paint f. Apply medium grayContinued (item 30, Appendix D). corrosion resistant

paint to the abradedarea.

Heat may be applied with a heat lamp to g. Airdry at least onespeed up curing; however do not exceed hour before handling.300°F(149°C). Approximately 20 min-utes will be required for the heat cure.

5-12

TM 55-2840-231-23

CHAPTER 6

FUEL SYSTEM

6-26-26-26-36-56-7

6-8.26-106-146-176-22

6-22.56-246-286-316-346-386-416-446-456-486-526-546-576-606-626-65

Change 11 6-1

TM 55-2840-231-23

Pc Air Filter - RemovalPc Air Filter - Cleaning and InspectionPc Air Filter - InstallationFuel Nozzle - RemovalFuel Nozzle - CleaningFuel Nozzle - InspectionFuel Nozzle - Installation

6-1. FUEL SYSTEM MAINTENANCE PROCEDURES

6-676-68

6-68.36-68.46-68.56-706-70

Visually inspect all subassemblies and accessories removed from the engines fuel system, Check for loose or mis-sing parts. Note any damage or excessive wear. Repair damaged parts where possible. Replace damaged parts thatcannot be repaired. Disassembly procedures provided enable required cleaning, inspection, repair or replacement.

6-2. Bleeding the Fuel System. Maintenance of the fuel system can result in air entrapment in the fuel lines and subse-quent false starts. Following maintenance, purge the air from the fuel system as follows:

a. Disconnect the input lead to the ignition exciter or pull the IGN ENG circuit breaker (refer to TM55-1520-235-10, TM 55-1520-228-20).

b. Disconnect the fuel hose at the fuel nozzle; place the open end of the hose in a bucket.

c. Move the twist grip to the IDLE detent and motor the engine until a solid stream of fuel flows from the discon-nected hose. (Use APU if available.)

d. Reconnect the fuel hose to the fuel nozzle and input lead to the ignition exciter or reset IGN ENG circuit breaker.

6-3. on governor to fuel control) is removed or disturbed during maintenance, check the control air tubing for leaks as fol-lows:

a. Disconnect the pressure sensing (PC) line from the pressure probe elbow in the diffuser scroll.

c. Use a liquid soap solution (item 1, table 2-1) to check the air tubes for leakage. Cover and parting surfaces onthe fuel control and governor which produce a slight bubbling of the soap solution do not represent a leak of sufficientmagnitude to warrant concern. These leaks were present during original calibration and were compensated for at thattime.

d. Reduce the pressure to 20-22 psi (0.14-1.54 kg/sq cm) and check the governor diaphragm for leakage. No leak-age is acceptable. If leakage is noted from the governor diaphragm, remove the safety wire from the screws, back offscrews and then torque to 8-11 inch lbs. Let screws rest for 20 minutes and retorque to same valve. If after this is com-pleted, the governor diaphragm still leaks, replace governor.

e. Reconnect the PC tube. Tighten coupling nuts to 80-120 in. lbs. Hold the PC filter while tightening the couplingnut. During aircraft run up, use the soap solution to verify no leakage around the reconnected Pc line prior to flight.Rinse water solution from the engine after the check is completed.

6-2 Change 13

TM 55-2840-231-23

6-4. Fuel System Tubes - Removal, Cleaning, and Installation.

INITIAL SETUP


Special ToolsMagnifying Glass, 10x (Appendix C)

Consumable MaterialsDrycleaning Solvent (item 1, Appendix D)

ENGINE/

REMOVAL

Fuel System Tubes Observe the following precautions when Remove and observeremoving fuel system tubes: precautions.

a. When loosening a coupling nut, alwaysuse a backup wrench on the mating fitting toprevent the fitting from turning.

b. Always use the proper size wrench toprevent rounding off the hex corners.

c. Attach the wrench to the fitting orcoupling nut in a manner that will preventcrushing of the fitting or coupling nut.

d. Never use a pipe wrench, pliers, or visegrips on a coupling nut or fitting.

CLEANING

Fuel System Tubes

Drycleaning solvent, P-D-680,used to clean parts is potentiallydangerous to personnel andproperty. Avoid repeated andprolonged skin contact. Avoidprolonged or repeated breathingof vapors. Do not use near openflame or excessive heat. Flashpoint of solvent is 100oF - 138oF(38oC - 59°C).

Use drycleaning solvent (item 1, Appendix Flush tubes with solventD). and blow dry.

Change 11 6 - 3

TM 55-2840-231-23

6-4. Fuel System Tubes - Removal, Cleaning, and Installation - Continued

ENGINE/-Continued

INSPECTION

Fuel System Tubes

INSTALLATION

Use the following criteria to determineextent of damage:

a. Kinks or dents which could obstruct fuelor air flow. Dents in fuel line are allowableup to 0.015 in. (0.38 mm). Dents inpneumatic air lines are allowable up to 1/8in. (3 mm), no sharp radius dents allowed.

b. Cracked or broken tubes or coupling nuts.

c. Cross-threaded, crushed, or otherwisedamaged coupling nuts.

d. Chafing within clamp areas in excess of0.010 in. deep (0.25 mm). Chafing is notallowed at or near the flared tubing end.

e. Nicks which exceed 0.010 in. (0.25 mmdeep.

f. Inspect tubes for cracks using a 10xmagnifying glass (Appendix C). Payparticular attention to the flared ends of thetubes for cracks and to the areas beneath thefloating ferrules for excessive frettingdamage.

NOTE

Excessive fretting is present when theferrule has chafed the tube sufficientlyto wear a step in the tube that can befelt with a thumbnail or otherinspection aid.

Failure to properly install, alignand torque fuel, oil, air fittingsand tubes could result in anengine failure.

NOTE

Observe precautions listed inREMOVAL when installing fueltubes.

Inspect and reject tubesfor damage. Observegiven wear limits.

Inspect tubes for cracksusing a 10x magnifyingglass (Appendix C). Tubesfound to contain cracksand/or fretting damageare to be replaced by newparts of the same partnumber as removed.

6-4 Change 11

TM 55-2840-231-23

6-4. Fuel System Tubes - Removal, Cleaning, and Installation - Continued

ENGINE/-Continued

INSTALLATION

Fuel System Tubes

Fuel System Tubes andAir Tubes

Rigid steel tubing must align with its matingfittings in the free state such that bothcoupling nuts will engage two full threads oftheir mating fittings with light fingerpressure. The tube must not be stretchedduring final tightening of the coupling nuts.Adjustments may be made by bending thetube at the principal bend or bends. Allbending must be accomplished with the tuberemoved from the engine. Flattening effect asa result of reforming shall not exceed 15percent of the tube OD.

Tighten No. 4 sizecoupling nut 80 to 120 in.lb (0.9-1.4 kg/m). TightenNo. 5 size coupling nuts150 to 200 in. lb (1.7-7.3kg/m).

Align rigid steel tubingwith its mating fittings.

Change 11 6-4.1/(6-4.2 blank)

6-5

TM 55-2840-231-23

6-5. Gas Producer Fuel Control - Rigging Check

INITIAL SETUP


AIRFRAME/

1. Gas Producer Check the rigging of the gas producer fuelRigging control after a deceleration check has re-

vealed the deceleration time to be less thanthe allowable limit. This check is also required after installation of a fuel control orany component of the rigging system. Makethe rigging check with the engine shut downusing the following procedure:

The allowable deceleration time is for anengine which is at normal operatingtemperature.

2. AIRFRAME/ Check to insure thatsufficient travel is providedto allow physical contactwith the gas producerminimum stop, at or beforethe full closed position ofthe twist grip.

Check the travel to theopposite end. Physicalcontact must be made withgas producer maximumstop at or before the fullopen position of the twistgrip.

Looseness encountered inrigging must be minimizedby replacement of wornitems and/or accuracy of therigging. Looseness thatcannot be removed must bewithin limits indicated inthe figure. Check thelooseness as follows:

Change 9

TM 55-2840-231-23

6-5. Gas Producer Fuel Control - Rigging Check - Continued

AIRFRAME/-Continued

2. AIRFRAME. a. Start with the twistgrip at the full openposition then rotate gripslowly to the IDLEposition, Pointer must beat the 30 degree mark.

b. Start with the twistgrip at the full closedposition then rotate gripslowly to the IDLEposition. The pointermust be no more than5/64 in. below the 30degree mark. If thepointer is more than 5/64in. below the 30 degreemark, rerig the aircraftlinkage to move thepointer closer to the 30degree mark.

NOTE

Make rigging adjustments using thepilot’s twist grip. If the copilot’scollective is installed, recheck thelinkage movement using the copilot’stwist grip. The pointer in IDLEposition, using the copilot’s twist grip,must be within 5/64 inch of the 30degree position when rotated fromthe full open or full closed positionand idle speed must be no lower thanidle speed obtained using the pilot’stwist grip. An engine performancecheck is required when riggingadjustment has been performed.

6-6 Change 11

TM 55-2840-231-23

6.6 Gas Producer Fuel Control - Idle Check

INITIAL SETUP

Applicable Configuration Special ToolsAll Wrench, Tool No 6798292

AIRFRAME/ NOTE

Dual control installation requires anidle speed check from the copilot’sside also. Idle speed must repeatevery time.

Check the repeatability of the idlespeed setting by running the engine.Generator current should be less than20 amperes. The stabilized idle speedshould repeat every time, regardlessof whether the fuel control throttleshaft is rotated slowly or rapidly fromthe full throttle to the idle position,and regardless of whether the pilot’sor the copilot’s twist grip is used.

Failure to repeat a stabilized idlespeed requires a recheck of the fuelcontrol rigging. Check for proper idlerigging as follows:

NOTE

Perform the entire idle speed checkwhenever fuel control rigging or idlespeed is adjusted.

1. Twist Grip. a. Roll twist grip to fullopen position then to idledetent. Mark (pencil) theprecise position of pointertip on the fuel controlquandrant with twist gripin IDLE position.

b. Release the idle detenton twist grip. Very slowlyroll the twist grip indirection of cutoff justenough to obtainperceptible movement ofpointer tip(approximately the widthof the pencil mark). Indexthe twist grip at thisposition.

6 - 7

TM 55-2840-231-23

6.6 Gas Producer Fuel Control - Idle Check - Continued

AIRFRAME/-Continued Very slowly roll the twistgrip in the direction ofincreased power fromIDLE position just enoughto obtain perceptiblemovement of pointer tip(approximately the widthof the pencil mark). Indexthe twist grip at thisposition. Move the pointerto exactly the 30 degreemark. Index the twist gripat this position.

c. Start the engine and letN1 stabilize in IDLEposition. Very slowly rollthe twist grip to indexmark in direction of cutoff. If N1 idle speeddecreases, take thefollowing correctiveaction.

d. If the pointer is at orabove the 30 degreemark, rerig aircraftlinkage to move pointertip to a point just belowthe 30 degree mark.

e. If pointer is more than5/64 in. (2.0 mm) below30 degree mark, rerigaircraft linkage to movecloser to 30 degree mark.The pointer must be at orwithin 5/64 in. below the30 degree mark.

6-8 Change 11

TM 55-2840-231-23

6-6. Gas Producer Fuel Control - Idle Check - Continued

AIRFRAME/-Continued

If N1 idle speed did not change, very slowlyroll the twist grip to index mark in thedirection of increased power. No increase inN1 speed is permitted before fuel controlpointer indicates 30 degrees as indicated ontwist grip index mark.

An increase in speed before the pointerreaches 30 degrees indicates the fuel controlinternal rigging is incorrect; replace the fuelcontrol. An increase at or above the 30degree mark is normal.

Using wrench 6798292, turn screw clockwiseto increase or counterclockwise to decreaseN 1 speed. A 1/8 turn adjustment changesengine speed approximate y 5%. If N 1 speeddoes not respond to the idle speed screwadjustment, the rigging is establishing idlespeed. Rerig as required. If N 1 speed doesrespond to the idle speed screw, make the62-65% (in the OH-6A), or 62-64% (in theOH-58A) N1 speed setting.

NOTE

Engine performance check is notrequired for idle speed adjustment ifrigging adjustment was notperformed. Following any riggingadjustments, perform the idle speedcheck.

When the rigging iscorrect, change idle speedadjustment screws toobtain a 62-65% N1 speedsetting (in the OH-6Ahelicopter) or 62-64% N1speed setting (in theOH-58A helicopter) withgenerator switch off. (Seefigure for location of fuelcontrol adjustment ).Adjust to 63% N1 speedsetting to allow forseasonal changes.

Change 11 6-8.1

TM 55-2840-231-23

6-7. Gas Producer Fuel Control - Deceleration Check

INITIAL SETUP

Applicable Configuration ReferencesAll para 6-5 and 6-7

1. AIRFRAME/

2. AIRFRAME/

6-8.2 Change 11

During rapid throttle movements,make appropriate anti-torquepedal corrections to prevent theaircraft from turning on loose orslick surfaces.

NOTE

Deceleration check is only requiredwhen using alternate fuel.

NOTE

JP-5/JP-8 fuel is designated as theArmy alternate fuel to be used in theT63-A-700. No deceleration timerestrictions are imposed on theengine when the Army primary fuel(JP-4) is used.

NOTE

Deceleration check. Ground check thefuel control system and associatedlinkage by performing a decelerationcheck. This check must be performedwith the engine at normal operatingtemperature.

NOTE

Perform each step in the sequencelisted. Recheck the deceleration rateafter each step to determine if thereis a need for further correction.Replace the fuel control if thedeceleration rate is stillunsatisfactory after all steps havebeen completed.

Turn generator switch off.

Rotate twist grip to fullopen hole collective at flatpitch and stabilize N2 atexactly 103% (trim asrequired) forapproximately fifteenseconds.

6-7. Gas Producer Fuel Control - Deceleration Check - Continued

3. AIRFRAME/ NOTE

Make rigging adjustments using thepilot’s twist grip. Recheck the linkagemovement using the copilot’s twistgrip. The limits of the figure shownbelow are applicable to both sets ofcontrols. The lower stop on the fuelcontrol is set at depot; do not attemptto adjust.

NOTE

TM 55-2840-231-23

Snap twist grip to IDLEposition. Simultaneouslystart a time count using astop watch or clock with asweep second hand. Stopthe time as N1 needlepasses through 65%, Theminimum allowable timeis two seconds,

If deceleration time isless than the timeallowed, make two morechecks to confirm thetime.

If the confirmeddeceleration time is lessthan the allowableminimum, perform arigging check. (Refer topara 6-5. )

Repeat the decelerationcheck. If the decelerationtime is less than timeallowable minimum,perform an IDLE speedcheck. (Refer to para 6-6. )

Repeat the decelerationcheck. If the decelerationtime is less thanallowable minimum,replace the fuel control.(Refer to para 6-1 1.)

An EPC is required after a riggingadjustment to the fuel control.

6 - 9

TM 55-2840-231-23

6-8. GAS PRODUCER FUEL CONTROL - REMOVAL

INITIAL SETUP


ENGINE/

1. Fuel Control Lever

2. Fuel Tube (5 and 6)

3. Fuel tube (9)

4. Air Tube (1)

5. Air Tube (2)

6. Air Tube (3)

6-10 Change 8

NOTE

Before replacing the fuel control tocorrect an engine malfunction, insurethat the pneumatic tubes and fittingsare not leaking and that the doublecheck valve is functioning properly.A malfunction which appears to be afuel control malfunction may becaused by erroneous pressures.

Remove the self-locking nutand remove the lever fromthe fuel control.

It will not be necessary to disturb the Remove tubes betweenclamping arrangement between the tubes. fuel pump (7) and control

(8).

Remove tube between thecontrol and fireshield.

Remove tube between thecontrol and governor.

Remove tube between thecontrol and governor.

Remove tube between thecontrol and accumulator.

Air Tube

TM 55-2840-231-23

6-8. GAS PRODUCER FUEL CONTROL - REMOVAL - Cont.

ENGINE/–Continued

7. Air Tube (4) Remove tube between thecontrol and governor.

Change 8 6-11

TM 55-2840-231-23

6-8. Gas Producer Fuel Control - Removal - Continued

ENGINE/ - Continued

8. Self- Locking Nutsand Washers

Carefully remove control from themounting studs.

Remove three self-locking nuts andwashers which securethe control to thegearbox. .

6-12

TM 55-2840-231-23

6-9 . Deleted.

6-10. Gas Producer Fuel Control - Fuel Filter - Cleaning and Replacement

INITIAL SETUP

Applicable Configuration Consumable MaterialAll Lubricating Oil (item 4, Appendix D)


GAS PRODUCER FUELCONTROL/

.

(6-13 blank) /6-14 Change 11

TM 55-2840-231-23

6-10. Gas Producer Fuel Control -Fuel Filter -Cleaning and Replacement. Continued

GAS PRODUCERFUEL CONTROL/ -Continued

Do not attempt to open a cloggedscreen with a sharp instrument.

1. Cleaning

NOTE

Spring (3) and retaining clip (7)are used only with filterassembly PN2539508.

Thoroughly clean ex-terior of fuel controlin the area of the plugto prevent contaminantsfrom getting into theport after it is opened.

Remove lockwire andremove plug (1), spring(3), and filter assembly(4). Discard preformedpacking (2).

Be sure strainer (8) is installed asshown in figure, Open end ofstrainer toward the outside of thecontrol, away from the spring. Donot install backwards,

Remove retaining clip(7), spring pin (6), andseparate washer (10),spring (9), and strainer(8) from filter assembly(4).

Use extreme care to insure that thepneumatic lines and fittings are notleaking. Erroneous pressures willcause fuel control malfunction.

Change 6 6-15

TM 55-2840-231-23

6-10. Gas Producer Fuel Control - Fuel Filter - Cleaning ond Replacement - Continued

GAS PRODUCER FUELCONTROL/-Continued

6-16

Use dry cleaning solvent (item 1, AppendixD)

Change 11

Clean filter assemblyparts ultrasonically ifequipment is available. Ifequipment is notavailable, agitate parts insolvent. Dry parts usingclean shop air regulatedto approximately 15 psig.Air pressure should beapplied to the exterior ofthe strainer. Repeat theprocedure if visualinspection with a brightlight shows that theinterior of the strainer isnot entirely free ofcontaminants.

Install strainer (8), spring(9), and washer (10) infilter sleeve (5). Securecomponents in the filtersleeve with spring pin (6)and retaining clip (7).

Lightly lubricate a newpreformed packing (2)with engine fuel andplace it on plug (1). Installfilter assembly (4), spring(3) and plug ( 1 ) in fuelcontrol. Tighten plug to65-70 in. lb (0.7-0.8 kg/m)and lockwire. Bleed thefuel system. (Refer toparagraph 6-2 ).

TM 55-2840-231-23

6-11. GAS PRODUCER FUEL CONTROL - INSTALLATION

INITIAL SETUP


Grease (item 37, Appendix D)Antiseize Compound (item 6, Appendix D)

ReferencesPara 1-63 thru 1-71, 6-2, 6-3, 6-5, 6-7, and

6-12

Change 8 6-17

TM 55-2840-231-23

6-11. Gas Producer Fuel Control - Installation - Continued

FUEL CONTROL/


1. Drive ShaftSplines, and Studs

ENGINE/

2. Fuel Control

When removing or installing fittingsin the fuel control, be careful not tocause a load on the drive shaft.

If a new fuel control is to be installed,transfer the tube fittings from theremoved control to the new control.Use new preformed packings. Lubri-cate preformed packings on fuel tubefittings with oil (item 4, Appendix D).Do not lubricate preformed packingson air tube fittings, Tighten unionsto 75-110 in. lb (0.9 -1.3 kg/m). Donot tighten jam nuts.

Grease (item 37, Appendix D)Antiseize Compound (item 6, Appendix D)Oil (item 4, Appendix D)

Make certain the fuel control drive splinesare properly engaged in the gearbox drivesplines; the fuel control must be flushagainst the gearbox mounting pad.

Coat fuel control driveshaft splines with lubri-cant, the studs withantiseize compound, andfuel tube fitting withoil.

Install fuel control onmounting pad studs.

6 - 1 8

TM 55-2840-231-23


FUEL CONTROL/ -Continued

3. Heating Tube

4. Air Tube (5)

If the engine has a fuelcontrol heating kit in-stalled, install heatingtube on the two studs atthe bottom of the fuelcontrol mounting pad.Secure the control withthree washers andself-locking nuts.Tighten nuts to70-85 in. lb (0.8 -1.0kg/m).

Install air tube betweenfuel control and governor.Tighten coupling nuts to80-120 in. lb (0.9 -1.4kg/m).

Change 6 6-19

TM 55-2840-231-23

6-11. GAS PRODUCER FUEL CONTROL - INSTALLATION - Cont.

FUEL CONTROL/–Continued

5. Air Tube (3) Install air tube (3) betweencontrol and accumulator.Tighten coupling nuts to8-80-120 in. lb (0.9-1.4 kg/m).Tighten jam nut on tubefitting to 55-80 in. lb (0.6-0.9kg/m).

1. Air Tube 5. Air Tube2. Air Tube 6. Fuel Tube3. Air Tube 7. Fuel Tube4. Fuel Tube

6-20 Change 8

6-11. Gas Producer Fuel Control - Installation. Continued

FUEL CONTROL/Continued

6. Air Tube (2) Install air tube (2) between control andgovernor. Tightencoupling nuts to 80-120in. lb (O.9- 1.4 kg/ m).Tighten Jam nut on tubefitting to 55-80 in. lb(0.6 -0.9 kg/m).

7. Fuel Tube (4)

8. Air Tube (l)

9. Fuel Tubes (6 and7)

10. Lever (Refer to paragraph 6-7.)

NOTE

Overtorquing nut causes binding ofthe lever shaft.

Install fuel tube (4) be-tween control and fire-shield. Tighten couplingnuts to 80-120 in. lb(0.9 -1.4 kg/m ).

Install air tube (1) be-tween control andgovernor. Tightencoupling nuts to 80-120in. lb (0.9 -1.4 kg/m).Tighten jam nut to 55-80 in. lb (0.6 -0.9 kg/m).

Install fuel tubes (6 and7) between fuel pumpand control. Tightencoupling nuts to 150-200in. lb (1.7 -2.3 kg/m).

Assemble lever on con-trol and secure with aself-locking nut. Posi-tion lever in accordancewith rigging instructionscontained in applicableaircraft manual.

Change 6 6-21

TM 55-2840-231-23


ENGINE/

11. Pneumatic Tubes

12. Fuel System

ENGINE/

(Refer to paragraph 6-3. )

(Refer to paragraph 6-2.

Check pneumatic tubesfor leaks.

Bleed the fuel system.

Test the engine asoutlined in paragraphs1-63 thru 1-71 and makethe following adjustmentsif required.

a. Idle speed. (Refer toparagraph 6-5. )

b. Start derichment.(Refer to paragraph 6-12. )

c. Start acceleration(AVIM) (paragraph6-12.1)

d. Max speed stop(paragraph 6-14. )

Do not adjust minimum stopscrew, it is a factory adjustment.

Make appropriate entryrelative to fuel controlreplacement in the enginelog.

6-12. Gas Producer Fuel Control - Start Derichment Adjustment

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Lockwire (item 7, Appendix D)

AIRFRAME/

1. Fuel Control

Do not disturb the pointer-to-shaft sealed wire at any time.This is an overhaul function only.

6-22 Change 11

TM 55-2840-231-23

6-12. Gas Producer Fuel Control - Start Derichment Adjustment - Continued

AIRFRAME /-Continued.

2. Lockwire

3. Locknut

During attempted start, T O Tmust be closely monitored toprevent overtemperature opera-tion. Record overtemperature inthe Engine Log.

Turn clockwise to enrich the startingfuel flow to improve stagnated starts,cold weather starts, or high altitudeground starts. Turn counterclockwisefor-a leaner fuel flow when starts are toohot. Make the adjustment in 10-degreemaximum increments (dots are 10degrees apart) and tighten locknut 20-25 lb in. (2.3 -2.8 N.m) after each setting.Check the starting peak TOT after eachsetting until satisfactory starts aremade.

Remove lockwire secur-ing adjustment locknutto Pc filter fitting.

L o o s e n a d j u s t m e n tlocknut.

Make adjustmentan Allen wrench.

Change 9

using

6-23

TM 55-2840-231-23

6-12. Gas Producer Fuel Control - Start Derichment Adjustment - Continued

AIRFRAME/-Continued

4 . L o c k n u t a n dLockwire. Lockwire (item 7, Appendix D). When desired

adjustment iso b t a i n e d ,secure locknutto Pc filter- fit-t i n g w i t hlockwire.

Monitor TOT closely after start derich-m e n t a d j u s t m e n t t o b e s u r eovertemperature limits are not exceed-ed.

NOTE

An Engine performance check is not re-quired for this adjustment,

6-12.1. Gas Producer Fuel Control - Start/Acceleration Fuel Flow Adjustment - AVIM.

INITIAL SETUP

Applicable Configuration Consumable MaterialsLatest Modified Fuel Control Lockwire (item 17, Appendix C)

AIRFRAME

1. Fuel Control The Start /accelerat ion fuel f lowschedule adjustment maintains the gasproducer fuel control starting schedulewithin acceptable limits during normalservice life.

To optimize engine starting, the start -derichment adjustment should be madein conjunction with the start/accelera-tion adjustment. (Refer to table andchart.)

6 - 2 4 Change 9

TM 55-2840-231-23

6-12.1. Gas Producer Fuel Control - Start /Acceleration Fuel Flow Adjustment - AVIM - Continued

AIRFRAME/Continued

Adjustments to Improve Starting.

Condition Recommended Adjustments

Excessive lightoff temperature - over Adjust start /acceleration counterclockwise.810° C(1490° F) with momentary If any additional correction is necessary,peak of one second max at 927° C a d j u s t s t a r t - d e r i c h m e n t(1700° F) for a period not to ex- counterclockwise. (Refer to subparagraphteed 10 seconds. N 1 speed below 2 and paragraph 6-12 for procedures.)20%.

Low lightoff temperature - lightoff Adjust start/acceleration clockwise. (Refert e m p e r a t u r e b e l o w to subparagraph 2 for procedure.)550 oC(1022 oF) with N1 speedbelow 20% and slow accelera-tion.

High rapid temperature rise with N1 Adjust start/derichment counterclockwise.speed at 25.30%. If any additional correction is necessary,

a d j u s t s t a r t / a c c e l e r a t e o ncounterclockwise. (Refer to subparagraph2 and paragraph 6-12 for procedures.)

Low lightoff temperature with slowstart - lightoff temperatureb e l o w ’ a p p r o x i m a t e l y550 OC(1022 OF) with startingtime approaching 60 seconds (ormore) and N1 speed hesitation at20-33%.

High lightoff temperature - over810 OC(1490 OF) with a momen-tary peak of one second max at927°C (1700OF) for a period notto exceed 10 seconds and N1speed at 35-55%.

Low lightoff temperature with slow-to-h u n g s t a r t s - l i g h t o f ftemperature below approximate-ly 550°C(1022OF) with startingtime approaching 60 seconds (ormore) and N1 speed hesitation at35-55%.

Adjust start-derichment clockwise. Ifadditional correction is necessary, adjuststart acceleration clockwise. (Refer tosubparagraph 2 and paragraph 6-12 forprocedures.)

Adjust start/acceleration counterclockwise.(Refer to subparagraph 2 for procedures.)

Adjust start/acceleration clockwise.(Refer to subparagraph 2 for procedures.)

Change 9 6-24.1

TM 55-2840-231-23

6-12.1. Gas Producer Fuel Control - Start/Acceleration Fuel Flow Adjustment - AVIM - Continued

AIRFRAME/Continued

6-24.2 Change 9

TM 55-2840-231-23


AIRFRAME/Continued

2. Lockwire

Do not use start/acceleration adjustmentto correct normal maintenance items suchas misrigging, air leaks, fuel leaks, faultyfuel nozzle, ignition problems, starter-generator systems problems, etc. Do notuse the start acceleration adjustment ex-clusively to improve engine starting. Ex-cessive clockwise settings before en-countering overtemperature results in asingle high peak TOT over a wide speedrange for a large part of the starting time.Use start-derich adjustment with start/ac-celeration adjustment to optimize enginestarting.

NOTE

To accurately determine proper adjust-ment, conditions under which the ad-justments are made should be consistent,i.e., a fully charged aircraft battery, thesame residual TOT and the same lightoffspeed.

There are eight positions for the adjuster(the neutral position is three clicks fromthe counterclockwise stop). Detent grooveshold the adjuster in the selected one ofthese positions without the need of a jamnut.

A required adjustment of more than twoclicks clockwise is an indication that thefuel control is not the cause of the pro-blem.

F o r l o w l i g h t o f f t e m p e r a t u r e o rslow/hung star ts , turn the adjusterclockwise.

An over adjustment of the start/ac-celeration clockwise setting can causeovertemperature starts or compressorsurge.

Remove l ockwi re andmake start /accelerationfuel flow adjustment asfollows:

M a k e a d j u s t m e n t i nchanges of one detent(click) at a time.

Change 9 6-24.3

TM 55-2840-231-23

6-12.1. Gas Producer Fuel Control - Start/Acceleration Fuel Flow Adjustment. AVIM Continued

AIRFRAME/Continued

NOTE

If adjuster is positioned to the fullclockwise stop and low l ightofftemperatures or slow/hung starts arestill encountered, ensure there are nopneumatic leaks.

For excessive lightoff temperatures t a r t s , t u r n t h e a d j u s t e rcounterclockwise.

An over adjustment of the start/ac-celeration counterclockwise setting cancause an increase in staring time andpossibly a hung start.

Lockwire (item 7, Appendix D).3. Lockwire

Make the adjustment inchanges of one detent(click) at a time.

When the final start/ac-celeration adjuster posi-t i on i s e s t ab l i shed ,lockwire the pointer ina c c o r d a n c e w i t hreferenced figure.

6-24.4 Change 9

TM 55-2840-231-23


AIRFRAME/Continued

Check idle speed and deceleration timeafter the final start setting is determin-ed.

NOTE

An engine performance check is re-quired for this adjustment.

Change 9 6 - 2 4 . 5

TM 55-2840-231-23

8-13. Preparing Gas Producer

INITIAL SETUP


Fuel Control For Storage and Shipment

Consumable MaterialsLubricating Oil (item 4, Appendix D)Drycleaning Solvent (item 1, Appendix D)Corrosion Preventive Compound (item 11, Appendix D)

ReferencesPara 1-36, 1-39, 2-7 and 2-20TM 38-750

GAS PRODUCERFUEL CONTROL/

NOTE

The procedure for removing the gasproducer fuel control from the metalshipping and storage (container isprescribed in the applicable provisionsof paragraph 2-20.

Prepare the gas producer fuel control for stor-age, shipment, and installation in a metalshipping and storage container, MS63048-1, asfollows. The fuel control consists of an airsection and a fuel section; each section mustbe treated separately when preparing the unitfor storage and shipment.

Do not permit fuel or oil to enter thedrive body cavity or any air pressureports,

a. Install shipping plugsin the compressor dis-charge pressure, govern-ing pressure, Py airpressure, and regulatedair pressure ports.

Change 96-24.6 U.S. Government Printing Office: 1987-754-043/43575

TM 55-2840-231-23

6-13. Preparing Gas Producer Fuel Control For Storage and Shipment - Continued

GAS PRODUCER FUELCONTROL/-Continued


Lubricating Oil (item 4, Appendix D) b. Drain residual fuelfrom fuel control. Placethrottle lever against themaximum stop. Pump/pour lubricating oil intoinlet port. When clean oilflows out of bypass andfuel outlet ports, removethe source of oil. Plug theinlet, bypass and outletports. Reposition thethrottle lever forshipping.

Change 11 6-25

TM 55-2840-231-23


GAS PRODUCERFUEL CONTROL/-Continnued

NOTE

If the engine fuel system was pre-served in accordance with paragraph1-36, step b maybe omitted.

Drycleaning solvent, P-D-680, usedto clean parts is potentially dangerousto personnel and property. Avoidrepeated and prolonged skin oontact.Avoid prolonged or repeatedbreathing of vapors, Do not usenear open flame or excessive heat.Flash point of solvent is 100°F -138°F (38OC - 590C).

Use drycleaning solvent (item 1, AppendixD).

Use corrosion preventive compound (item11, Appendix D).

c. Clean exterior of thefuel control with a cleancloth dampened withsolvent. Air dry or wipewith a clean lint-freecloth. Blow out allcrevices with dry, filtered,low-pressure compressedair.

d. Coat external baremetal surfaces includingthe splines with corro-sion preventive compound.

e. Attach a tag to thefuel control stating:FUEL CONTROLPRESERVED WITHLUBRICATING OIL,MIL-L-6081, GRADE1010.

6-26

TM 55-2840-231-23


GAS PRODUCERFUEL CONTROL/ -C ontinued

f. Attach a properlyfilled out DD Form1577-2 (Unserviceable-Reparable tag). Referto paragraph 1-39 foradditional informationconcerning tags.

g. Prepare DA Form2410 (ComponentRemoval and Repair/Overhaul Record) ac-cording to TM 38-750and place in a grease-proof envelope. (Referto paragraph 1-39.)

h. Wrap fuel controlwith barrier material toprevent contact with thecushioning material andto prevent the loss ofthe corrosion preventivecompound. Securebarrier material withpressure-sensitive tape.

i. Prepare the containerfor use in accordancewith paragraph 2-7.

j. Install the fuel con-trol upright in thecontainer in accordancewith paragraph 2-7.

k. Stencil the containerin accordance with para-graph 1-39.

6-27

TM 55-2840-231-23

6-14. Fuel Control Max Speed Stop - Check

INITIAL SETUP

Applicable Configuration Special ToolsAll Fuel Control Max Stop Screw Setting

Fixture, Tool No. 6872482—

1. Control Stick

Because engines differ on required-to-runfuel flow requirements, it may be necessaryto adjust gas producer fuel control maximumstop to maintain N2 speed of 103% rpm at thehigher power setting. It may also benecessary to make an N1 adjust duringacceptance testing to meet the requirementfor takeoff power.

The max speed stop setting can be checkedduring ground operation of the engine byfirst installing a fixture (spacer) between thethrottle lever stop and the max speed stopscrew. The spacer (Fuel Control Max StopScrew Setting Fixture 6872482) is sized tostop the throttle lever at 84% N 1 speed whichis 20% below the 104% max continuous limitof the engine. Make the max speed stopsetting as follows:

Attach a warning note tothe pilot’s control stick.The note shall read:

ENGINE/

2. Fuel Control

3. Throttle LeverRetaining Nut

Maintenance tool installedon the fuel control.

Make a match markacross the serrations offuel control throttle leverand arm for reference incase the relative index isdisturbed during check.

Remove the throttle leverretaining nut. Do notremove the throttle lever.

6-28 Change 11

TM 55-2840-231-23

6-14. Fuel Control Max Speed Stop - Check - Continued

INITIAL SETUP

Applicable Configuration Special ToolsAll - Fuel Control Max Stop Screw Setting

Fixture, Tool No. 6872482

4. Throttle Lever Shaft Place the Fuel ControlMax Stop Screw SettingFixture 6872482 (20% N1Spacer Tool) on the levershaft,

Adjust Bendix control P/N2524909-2 and later,start/accelerationadjustment (paras 6-12and 6-12.1)

Change 11 6-28.1 /(6-28.2 blank)

TM 55-2840-231-23


Ensure aft engine oil coolercowling is secured to prevent20% N1 fixture red flag frombeing blown into oil cooler shaftarea during engine operation.

Overtightening the nut can causebinding of the throttle shaft.

AIRFRAME/

The helicopter may lift off duringthis check if it is not sufficientlyloaded.

Check for max N 1 rpmwith tool installed asfollows:

a. Start engine andstabilize at idle.

b. Advance throttle as faras it will go. Adjust beepto maximum position.

Change 11 6-29

TM 55-2840-231-23


AIRFRAME/ -Continued

c. Lift collective slowlyuntil N2 rpm decays 3or 4%. At this pointN1 is at max rpm.Record N1.

6. Fuel Control

NOTE

Assure the accuracy of the TOT andN1 indicating systems prior to ad-justing the max speed stop screw.

EXAMPLE:82.4% N1 indicator reading

+20.0% tool allowance102.4% N1 max setting

d. Make a normalengine shutdown.

Adjust max speed stopscrew as follows, ifrequired.

a. Add 20% to N1 read-ing to account for fix-ture 6872482. Thetotal should be 104%.

b. If N1 max setting isabove 104%, make noadjustment. If settingis less than 104%, as inexample, turn maxspeed atop screw clock-wise into casting toincrease N1 speed.

It is recommended that screw be turned inincrements of one turn maximum beforesetting is rechecked. Repeat the settinguntil 104% is attained. One turn equalsapproximately 1% speed.

Remove fixture 6872482and reinstall throttlelever nut. Tighten nutto 40-60 in. lb (0.5 -0.6 kg/m ). Be surethrottle lever matchmark is still alined,

6-30

TM 55-2840-231-23


Check that throttlelever stop contacts maxspeed stop screw.

AIRFRAME/ Remove warning notefrom pilot’s controlstick.

NOTE

This concludes the ground adjustmentof the max speed stop screw. However,if the allowable limit of one of thethree main indicators (torque, tempera-ture, or N1 speed) cannot be reachedin flight, readjust the max speed stopscrew. Do not exceed existing torque,temperature or N1 limits.

6-15. Fuel Pump - Removal

INITIAL SETUP


ENGINE/

1. Before-Filter and Disconnect lines.After-Filter PressureLines (7 and 8)

6-31

TM 55-2840-231-23

6-15. Fuel Pump - Removal - Continued

ENGINE/ - Continued

2. Seal Drain Line (6)Disconnect from fuelpump (5).

3. Fuel Supply HoseDisconnect at pumpinlet (4).

4. Fuel Tubes (2 and 3) It will not be necessary to disturb clamping Remove fuel tubes be-arrangement between the tubes. tween fuel pump and

control.

6-32

TM 55-2840-231-23


ENGINE/-Continued

5. Bolts (14) If engine has an autoreignition systeminstalled, remove twobolts (14) securing plate(13) to bracket (12).

6. Nuts (16) and Washers(15)

Remove three self-lockingnuts (16) and washers(15) which secure fuelpump (10) and plate (13)to gearbox.

Change 11 6-33

TM 55-2840-231-23


ENGINE/ - Continued

7. Pump and Plate

8. Gasket (11) andReformed Pecking(9)

Remove pump and platefrom mounting studs.

Remove and discardmounting flange gasket(11 ) and preformedpacking (9).

If a new pump is to be installed, remove thetube fittings and keep them for installationin the new pump. Discard the preformedpackings.

6-16. Fuel Pump - Installation

INITIAL SETUP



ReferencesPara 1-63 thru 1-71

If a new pump is to be installed, transfertube fittings from removed pump to newpump. Use new preformed packings lubri-cated with oil (item 4, Appendix D).Tighten fittings in inlet, discharge, andbypass ports to 75-110 in. lb (0.9 -1.3kg/m). Tighten fittings in the before-filter,after-filter, and seal drain ports to 55-80in. lb (0.6 -0.9 kg/m).

6-34

TM 55-2840-231-23

6-16. Fuel Pump - Installation - Continued


6-35

TM 55-2840-231-23


1. Preformed Packing Lubricating Oil (item 5, Appendix D). Lubricate new preformed(1) packing (1) and install

on pump drive.

2. Fuel Pump (2) Lubricating Oil (item 5, Appendix D). Coat fuel pump drivesplines with lubricatingoil.

T63-A-700 If the engine has an autoENGINE/ reignition system in-

stalled, install pumpwith new gasket (3) onmounting pad studs.

3. Fuel Pump (2)

6-36

If the engine has anauto reignition systeminstalled, install plate(4) on lower mountingstud. Secure plate tobracket (5) with twobolts (6). Tightenbolts to 35-40 in. lb(0.4 -0.5 kg/m).

secure pump withthree washers (7) andself-locking nuts (8).Tighten nuts to 70-85in. lb (0.8 -1.0 kg/m).

TM 55-2840-231-23


6-37

TM 55-2840-231-23


ENGINE/-Continued

4. Fuel Tubes (9 and 10)

5. Fuel Supply Hose

6. Before-Filter, After-Filter, and Seal DrainHoses (13. 14 and 15)

Install fuel tubes betweenfuel pump (12) andcontrol. Tighten tubecoupling nuts to 150-200in. lb (1.7-2.3 kg/m).

Connect fuel supply hoseat pump inlet (11). Tightencoupling nut to 150-200in. lb (1.7-2.3 kg/m).

Connect hoses. Tightencoupling nuts to 80-120in. lb (0.9-1.4 kg/m).

NOTE

On the first start after fuel pump hasbeen changed, return the gasproducer lever to fuel cutoff andmotor the engine for about 10 secondsif a false start occurs or if a start isnot completed within 45 seconds.

Following installation of the fuelpump test the engine as outlined inparagraphs 1-63 thru 1-71.

6-17. Fuel Pump and Filter Assembly - Preparation For Storage and Shipment

INITIAL SETUP


Lubricating Oil (item 4, Appendix D)Corrosion Preventive Compound (item 11,

Appendix D)Tape (item 3, Appendix D)

ReferencesPara 1-36, 1-39, 2-7, 2-20 and 1-6

6-38 Change 11

TM 55-2840-231-23

6-17. Fuel Pump and Filter Assembly - Preparation For Storage and Shipment - Continued

NOTE

The procedure for removing the fuelpump and filter assembly from themetal shipping and storage containeris prescribed in the applicable pro-visions of paragraph 2-20.

Prepare the fuel pump and filter assembly forstorage, shipment, and installation in a metalshipping and storage container, MS63052-1,as follows:

1. Fuel Pump andFilter Assembly

Drycleaning solvent, P-D-680, usedto clean parts is potentially dangerousto personnel and property. Avoid re-peated and prolonged skin contact.Avoid prolonged or repeatedbreathing of fumes. Do not usenear open flame or excessive heat.Flash point of solvent is 100° F -138°F (38°C - 59°C).

Solvent (item 1, Appendix D).


a. Clean exterior of fuelpump with a clean clothdampened with solvent.Air dry or wipe with aclean lint-free cloth.Blow out all creviceswith dry, filtered, low-pressure compressed air.

6-39

TM 55-2840-231-23


Oil (item 4, Appendix D) b. Pump lubricating oilinto fuel inlet portuntil fuel-free oil flowsfrom the outlet port.Drain excess oil fromfuel pump.

NOTE

If the engine fuel system was pre-served in accordance with paragraph1-36, step b maybe omitted.

c. Install shipping plugsin all ports to prevententry of foreign material.

Corrosion Preventive Compound (item 11, d. Coat external bareAppendix D). metal surfaces including

the splines with corro-sion preventive com-pound.

e. Attach a tag to thefuel pump stating: FUELPUMP PRESERVEDWITH LUBRICATINGOIL, MIL-L-6081,GRADE 1010.

f. Attach a properly filled”out DD Form 1577-2(Unserviceable-Reparabletag). Refer to paragraph1-39, for additionalinformation concerningtags.

g. Prepare DA Form 2410(Component Removal andRepair/Overhaul Record)according to TM 38-750and place in a greaseproofenvelope. (Refer toparagraph 1-39.)

6 - 4 0

TM 55-2840-231-23


Tape (item 3, Appendix D). h. Wrap fuel pump withbarrier material toprevent contact with thecushioning material andto prevent the loss ofthe corrosion preven-tive compound. Securebarrier material withtape.

i. Prepare containerfor use in accordancewith paragraph 2-7.

j. Install fuel pump up-right in the containerin accordance withparagraph 2-6.

k. Stencil container inaccordance with para-graph 1-39.

6-18. Power Turbine Governor - Removal

INITIAL SETUP


NOTE

Before replacing the power turbinegovernor to correct an engine mal-function, insure that the pneumatictubes and fittings are not leakingand the double check valve is func-tioning properly. A malfunctionwhich appears to be a governor mal-function may be caused by erroneouspressures.

6-41

TM 55-2840-231-23

6-18. Power Turbine Governor - Removal - Continued

ENGINE/

1. Self-Locking Nutsand Lever

2. Air Tube (7)

3. Air Tube (3)

4. Air Tube (4)

5. Air Tube (2)

6. Air Tube (8)

GOVERNOR/

7. Self-Locking Nuts(9), Washers (10)

Remove self-lockingnut and remove leverfrom governor (6).

Remove air tube (7)between scroll andgovernor tee.

Remove air tube (3)between governor tee (5)and fuel control.

Remove air tube (4)between governor andfuel control.

Remove air tube (2) be-tween governor andsecond accumulator (l).

Remove air tube (8)between governor andcontrol.

Remove three self-locking nuts (9), andwashers (10) securinggovernor to gearbox.Remove governor frommounting studs.

6-42

TM 55-2840-231-23

6-18. Power Turbine Governor - Removal - Continued

ENGINE/ - Continued

Change 3 6-43

TM 55-2840-231-23

6-19. Power Turbine Governor - Drive Gear Replacement

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Grease (item 18, Appendix D)

POWER TURBINEGOVERNOR/

1. Retaining Ring

2. Drive Gear, Spring,and Drive Sleeve

3. Drive Shaft andDrive Gear

4. Drive Sleeve

6. spring

6. Spring

7. Drive Gear

Grease (item 18, Appendix D).

Remove and discardretaining ring securingdrive gear on governordrive shaft.

Slide drive gear springand drive sleeve fromdrive ahaft.

Coat splined surfaces ofdrive shaft and drivegear with grease.

Install drive sleeve ondrive shaft with the flatside toward governor.

Slip spring on driveshaft and engage straighttang on the end ofspring in the small holein drive aleeve.

Engage straight tang onopposite end of springin small hole in drivegear.

Rotate drive gear 90degrees clockwise toimpose a spring preloadand engage drive gearin splines on drive shaft.Slip drive gear ontoshaft until drive sleeveand drive gear segmentsengage; then install anew retaining ring onend of drive shaft.

6-44

TM 55-2840-231-23

6-20. Power Turbine Governor - Installation


Consumable MaterialsGrease (item 37, Appendix D)Antiseize Compound (item 6, Appendix D)

ReferencesPara 1-63 thru 1-71 and 6-3

When removing or installing fittingsin the governor, be careful not tocause a load on the drive shaft.

If a new governor is to be installed,transfer the tube fittings from theremoved governor to the new gover-nor. Use new preformed packings;do not lubricate. Do not tightenjam nuts. Tighten nipples to 75-110in. lb (0.9 -1.3 kg/m).

POWER TURBINEGOVERNOR/

1. Drive Shaft

ENGINE/

Grease (item 37, Appendix D)Antiseize Compound (item 6,Appendix D).

Coat governor driveshaft splines with lubri-cant and the studs withantiseize compound.Do not lubricate tubefittings.

Install governor onmounting pad studs.Make certain governordrive splines are properlyengaged in gearboxdrive splines, thegovernor must be flushagainst gearbox mount-ing pad.

6-45

TM 55-2840-231-23

6-20. Power Turbine Governor - Installation - Continued

6 - 4 6

6-47

TM 55-2840-231-23

6-20. Power Tubine Governor- Installation - Continued

ENGINE/ - Continued

3. Air Tube (2) Install air tube (2) be-tween governor andsecond accumulator (6).Tighten coupling nutsto 80-120 in. lb (0.9-1.4 kg/m).

4. Air Tube (4)

5. Air Tube (3)

6. Air Tube (5)

7. Governor Lever

Perform a fuel system pneumatic leak check,(Refer to para 6.3. )

Overtorquing will cause bindingof the lever shaft.

Install air tube (4) be-tween governor endcontrol. Tightencoupling nuts to 80-120 in. lb (0.9-1.4 kg/m).Tighten elbow jam nutto 55-80 in, lb (0.6-0.9kg/m).

Install air tube (3) be.tween governor tee andcontrol. Tightencoupling nuts to 80-120in. lb (0.9-1.4 kg/m),Tighten tee jam nut to55-80 in. lb (0.6-0.9Win).

Install air tube (5) between scroll and governortee. Tighten couplingnuts to 80-120 in. lb(0.9-1.4 kg/m).

Install governor leveron governor shaft endposition approximately90 degrees to centerlineof indicator on stopassembly Secure leverwith self-locking nut.Tighten nut to 40-50 in.lb (0.5-0.6 kg/m).

TM 55-2840-231-23

6-20. Power Turbine Governor - Installation - Continued

ENGINE/-Continued Adjust aircraft linkage asoutlined in the applicableAircraft MaintenanceManual.

6-21. Deleted.

6-48 Change 11

Test the engine asoutlined in paragraphs1-63 thru 1-71. Makeappropriate entry relativeto governor replacementin the engine historicalrecords.

Pages 6-49 through 6-51 deleted.

TM 55-2840-231-23

6-22. Power Turbine Governor - Preparation For Storage and Shipment

INITIAL SETUP


Corrosion Preventive Compound (item 11,Appendix D)

Tape (item 3, Appendix D)Barrier Material (item 2, Appendix D)

ReferencesPara 1-39, 2-7 and 2-20

NOTE

The procedure for removing thepower turbine governor from themetal shipping and storage con-tainer is prescribed in the applicableprovisions of paragraph 2-20.

Prepare the power turbine governor for stor-age, shipment, and installation in a metalshipping and storage container, MS27684-2,as follows:

Use extreme care to prevent foreignmaterial from entering the pneumatictubes or the governor ports.

a. Install shipping plugsin all ports to prevententry of foreign material.

Drycleaning solvent, P-D-680, usedto clean parts is potentially dangerousto personnel and property. Avoidrepeated and prolonged skin con-tact. Avoid prolonged or repeatedbreathing of vapors. Do not use nearopen flame or excessive heat. Flashpoint of solvent is 100°F - 138°F(38°C - 59°C).

6 - 5 2

TM 55-2840-231-23

6-22. Power Turbine Governor - Preparation For Storage and Shipment - Continued

Barrier Material (item 2, Appendix D)Tape (item 3, Appendix D)

serviceable-Repairabletag), Refer to paragraph1-39 for additional in-formation concerning tags.

e. Prepare DA Form 2410(Component Removal andRepair/Overhaul Record)according to DA Pamphlet738-751 and place in agrease-proof envelope.(Refer to paragraph 1-39.)

f. Wrap governor with bar-rier material to preventcontact with the cushioningmaterial and to prevent theloss of the corrosion pre-ventive compound. Securebarrier material with tape.

g. Prepare container foruse in accordance withparagraph 2-7.

Change 11 6-53

TM 55-2840-231-23

6-22. Power Turbine Governor - Preparation For Storage and Shipment - Continued

h. Install governorupright in the container inaccordance with paragraph2-7.

i. Stencil container inaccordance with paragraph1-39.

6-23. Diaphragm - Type (Cylindrical) Valve - Removal

INITIAL SETUP


ENGINE/

1. Clamp (1)

2. Air Hose (2)

3. Accumulator (7)

4. Union (11) and Elbow(9)

6-54 Change 13

TM 55-2340-231-23

6-23. Diaphragm - Type (Cylindrical) Valve - Removal - Continued

5. Clamp Assembly (6)

6. Check Valve (13)

Remove clamp assembly(6) from fireshield andcheck valve (13).

Hold accumulate (16)with backup wrench andremove check valve (13)by turning on hexagonalsurface on check valve ad-jacent to union. Discardo-ring.

Change 13 6-55

TM 55-2840-231-23

6-23. Diaphragm - Type (Cylindrical) Valve - Removal - Continued

6-56 Change 13

TM 55-2840-231-23

6-23. Diaphragm - Type (Cylindrical) Valve - Installation

INITIAL SETUP

Change 13 6-57

TM 55-2840-231-23

6-24. Diaphragm - Type (Cylindrical) Valve - Installation - Continued

6-58 Change 13

TM 55-2840-231-23

6-24. Diaphragm - Type (Cylindrical) Valve - Installation - Continued

7. Nut

8. Clamp (1)

9. Nut

10. Clamp (16)

11. Nut (18)

12. Clamp Assembly (6)

Place new o-ring onaccumulator (7). Do notlubricate o-ring.

Screw accumulator onelbow (19). Hold backupwrench on elbow andtighten accumulator 55-80in. lb (0.6-0.9 kg/m) byturning on hexagonalsurface on accumulatoradjacent to elbow.

Install nut on hose (2) tounion (4). Do not tighten.

Install clamps (1) andtighten clamping nuts to35-40 in. lb (0.4-0.5 kg/m).

Hold union (4) withbackup wrench. Tightennut on hose (2) to 80-120in. lb (0.9-1.4 kg/m).

Change 13 6-59

TM 55-2840-231-23

6-25. Accumulator - Removal

Para 6-30

6-60

6-61

TM 55-2840-231-23

6-25. Accumulator - Removal - Continued

ENGINE/ - Continued

11. Preformed packing(12)

Do not torque through thedouble check valve at any time.When the double check valveis removed use extreme careto prevent foreign materialsfrom entering the pneumaticlines or the double check valve.

Discard.

TM 55-2840-231-23

6-26. Accumulator - Installation

INITIAL SETUP

Applicable Configuration ReferencesAll Para 6-3

ENGINE/

1. New preformedpacking (11)

2. Double checkvalve (10)

3. Double checkvalve (10)


5. Union (8) andelbow (7)

6. Check valve (10)

7. Clamp (12) andnut (14)

6-62

NOTE

Do not lubricate preformedpacking.

NOTE

Do not lubricate preformedpacking.

Place on accumulator(13).

Screw on accumulator(13). Hold accumula-tor with backupwrench.

Tighten 55-80 in. lb(0.6-0.9 kg/m) byturning on the hexagonalsurface of the checkvalve adjacent to theaccumulator.

Place on union (8).

Screw on check valve(10).

Hold with backupwrench on hexagonalsurface adjacent tounion and tighten union55-80 in. lb (0.6-0.9kg/m).

At this point it may benecessary to loosen inorder to align assembly.

TM 55-2840-231-23

6-26. Accumulator - Installation - Continued

ENGINE/ - Continued

8. Elbow (15) Hold with backupwrench and loosen nut(16). Loosen clampso accumulator (13)and assembly may beturned. Leave assem-bly loose and continueinstallation.

9. clamp (4)


11. Accumulator (5)

12. Nut on base (2)

13. clamp (1)

14. Union (4)

NOTE

Do not lubricate preformedpacking,

Install on check valve(10). Attach clamp tofireshield using bolt,spacer, washer and nut.Do not tighten.

Place on accumulator(5).

Screw on elbow (7).Hold backup wrenchon elbow and tightenaccumulator 55-80 in.lb (0.6-0.9 kg/m) byturning on the hexag-onal surface on theaccumulator adjacentto the elbow.

Install to union (3).Do not tighten.

Adjust and tightenclamping nut to 35-40in. lb (0.4-0.5 kg/m).

Hold with backupwrench. Tighten nuton hose (2) to 80-120in. lb (0.9-1.4 kg/m).

6-63

TM 55-2840-231-23

6-26. Accumulator - Installation - Continued

ENGINE/ - Continued

15. Clamping nut onclamp (12)

16. Elbow (15)

17. Clamping nuton clamp assembly(4)

Tighten to 35-40 in. lb(0.4-0.5 kg/m).

Hold with backupwrench adjacent to nut(14) and tighten nutto 55-80 in. lb (0.6-0.9kg/m).

Tighten to 35-40 in. lb(0.4-0.5 kg/m),

6-64

TM 55-2840-231-23

6-27. Fuel Filter - Replacement

INITIAL SETUP


Lubricating Oil (item 4, Appendix D)Lockwire (item 17, Appendix D)

FUEL PUMP/

1F.uel Filter The fuel filter is a 5 or 10-micron paperelement located inside the fuel pump. It isretained by a threaded cover and the lower sideof the pump.

When there is evidence that thefuel pump filter has been by-passedthe Gas Producer Fuel Control Fil-ter Assembly must be replaced.

2. Cover (5)

3. Element (3)

4. Preformed Packings(2 and 4)

Drycleaning solvent P-D-680, used toclean parts is potentially dangerous topersonnel and property. Avoid repeatedand prolonged skin contact. Avoid pro-longed or repeatad breathing of vaporsDo not use near open flame or excessiveheat. Flash point of solvent is 100°F -138°F (38°C - 59°C).

Cut the lockwire andloosen the cover by turningthe hex. Place a containerunder the pump assemblyas some fuel spillage is likely.

Remove the cover and theelement.

Remove and discard preformedpackings. Discard element(3).

6-65

TM 55-2840-231-23

6-27. Fuel Filter - Replacement - Continued

FUEL PUMP/ -Continued

5. Cover (5)

6. Reformed Packings(2 and 4)

Drycleaning Solvent (item 1, Appendix D).

Oill (item 4, Appendix D).

Clean the filter cover witha spray of solvent, or witha fuel soaked cloth.

Lubricate new preformedpackings with oil. Placepreformed packing (2) onelement (3) and preformedpacking (4) on cover (5).

6 - 6 6 Change 3

TM 55-2840-231-23

6-27. Fuel Filter - Replacement - Continued

FUEL PUMP/ -Continued

Be sure the element is insertedwith the open end and shouldertoward the pump and the smallpreformed packing firmly seatedagainst the housing before install-ing the cover.

7. Element (3)

6-27.1. Pc Air Filter - Removal

INITIAL SETUP


ENGINE/Pc Air Filter

Lockwire (item 17, Appendix D). Insert new element (3) intofuel pump (1) and installcover (5). Tighten cover to180-200 in. lb, (2.1-2.3kg/m) and secure withLockwire. Bleed the fuels y s t e m . ( R e f e r t oparagraph 6-2.)

Disconnect air tubes (1and 2) from both ends offilter (3). Hold the filterwhile loosening couplingnuts (4 and 5). Remove nut(6) and bolt (7) securingfilter clamp (8) to filterm o u n t i n g b r a c k e t .R e m o v e f i l t e r a n dseparate clamp from thefilter.

Change 7 6-67

TM 55-2840-231-23

6-27.1. Pc Air Filter - Removal - Continued

6-27.2. Pc Air Filter - Cleaning and Inspection

INITIAL SETUP

Applicable ConfigurationAll Consumable Materials

D r y c l e a n i n g , S o l v e n t (item 1A, Appendix D).Antiseize Compound (item50, Appendix D).Lockwire (item 7, Appen-dix D).

6-68 Change 7

TM 55-2840-231-23

6-27.2. Pc Air Filter - Cleaning and Inspection - Continued

1. Cleaning Clean the filter assemblyultrasonically if equipmentis available. If equipment isnot available, cap the outletfitting of filter element witha clean metal cap (AN820-4 or equivalent).

Remove lockwire and sepa-rate filter element (1) andpreformed packing (2) fromfilter housing (3).

Change 7 6-68.1

TM 55-2840-231-23

6-27.2. Pc Air Filter - Cleaning and Inspection - Continued

2. Inspection

Do not use a cloth to dry the filterelement.

6-68.2 Change 12

TM 55-2840-231-23

6-27.3. Pc Air Filter - Installation

NOTE

Perform fuel system pneumatic leakcheck in accordance with paragraph6-3.

Change 13 6-68.3

TM 55-2840-231-23

6-27.3. Pc Air Filter - Installation

INITIAL SETUP


AllConsumable Materials

6-68.4 Change 11

TM 55-2840-231-23

6-27.4. Inspection of Engine Fuel Pump Filter Bypass Valve for Proper Operation

INITIAL SETUP


All

ENGINE/1. Fuel Pump Filter BypassValve Inspection

a. Test the enginefuel pump filter bypassvalve for proper opera-

paragraph 6-27. In-

Change 13 6-68.5

TM 55-2840-231-23

6-27.4. Inspection of Engine Fuel Pump Filter Bypass Valve for Proper Operation - Continued

ENGINE/Fuel Pump Filter BypassValve Inspection - Contin-ued

(6) Momentarilyactuate the fuel boostpump. The fuel filtercaution light should il-luminate and fuelshould flow from thetubing indicating thepump bypass is work-ing. Refer to paragraph6-27.5 for correctiveaction if the bypass isnot working.

(7) Remove the fil-ter cover. Fill the cleartubing with fuel (savedfrom item (6)) to raisethe fuel level 12 to 24inches above the fuelpump after filter senseline port.

(8) Observe the fil-ter housing area forleakage. Leakage ex-ceeding 10 drops perminute is not accept-able. Refer to para-graph 6-27.5 for cor-rective action.

(9) Remove the capfrom the filter boss andremove the fitting andtubing from the afterfuel pump filter senseline.

(10) Reconnect theafter fuel pump faltersense line to the fuelfilter pressure switch.

b. Reinstall or re-place the fuel filter asrequired in accordancewith paragraph 6-27.

6-68.6 Change 13

TM 55-2840-231-23

6-27.4. Inspection of Engine Fuel Pump Filter Bypass Valve for Proper Operation - Continued

ENGINE/Fuel Pump Filter BypassValve Inspection - Contin-ued

Replace both fuel filter o-rings whenreusing same filter.

6-27.5. Correction Procedures for Engine Fuel Pump Filter Bypass Valve.

INITIAL SETUP


All

ENGINE/Fuel Pump Filter BypassValve Correction Procedures

a. If fuel pump failedbypass test in para-graph 6-27.4, items (6)or (8), then clean asfollows:

(1) Remove fuelpump in accordancewith paragraph 6-15.

(2) Remove fuelfilter in accordancewith paragraph 6-27.

(a) Cut and re-move lockwire retain-ing filter bypass plugin the pump housing,reference TM55-2840-231-23P, fig-ure 13, item 9.

(b) Unscrew andremove plug, item 9.

(c) Removespring, item 11, piston,item 13, and sleeve,item 14.

Change 13 6-68.7

TM 55-2840-231-23

6-27.5. Correction Procedures for Engine Fuel Pump Filter Bypass Valve - Continued.

ENGINE/Fuel Pump Filter BypassValve Correction Procedures- Continued

(d) Remove anddiscard o-ring, item10, and o-ring, item15 .

(e) Clean the pis-ton, item 13, andsleeve, item 14, usingpetroleum solvent,item 1, Appendix 1.

(f) Clean bypassvalve area and filterbow area of the pumphousing, item 64, usingpetroleum solvent.

(g) Replace o-ring, item 15, NSN5330-00-248-388, lu-bricate lightly andsleeve, item 14, usingitem 4, Appendix D.

(h) Install sleeve,item 14, in pump hous-ing, item 64.

(i) Install piston,item 13 and spring,item 11, in sleeve, item14.

(j) Replace o-ring, item 10, NSN5330-00-263-8031.Lubricate and installplug, item 9, with item14, Appendix D.

(k) Install cap,item 9, into pumphousing, item 64,torque 105-125 in. lband safety wire.

6-68.8 Change 13

TM 55-2840-231-23

6-27.5. Correction Procedures for Engine Fuel Pump Filter Bypass Valve - Continued

a. Test bypass perparagraph 6-27-4.items (5) and (6). If by-pass malfunction is notcorrected by cleaning/replacing bypass valve,replace fuel pump.

b. Reinstall fuelpump in accordancewith paragraph 5-16.Prior to installing fuelinlet line to pump, ac-tuate aircraft boostpump to purge anycontaminated fuel fromthe fuel line.

Change 13 6-68.9/6-68.10 blank)

TM 55-2840-231-23

6-29. Fuel Nozzle - Cleaning - Continued

FUEL NOZZLE/ - Continued

2. Spray Tip

3. Air Shroud

6 - 6 9

TM 55-2840-231-23

6-30. Fuel Nozzle - Inspection

INITIAL SETUP


1. FUEL NOZZLE

2. Spray Tip

Visually inspect for dam-aged mirror finish or edgeof spray tip. Replace dam-aged nozzles.

Visually inspect for carbonlodged in the spray tip.Flow fuel through nozzleand replace if carbon can-not be f lushed out

6-31. Fuel Nozzle - Installation

INITIAL SETUP


ENGINE/

1. Nozzle


NOTE

Do not lubricate the fuel nozzlethreads.

Lockwire (item 17, Appendix D) Carefully install nozzle inouter combustion case andtighten to 200-300 in. lb(2.9-3.5 kg/m). Lockwirethe nozzle to the spark ig-n i ter .

Connect fuel hose tonozzle. Hold fuel hose toprevent twisting and tight-en the coupling nut to80-120 in. lb (0.9- 1.4kg/m).

6-70 Change 13

TM 55-2840-231-23

CHAPTER 7

ELECTRICAL SYSTEM

This chapter contains procedures for the maintenance and preservation of the electrical system. Para-graphs following outline disassembly, inspection, repair, and additional requirements needed to maintainthe electrical system and related parts. Procedures requiring maintenance on the Aviation IntermediateMaintenance (AVIM) level are specified and must be performed as such. Paragraphs in which the mainte-nance level is not specified shall be considered Aviation Unit Maintenance (AVUM) and may be performedat this level or a higher level of maintenance.

Page

Electrical System Maintenance Procedures 7-1Auto-Reignition Control - Removal and Installation 7-1Ignition Exciter - Removal, Inspection and Installation 7-5Spark Igniter - Removal, Cleaning, Inspection, Testing and Installation 7-7Spark Igniter Lead - Removal, Inspection, Installation and Check 7-10

7-1. ELECTRICAL SYSTEM MAINTENANCE PROCEDURES.

Visually inspect all subassemblies and accessories removed from the engines electrical system. Check forloose or missing parts. Note any damage or excessive wear. Repair damaged parts where possible. Replacedamaged parts that cannot be repaired. Disassembly procedures provided enable required cleaning, inspec-tions, repair or replacement.

7-2. Auto-Reignition Control - Removal and Installation.

INITIAL SETUP


Consumable MaterialsNone

ENGINE/Auto-ReignitionControl

1. Removal Disconnect aircraft elec-trical harness from auto-reignition control (2).

7-1

TM 55-2840-231-23

7-2. Auto-Reignition Control - Removal and Installation - Continued

ENGINE/Auto-Reignition Control -Continued

Disconnect auto-reignitionsensing tube (1) from thecontrol.

When the bolts and nuts are removedfrom control (2), the cover is notsecured to the case of the control.Handle the control carefully to pre-vent dropping the case out of thecover.

7-2

TM 55-2840-231-23


ENGINE/Auto- If the control is not mountedReignition Control - on vibration dampers, removeContinued four bolts (4) and washers

(3) and remove control (2)from its mounting bracket.

If control is mounted on vi-bration dampers, removefour nuts (9) and washers(8) and remove control (2)from its mounting bracket.The four washers (6) andvibration dampers (7) onthe bottom of the mountingbracket may come off withthe control. If they remainon bolts (5) but are loose,remove them.

ENGINE/6877187 Auto-Reignition Control

2. Installation If a new auto-reignitioncontrol (2) is being installed,remove the four nuts fromthe bottom of the controland install them on the bot-tom of the removed control.

secure the control to itsmounting bracket on theengine with four washers(3) and bolts (4). Insurethat the Pc pressure portis toward the front of theengine. Tighten the boltsto 35-40 in. lb (0.4-0.5kg/m).

Connect auto-reignitionsensing tube (1) to control(2). Tighten the couplingnut to 80-120 in. lb (0.9-1.4 kg/m).

Connect the aircraft elec-trical harness to the elec-trical connector on control(2).

7-3

TM 55-2840-231-23


ENGINE/68770031 Auto-Reignition Control

3. Installation If a new auto-reignitioncontrol (2) is being install-ed, remove the four nuts(9), washers (8), and bolts(5) from the new control.Install the bolts in the re-moved control and securewith the old washers (8)and nuts (9).

Place four vibration dam-pers (7) and washers (6)on bolts (5), if removed.Assemble control (2) onthe four bolts (5) andsecure with four washers(8) and nuts (9). Insurethat the Pc pressure port istoward the front of theengine. Tighten nuts (26)to 35-40 in. lb (0.4-0.5kg/m).

Connect auto-reignitionsensing tube (1) to control(2). Tighten the couplingnut to 80-120 in. lb (0.9-1.4 kg/m).

Connect the aircraft elec-trical harness to the elec-trical connector on control(2).

7-4

7-2.1 Deleted

TM 55-2840-231-23

Change 11 7-4.1 /(7-4.2 blank)

TM 55-2840-231-23

7-3. Ignition Exciter - Removal, Inspection and Installation

INITIAL SETUP


ENGINE/Ignition Exciter

To avoid electrical shock insureignition system has been offfor at least five minutes beforedisconnecting any leads, Groundleads to engine using an insulatedscrewdriver.

7-5

TM 55-2840-231-23

7-3. Ignition Exciter - Removal, Inspection and Installation - Continued

ENGINE/Ignition Exciter- Continued

1. Removal

2. Inspection

Do not energize ignition exciter ifspark igniter and lead aredisconnected.

Disconnect power inputlead and igniter lead (4)from exciter.

Remove three nuts (1) andwashers (2) which secureexciter (3) to gearboxhousing.

Visually inspect forgeneral condition ofexciter, input powerterminal, and igniter leadconnector. Nicks, dents,etc are acceptable ifdamage does not extendthrough the case or cover.Bent or misalignedeletrical connector isacceptable if theconnector base is notexcessively distorted,bulged, or cracked. Theconnector ends mustassemble properly withno evidence of internaldamage.

Connect a knownsatisfactory igniter leadand spark igniter of typeused on engine to theignition exciter.

Apply 28 volts dc to theinput terminal of theignition exciter using aminimum wire size of 1 6gauge. Observe firing. If arepetitive spark rate ofless than six sparks persecond is observed,replace the ignitionexciter.

7-6 Change 11

TM 55-2840-231-23

7-3. Ignition Exciter - Removal, Inspection and Installation - Continued

ENGINE/ignition Exciter- Continued

Do not operate the exciter formore than 4 minutes in any 30minute period.

3. Installation Install serviceable exciteron the engine and connectelectrical leads.

Tighten attaching self-locking nuts (1) to 30-40in. lb (0.4-0.5 kg/m).

Tighten the igniter lead(4) coupling to 50-70 in.lb (0.6-0.8 kg/m).

Tighten input lead nut to8-12 in. lb (0.1-0.15 kg/m).

7-4. Spark Igniter - Removal, Cleaning, Inspection, Testing and Installation

INITIAL SETUP



ENGINE/-Spark Igniter

To avoid electrical shock, insureignition system has been off for atleast five minutes before removingigniter to dissipate all energystored in condenser. Groundigniter lead to engine using anindicated screwdriver.

Change 11 7 - 7

TM 55-2840-231-23

7-4. Spark Igniter - Removal, Cleaningr Inspection, Testing and Inspection - Continued

ENGINE/Spark Igniter -Continued

To preclude the possibility of thecombustion chamber becomingmisaligned, do not remove thefuel nozzle and the spark igniterat the same time.

1. Removal Disconnect igniter lead atigniter. Prevent lead fromtwisting while removingnut.

Separate lead fromigniter by pullingstraight out without anyrotational motion.

Remove lockwire andunscrew igniter.

7-8 Change 11

TM 55-2840-231-23

7-4. Spark Igniter - Removal, Cleaning, Inspection, Testing and Installation - Continued

7-9

TM 55-2840-231-23

7-4. Spark Igniter - Removal, Cleaning, Inspection and Installation - Continued

7-5. Spark Igniter Lead -Removal, Inspection, Installation and Check

INITIAL SETUP


7-10 Change 13

TM 55-2840-231-23

7-5. Spark Igniter Lead - Removal, Inspection, Installation and Check - Continued

ENGINE/Spark Igniter Lead -Continued

1. Removal Remove lead (13) fromthe ignition exciter (1)and spark igniter (14).

Remove bolts (3) and nuts(5) securing clamps (2 and4) together.

Remove bolt (10) and nut(12) securing clamp (11)to bracket ( 9).

Remove two bolts (6 and 7)and nuts (8) securing thelead to the fireshield.Remove the lead.

7-11

TM 55-2840-231-23


ENGINE/Spark Igniter Lead -Continued

NOTE

Bolt (6) also secures the accumu-lator bracket and spacer to thefireshield.

2. Inspection

3. Installation

a. Inspect the outer partof the lead for braiddamage; replace lead ifthere are more than fivebroken strands in any lo-calized area, the braidedconduit is punctured,or discolored and brittlefrom extreme heat.

b. Inspect terminals of leadto ensure all parts areintact and no pitting isevident; replace lead ifany part is missing orpitting is present.

Insert the igniter lead (13)through the hole in thefireshield. Secure the leadto the fireshield with bolt(7) and nut (8). Secureaccumulator clamp, spacer,and igniter lead with bolt(6) and nut (8). Tightenthe nuts to 35-40 in. lb(0.4-0.5 kg/m).

Connect the igniter lead tothe ignition exciter (1) andtighten the coupling nut to50-70 in. lb (0.6-0.8 kg/m).

Connect the igniter leadto the spark igniter (14)and tighten the couplingnut to 70-90 in. lb (0.8-1.0 kg/m).

7-12

TM 55-2840-231-23


ENGINE/Spark IgniterLead - Continued

Secure the lead to the airtubing at the powerturbine governor withfour clamps (2 and 4), twobolts (5) and nuts (7).Tighten the nuts to 35-40in. lb (0.4-0.5 kg/m).

Secure the igniter lead tobracket (9) with clamp(11), bolt (10) and nut(12). Tighten the nut to35-40 in. lb (0.4-0.5 kg/m)

ENGINE/Ignition System

4. Check The following procedure can be used to checkthe operation of the ignition system.

To preclude the possibility of thecombustion chamber becomingmisaligned, do not remove thefuel nozzle and the spark igniterat the same time.

Remove the spark igniterlead (13) from the sparkigniter.

Remove the spark igniter(14).

When assembling ordisassembling a lead and anigniter which is not installed onthe engine, turn the lead nut andnot the spark igniter.

Change 11 7-13

TM 55-2840-231-23


ENGINE/Ignition System -Continued

Attach the spark igniterlead to the spark igniter.

Apply 28 volts dc across theignition exciter. Observe orlisten for spark.

Install spark igniter andspark igniter lead on theengine. Tighten the sparkigniter to 150-200 in. lb(1.7-2.3 kg/m) and lockwireto the fuel nozzle. Tightenthe lead to 70-90 in. lb(0.8-1.0 kg/m).

7-14

TM 55-2840-231-23

CHAPTER 8

OIL SYSTEM

This chapter contains procedures for the maintenance and preservation of the oil system. Paragraphsfollowing outline disassembly, inspection, repair and additional requirements needed to maintain the oilsystem and related parts. Procedures requiring maintenance on the Aviation Intermediate Maintenance(AVIM) level are specified and must be performed as such. Paragraphs in which the maintenance level isnot specified shall be considered Aviation Unit Maintenance (AVUM) and may be performed at this levelor a higher level of maintenance.

Oil System Maintenance ProceduresOil Filter Housing - Removal and InstallationOil Filter - RemovalOil Filter - CleaningOil Filter - InstallationOil Pressure Regulator - Removal, Installation, Inspection, Testing and

AdjustmentInternal Oil Check Valve - Removal and InstallationExternal Oil Check Valve - Removal, Cleaning, Inspection and InstallationOil Pressure Reducer - Removal and InstallationOil Tubing and Fittings - Inspection and Replacement

8-18-28-48-58-6

8-78-108-118-148-15

8-1. OIL SYSTEM MAINTENANCE PROCEDURES.

Visually inspect all subassemblies and accessories removed from the engine’s oil system. Check forloose or missing parts. Note any damage or excessive wear. Repair damaged parts where possible.Replace damaged parts that cannot be repaired. Disassembly procedures provided enable requiredcleaning, inspection, repair or replacement.

Change 11 8 - 1

TM 55-2840-231-23

8-2. 0il Filter Housing - Removal and Installation

INITIAL SETUP


ENGINE/

1. Oil Filter HousingRemoval

a. Remove eight self-lockingnuts (1) and washers (2).Disengage clamp (3) fromthe stud at the RH sideof the housing (if installed).

b. Lift housing (4) out ofthe gearbox. Discard gas-ket (5).

c. Remove check valve (7).Discard preformed packings(6) and (8).

d. Remove preformed pack-ings (9 and 10) from oiltubes (11 and 12) anddiscard preformed packings.

8-2

TM 55-2840-231-23

8-2. Oil Filter Housing - Removal and Installation - Continued

ENGINE/ - Continued

Prolonged contact with lubricating oil(item 5, Appendix D) may cause a skinrash. Those areas of skin and clothingthat come in contact with lubricatingoil should be thoroughly washed imme-diately. Enclosed areas where lubricatingoil is used should be adequately ventilatedto keep mist and fumes to a minimum.

2. Installation Lubricating Oil (item 5, Appendix D). a. Lubricate new preformedpackings (9 and 10) withoil and install on oil tubes(11 and 12) and installon check valve (7). Installthe check valve in thegearbox.

b. Place new gasket (5) onthe gearbox.

c. Insert housing (4) intothe gearbox and engagethe mounting studs. Insurethat the housing is matedwith oil tubes (11 and 12)and with check valve (7).

d. T63-A-700 only. If theengine has an auto reigni-tion system installed,place tube clamp (3) onthe stud at the RH aideof the housing.

e. Retain the oil filterhousing with eight washers(2) and self-locking nuts(l). Tighten the nutsto 35-40 in. lb (0.4-.5kg/m).

8-3

TM 55-2840-231-23

8-3. Oil Filter - Removal

INITIAL SETUP

Applicable Configuration Special ToolsAll Puller, Tool No. 6798860

ENGINE/

1. Oil Filter a. Remove nuts andwashers. Using puller,slowly remove cap withpreformed packings fromhousing located on top ofgearbox.

b. Use a clean suctiongun or another suitabledevice to remove puddledoil from within the filterhousing before removingfilter element. Do notdamage filter element.Examine sediment forevidence of metalparticles.

c. Remove filter elementand preformed packing.Discard the preformedpacking.

d. Temporarily reinstallcap to prevent dirt fromentering the housing.

8-4 Change 11

TM 55-2840-231-23

8-4. OIL FILTER – CLEANING

INITIAL SETUP


Special ToolsUltrasonic Cleaning Equipment

(if available)

Consumable MaterialsDrycleaning Solvent (item 1, Appendix D)

OIL FILTER/

1. Element

Drycleaning solvent, P-D-680, used toclean parts is potentially dangerousto personnel and property. Avoidrepeated and prolonged skin contact.Avoid prolonged or repeated breathingof vapors. Do not use near open flameor excessive heat. Flash point of solventis 100°F -138°F (38°C-59°C).

Solvent (item 1, Appendix D).

Thoroughly clean oil filter cavity of all residualoil and/or sludge prior to the installation of acleaned or new filter element. If metal particlesare present, remove and examine magneticplugs in gear case.

Agitate filter element insolvent until clean.

Air dry filter element.

Change 8 8-5

TM 55-2840-231-23

8-5. Oil Filter - Installation

INITIAL SETUP

Applicable Configuration Consumable MaterialsAl l Lubricating Oil (item 5, Appendix D)

OIL FILTER/

Prolonged contact with lubricating oil(item 5, Appendix D) may cause a skinrash. Those areas of skin and clothingthat come in contact with lubricatingoil should be thoroughly washedimmediately. Enclosed areas wherelubricating oil is used should be ade-quately ventilated to keep mist andfumes to a minimum.

1. Cap and Preformed Lubricating Oil (item 5,Packings

Appendix D) Remove cap with preformedpackings from housing.Discard preformed packings.Clean cap with a clean lint-free cloth. Install newpreformed packings lubri-cated with lubricating oilon filter cap.

2. Element and Pre-

formed PackingsInstall new preformed pack-ing and cleaned filter element

3. Cap

4. Nuts

in filter housing.

Install filter cap.

Tighten nuts which securefilter cap to housing to30-45 in. lb (0.3-0.5 kg/m).

After the filter element has been cleaned orreplaced, run the engine for a short durationand check the splitline for leaks.

8-6

TM 55-2840-231-23

8-6. OIL PRESSURE REGULATOR – REMOVAL, INSTALLATION, INSPECTION, TESTINGAND ADJUSTMENT

INITIAL SETUP



ENGINE/NOTE

Do not remove the pressureregulator unless the oil pressurecannot be adjusted within limits.

1. Oil PressureRegulator Removal

Remove lockwire and turnguide (see figure) out ofhousing. Remove springand poppet from thehousing. Discard preformedpacking.

2. Installation


Lubrication oil (item 5, Appendix D). Lubricate preformedpacking with oil and placeon guide. Install poppet,spring, and guide inhousing. Turn the guide inuntil it bottoms then backit out 5½ turns.

Change 8 8-7

TM 55-2840-231-23

8-6. Oil Pressure Regulator - Removal, Installation, Inspection, Testing and

ENGINE/ - Continued

3. Inspection

4. Testing

Item

Oil pressureDuring start

Idle to 78% N178-89% N190% N1 and above

NOTE

Adjustment - Continued

Adjust the regulatingvalve as outlined in item 5,Adjustment.

a. Check external conditionof regulator; insure thatthe regulator is lockwired.If regulator is not lockwired,check the adjustment asoutlined in item 5, Adjust-ment.

b. If oil pressure cannot beadjusted within limits,remove the regulator.Check for a broken springor evidence of poppetsticking. Check for damageor wear on the poppetseating surface.

Oil pressure limits apply to anengine that is at normal operatingtemperature.

a. With engine running atground idle, check thatthe oil pressure is 50psig minimum.

b. With engine operating atmaximum speed, checkthat oil pressure iswithin limits. (Refer tofollowing table.)

Limit Remarks

Increasing pressure by the time 20% N1 is Abort start if pressure doesreached not start increasing.50 psig minimum90-130 psig115-130 psig

8-8

TM 55-2840-231-23

8-6. Oil Pressure Regulator - Removal, Installation, Testing and Adjustment - Continued

ENGINE/ - Continued NOTE

Oil pressure limits are based on an oilinlet temperature of 180° F-225°F(82.2°C-93.3°C).

Oil temperatureFor starting -65°F(-54°C) minimum

*For operation aboveidle 35°F(1.7°C) minimum

Normal range 180°F-200°F(82.2°C-93.3°C)Maximum 225°F(107.2°C)maximum

NOTE

During cold weather operations, 150psig engine oil pressure is permittedfollowing engine start. When the130 psig limit is exceeded, operateengine at idle RPM until normal en-gine oil pressure is obtained. Whenengine oil pressure is within normallimits, engine may be operated withinfull range of temperature limits (-54°Cto 107°C) without regard to engineoil temperature markings.

*For test cell only.

NOTE

Any adjustment made to the oilpressure regulator should be verifiedby a calibrated direct-reading pressuregage connected at the oil pressure sens-ing port on the front of the gearbox.

5. Adjustment

Operate at idle until withinlimit.

Reduce power to maintainlimit.

a. Remove the lockwirefrom the pressure regulator.

b. Using a wrench, turnguide clockwise to in-crease pressure; counter-clockwise to decrease.Adjust the regulator untiloil pressure is withinlimits of preceding item4. One turn will changeoil pressure approximately13 psig.

8-9

TM 55-2840-231-23

8-6. Oil Pressure Regulator - Removal, Installation, Testing and Adjustment - Continued

ENGINE/ - Continued

NOTE

An approximate starting adjustmentcan be made by bottoming guide;then backing out 5½ turns.


8-7. Internal Oil Check Valve - Removal and Installation

INITIAL SETUP

Applicable Configuration ReferencesAll

GEARBOX/

Internal Check Valve

c. Lockwire guide afteradjustment to preventmovement in eitherdirection.

Para 8-2

8 - 1 0 Change 8

TM 55-2840-231-23

8-7. Internal Oil Check Valve - Removal and Installation - Continued

GEARBOX/The internal oil check valve is located underthe oil filter housing, inside the gearbox. Itserves to prevent oil from draining out of theoil tank and into the gearbox while theengine is shut down.

1. Removal Refer to paragraph 8-2.

2. Installation Refer to paragraph 8-2.

8-8. External Oil Check Valve - Removal, Cleaning, Inspection and Installation

INITIAL SETUP

Applicable Configuration Consumable MaterialsA l l

ENGINE/

External Oil Check Valve

1. Removal

Drycleaning Solvent (item 1, Appendix D)

The external check valve (4) is located in theoil supply tube to the turbine. It serves toprevent oil from draining into the turbinebearing cavities while the engine is shutdown.

Remove self-locking nut(5) and bolt (1) thatsecure clamps (2 and 3)together.

Configuration B only —remove self-locking nut(9) and bolt (6) thatsecure clamps (7 and 8)together.

Loosen the two oil tubecoupling nuts and removecheck valve (4) from theengine.

Change 11 8-11

TM 55-2840-231-23

8-8. External Oil Check Valve - Removal, Cleaning, Inspection and Installation - Continued

ENGINE/External OilCheck Valve - Continued

Drycleaning solvent, P-D-680,used to clean parts is potentiallydangerous to personnel andproperty. Avoid repeated andprolonged skin contact. Avoidprolonged or repeated breathingof vapors. Do not use near openflame or excessive heat. Flashpoint of solvent is 100° F-138°F(38°C-59°C).

2. Cleaning Solvent (item 1, Appendix D) Clean external checkvalve by flushing withsolvent and air dry.

8-12 Change 11

TM 55-2840-231-23

8-8. External Oil Check Valve - Removal, Cleaning, Inspection and Installation - Continued

ENGINE/-Continued

3. Inspection Replace the valve if it isnot within the followinglimits:

a. Cracking pressure:5 ± 1 (0.35 + 0.07 kg/sqcm) psi.

b. Leakage (internal): 10drops per minute max at3 psi (0.21 kg/sq cm).

c. Leakage (external):None allowed. If externalleakage is encountered,reject valve.

Be sure the check valve isinstalled with the hex endmarked “OUT” and the arrowpointing toward the rear of theengine.

4. Installation a. Install the check valve (4) in the pressure oiltube with the hex endmarked “OUT” and thearrow pointing towardsthe rear of the engine,Tighten the coupling nutsto 80-120 in. lb (0.9- 1.4kg/m).

b. Configuration B only- secure clamps (7 and 8)together with bolt (6) andnut (9). Tighten the nut to35-40 in. lb (0.4-0.5 kg/m).

c. Secure clamps (2 and 3)together with bolt (1) andnut (5). Tighten the nut to35-40 in. lb (0.4-0.5 kg/m).

Change 11 8-13

TM 55-2840-231-23

8-9. Oil Pressure Reducer - Removal and Installation

INITIAL SETUP

Applicable Configuration Consumable MaterialsAll Lubricating Oil (item 5. Appendix D)

ENGINE/

Oil Pressure Reducer

1. Removal

Prolonged contact with lubricating oil(item 5, Appendix D) may cause a skinrash. Those areas of skin and clothingthat come in contact with Iubricatingoil should be thoroughly washed imme-diately. Enclosed areas where lubricatingoil is used should be adequately ventilatedto keep mist and fumes to a minimum.

8-14

Disconnect the oil tube fromthe oil pressure reducer.

Remove oil pressure reducerfrom the compressor frontsupport. Discard preformedpacking and oil pressure re-

TM 55-2840-231-23

8-9. Oil Pressure Reducer - Removal and Installation - Continued

8-10. Oil Tubing and Fittings - Inspection and Replacement


Change 13 8-15

TM 55-2840-231-23

8-11. Inspection Procedures

INITIAL SETUPApplicable Configuration

All

ENGINE/

1. Inspection Procedures. The following oil checks are to be per-formed during scheduled oil changes. Re-fer to TM 55-2840-231-23P for figureand item numbers.

NOTE

These procedures to insure adequateoil flow shall he accomplished when anew, newly overhauled or depreservedengine is placed in service.

a. Drain the oil tank.b. Remove the magnetic chip detector,figure 6, item 65, from the bottom of thegearbox and drain residual oil.c. Remove and clean or replace the oilfilter, figure 16, item 50.d. Refill the oil tank with engine oil(MIL-L-23699 or MIL-L-7808).e. Remove and clean the magnetic chipdetector on the forward side of the gear-box. While both magnetic plugs are re-moved, motor engine with the starter andpermit a small amount of oil (1 or 2ounces) to flow from the openings in thegearbox. This will assist in rinsing thegearbox of carbon particles. Reinstall thecleaned magnetic plugs.f. Loosen the fittings and remove the line,figure 5, item 58B, going to the “T” fit-ting, figure 5, item 51B, that feeds oil tothe number six and seven bearing (pres-sure oil fitting screen, figure 5, item 19A,assembly). Motor the engine and permit asmall amount of oil (1 or 2 ounces) tocome out the end of the oil tube. Cleanand reinstall the screen and tube assem-bly. Tighten pressure oil tube couplingnuts to 80 to 120 in. lbs. Tighten clampnuts, figure 5, item 13, to 35 to 40 in. lbs.

8-16 Change 13

TM 55-2840-231-23

8-11. Inspection Procedures - ContinuedENGINE/ - Continued

(b) Use exterior power source to ensureN1 rotation of 16 percent (TM55-1520-228-23).

(d) Open ignition circuit breaker andmake a preliminary rotation of the enginefor 15 seconds to ensure that the oil linesand external sump are full of oil and thereis oil flow.

paragraph 8-8.3 of this manual. Inspec-tion prior to engine removal.

Change 13 8-16.1

TM 55-2840-231-23

8-11. Inspection Procedures - Continued

h. Motor the engine with the starter untilpositive oil pressure indication is ob-tained. Do not exceed starter limitation(refer to TM 55-1520-214-10/TM55-1520-228-10).i. After all work is completed make aground run. Check for leaks and monitoroil pressure for the first five minutes ofengine operation. Check and reservice theoil tank to proper level.

8-16.2 Change 13

TM 55-2840-231-23

8-12. External Sump Removal and Installation

INITIAL SETUP


All

ENGINE/

1. Removal

2. Installation

a. Remove two bolts (1)holding the scavenge oilexternal sump (2) to thefirewall shield. Removesump. Discard preformedpacking (3).

b. Install preformedpacking (3) in the sealgroove over the powerturbine support scavengeoil opening. Apply a lightcoat of sealer (Permatex1372W), NSN8030-00-599-7753) overthe preformed packing.Position sump (2) on thefirewall shield, apply hightemperature lubricant(Never Seez CompoundCorp., 2910 South 18thAve., Broadview, IL.,60153, NSN8030-00-105-0270, totwo bolts (1) and install.Tighten bolts to 35 to 40in.-lb and secure withlockwire (P/NMS20995C20, NSN9505-00-596-5101).

Change 13 8-17

TM 55-2840-231-23

8-12. External Sump Removal and Installation - Continued

External Sump Removal and Installation -continued

8-18 Change 13

TM 55-2840-231-23

CHAPTER 9

MISCELLANEOUS EQUIPMENT/AIR SYSTEM

This chapter contains procedures for the maintenance and preservation of the miscellaneousequipment. Paragraphs following outline disassembly, inspection, repair and additional requirementsneeded to maintain miscellaneous equipment and related parts. Procedures requiring maintenance onthe Aviation Intermediate Maintenance (AVIM) level are specified and must be performed as such.Paragraphs in which the maintenance level is not specified shall be considered Aviation UnitMaintenance (AVUM) and may be performed at this level or a higher level of maintenance.

Miscellaneous Equipment Maintenance ProceduresAnti-Icing Valve Poppet Seat - ReplacementAnti-Icing Valve Poppet Seat - InstallationAnti-Icing Air Valve - RemovalAnti-Icing Air Valve - TestingCompressor Bleed Valve - TestingCompressor Bleed Valve - RemovalCompressor Bleed Valve - Installation

9.1 MISCELLANEOUS EQUIPMENT MAINTENANCE PROCEDURES.

9-19-29-39-59-69-69-99-10

Visually inspect all subassemblies and accessories removed from the engine. Check for loose ormissing parts. Note any damage or excessive wear. Repair damaged parts where possible. Replacedamaged parts that cannot be repaired. Disassembly procedures provided enable required cleaning,inspection, repair or replacement of the miscellaneous equipment.

Change 11 9-1

TM 55-2840-231-23

9-2. Anti-Icing Valve Poppet Seat - Replacement

INITIAL SETUP


ANTI-ICING VALVE/

1. Poppet Seat Replace teflon poppet seatas follows:

a. Remove cotter pin (6),washer (5) and pin (3).Detach actuating lever (2)from valve. Discard cotterpin.

b. Remove lockwire andunscrew poppet guide(4) from valve body (11).Separate poppet (8) fromthe body.

c. Remove screw (10) andseparate poppet seat (9)from the poppet.

d. Install replacementpoppet seat (9). Retainthe seat with screw (10).Stake screw securely asshown in figure.

9-2

TM 55-2840-231-23

9-2. Anti-Icing Valve Poppet Seat - Replacement - Continued

ANTI-ICINGVALVE/ - Continued

e. Insert poppet and seatinto valve body (11 ) andscrew the poppet guide(4) onto the body. Tightencoupling nut to 65-75 in.lb (0.7-0.9 kg/m). Do notIockwire at this time.

f. Aline actuating lever (2)with hole in poppet guide(notch in the lever towardthe guide) and insert pin(3). Secure pin with washer(5) and cotter pin (6).

g. Recheck valve for leakage.Replace valve assembly ifleakage is still excessive.

9-3. Anti-Icing

INITIAL SETUP

Valve Poppet Seat - Installation

Applicable Configuration Consumable MaterialsAl l Antiseize Compound (item 6, Appendix D)


COMPRESSOR/

1. Preformed Antiseize Compound (item 6, Appendix D). Place new preformed pack-Packing (4) ing (4) with backed-off jam

nut (3) on anti-icing valve(2). Apply antiseize com-pound lightly to treadsand install valve in diffuserscroll. Do not tighten jamnut (3).

9-3

TM 55-2840-231-23

9-3. Anti-Icing Valve Poppet seat - Installation - Continued


2. Air Tubes (1 and 5)

3. OH-6 HELICOPTERPoppet Guide (8) andLever (6)

4. OH-58 HELICOPTERPoppet Guide (8) andLever (6)

Lockwire (item 7, Appendix D) Connect air tubes (1 and 5)to valve. Tighten couplingnuts to 150-200 in. lb (l.7-2.8 kg/m). Tighten jam nut(3) to 100-150 in. lb (1.2-1.7 kg/m) and Iockwire.

Lockwire (item 7, Appendix D) Loosen poppet guide (8)and position lever (6)parallel with verticalcenterline of engine. Tightenpoppet guide to 65-75 in. lb(0.7-0.9 kg/m) and lock-wire.

Lockwire (item 7, Appendix D) Loosan poppet guide (8) andposition lever (6) parallelwith horizontal centerlineof engine. Tighten poppetguide to 65-75 in. lb (0.7-0.9 kg/m) and Iockwire.

Change 69-4

TM 55-2840-231-23

9-4. Anti-Icing Air Valve - Removal

INITIAL SETUP


All

ENGINE/

1. Air Tubes (1 and 5)

2. Aircraft Linkage

ENGINE/

3. Air Valve

Disconnect air tubes (1and 5) at anti-icing airvalve (2). Disconnectair tubes at compressorfront support only ifnecessary.

Disconnect aircraftlinkage from valve le-ver.

Remove lockwire,loosen jam nut (3), re-move air tube (1) andunscrew valve fromdiffuser scroll. Discardpreformed packing.

9 - 5

TM 55-2840-231-23

9-5. Anti-Icing Air Valve - Testing

INITIAL SETUP


ANTI-ICING VALVE/

Testing a. Apply 100 psig airpressure to the valve inletwith a 0.025 in. orificeinstalled between the airsource and valve inletafter installing gauges tomonitor the air pressureon both sides of the orifice.

b. Apply 3.75 lbmaximum force to holdlever in the closed position.

c. Allow air pressure onboth sides of the orifice tostabilize, maintainingpressure at the orificeinlet at 100 psig.

If the valve leakage is excessive such thatpressure downstream of the orifice decreases,replace the assembly.

9-6 Change 13

TM 55-2840-231-23

9-6. Compressor Bleed Valve-Testing

INITIAL SETUP

Applicable Configuration Equipment ConditionAll Bleed Valve must be on engine

NOTE

• (For OH-6A AIRCRAFT) ReplaceOH-6A elbow jet assembly (4) witha standard elbow (3) prior totesting. The bleed valve operationfigure DOES NOT APPLY when jetassembly (4) is installed. ReinstallOH-6A jet assembly (4) whentesting is completed. Retainstandard elbow for future use.

• OH-58A aircraft shall have thestandard elbow (3) installed.

ENGINE/

1. Bleed Valve

2. Jet Assembly (4) Jet assembly (4) must beremoved and replacedwith a standard elbowfitting (3) prior to testing.Turn off all bleed air.

Change 11 9 - 6 . 1 / ( 9 - 6 . 2 b l a n k )

TM 55-2840-231-23

9-6. Compressor Bleed Valve - Testing - Continued

ENGINE/ - Continued

3. Deleted.

AIRFRAME/

4. Engine

5. Bleed Valve

Have observer monitor the bleed valve.

Pilot and observer use helmets and extensioncord to passenger communication box.

observer use flash light.

Run up engine to103% N2.

a. Bleed valve is notfully closed.

(1) Apply collectiveuntil valve is fullyclosed.

(2) It may be neces-sary to increase theaircraft gross weight toavoid liftoff.

9 - 7

TM 55-2840-231-23


AIRFRAME/ - Continuedb. With the bleed valve closed.friction collective and reducethrottle to engine idle. Let N2stabilize. Observer should checkthat bleed valve is fully open.

C. Slowly increase throttle untilobserver indicates bleed valvestarts to close record N1.

d. Coontinue to increase throttleuntil observer indicates bleedvalve is fully closed record N1.

Bleed valve should start closing on or above the e. Collective - down, frictionlower line of unshaded area and be fully closed on off.or below the upper line of the unshaded area of thebleed valve operation chart below.

AMBIENT TEMPERATURE

After testing retain the standard elbow fitting(3) [for OH-58 aircraft], or reinstall the jetassembly [(4) for OH-6A aircraft], andConnect all Pc lines.

9 - 8 Change 13

TM 55-2840-231-23


ENGINE/ - Continued

3. Deleted.

AIRFRAME/

4. Engine

5. Bleed Valve

Have observer monitor the bleed valve. Run up engine to103% N2.

Pilot and observer use helmets and extensioncord to passenger communication box.

observer use flash light.a. Bleed valve is not

fully closed.

(1) Apply collectiveuntil valve is fullyclosed.

(2) It may be neces-sary to increase theaircraft gross weight toavoid liftoff.

9 - 9

TM 55-2840-231-23

9-8. Compressor Bleed Valve - Installation

INITIAL SETUP


ENGINE/

1. Bleed Valve

Consumable MaterialsLubricating Oil (item 5, Appendix D)Antiseize Compound (item 6, Appendix D)

Antiseize compound (item 6, Appendix D)a. Install bleed valve (2)and new gasket (11) inmounting flange. Retainwith three nuts (8), bolts(9), and washers (10).Apply antiseize compoundto the bolts. The 1/4-28bolt goes in the left hole(looking forward).

b. Tighten nut on 1/4-28bolt to 70-85 in. lb(0.8-1.0 kg/m) and theother two nuts to 35-40in. lb (0.4-0.5 kg/m).

9-10 Change 13

9-8. Compressor Bleed Valve - Installation - Continued

ENGINE/-Continued

2. Deleted

3. ENGINE/PreformedPacking (13), Elbow (3), orJet Assembly (4).

ENGINE/

4. Compressor DischargePressure Sensing Tube (1)

5. Deleted.

TM 55-2840-231-23


Use jet assembly P/N 6875147 onOH-6A aircraft only. Usestandard elbow P/N MS24394J4or remove the orifice from theP/N 6875147 assembly onOH-58A aircraft.

Lubricate preformedpacking with engine oiland place on elbow (3) orjet assembly (4). Installelbow or jet assembly inthe bleed valve. Do nottighten the jam nut.

Attach compressordischarge pressuresensing tube (1) to valveelbow (3) or jet assembly(4). Tighten coupling nutto 80-120 in. lb (0.9-1.4kg/m). Tighten jam nut(12) to 55-80 in. lb (0.6-0.9 kg/m).

Pages 9-12 through 9-15/(9-16 blank) Deleted.

Change 11 9-11

TM 55-2840-231-23

A R 7 5 0 - 2 2DA Pamphlet 738-751

MIL-M-3171MIL-STD-129TB 55-1500-314-24

TM 55-1500-333-24TB 43-0106TB 55-9150-200-24TM 55-1500-204-25/1TM 55-1520-214-10TM 55-1520-214-23

TM 55-1520-228-10TM 55-1520-228-23TM 55-4920-243-15

TM 55-4920-244-14TM 750-244-1-5

TM 55-1500-328-25TB 55-8100-200-24TM 55-4920-328-13

APPENDIX A

REFERENCES

Maintenance of Supplies and Equipment, Army Oil Analysis ProgramFunctional Users/Manual for the Army Maintenance Management System -

Aviation (TAMMS-A)Magnesium Alloy, Processes for Pretreatment and Prevention of CorrosionMarking for Shipment and StorageHandling, Storage and Disposal of Army Aircraft Components Containing

Radioactive MaterialsCleaning Procedures for Army AircraftAeronautical Equipment Army Oil Analysis Program (AOAP)Engine and Transmission Oils, Fuels, and Additives for Army AircraftGeneral Aircraft Maintenance ManualOperator’s Manual: Helicopter, Observation OH-6A (Hughes)AVUM and AVIM Maintenance Manual: Helicopter, Observation OH-6A

(Hughes)Operator’s Manual: Army Model OH-58A HelicopterAVUM and AVIM Maintenance Manual: Army Model OH-58A HelicopterOperator, Organizational, DS, GS, and Depot Maintenance Manual:

Vibration Monitoring KitTester, Exhaust Gas Temperature, Model BH 112JA36Procedures for the Destruction of Aircraft and Associated Equipment to

Prevent Enemy UseAeronautical Equipment Maintenance Management Policies and ProceduresMaintenance of Specialized Reuseable Containers for Aircraft EquipmentOperator’s Organizational DS and GS Maintenance Manual for Engine Test

System

Change 11 A-1/(A-2 blank)

TM 55-2840-231-23

APPENDIX B

MAINTENANCE ALLOCATION CHART

Section I. INTRODUCTION

B-1. MAINTENANCE ALLOCATION CHART.

a. This Maintenance Allocation Chart (MAC) (Section II) assigns maintenance functions in accordancewith the Three Levels of Maintenance concept for army aircraft. These maintenance levels, Aviation UnitMaintenance (AVUM); Aviation Intermediate Maintenance (AVIM) and Depot Maintenance are depicted onthe MAC as:

AVUM which corresponds to the O Code in the RPSTL

AVIM which corresponds to an F Code in the RPSTL

DEPOT which corresponds to a D Code in the RPSTL

b. The maintenance to be performed below depot and in the field is described as follows:

(1) Aviation Unit Maintenance (AVUM) activities will be staffed and equipped to perform highfrequency “On-Aircraft” maintenance tasks required to retain or return aircraft to a serviceable condition.The maintenance capability of the AVUM will be governed by the Maintenance Allocation Chart (MAC) andlimited by the amount and complexity of ground support equipment (GSE), facilities required, and numberof spaces and critical skills available. The range and quantity of authorized spare modules/components willbe consistent with the mobility requirements dictated by the air mobility concept. (Assignments of main-tenance tasks to divisional company size aviation units will consider the overall maintenance capability ofthe division, the requirement to conserve personnel and equipment resources and air mobility requirements.)

(a) Company Size Aviation Units: Perform those tasks which consist primarily of preventivemaintenance and maintenance repair and replacement functions associated with sustaining a high level ofaircraft operational readiness. Perform maintenance inspections and servicing to include preflight, daily,intermediate, periodic and special inspections as authorized by the MAC or higher headquarters. Identifythe cause of equipment/system malfunctions using applicable technical manual troubleshooting instructions,built-in-test equipment (BITE), installed aircraft instruments, or easy to use/interpret diagnostic/fault isola-tion devices (TMDE). Replace worn or damaged modules/components which do not require complex adjust-ments or system alinement and which can be removed/installed with available skills, tools and equipment.Perform operational and continuity checks and make minor repairs to the electrical system. Inspect, serviceand make operational, capacity and pressure checks to hydraulic systems. Perform servicing, functionaladjustments, and minor repair/replacement to the flight control, propulsion, power train and fuelsystems.Accomplish air frame repair which does not require extensive disassembly, jigging, or alinement. The manu-facture of air frame parts will be limited to those items which can be fabricated with tools and equipmentfound in current air mobile tool and shop sets. Evacuate unserviceable modules/components and end itemsbeyond the repair capability of AVUM to the supporting AVIM.

(b) Less than Company Size Aviation Units: Aviation elements organic to brigade, group,battalion headquarters and detachment size units are normally small and have less than ten aircraft assigned.Maintenance tasks performed by these units will be those which can be accomplished by the aircraft crew

B-1

B-2

TM 55-2840-231-23

chief or assigned aircraft repairman and will normally be limited to preventive maintenance, inspections,servicing, spot painting, stop drilling, application of nonstress patches, minor adjustments, module/component fault diagnosis and replacement of selected modules/components. Repair functions will nor-mally be accomplished by the supporting AVIM unit.

(2) Aviation Intermediate Maintenance (AVIM) provides mobile, responsible “One Stop” main-tenance support. (Maintenance functions which are not conducive to sustaining air mobility will be as-signed to depot maintenance). Performs all maintenance functions authorized to be done at AVUM. Re-pair of equipment for return to user will emphasize support or operational readiness requirements. Auth-orized maintenance includes replacement and repair of modules/components and end items which can beaccomplished efficiently with available skills, tools, and equipment. Establish the Direct Exchange (DX)program for AVUM units by repairing selected items for return to stock when such repairs cannot be ac-complished at the AVUM level. Inspects, troubleshoots, tests, diagnoses, repairs, adjusts, calibrates, andalines aircraft system modules/components. AVIM units will have capability to determine the serviceabilityof specified modules/components removed prior to the expiration of the Time Between Overhaul (TBO) orfinite life. Module/component disassembly and repair will support the DX program and will normally belimited to tasks requiring cleaning and the replacement of seals, fittings and items of common hardware.Air frame repair and fabrication of parts will be limited to those maintenance tasks which can be performedwith available tools and test equipment. Unserviceable reparable modules/components and end items whichare beyond the capability of AVIM to repair will be evacuated to Depot Maintenance. This level will per-form aircraft weight and balance inspections and other special inspections which exceed AVUM capability,Provides quick response maintenance support, including aircraft recovery and air evacuation, on-the-jobtraining, and technical assistance through the use of mobile maintenance contact teams. Maintains author-ized operational readiness float aircraft. Provides collection and classification services for serviceable/unserviceable material. Operates a cannibalization activity in accordance with AR 750-50. (The aircraftmaintenance company within the maintenance battalion of a division will perform AVIM functions con-sistent with air mobility requirements and conservation of personnel and equipment resources. Additionalintermediate maintenance support will be provided by the supporting nondivisional AVIM unit.)

a. The Maintenance Allocationand the following consideration:

Chart assigns maintenance functions based on past experience

(1)

(2)

(3)

b. The

Skills available.

Time required.

Tools and test equipment required and/or available.

assigned levels of maintenance authorized to perform a maintenance function is indicated.

c. A maintenance function assigned to a lower maintenance level to be performed at any highermaintenance level.

d. A maintenance function that cannot be performed at the assigned level of maintenance for anyreason may be evacuated to the next higher maintenance organization. Higher maintenance levels willperform the maintenance functions of lower maintenance levels when required or directed by theappropriate commander.

B-2

TM 55-2840-231-23

e. The assignment of a maintenance function will not be construed as authorization to carry theassociated repair parts in stock. Information to requisition or otherwise secure the necessary repairparts will be as specified in the Repair Parts, Special Tools List.

f. Normally there will be no deviation from the assigned level of maintenance. In cases of operationalnecessity, maintenance functions assigned to a maintenance level may, on a one-time basis and at therequest of the lower maintenance level, be specifically authorized by the maintenance officer of the levelof maintenance to which the function is assigned. The special tools, equipment, etc. required by thelower lever of maintenance to perform this function will be furnished by the maintenance level to whichthe function is assigned. This transfer of a maintenance function to a lower maintenance level does notrelieve the higher maintenance level of the responsibility of the function. The higher level ofmaintenance has the authority to determine:

(1) If the lower level is capable of performing the work.

(2) If the lower level will require assistance or technical supervision and on-site inspection.

(3) If the authorization will be granted.

g. Maintenance of the US Army Communications and Electronics Material Readiness Commandequipment will be performed by designated US Army CERCOM personnel.

h. Changes in the Maintenance Allocation Chart will be based on continuing evaluation and analysisby responsible technical personnel and on reports received from field activities,

B-3. DEFINITIONS.

Maintenance functions. Maintenance functions will be limited to and defined as follows:

a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical and/orelectrical characteristics with established standards through examination.

b. Test. To verify serviceability and detect incipient failure by measuring the mechanical orelectrical characteristics of an item and comparing those characteristics with prescribed standards.

c. Service. Operations required periodically to keep an item in proper operating condition, i.e. toclean (decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, orcompressor air supplies.

d. Adjust. To maintain, with prescribed limits, by bringing into proper or exact position, or by settingthe opening characteristics to specified parameters.

e. Align. To adjust specified variable elements of an item to bring about optimum or desiredperformance.

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or testmeasuring and diagnostic equipment used in precision measurement. Consists of comparisons of twoinstruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancyin the accuracy of the instrument being compared.

g. Install. The act of emplacing, seating, or fixing into position an item, part, or module (componentor assembly) in a manner to allow the proper functioning of an equipment or system.

h. Replace. The act of substituting a serviceable like type part, subassembly, or module (componentor assembly) for an unserviceable counterpart,

Change 11 B-3

B-4

B-5

TM 55-2840-231-23

i. Repair. The application of maintenance services or other maintenance actions to restore service-ability to an item by correcting specific damage, fault, malfunctions, or failure in a part, subassembly,module (component or assembly), end item, or system.

j . Overhaul. That maintenance effort (service/action) necessary to restore an item to a completelyserviceable/operational condition as prescribed by maintenance standards (i.e. DMWR) in appropriate tech-nical publications. Overhaul is normally the highest degree of maintenance performed by the Army. Over-haul does not normally return an item to like new condition.

k. Rebuild. Consists of those services/actions necesssary for the restoration of unserviceable equipmentto a like new condition in accordance with original manufacturing standards. Rebuild is the highest degreeof material maintenance applied to Army equipment. The rebuild operation includes the act of returningto zero those age meaaurements:(houm/mfles, etc.) considered in classifying &my equipments/components.

The standard groupings shown below are used, as applicable, throughout this MAC. Maintenance manualsand RPSTLs will reflect these standard groupings as individual chapters with sections in each chapter rela-tive to the individual complete systems, subsystems, modules components, assemblies, or specific partsnoted.

The letters “AVUM, AVIM and Depot” as placed on the Maintenance Allocation Chart, indicate thelevel of Maintenance responsible for performing the particular maintenance function based upon assignedskills, tools and test equipment and time required to accomplish maintenance.

GroupNumber

0400

0401

0402

0403

0404

Description

ENGINE SYSTEM

ENGINE GENERAL

Servicing, handling, inspection requirements, lubrication charts, overhaul &retirement schedules. External lines & hoses. (As applicable.)

COMPRESSOR SECTION

Rotor, blades, vanes, impeller, stators, inlet guide vanes, main frame, particleseparator, bleed valve, bearings, seals external lines & hoses.

COMBUSTION SECTION

Liners, nozzles, stators, rotor, seals, couplings, blades.

POWER-TURBINE

Nozzles, rotors, blades, exit guide vanes, exhaust frame, drive shaft, bearings,seals, external lines & hoses.

B-4

B-6

B-7

TM 55-2840-231-23

GroupNumber

0405

0406

0407

0408

Description

ACCESSORY GEARBOX

Input and output gears, seals, chip detector, housings, drive shaft, bearings,Seals.

FUEL SYSTEM

Fuel Control, fuel boost pump, governor, fuel filter assembly, sequence valve,fuel manifold fuel nozzle, external lines & hoses.

ELECTRICAL SYSTEM

Electrical control units, exciters, thermocouples, ignition harness, electrical cables,history recorders, torque overspeed sensor, NP sensor, alternate stator, blowers.

OIL SYSTEM

Tanks, oil filter, oil cooler, lube and scavenge pumps, oil filter bypass sensor,external lines & hoses.

The symbol _._ identifies the lowest level of maintenance authorized to perform a maintenance functionand indicates that work time figures are being developed and will be entered at a later date. When developed,this time will appear: for example as, 0.1 and also indicates the lowest level of authorized maintenance.

TOOLS AND TEST EQUIPMENT (Section III).

Special totals, teat, and support equipment required to do maintenance functions are listed with a refer-ence number to permit cross-referencing to column 5 in the MAC. In addition, the maintenance categoryauthorized to use the device is listed along with the item National Stock Number and, if applicable, thenumber to aid in identifying the tool/device.

B-8. REMARKS (Section IV).

Column 6 of the MAC contains alphabetic reference codes which are explained in Section IV of thisappendix.

B-5

TM 55-2840-231-23

Section II. MAINTENANCE ALLOCATION CHART

NOMENCLATURE OF END ITEMS

(1)

GroupNumber

04

0401

0402

040201

040202

040203

ENGINE AIRCRAFT GAS TURBINEMODEL T63-A-700

(2) (3) (4) (5)

Maintenance Maintenance Category Tools andComponent/Assembly Function AVUM AVIM Depot Equipment

NOTE

The AVUM Maintenance functions identifiedherein are restricted to Company size (AVUM No.2) units. These units are authorized SC 4920-99 -CL-A92 (AVUM No. 2) Tool Set and have 10 ormore Aircraft assigned,5-16(1) (a) and (b).

ENGINE SYSTEM

I’URBINE ENGINE

COMPRESSORSECTION

COMPRESSORASSEMBLY

[NLET GUIDE VANES

COMPRESSOR CASEHALVES

INSPECTTEST

SERVICEINSTALLREPLACEREPAIR

OVERHAUL

INSPECTSERVICEINSTALL

REPLACE

REPAIR

INSPECT

INSPECTSERVICEINSTALLREPLACEREPAIR

Refer to

——

————

———

—

—

—

.————

paragraph

—

—

1702,06,170905,1707,16,17,1907,10,16,17,1916,17,1908,23

1705,1701,03,04,07,10,15,16,1701,03,04,07,10,15,16,1717,19

17

1705,1701,16,1701,16,1717,19

(6)

Remarks

ABCDD

c

.

c

E

B-6 Change 11

TM 55-2840-231-23

Change 11 B-7

TM 55-2840-231-23

B-8 Change 13

TM 55-2840-231-23


ENGINE AIRCRAFT GAS TURBINE

(1) ( 4 )

GroupNumber

Maintenance Category

040503

0406

040601

040602

040603

040604

040605

MODEL T63-A-700

(2)

Component/Assembly

MAGNETIC CHIPDETECTOR

FUEL SYSTEM

FUEL CONTROL

FUEL CONTROLFUEL FILTER

GOVERNOR

FUEL PUMP

FUEL FILTER

(3)

MaintenanceFunction

INSPECTTESTSERVICEINSTALLREPLACE

INSPECTTESTSERVICEADJUSTINSTALLREPLACEREPAIROVERHAUL

INSPECTSERVICEINSTALLREPLACE

INSPECTTESTADJUSTINSTALLREPLACE

INSPECTINSTALLREPLACEREPAIROVERHAUL


AVUM

—————

———————

————

——

——

————

——.—

AVIM

—

Depot

—

—

(5)

Tools andEquipment

1717171717

1711,171711,12,14,1716,17,1916,17,1916,17,19

171716,1716,17

1716,171716,1716,17

1716,1716,1716,17

171716,1716,17

(6)

Remarks

Change 11 B - 9

TM 55-2840-231-23



(1)

GroupNumber

040605

040606

040607

040608

040609

040610

040611

0407

040701

Pc AIR FILTER

FUEL NOZZLE

DOUBLE CHECKVALVE

ACCUMULATORS

FUEL CHECKVALVE

DELETED

EXTERNAL LINESAND HOSES

ELECTRICALSYSTEM

EXCITER ASSEMBLY

B-10 Change 11

MODEL T63-A-700

(3)

MaintenanceFunction

INSPECTSERVICEINSTALL


INSPECTINSTALLREPLACEREPAIR

INSPECTTESTSERVICEINSTALLREPLACE

INSPECTINSTALLREPLACE

INSPECTINSTALLREPLACE

INSPECTTESTINSTALLREPLACE

(4)

Maintenance Category

AVUM

———

————

———

—————

———

———

————

AVIM Depot

—

(5)

Tools andEquipment

161616

171716,1716,17

1716,1716,17

1716,171716,1716,17

1716,1716,17

171717

171716,1716,17

(6)

Remarks

TM 55-2840-231-23



Change 13 B-11

TM 55-2840-231-23



MODEL T63-A-700

B-12 Change 11

TM 55-2840-231-23

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS


Tool or TestEquipmentReference

Code

0102

030405

06

070809

10111213

1415

1617

18

19

20

21

22

23

24

25

26

MaintenanceCategory

AVUMAVUM

AVUMAVUMAVUM

AVUM

AVUMAVIM

AVIM

AVUMAVUMAVUMAVUM

AVUMAVUM

AVUMAVUM

AVUM

AVUM

AVIM

AVIM

AVIM

AVIM

AVIM

AVIM

AVUM


Nomenclature

ADAPTER, ENGINE TURNINGBRACKET MOUNTING COM-

PRESSOR VIBRATIONPICKUP

CLAMP, LOOPCLAMP, LOOPKIT, PROTECTOR COMPRES-

SOR CLEANINGKIT, VIBRATION SIGNAL

SOURCELIFT, ENGINE ASSEMBLYPULLER KIT, MECHANICALSTAND TEST, ENGINE,

MODULARSTAND, ENGINE TURNOVERSTOP WATCHWRENCH, GROUND IDLEPULLER, LUBE OIL FILTER

CAPFIXTURE , SETTINGFIXTURE ASSEMBLY COM-

PRESSORTOOL SET AVUM SET NO. 2TOOL KIT, AIRCRAFT

MECHANICS GENERALTOOL KIT, ELECTRICAL

REPAIRMANSTOOL KIT, ENGINE REPAIR-

MANSSHOP SET, AVIM, ELECTRI-

CAL INSTRUMENTSHOP SET, AVIM, MACHINE

SHOPSHOP SET, AVIM, SHEET

METALSHOP SET, AVIM, TOOL CRIB

SHOP SET, AVIM, TURBINEENGINE

SHOP SET, AVIM, WELDING

JET-CAL ANALYSER

National/NATOStock Number

4920-00-923-3188

4920-00-030-10225340-00-945-02445340-00-945-0242

1730-00-122-5244

4920-00-879-03315120-00-924-77225120-00-945-0186

4920-00-167-91784920-00-924-57266645-00-250-46805120-00-763-7565

5120-00-088-10719820-00-028-0083

4920-00-923-31904920-00-567-0476

5180-00-323-4692

5180-00-323-4915

5180-00-323-49444920-00-165-1453

4920-00-405-9279

4920-00-166-5505

4920-00-472-4183

4920-00-224-3684

4920-00-163-5093

4920-00-673-5514

ToolNumber

6799790

687253967999526799953

6798861

171170-010467969636796941

LTCT10465-026795579105318786798292

67988606872482

679566-100SC492099CLA92

SC518099CLA01

SC518099CLA06

SC518099CL07SC492099CL91

ELAMSC492099CLA91

MAAMSC492099CLA915

MAMSC492099CLA91

TCAMSC492099CLA91

ENTAMSC492099CLAW

EAMBH-112-JA-36

Change 11 B-13

TM 55-2840-231-23

ReferenceCode

A

B

c

D

E

F

B-14 Change 11

Section IV. REMARKS

T63-A-700 TURBINE ENGINE

Remarks/Notes

Functional Test at AVUM — Engine in Airframe

Functional Test at AVIM — Engine in METS

Water/Solvent Solution Wash

Reference TM 55-1520-228-23

Blend-Repair Only

Weld-Repair

TM 55-2840-231-23

A P P E N D I X C

SPECIAL TOOLS AND SUPPORT EQUIPMENT

A listing and illustration of special tools and support equipment is presented in this Appendix. Thislisting provides a convenient reference for special tools and support equipment available to performmaintenance functions on the engine. It is primarily intended as a ready reference for maintenancepersonnel in determining what equipment is available. All tools and equipment are arrangednumerically according to part number.

Figure

C-8C-l0C-3C-6C-4C-5C-11C-12C-7C-1C-2C-2C-13C-9

———

—

——

—

Nomenclature

Magnifying Glass, 10xStand, Turnover Engine AssemblyWrench, Box, StraightFixture, Assembly, CompressorPuller Kit, MechanicalLift, Engine AssemblyPuller, CompressorWrench, Ground IdlePuller, Lube Oil Filter CapProtector Kit, CompressorAdapter, Engine TurningClamp, LoopClamp, LoopFixture Max Stop ScrewStand, Test, Engine, ModularTester, Jet Ignition SystemKit, Vibration MonitoringKey Socket, Head Screw-Hex Type No.

9164 In.Wrench, Torque, 1/4 In. Drive, 30 No. to

150 No., ClickTool Kit, Engine RepairmanShop Set, Aircraft Maintenance Fixed Base,

Welding, Set CTool Set, Set No. 2

Part Number

66M95679557967955886795966-1006796941679696367982506798292679886067988616799790679995267999536872482LTCT10465-O211-4700-1171170-0104GGGK00275

GGG-W-686Type 111 Class 1SC5780-00-CL-A07SC4920-99-CL-A10

SC492099CLA92

National/NATOStock Number

6650-00-490-26274920-00-924-57265120-00-761-36464920-00-923-31905120-00-945-01865120-00-924-77225120-00-759-83695120-00-763-75655120-00-088-10711730-00-122-52444920-00-923-31885340-00-945-02445340-00-945-02424920-01-028-00834920-00-167-91784920-00-587-58864920-00-879-03315120-00-984-0247

5130-00-542-4489

5180-00-323-49444920-00-163-5093

4920-00-567-0476

Change 11 C-1

Figure C- 6Figure C-5

Figure C-4

Figure C-2

Figure C-1

Figure C-3

TM 55-2840-231-23

C-2

TM 55-2840-231-23

Figure C-7. Compressor ProtectorKit 6798861

Figure C-8. Engine AssemblyTurnover Stand 6795579

Figure C-9. Modular Engine Test StandLTCT10465-02

C-3

TM 55-2840-231-23

Figure C-10. Straight Box Wrench6795588

Figure C-11. Ground Idle Wrench6798292

Figure C-12. Lube Oil Filter Cap Puller6798860

Figure C-13. Fixture Setting, Fuel ControlMaximum Stop Screw 6872482

C-4

TM 55-2840-231-23

APPENDIX D

EXPENDABLE SUPPLIES AND MATERIALS LIST

Section I. INTRODUCTION

D-1. SCOPE.

This appendix lists expendable supplies and materials you will need to operate and maintain the T63-A-700 Turboshaft engine. These items are authorized to you by CTA 50-970, Expendable Items (ExceptMedical, Class V, Repair Parts, and Heraldic Items).

D-2. EXPI.ANATION OF COLUMNS

a. Column 1- Item number. This number is assigned to the entry in the listing and is referenced in thenarrative instructions to identify the material (e.g., “Use cleaning compound (item 5, Appendix D” ) .

b. Column 2- Level. This column identifies the lowest level of maintenance that requires the listed item.

c. Column 3- National Stock Number. This is the National stock number assigned to the item; use it torequest or requisition the item.

d. Column 4- Description. Indicates the Federal item name alphabetically and, if required, a descriptionto identify the item. The last line for each item indicates the part number followed by the Federal SupplyCode for Manufacturer (FSCM) in parentheses, if applicable.

e. Column 5- Unit of Measure (U/M). Indicates the measure used in performing the actual maintenancefunction. This measure is expressed by a two-character alphabetical abbreviation (e.g., ea, in, pr). If the unitof measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy yourrequirements.

Change 11 D-1

TM 55-2840-231-23

(1)

ItemNumber

1

1A

2

3

4

6

6

7

8

9

10

11

12

13

14

16

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST

(2)

Level

D-2 Change 7

(3)National

StockNumber

6850-00-264.9038

6850-00-274-5421

8135-00-282-0565

7510-00-890-9872

9150-00.273-2388

9150-00-180-6266

9150-00-543-7220

9505-00-618-0257

6850-00-264-6572

8030-00.244.1298

7510-00-227-1444

6850-00-209-7235

8131-00-664-0057

6810-00-1844800

8115-01-053-

8135-00-224-8885

(4)

DescriptionDrycleaning Solvent (Petroleum solvent)P-D-680, Type I

Drycleaning Solvent P-D-680, Type 11

Barrier Material, Water-VaporproofMIL-B-131, class 1

Tape, Packaging, WaterproofPPP-T-60, Type IV

Lubricating Oil (for assembly and preservation only)MIL-L6081, Grade 1010

Lubricating OilMIL-L-7808 or MIL-L-23699

Antiseize CompoundMIL-L-25681

Lockwire, 0.020-in. diaMS20995C20

Dehydrating Agent (desiccant, 16 unit bag)MIL-D-3464

Corrosion Preventive CompoundMIL-C-16173, Grade 3

White Stencil InkTT-I-1795

Corrosion Preventive CompoundMIL-C-6529, Type III

Cushioning Material, Bound FiberPPP-C-1120, Type III

Trichlorethylene O-T-634

Fiberboard Container PPP-B-636

Barrier Material, Greaseproofed, WaterproofedMILB-121, Type I, Grade A, Class 1

TM 55-2840-231-23

(1)

ItemNumber

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

82

83

(2)

Level

(3)National

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

StockNumber

9150-00-616-9020

9505-00-2934208

9160-00-223-4003

9150.00-753-4649

6810-00-880-7383

6850-00-550-5665

6850-00-803-6420

6850-00-597-1628

6850-00.209.7230

9150-00.235.9061

6850-00.181-7594

6350-00-246-0338

5350-00.186-8856

8010-00-831-5936

8010-00-831-5934

5350-00-186-8855

6810-00-281-2786

8010-00-831-9398

(4)

Description

Aircraft Grease MIL-G-25537

Lockwire, 0.032 in. dia MS20995C32

Grease MIL-G-3545

Lubriplate 130A or equivalentVV-G-632, Type B, Grade 1

Denatured Alcohol Commercial

Solvent Turco 481MIL-C-16480

Carbon Removal CompoundTurco, Super CarbMIL-D-26549

Cresol Base Cleaning CompoundTurco Products Inc. Formula 3097 orequivalent

Rust Preventive Cities Service Anti-Corrode 204or equivalent

Oil MIL 3100

Water Soluble Cleaner (B& B 9100)

Abraaive Paper, Grade 320

Emery Cloth, No. 400 grit

Paint Thiner

Gray Corrsion Resistant Paint

Emery Cloth, No. 500 grit

MethylethyIketone TT-M-261

Heat Resistant Aluminum Paint

(5)

U/M

LB

lLB

GL

CL

GL

GL

QT

CL

QT

Change 3 D-3

TM 55-2840-231-23

(1)

ItemNumber

34

35

36

37

38

39

40

41

42

43

44

46

46

47

48

49

50

(2)

Level

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVIM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

AVUM

(3)

NationalStock

Number

8010-00-831-5934

8010-00-160-5787

5350-00-224-7201

9150-00-944-8953

8030-00-209-8005

6810-00-184-4796

3439-00-166-9584

9150-00-754-0064

5350-00-221-0572

9130-00-256-8613

NO NSN ASSIGNED

8520-00-228-0598

NO NSN ASSIGNED

6810-00-275-6010

7510-00-285-5812

8030-00-938-1947

NO NSN ASSIGNED

(4)

Description

Corrosion Resistant PaintSaran Chemical Co. HC100 or WC100, Detroit, MI

Lacquer Thinner, Fed. Sped. TT-T-266

Abrasive Paper, No. 400 wet or dryP-P-101

Grease MIL-G-81322

Antiseize Compound TT-A-580

Acetone O-A-51

Weld Rod AMS 5786

Molykote (Lubri-Bond A, Electrofilm Inc. )MIL-L-23398

Crocus Cloth FSP-C-458

Fuel MIL-T-5624, Grade JP-4

Sermetel Paint Teleflex Inc. Sermetel 196

Liquid Soap Solution P-S-624

Cleated Plywood Box(12 x 12 x 14 inches) PPP-13-601

Methanol (Grade A or B)O-M-232

Marking Pencil (Yellow) ColorbrightNo. 2107 (73865) or Equivalent

Corrosion Preventative Compound Clear-WD40 or equivalent 16 oz MIL-C-81309

Nickel Ease, Anti-Seize Compound, FelPro Inc, Skokie, IL 60076

(5)

U/M

GL

LB

GL

D-4 Change 11

TM 55-2840-231-23

(1)

ItemNumber

51

52

535455565758

(3) (4)National

stockNumber Description.

8040-00--941-9984 Sealant RTV GE-106, MIL-A-46106 (aceticacid base), or

Sealant, RTV DC-732, MIL-A-46106 (aceticacid base), or

NO NSN ASSIGNED Sealant, RTV DC-738 White (alcohol base), orSealant RTV DC-739 Black or White (alcoholbase), orSealant, RTV DC-3145 Clear (alcohol base), orSealant, RT’V GE-162 White (alcohol base), orSealant, RTV GE-189 Gray (alcohol base)

6850-00-550-5565 Ultrasonic cleaner solventRichardson chemical co., Allied-wite Div.Kelite No. 235, Chicago, IL

NO NSN ASSIGNED Mineral SpiritsNO NSN ASSIGNED Sewing Thread6850-01-372-8303 Type II (MIL-C-85704)6850-01-372-8304 Type II (MIL-C-85704)6850-01-370-5245 Type IIA (MIL-C-85704)6850-01-370-5244 Type IIA (Mil-C-85704)

(5)

U/M

5Gal55 Gal5 Gal55 Gal

Change 12 D-5/(D-6 blank)

TM 55-2840-231-23

APPENDIX E

SCHEMATIC DIAGRAMS

(Not Applicable)

E-1/(E-2 Blank)

TM 55-2840-231-23

APPENDIX F

ILLUSTRATED LIST OF MANUFACTURED ITEMS

(Not Applicable)

F-1/(F-2 Blank)

G-1

TM 55-2840-231-23

APPENDIX G

TORQUE VALUES AND DIMENSIONAL LIMITS, OVERHAULAND RETIREMENT SCHEDULE

Section I. TORQUE VALUES

This appendix contains information for tightening bolts, nuts, and connectors used for components andmodular assemblies of the engine. This information includes minimum and maximum torque values,wrench arc angles, and special instructions.

G-2. Torque Values. Torque values are listed in table G-1 of this section. The table contains torqueyalues for bolts, screws, studs, flared tubing, tube fittings, flexible hose connectors, etc. and are presentedas a specific value for each individual application. The torque values are listed in numerical order by figurereference number.

G-3. Dimensional Limits. Dimensional limits are listed in table G-2 of Section II. The table providesdimensional limits for determining and maintaining proper relationship between mating parts within anassembly. The table also includes all clearances, backlashes, plugs, runouts, etc., arranged in numericalorder by figure reference number.

G-4. Overhaul Interval and Retirement Schedule. The overhaul interval and retirement schedule is listedin table G-3, Section III. Items which have an established operating interval before they are overhauledor retired from service are contained in this table.

Table G-1. Torque Values

Ref.No.

1

2

3

4

5

None

Fig.No.

G-1

G-1

G-1

G-1

G-1

G-2

Description

Shipping Container Closure Flange Nuts

Shipping Container Mounting AdapterNut

Shipping Container Mounting BracketBolts

Shipping Container Records ReceptacleNuts

Shipping Container Service ReceptacleNuts

Compressor Shipping Container LockingRing Nut

Minimum(kg/m) (in. lb)

(1.7) 150

(0.5) 40

(1.0) 85

(0.3) 30

(0.2) 15

(0.7) 65

Maximum(kg/m) (in. lb)

(1.9) 165

(0.6) 50

(1.3) 110

(0.5) 45

(0.3) 25

(0.9) 75

G-1

TM 55-2840-231-23

Ref.No.

1

2

3

1

2&3

4

2

3

5

1

None

4

12

13

Fig.No.

G-3

G-3

G-3

G-4

G-4

G-4

G-5

G-5

G-5

G-5

None

G-5

G-5

G-5

Table G-1. Torque Values - Continued

Description

Auto Reignition Sensing Tube CouplingNuts

Compressor Front Support Scavenge OilTube

Fitting Jam NutCoupling Nuts

Compressor Mounting Bolts

Outer Combustion Case Splitline Nuts

Burner Drain Valve

Ignition Lead-to-Combustion CaseBracket Nut

Governor-to-Check Valve Air TubeFitting (in governor)Coupling Nuts

Governor-to-Control Air TubeFitting (in control)Coupling Nuts

Scroll-to-Governor Air TubeFitting Jam NutsCoupling Nuts

Accumulator-to-Check Valve

Accumulator Clamp Attaching Nut

Control-to-Regulator Air TubeFitting Jam NutsCoupling Nuts

Pump-to-Control Fuel TubeFittingsCoupling Nuts

Control-to-Pump Fuel TubeFittingsCoupling Nuts


(0.9)

(0.9)(1.7)

(0.8)

(0.2)

(1.4)

(0.6)

(0.9)(0.9)

(0.9)(0.9)

(0.6)(0.9)

(0.6)

(0.4)

(0.6)(0.9)

(0.9)(1.7)

(0.9)(1.7)

80

75150

70

20

120

55

7580

7580

5580

55

35

5580

75150

75150


(1.4) 120

(1.3) 110(2.3) 200

(1.0) 85

(0.3) 30

(1.6) 140

(0.9) 80

(1.3) 110(1.4) 120

(1.3) 110(1.4) 120

(0.9) 80(1.4) 120

(0.9) 80

(0.5) 40

(0.9) 80(1.4) 120

(1.3) 110(2.3) 200

(1.3) 110(2.3) 200

G-2

TM 55-2840-231-23


Ref.No.

8

9

10

11

7

18

14

15

16

17

6

1

2

Fig.No.

G-5

G-5

G-5

G-5

G-5

G-5

G-5

G-5

G-5

G-5

G-5

G-6

G-6

Description

Control-to-Fireshield Fuel TubeFireshield Fitting Jam NutCoupling Nuts

Gas Turbine Scavenge Oil TubeFitting Jam NutCoupling Nuts

External Sump Scavenge Oil TubeFitting Jam NutCoupling Nuts

Check Valve-to-Turbine Pressure OilTube


Accumulator-to-Control Air TubeFitting Jam NutsCoupling Nuts

Gearbox-to-Check Valve Pressure OilTube


Fuel Supply HoseFittingCoupling Nut

Fuel Pump Seal Drain HoseFittingCoupling Nut

Before Filter Pressure HoseFittingCoupling Nut

After Filter Pressure HoseFittingCoupling Nut

Fireshield-to-Fuel Nozzle Hose CouplingNuts

Fuel Nozzle

Power Turbine Governor Mounting FlangeNuts


(0.6) 55(0.9) 80

(0.9) 75(1.7) 150

(0.9) 75(1.7) 150

(0.9) 75(0.9) 80

(0.6) 55(0.9) 80

(0.9) 75(1.7) 150

(0.9) 75(1.7) 150

(0.6) 55(0.9) 80

(0.6) 55(0.9) 80

(0.6) 55(0.9) 80

(0.9) 80

(2.3) 200

(0.8) 70


(0.9)(1.4)

(1.3)(2.3)

(1.3)(2.3)

(1.3)(1.4)

(0.9)(1.4)

(1.3)(2.3)

(1.3)(2.3)

(0.9)(1.4)

(0.9)(1.4)

(0.9)(1.4)

(1.4)

(3.5)

(1.0)

80120

110200

110200

110120

80120

110200

110200

80120

80120

80120

120

300

85

Change 11 G-3

TM 55-2840-231-23

REF.NO.

3

4

5

None

6

7-8

None

1

2

l&2

3

4

1

2

3

4

5

6

None

FIG.NO.

G-6

G-6

G-6

G-7

G-8

G-8

G-9

G-10

G-10

G-11

G-11

G-11

G-12

G-12

G-12

G-12

G-12

G-12

None

Table G-1. Torque Valves - Continued

DESCRIPTION

Fuel Pump Mounting Flange Nuts

Auto Reignition Mount Plate-to-Bracket Bolts

Gas Producer Fuel Control MountingFlange Nuts

Fuel Filter Cover

Fuel Control Fuel Filter Plug

Fuel Control and Governor Lever Shaft Nuts

Magnetic Chip Detectors

Oil Filter Cap Nuts

Oil Filter Housing Mounting Flange Nuts

External Oil Check Valve Clamp Nuts

Oil Pressure Reducer

Compressor Front Support Pressure OilTube

FittingCoupling Nuts

Scroll-to-Bleed Valve Air TubeFitting Jam NutsCoupling Nuts

Bleed Valve Mounting Flange Nuts1/4-28 Nut10-32 Nuts

Anti-Icing Air Tube (RH) Coupling Nuts

Anti-Icing Valve Jam Nut

Anti-Icing Air Tube (LH) Coupling Nuts

Anti-Icing Valve Poppet Guide

Fuel Control Heater Valve Nipples

MINIMUM(kg/m) (in.lb)

(0.8)

(0.4)

(0.8)

(2.1)

(0.7)

(0.5)

(0.7)

(0.3)

(0.4)

(0.4)

(0.6)

(0.6)(0.7)

(0.7)(0.9)

(0,8)(0.4)

(1.7)

(1.2)

(1.7)

(0.7)

(0.6)

70

35

70

180

65

40

60

30

35

35

50

5065

5580

7035

150

100

150

65

55

MAXIMIM(kg/m) (in.lb)

(1.0)

(0.5)

(1.0)

(2.3)

(0.8)

(0.7)

(0.9)

(0.5)

(0.5)

(0.5)

(0.9)

(0.9)(1.2)

(0.9)(1.4)

(1.0)(0.5)

(2.3)

(1.7-)

(2.3)

(0.9)

(0.9)

85

40

85

200

70

60

80

45

40

40

75

75100

80120

8540

200

150

200

75

80

G-4 Change 8

TM 55-2840-231-23

Ref.No.

None

None

1

2&5

3

4

6

None

7

8

9

None

None

1

2

3

None

None

ParaNo.

None

None

G-13

G-13

G-13

G 1 3

G-13

None

G-13

G-13

G-13

None

None

G-14

G-14

G-14

G-15

G-16


Description

Fuel Control Heater Valve Mountingclamp Nuts

Fuel Control Heater Hose Coupling Nuts

Ignition Exciter Mounting Nuts

Igniter Lead Clamp Nuts

Igniter Lead-to-Fireshield Attaching Nuts

Igniter Lead-to-Combustion Case MountingBracket Nut

Igniter Lead Coupling NutsLead-to-ExciterLead-to-Igniter

Ignition Exciter Input Lead Nut

Spark Igniter

Auto Reignition Control Mounting Bolts

Auto Reignition Control Mounting Nuts

Thermocouple Terminal Assembly MountingNuts

Thermocouple Leads-to-Terminal AssemblyNuts

No. 8-32 NutNo. 10-32 Nut

Compressor Case-to-Front Support Nuts

Compressor Case-to-Front Diffuser Nuts

Compressor Case Horizontal Splitline Nuts

Diffuser Scroll Mounting Screws

Adapter Spur Gearshaft Retaining Nut


(0.4) 35

(0.9) 80

(0.3) 30

(0.4) 35

(0.4) 35

(0.6) 55

(0.6) 50(0.8) 70

(0.1) 8

(1.7) 150

(0.4) 35

(0.4) 35

(0.4) 35

(0.2) 17(0.2) 17

(0.1) 10

(0.1) 10

(0.1) 10

(0.2) 16

(0.5) 50


(0.5) 40

(1 .4 ) 120

(0.5) 40

(0.5) 40

(0.5) 40

(0.9) 80

(0.8) 70(1.0) 90

(0.1) 12

(2 .3 ) 200

(0.5) 40

(0.5) 40

(0.5) 40

(0.3) 25(0.3) 25

(0.2) 15

(0.2) 15

(0.2) 15

(0.2) 17

(0.6) 55

G-5

TM 55-2840-231-23TM 55-2840-231-23

Ref.No.

1

2

3

4

5

6

7

8

9

10

11

12

ParaNo.

G-17

G-17

G-17

G-17

G-17

G-17

G-17

G-17

G-17

G-17

G-17

G-17


Description

Turbine-to-Gearbox Mounting Stud (Upper)

Turbine-to-Gearbox Mounting Studs(Lower)

Rear Power Takeoff Pad Studs

Fuel Control and Governor Pad Studs

Starter-Generator Pad Studs

Fuel Pump and Spare Accessory Pad Studs

Oil Filter Housing Mounting Studs (ShortStuds)

Oil Filter Housing Mounting Studs (LongStuds)

Oil Filter Housing Mounting Studs (MediumLength Stud)

Tachometer Pad Studs

Front Power Takeoff Pad Studs

Ignition Exciter Mounting Studs


(1.2)

(0.6)

(0.6)

(0.6)

(1.2)

(0.6)

(0.2)

(0.2)

(0.2)

(0.6)

(0.6)

(0.2)

105

50

50

50

105

50

20

20

20

50

50

20


(2.4) 210

(1.2) 100

(1.2) 100

(1.2) 100

(2.4) 210

(1.2’) 100

(0.5) 40

(0.5) 40

(0.5) 40

(1.2) 100

(1.2) 100

(0.5) 40

G-6

TM 55-2840-231-23

Ref.N o .

None

1

2

3

4

5

6

7,8,9

10

11

12

Fig.No.

G-16

G-1 7

G-17

G-17

G-17

G-17

G-17

G-17

G-17

G-17

G-17

Section II. DIMENSIONAL LIMITS

Table G-2. Dimensional Limits

Description

Adapter Spur Gearshaft Runout

Turbine-to-Gearbox Mounting Stud(Upper) Setting Height

Turbine-to-Gearbox Mounting Studs(Lower) Setting Height

Rear Power Takeoff Pad StudsSetting Height

P/N 6851928 and 6870734Cover

P/N 6856797 Cover

Fuel Control and Governor PadStuds Setting Height

Starter-Generator Pad Studs SettingHeight

Fuel Pump and Spare AccessoryPad Studs Setting Height

Oil Filter Housing Mounting StudsSetting Height

Short StudsLong StudsMedium Length Studs

Tachometer Pad Studs SettingHeight

Front Power Takeoff Pad StudsSetting Height

Ignition Exciter Mounting StudsSetting Height

Minimum(cm) (in.)

(0.000) 0.000 TIR

(1.68) 0.66

(1.52) 0.60

(2.31) 0.91

(1.22) 0.48

(1.52) 0.60

(2.26) 0.89

(2.16) 0.85

(1.37) 0.54(2.97) 1.17(2.01) 0.79

(1.57) 0.62

(1.57) 0.62

(1.07) 0.42

Maximum(in.) (cm)

0.003 TIR (0.008)

0.70

0.64

0.95

0.52

0.64

0.93

0.89

0.581.210.83

0.66

0.66

0.46

(1.78)

(1.63)

(2.41)

(1.32)

(1.63)

(2.36)

(2.26)

(1.47)(3.07)(2.11)

(1.68)

(1.68)

(1.17)

G-7

TM 55-2840-231-23

Figure G-1. Engine Shipping Container Parts Requiring Special Torque Values

G-8

TM 55-2840-231-23

Figure G-2. Compressor Shipping Parts Requiring Special Torque Values

G-9

TM 55-2840-231-23

Figure G-3. Compressor Parts Requiring Special Torque Values

G-10

TM 55-2840-231-23

1. NUT (24)2. DRAIN VALVE (T63-A-5A)

PLUG (T63-A-700)3. PLUG (T63-A-5A)

DRAIN VALVE (T63-A-700)4. JAM NUT

Figure G-4. Combustion Section Parts Requiring Special Torque Values

G-11

TM 55-2840-231-23

Figure G-5. Fuel, Oil, and Air Tubing Parts Requiring Special Torque Values

(Sheet 1 of 2)

G-12

TM 55-2840-231-23

Figure G-5. Fuel, Oil, and Air Tubing Parts Requiring Special Torque Values(Sheet 2 of 2)

G-13

TM 55-2840-231-23

Figure G-6. Fuel System Parts Requiring Special Torque Values

G-14

TM 55-2840-231-23

Figure G-7. Fuel Filter Cover

Change 8 G-15

TM 55-2840-231-23

Figure G-8. Fuel Control Fuel Filter Plug and Fuel Control and Governor Lever ShaftNut Location

G-16 Change 8

TM 55-2840-231-23

NOTE: THERE ARE TWO MAGNETIC CHIP DETECTORS.ONE IS LOCATED AT THE OIL OUTLET PORTAND THE OTHER IS LOCATED AT THE BOTTOMOF THE ACCESSORY GEARBOX.

Figure G-9. Magnetic Chip Detector

G-17

TM 55-2840-231-23

Figure G-10. Oil Filter and Related Parts Requiring Special Torque Values

G-18

TM 55-2840-231-23

Figure G-11. External Oil Lines and Related Parts Requiring Special Torque Values

G-19

TM 55-2840-231-23

Figure G-12. Air Tubes, Poppet Guides, and Related Parts Requiring SpecialTorque Values

G-20

TM 55-2840-231-23

Figure G-13. Ignition System and Related Parts Requiring Special Torque Values

G-21

TM 55-2840-231-23

Figure G-14. Compressor Case Assembly and Related Parts Requiring SpecialTorque Values

G-22

TM 55-2840-231-23

Figure G-15. Diffuser Scroll

G-23

TM 55-2840-231-23

Figure G-16. Adapter Spur Gearshaft

G-24

TM 55-2840-231-23

Figure G-17. Location of Gearbox External Studs

G-25

TM 55-2840-231-23

Section III. OVERHAUL AND RETIREMENT INTERVAL

Table G-3. Overhaul and Retirement Interval - Continued

Overhaul RetirementInterval (hr) Interval (hr) Item Part Number

Engine

1000 Engine

750 Compressor

1000 Compressor

1000 Fuel Pump(024731-102)

2000 Fuel Pump

1000 Bleed Valve(A45413A)

1000 Bleed Valve

450

750

2000

NOTE

AU compressors with yellow plastic liners installedshall have an overhaul interval of 450 hours.

NOTE

Only the engines identified by the suffix "B" afterthe engine serial number and its applicable compo-ments indicated in Table G-3 will have the 1000hour (TBO). Example: AE40100AB; AE402603B.On all other T63 engines not identified by the suffix"B" after the engine serial number, the TBO willremain 750 hours and the fuel control, power turbinegovernor, fuel pump. bleed valve and compressorwill be returned with the engine to overhaul whenthe engine reaches its 750 hour TBO.

Fuel Control

Fuel Control

Oil Pump Assy

6852600

6874201

6876265

6876266

6854292

6899253

6870460

6874979

6858454(2524246-5)

6872037(2524246-6)

386500-5

G-26 Change 13

TM 55-2840-231-23



1000 Fuel Control 6871111(2524437-3)

2000 Fuel Control 23006271(2524909-1)

2000

2000

2000

2000

2000

2000

1000

Fuel Control 23007859(2524909-2)

Fuel Control 23037271(2424909-3)

Fuel Control 2524909-4

Governor 23006272(2524910-1)

Governor 23007876(2524910-2)

Governor 23030647(2524910-3)

Governor 6874255(2524438-1)

2000 Impeller 6851116

2000 Impeller 6854131

3050 Impeller 6876367

NOTE

First stage wheels have a retirement life of 1550hours on engines that have a "B" in the suffix on theserial number. If an engine does not have a "B" inthe suffix on the serial number. If an engine does nothave a "B" in the Suffix of the serial number, theretirement life is 750 hours.

NOTE

Retirement life depends on the specific part numberand application, whether used in a T63-A-700 orT63-A-720.

Change 13 G-27

TM 55-2840-231-23



1550 1st Stage Wheel 6852171

1550 1st Stage Wheel 6886407

1550 2nd Stage Wheel 6857912



2500 3rd Stage Wheel 6843393

2500 4th Stage Wheel 6847449

G-28 Change 11

H-2

TM 55-2840-231-23

APPENDIX H

GENERAL MAINTENANCE PRACTICES

H-1. APPENDIX OVERVIEW.

This appendix contains general maintenance practices. Maintenance personnel will become familiarwith them before starting to work on the engine or on any of the engine subassemblies or components.

Be sure to comply with all assembly lubrication procedures. Failure to do so could result in oil systemcontamination.

•Antiseize compounds will not be used to lubri-cate a surface that will come in contact withengine oil.•Do not use a lubricant on carbon seals.

The lubricants used during assembly are listed under Expendable Supplies and Materials in appendix D.

Be sure all surfaces that need lubrication are clean and free of moisture and solvents before applyingthe lubricant.

Do not contaminate highly-finished surfaces with body moisture or other agents before lubricating.This could cause corrosion after lubricant is applied.

Lubricating oil (item 5, Appendix D) is the type of oil meant wherever the term “light coat of oil” orthe word "oil" is used in assembly procedures.

Unless otherwise noted, use a light coat of lubricating oil to lubricate threads of bolts, screws, studs,coupling nuts and fasteners used in assembly. Failure to do this may cause bolts to be improperly torquedor may cause shank nuts to become loosened during assembly, and may cause bolt seizure and/or failureduring removal.

H-3. USE OF JACKING SCREWS.

Jacking screws are used to remove tight-fitting covers and flanged parts.

Bolts referenced in disassembly procedures are used as jacking screws.

In procedures that specify using jacking screws, do the following:

a. Manually thread bolts into holes until they bottom.

b. Alternately turn bolts clockwise one-quarter of a turn, one at a time, until part being jacked canbe freely removed from engine.

H-1

TM 55-2840-231-23

Captive bolts are part of a component and remain installed (captive) on the component after beingunthreaded from the mounting surface in which they are threaded.

When the word “loosen” is used in reference to a captive bolt, it means that the captive bolt must beremoved from the mounting surface but not from the component to which it is captive.

To remove captive bolts from parts to which they are attached, pull bolt away from part until threadsengage threaded hole in part. Then turn bolt counterclockwise until it is disengaged.

Replace captive bolts as follows:

a. AVUM: Try to remove bolt by hand. If bolt hangs up, return part to AVIM.

Cap or plug all openings.

b. AVIM: Chase threads enough to allow removal by hand. Inspect insert in accessory for damage.

There are two types of electrical coupling connectors: those with hex coupling nuts and those withknurled coupling rings. Observe the following practices:

● Do not lubricate electrical connectors.● Do not use tools on knurled coupling rings.● Do not cross thread coupling connectors.

Hex coupling nuts. Install, hand-tighten, and wrench arc tighten hex coupling nuts according to theassembly instructions in this manual.

Knurled coupling rings. Mate connectors that have knurled coupling rings as follows:

NOTE

When mating or disconnecting a connector thathas a knurled coupling ring, ratcheting will befelt as the ring is turned. This is normal. It ispart of the self-locking feature of the connector.If there is no ratcheting, the cable will be re-moved and the. connector replaced.

a. Check mating receptacle for bent pins. If they are bent, see applicable inspection paragraph forrepair limits.

b. Aline axis of electrical cable plug connector with axis of mating receptacle to avoid damage to pinsin receptacle.

H-2

H-6

H-7

TM 55-2840-231-23

c. Aline keys of plug connector and keyways of receptacle by rotating connector until it slides intomating receptacle.

NOTE

There is a colored circumferential line (dark band)around the mating receptacle. When this line iscovered (no longer visible), and the connectors arefirmly seated, the connectors are fully mated.

Aircraft electrical connectors may also have acolored line and may require a different matingprocedure. See applicable aircraft manual forinstructions.

d. Push in on plug connector. Carefully thread coupling ring onto mating receptacle. Alternatelypush in on plug connector and hand-tighten coupling ring until plug connector is firmly seated and darkband on mating receptacle is covered (no longer visible).

e. Apply a side-load to plug connector. There will be no movement between the plug connector andreceptacle.

Unless otherwise specified, apply a light coat of lubricating oil to packings.

Before installing packings and parts containing packings, lubricate all grooves, lead-in chamfers, bores,and surfaces with lubricating oil.

Wipe off excess oil before assembling parts.

Do not reuse packings that were removed during disassembly. Use new packings at final assembly.

Remove packings by hand if possible. Use the following procedure to remove packings if they aredifficult to remove by hand.

Tools can damage packing grooves, causing fuelor oil leaks.

a. Stick a scriber into the packing. Do not touch packing groove with the scriber.

b. Lift packing out of groove.

c. Discard packing.

a. The following information applies to all wrench-arc tightening procedures.

H-3

TM 55-2840-231-23

(1) Before tightening, be sure that all threads and that all sealing and mating surfaces are cleanand free of nicks, burrs, and scratches.

(2) Lubricant used on threads will be the same as that used in the engine oil system. Do notlubricate electrical connectors.

(3) Open-end wrenches with 15° offset angled heads will normally be used for wrench-metightening.

b. When specified in the assembly or installation procedures, use the following procedures to tightenthreaded parts.

NOTE

The snug (no torque) condition is reached when apositive increase in resistance (on the nut) to turn-ing is felt (greater than run-on torque), when partsappear to be properly seated, and when no loosenessbetween mating parts is noted.

(1) Tightening to 15° wrench arc.

(a) Snug the nut.

(b) Place an open-end wrench on nut.

(c) Establish a line of sight using wrench handle.

(d) Use the angular difference between handle and wrench flats (15°) to visually measureamount that the nut will have to be turned.

(e) Turn wrench until flats on nut (engaged by wrench) are alined with line of sight estab-lished by handle in step (c).

(2) Alternate method for tightening to 15° wrench arc.

(a)

(b)

(c)

(d)

Snug the nut.

Place an open-end wrench on nut.

Use the engaged nut flats to establish a line of sight.

Turn wrench until handle is alined with line of sight,

(3) Tightening to 60° and 120°wrench arc. In this method of tightening, primarily used for tubefittings, the flats on the union are-used as a reference. Wrenches other than open-end wrenches (crowfeetor tubing wrenches) may be used.

(a) Snug the nut.

(b) Use the corners on the coupling nut between the flats on mating union to gage theamount that coupling nut will have to move.

H-4

TM 55-2840-231-23

(c) Turn coupling nut 1 flat for 60° wrench arc.

(d) Turn coupling nut 2 flats for 120° wrench arc.

(4) Tightening to 30° wrench arc.

(a) Snug the nut.

(b) Place an open-end wrench on nut.

(c) Note position of wrench handle. (Pick out point of reference on engine in line with handle.)

(d) Invert wrench using the same nut flats. The angular difference between the centerlines of thewrenches in the two positions is 30°.

(e) Turn wrench to position established in step (c).

H-8. ENGINE POWER LOSS, N2 DROOP OR FLAMEOUT.

Check maintenance procedures for OH-58 aircraft when a power loss, N2 droop, or flameout occurs. N2 droopmay occur during a normal flight maneuver requiring a rapid increase in power (i.e., rapid collective and/or tailrotor inputs, high G turn, steep turn). If N2 droop occurs, but low RPM warning is not activated and N2 recoversto 103 percent on OH-58A aircraft, and further N2 droop is not experienced, no maintenance action is required.

NOTE

For all maintenance actions notedbelow, pneumatic line fittings are tobe torqued to specified values utiliz-ing a torque wrench. All lines are tobe installed so that there is nopreload or deformation of the line inaccordance with applicable TM’s.

a. When a power loss, N2 droop, or flameout occurs (in parameters other than those established in para-graph above), check/inspect to determine the reason/reasons in accordance with the troubleshooting charts inTM 55-2840-231-23 for OH-58A/-700 engine.

b. If the reason/reasons for power degradation cannot be established using the procedures specified in para-graph above, request assistance horn AVIM maintenance and proceed with the maintenance actions noted inparagraphs (1) through (4) below. If this is a recurrence of power degradation on this aircraft/engine and themaintenance actions listed below have been complied within the last 100 flying hours, replace the engine.

(1) Recheck engine throttle controls for proper rigging. Check the throttle angle on the fuel control atthe idle detent for the pilot’s and copilot’s twist grip and physical contact with minimum and maximum stops.Maximum allowable variation between the pilot’s and copilot’s twist grip is 5/64 inch as measured on the fuelcontrol sector at idle. Re-rig controls if not within specifications in accordance with TM 55-1520-228-23 andTM 55-2840-231-23 for OH-58A aircraft.

Change 13 H-5

TM 55-2840-231-23

(2) Remove engine fuel and pneumatic lines. Inspect fittings and lines for cracks, chafing,scratches/dents and improper seating on sealing surfaces. Inspect for contamination. Clean all lines inaccordance with applicable technical manuals. Reinstall pneumatic lines and filter. Leak check pneumaticsystem in accordance with TM 55-2840-231-28.

(3) Remove all hoses, fittings and valves including shut-off valve from the fuel boost pump to the en-gine. Clean and inspect for damage and restrictions in accordance with TM 55-1520-228-23. Reinstall orreplace as applicable. Bleed the fuel system in accordance with the appropriate technical manual. With theaircraft fuel shutoff valve open, start the fuel boost pump and check all accessible fuel line connections and fit-tings outside the fuel cell for leakage, inspect and lubricate starter generator splines. Check calibration ofdual tachometer (N2 and rotor RPM).

(4) Check main and tail rotor systems for proper rigging and pitch angle, and re-rig as necessary.

c . If the reason/reasons for power degradation cannot be established using the procedures specified in para-graphs a. and b. above, replace the fuel control governor and double check valve (unless replaced in para a.above). Perform deceleration check, if satisfactory, perform test flight in accordance with established proce-dures.

d. Aircraft are restricted from NOE contour, low level, and night flight for 10 hours after completion of thepreceding procedures and must be flown at an altitude to allow safe autorotation as defined in TM 55-1520-228-10 or TM 55-1520-235-10 charts. After completion of the 10-hour restriction, repeat deceleration check. Ifsatisfactory, perform test flight in accordance with established procedures. No further flight restrictions areimposed.

H-6 Change 13

TM 55-2840-231-23

GLOSSARY

This glossary contains abbreviations and definitions of unusual terms found throughout this manual. Section 1lists abbreviations and the word or phrase from which the abbreviation is derived. Section II contains definitions ofunusual terms. Terms are listed alphabetically. Efforts have been made to include terms that may cause disagree-ment among those using this manual.

Section I. ABBREVIATIONS

APU

cm

cu ft

Dia

est.

FOD

GPTOT

ft-lb

HIT

in.

in.-lb

kg/m

1

lb

LE

LH

m

MAC

max.

min.

Auxiliary Power Unit

Centimeter

Cubic Feet

Diameter

Estimate

Foreign Object Damage

Gas Producer Turbine Outlet Temperature

Foot-Pound

Health Indicator Test

Inch

Inch-Pound

Kilogram/Meter

Liter

Pound

Leading Edge

Left Hand

Meter

Maintenance Allocation Chart

Maximum

Minimum

Glossary-1

TM 55-2840-231-23

Section I. ABBREVIATIONS - Continued

mm

OAT

OD

Pa

Pc

P g

Po

Pr

Psig

Pt

Py

P1

P2

QA/QC

qt

R

RH

SHP

TE

TIR

TMDE

TOT

Millimeter

Outside Air Temperature

Outside Diameter

Ambient Pressure

Compressor Discharge Pressure

Governing Reset Pressure

Control Bypass

Regulated Air Pressure

Pound Square Inch Gauge

Acceleration Billows Pressure

Governor Servo Pressure

Control Inlet Fuel

Metered Fuel Flow

Quality Assurance/Quality Control

Quart

Radius

Right Hand

Shaft Horse Power

Trailing Edge

Total Indicated Reading

Test, Measurement and Diagnostic Equipment

Turbine Outlet Temperature

Glossary-2 Change 13

TM 55-2840-231-23

Section II. DEFINITION OF UNUSUAL TERMS

A

ABRASION - A roughened surface.

ABRASIVE CLOTH - A cloth coated with grit, used for hand cleaning, polishing, removing corrosion andpaint, etc. Sometimes referred to as emery cloth.

ACCESSORY - A self-contained unit, mounted on a higher assembly, designed to do a specific job. Fuelpumps, fuel controls and like parts are typical accessories.

ADAPTER - Any device that makes it possible to use parts or pieces of equipment that were not designedto be used together.

ASSEMBLY - A unit normally removed and reassembled as a single item, consisting of accessories andcomponents that operate together for a specific purpose. Typical assemblies are: engine, torque sensorshaft and sleeve assembly, power takeoff assembly.

AVERAGE DIAMETER - A number found by adding several measurements, usually 3 or more, of thesame diameter and dividing the sum by the number of measurements taken.

B

BACKLASH - A term used to describe the distance that a working part has to move before it moves itsmating part. The motion lost between two connected parts when the direction of motion is changed isalso considered backlash. This loss of motion or looseness, is caused by design tolerances or by the wearingof working parts (such as clevis pin in rod-end bearing).

BEND - Distortion in a part.

BLENDING - An operation in which surfaces are worked by hand to produce a smooth surface withoutabruptly changing its contour.

BREAK - Separation of part.

BUCKLING - A large-scale deformation of the original ‘contour of a part, usually due to pressure orimpact from a foreign object, structural stresses, excessive localized heating, high-pressure differentials,or to any combination of these.

BULGE - An area on a sheet metal part that has swelled outward.

BURR - A rough or sharp edge on a hole or comer, usually caused by machining, sometimes by wearing.

C

CALIBRATE - The work done in testing and/or adjusting an instrument or accessory to known standards.

CHIPPING - Breaking away of metallic particles.

Glossary-3

TM 55-2840-231-23

COMPONENT - A unit somewhat similar to an accessory in that it is self-contained but differing in thatit is designed to control operations. Valves, switches, solenoids, etc., are typical components.

CONFIGURATION - A term referring to the form, shape or contour of a part or parts.

CONTAMINATION (FOREIGN MATERIAL) - Any foreign substance such as metal chips, lint, rust andwater that would be harmful to the functioning of a part or system.

CORROSION - A mass of small pits which cumulatively create a large cavity (usually shallow) in the sur-face of the parent metal.

CRACK - Parting of parent metal.

D

DEFECT - A general term covering any flaw affecting the usefulness or serviceability of a part.

DENT - A completely smooth surface depression caused by pressure or impact from a smooth ball-likeforeign object. The parent material is displaced, but usually none is separated.

DESICCANT - A drying agent; usually place in containers, along with parts being stored, to absorb moistureand prevent rusting.

DIAMETER - The length of a chord passing through the center of a circle.

DISCOLORATION - The change in color of a surface, which usually becomes darker. Usually caused byheat or buildup of varnish film.

DISTORTION - Twisting or bending out of a normal, natural or original shape, usually caused from beingexposed to excessive pressure or temperature either when restrained or unrestrained.

E

EROSION - The clearing away of metal.

F

FIT - The amount of tightness or looseness between mating parts when assembled together.

FLAKING - Breaking away of paint or plate.

FLUSH - A shop term used in describing two surfaces that are even with each other. The term is alsoused to describe the washing or cleaning of chips or dirt by pressure flushing.

FOREIGN MATERIAL - See CONTAMINATION.

FOREIGN OBJECT - Any object such as a tool, piece of equipment, engine part (nut, bolt, lockwire) thatcould in any way damage the engine.

FRAYING - Wearing or rubbing of areas, generally used in reference to darnage on wire-braid covering(of Teflon hose) or on thermocouple harnesses.

Glossary-4

TM 55-2840-231-23

FRETTING - Wearing away of metal by rubbing against another metal (generally associated with pressfit or close fitting parts).

G

GAP - An opening or space; a break in continuity.

GLAZING - A hard, glossy surface.

GOUGE - A wide rough scratch or group of scratches, usually with one or more sharply impressed corners,and frequently accompanied by deformation or removal of parent material.

GROOVE - A long narrow, continuous cavity or impression caused by pressure of a moving surface incontact with the parent material.

I

INDICATIONS - Surface defect, not necessarily a crack.

INTERFERENCE - Anything that prevents a part, component, etc. from being assembled or disassembled.

L

LAPPING - Smoothing or polishing two surfaces, with or without abrasives, to a high degree of accuracy.

LEAK - The entering, escaping or by-passing (contrary to intention) of liquids or gases from their normalpassage or containment, usually caused by a hole or improper sealing. The act of leaking is called leakageand the measurement of leakage is called leakage rate.

LOOSE - Abnormal movement of a part.

M

MATCHED - Fitted together or made suitable to be fitted together.

MATING SURFACES - Two surfaces that join or fit together.

N

NICK - A surface impression with sharp comers or bottom, usually caused by pressure or impact from asharp-edged foreign body. The parent material is displaced but usually none is separated.

NOISY - An abnormal sound condition of moving parts, usually an increase in volume or a change of pitch.

P

PEENING - Surface deformation.

PICKUP - Transfer of one material onto another.

PIT’TING - Very shallow depressions in a surface, usually caused by chemical reaction, (rusting chemicalcorrosion).

Glossary-5

TM 55-2840-231-23

sSCORING - Multiple scratches, usually parallel and resulting from the same cause.

SCRATCH - A long, narrow sharp-cornered impression caused by the movement of a sharp object acrossthe surface of the parent material.

SETUP - A general term used to describe the work done in setting up tools, fixtures, etc. to do aspecific job.

T

TEAR - A forcible, somewhat crude pulling or wrenching away of material so that ragged or irregular edgesresult.

TOLERANCE - The range of variation allowed in maintaining a specified dimension in making a part.

TORQUE - To tighten a nut, bolt, or fitting, using a torque wrench, to a specified value expressed asinch-pounds or as foot-pounds.

TOTAL INDICATOR READING (TIR) - Is the total movement of the pointer of an indicator whenmeasuring the amount of out-of-roundness, out-of-flatness or other deviations of a part.

U

UNBALANCE - Unequal distribution of weight about the axis of rotation; usually results in vibration.

W

WARPED - Not true to an established plane or line; out of true shape.

WEAR - Relatively slow removal of parent material from any cause, frequently not visible to the nakedeye.

WELD - Metal fused by heating, with or without pressure applied, with or without using filler material.

Glossary-6

TM 55-2840-231-23

ALPHABETICAL INDEX - Continued

S u b j e c t

Abnormal Flight ManeuverInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Acceleration Bleed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessory Gearbox Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accident Engine

Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accumulator

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adapter Spur Gearshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AdjustmentOil Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .After Inflight Auto Reignition Operation

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Bleed Extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Tubes, Poppet Guides, and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Requiring Special Torque ValuesAnti-Icing Air Valve

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti-Icing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti-Icing Valve Poppet SeatInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix AReferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix BMaintenance Allocation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix CSpecial Tools and Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix DExpendable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix ESchematic Diagrams (Nonapplicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix FIllustrated List of Manufactured Items(Non applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix GTorque Values and Dimensional Limits, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhaul and Retirement Schedule

Appendix HGeneral Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph,Figure,Table

1-451-235-1

1-37

6-266-25F G-162-21

8-61-5

1-461-24F G-12

9-49-51-22F 1-13

9-39-2

Change 11 Index 1

TM 55-2840-231-23


Subject A - Continued

Appendix Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auto-Reignition Control

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B

Bleed Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...B1eeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Burner Drain Valve

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal, Cleaning, Testing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cCannibalized Preservation

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Captive Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check

Fuel Control Max Speed Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burner Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Case Half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Exterior Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel System Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gas ProducerFuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic Chip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and ReplacementGas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . .

Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....Combustion Liner

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Weld-Repair (AVIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Combustion Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


H-1

7-27-27-2

F 1-192-4.16-2

3-113-113-113-113-11

1-38H-4

6-147-5

2-4.13-112-102-131-628-86-296-46-105-58-47-4

6-101-50

3-43-53-11-13F 1-63-73-6

Index 2 Change 11

TM 55-2840-231-23


C - Continued

Combustion Section Parts Requiring Special Torque Values . . . . . . . . . . . . . . . . . . . .Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor

Preparation for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparation for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparation for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompressorRemoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompressorRemoving From Shipping Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompressorSpecial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Assembly Fixture 6795966-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Blades

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Bleed Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Bleed Control Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Bleed Valve

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor CaseRepair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Case Assembly and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Requiring Special Torque Values

Compressor Case HalfCleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Cleaning to Remove Salt Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Contamination

Compressor Cleaning to Restore Lost Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Discharge Air Tube

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Weld-Repair (AVIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Discharge Air Tube Seal RingInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Front SupportInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Parts Requiring Special Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Plastic Coating

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


F G-41-112-6

2-72-72-7

2-2

2-201-44

1-44F 1-4F C-3

2-142-15F 1-14F 1-15

2-4.19-89-79-6

2-11F G-14

2-102-15.12-92-5

2-4

3-83-9

3-10

2-82-1F G-3

2-10.1

Change 11 Index 3

TM 55-2840-231-23


Paragraph,

S u b j e c t C - Continued

Compressor Protector Kit 6798861 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Puller 6798250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Rotor


Compressor Rotor BladesCleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Rotor and BladesInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Shipping Container Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Shipping Parts Requiring Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque ValuesCompressor Stator Vane

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Container Air Pressure Vs. Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D

Damaged PreservationEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Damaged, Cannibalized, or Failed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preservation

Deceleration CheckGas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Depreservation

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Destruction of Army Material to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . .Diaphragm - Type (Cylindrical) Valve

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Difference Between Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diffuser Scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Diffuser Vent Orifice Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensional Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling Engine Into Major Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assemblies

Dismantling Major Functional AssembliesEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drainage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Gear Replacement

Figure,Table

F C-7F C-5

2-142-15

2-13

2-142-15F 1-17F G-2

2-10.2T 1-5

1-381-38

6-7B-3

1-351-4

6-246-23DeletedF G-152-162-172-18G-3T G-21-33

1-331-57

Power Turbine Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Index 4 Change 11

TM 55-2840-231-23


Subject D - Continued

Dropped During Handling InspectionEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E

Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical System Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine

Cannibalized Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Damaged Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Depreservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dismantling Major Functional Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dropped During Handling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Failed Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Into Reusable Metal Shipping and

Storage Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Turnover Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal From Shipping Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Assembly Lift 6796963 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Assembly Turnover Stand 6795579 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Container

Humidity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Internal Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Internal Pressure and Humidity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Exterior SurfaceCleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Fuel and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Lubrication Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Motoring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Operating Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Shipping Container Parts Requiring Special

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Shipping Container Stenciling and Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Turning Adapter 6799790 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Purpose, Capabilities and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Collector Support

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Expendable Supplies and Materials List

Appendix D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Explanation of Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Oil Check Valve

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1-31

H-51-567-1

1-381-381-351-331-311-38

1-301-321-251-361-29F C-4F C-8

1-411-411-41

1-62F 1-2F 1-91-671-68

F G-1F 1-161-66F C-11-7

4-2

D-2

8-88-88-8

Change 11 Index 5

TM 55-2840-231-23


Paragraph,Figure,

E — Continued

External Oil Check Valve - Continued Removal, Cleaning, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .External Oil Lines and Related Parts Requiring Special Torque Valves . . . . . . . . . .

F

Failed PreservationEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter AssemblyPreparation For Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixture Setting, Fuel Control Maximum Stop Screw 6872482 . . . . . . . . . . . . . . . . . . .Forms, Records, Tags and Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Control Fuel Filter Plug and Fuel Control and Governor Lever Shaft

Nut Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Control Heater Shutoff Valve

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Control Heating TubeInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation ..., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Control Max Speed StopCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Control System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Filter

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Filter Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel PumpInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparation For Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump and Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation For Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel System Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel System Parts Requiring Special Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel System Pneumatic Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table

8-8F G-11

1-38

6-17F C-131-39

F G-8

DeletedDeletedDeleted

DeletedDeletedDeleted

6-14F 1-3

6-27F G-71-19F 1-116-296-306-316-28

6-166-176-151-17F 1-86-171-546-1F G-66-3

Index 6 Change 11

TM 55-2840-231-23


F - Continued


Fuel System TubesCleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal, Cleaning, and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel, Oil, and Air Tubing Parts Requiring Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque ValuesFunctional Test Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G

Gas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . . .Cleaning and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deceleration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Idle Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rigging Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start Derichment Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GasProducer Fuel Control Drive GearReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GearboxInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox External SealsReplacement (AVIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox External StudReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox Housing and CoverPainting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ground Idle Wrench 6798292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Health IndicatorTest (HIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Humidity Check

Engine Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-46-46-46-41-10F G-5

1-71T 1-11

1-156-106-106-76-66-116-86-106-56-12

6-9

5-2

5-3

5-4

5-61-63G-11-471-481-49

F C-11

1-511-72

1-41

Change 11 Index 7

TM 55-2840-231-23


Paragraph,Figure,

Idle CheckGas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idle and Flight Autorotation GPTOT Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ignition Exciter

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition System and Related Parts Requiring Special Torque Values . . . . . . . . . . . .Illustrated List of Manufactured Items (Not Applicable)

Appendix F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection

AbnormalFlightManeuver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adapter Spur Gearshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .After Inflight Auto Reignition Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Combustion Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Combustion Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Discharge Air Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Discharge AirTube Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Front Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Plastic Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Rotor and Blades.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Stator Vane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diffuser Scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Collector Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ignition Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic Clip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Tubing and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outer Combustion Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Turbine Outer Coupling Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressurized Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thermocouple Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbine Overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and ReplacementOil Tubing and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table

6-6F 1-20

7-37-37-37-31-20F 1-12F G-13

1-452-211-463-43-72-143-83-102-82-10.12-142-142-10.22-164-26-305-27-35-58-68-103-24-41-407-47-54-31-43

8-10

Index 8 Change 11

TM 55-2840-231-23


I - Continued

Inspection of Engine Dropped During Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Anti-Icing Valve Poppet Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auto-Reignition Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Burner Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Case Half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diaphragm -Type (Cylindrical) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Control Heater ShutoffValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Control Heating Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel PumpFuel System Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ignition Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Internal Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic Chip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Turbine Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thermocouple Terminal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Into Reusable Metal Shipping andStorage ContainerEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Engine in Turnover Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Turnover Stand

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instrumentation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Internal Oil Check Valve

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal Pressure CheckEngine Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal Pressure and Humidity CheckEngine Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1-31

6-269-37-23-112-69-82-15.16-248-89-99-106-316-166-46-117-38-75-58-58-28-98-66-207-47-54-4

1-301-32

1-321-65

8-78-78-7

1-41

1-41

Change 11 Index 9

TM 55-2840-231-23


L - Continued

Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location ofGearbox External Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Loop Clamps 6799952 and 6799953 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lube Oil Filter Cap Puller 6798860 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricating Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Forms, Records and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic Chip Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic Chip Detectors

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal, Inspection, Cleaning, Installation

and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Allocation Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Forms, Records and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Puller Kit 6796941 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Miscellaneous Equipment Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modification Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modular Engine Test Stand LTCT10465-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O

Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Changeover Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filter

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Filter HousingInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Filter and Related Parts Requiring SpecialTorque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Reducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


T 1-31-25F G-17F C-2F C-12H-21-551-18

1-3F G-9

5-55-55-55-5

5-55-5B-1

1-3F C-69-1T 1-11-2F C-9

1-601-61

8-48-58-3

8-28-28-2

F G-10

8-9

Index 10 Change 11

TM 55-2840-231-23


Paragraph,Figure,

Subject O - Continued Table

Oil Pressure Reducer - Continued.8-9. . . . . . . . . . . . . . . . . . . . . . . .

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

8-68-68-68-68-68-6F1-108-1

8-108-108-101-69

3 - 23 - 3T-G-3T1-7T 1 - 6

5-6T 1 - 41-166-196-206-226-186-214-1F1-51-14F 1 - 7

H - 6

6-176-17

Change 13 Index 11

TM 55-2840-231-23


Subject P - Continued


Preparation For Storage and Shipment - ContinuedFuel Pump and Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Turbine Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation for ShipmentCompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation for StorageCompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation for Storage and ShipmentCompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation for TestPreparing Gas Producer Fuel Control for

Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preservation

Accident Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Presentation Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Presentation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressurized Container

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Q

Quality Assurance Quality Conntrol (QM/QC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R

ReferencesAppendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remarks (Section IV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Anti-Icing Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auto-Reignition Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Burner Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Combustion Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Case Half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diaphragm - Type (Cylindrical) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,Fuel Control Heater Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Control Heating Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel System Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ignition Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Internal Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic Chip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-176-22

2-7

2-7

2-7

6-13

1-371-361-341-58

1-40

1-6

B-8

6-259-47-23-113-62-29-62-96-238-89-99-106-286-156-46-87-38-75-5

Index 12 Change 11 U.S. GOVERNMENT PRINTING OFFICE: 1995-655-121/20339

TM 55-2840-231-23


Subject R - Continued

Removal - ContinuedOil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Turbine Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thermocouple Terminal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal From Shipping Container Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation

Auto-Reignition Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Control Heater ShutoffValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Control Heating Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Internal Oil Check Valve.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pc Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thermocouple Terminal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal, Cleaning, Inspection, Testing and InstallationSpark Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal, Cleaning and InstallationBurner Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal, Cleaning, and InstallationFuel System Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal, Inspection and InstallationIgnition Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal, Inspection, Cleaning, Installation and TestingMagnetic Chip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal, Inspection, Installation and CheckSpark Igniter Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal, Installation, Inspection, Testing and AdjustmentOil Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing From Shipping ContainerCompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RepairCompressor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Rotor and Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diffuser Scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . . . . . . . . . . .Replacement

Anti-Icing Valve Poppet Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


8-38-28-98-66-187-47-54-41-29

7-29-99-108-78-28-96-674-4

7-4

3-118-8

6-4

7-3

5-5

7-5

8-6

2-20

2-152-112-152-152-171-26

9-2

Change 11 Index 13

TM 55-2840-231-23


Paragraph,Figure,

Subject R - Continued

Replacement - ContinuedFuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gas Producer Fuel Control Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gearbox External Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Tubing and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement(AVIM)Gearbox External Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rigging CheckGas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rigid Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S

Schematic Diagrams (Nonapplicable)Appendix E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......

Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shipping Container Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal, Cleaning, Inspection, Testing and Installation . . . . . . . . . . . . . . . . . . .Testin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Igniter LeadCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal, Inspection, Installation and Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special InspectionCompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special InspectionCompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special Tools and Support Equipment

Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start Derichment Adjustment

Gas Producer Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Straight Box Wrench 6795588 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Symptom Index(METS ) . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

6-276-106-95-48-10

5-3

6-51-53

1-1D-11-271-28

7-47-47-47-47-47-4

7-57-57-57-57-5

1-44

1-441-42

B-4

6-12F C-10B-5T 1-8

Index 14 Change 11

TM 55-2840-231-23


Subject T

T63-A-700 Turboshaft Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature Measurement System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TestingAnti-Icing Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Burner Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic Chip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermocouple AssemblyInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermocouple Terminal AssemblyInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools and Test Equipment (Section III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Values and Dimensional Limits, Overhauland Retirement Schedule

Appendix G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbine Overtemperature

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

U

Universal Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of Jacking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Use of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Use ofthe Maintenance Allocation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vVibration ofEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wWeld-Repair (AVIM)

Combustion Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Compressor Discharge Air Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Outer Combustion Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Work Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6Wrench-Arc Method for Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7

U.S. GOVERNMENT PRINTING OFFICE: 1989 654-127/87038

Change 11 lndex15/(lndex16blank)

4-3

4-44-44-4B-7G-2T G-1

1-471-12

1-43

1-52F 1-18H-31-59B-2

1-70c.

9-53-119-71-70c.8-85-58-67-4


F 1-11-211-70T 1-10

TM 55-2840-231-23

By Order of the Secretary of the Army:

Official:

E. C. MEYERGeneral, United States Army

Chief of Staff

J. C. PENNINGTONMajor General, United States Army

The Adjutant General

DISTRIBUTION:To be distributed in accordance with DA Form 12-31 Organizational Maintenance

Requirements for OH-6 and OH-58 aircraft.

U.S. GOVERNMENT PRINTING OFFICE 1986 491-885/40282

The Metric System and Equivalents

Linear Measure

1 centimeter = 10 millimeters = .39 inch1 decimeter = 10 centimeters = 3.94 inches1 meter = 10 decimeters = 39.37 inches1 dekameter = 10 meters = 32.8 feet1 hectometer = 10 dekameters = 328.08 feet1 kilometer = 10 hectometers = 3,280.8 feet

Weights

1 centigram = 10 milligrams = .15 grain1 decigram = 10 centigrams = 1.54 grains1 gram = 10 decigram = .035 ounce1 dekagram = 10 grams = .35 ounce1 hectogram = 10 dekagrams = 3.52 ounces1 kilogram = 10 hectograms = 2.2 pounds1 quintal = 100 kilograms = 220.46 pounds1 metric ton = 10 quintals = 1.1 short tons

inchesfeetyardsmilessquare inchessquare feetsquare yardssquare milesacrescubic feetcubic yardsfluid ouncespintsquartsgallonsouncespoundsshort tonspound-feetpound-inches

Liquid Measure

1 centiliter = 10 milliters = .34 fl. ounce1 deciliter = 10 centiliters = 3.38 fl. ounces1 liter = 10 deciliters = 33.81 fl. ounces1 dekaliter = 10 liters = 2.64 gallons1 hectoliter = 10 dekaliters = 26.42 gallons1 kiloliter = 10 hectoliters = 264.18 gallons

Square Measure

1 sq. centimeter = 100 sq. millimeters = .155 sq. inch1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres1 sq. kilometer = 100 sq. hectometers = .386 sq. mile

Cubic Measure

1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet

Approximate Conversion Factors

To

centimetersmetersmeterskilometerssquare centimeterssquare meterssquare meterssquare kilometerssquare hectometerscubic meterscubic metersmilliliterslitersliterslitersgramskilogramsmetric tonsnewton-metersmewton-meters

oF F a h r e n h e i ttemperature

Multiply by

2.540.305.914

1.6096.451

.093

.8362.590

.405

.028

.76529,573

.473

.9463.785

28.349.454.907

1.365.11375

To change

ounce-inchescentimetersmetersmeterskilometerssquare centimeterssquare meterssquare meterssquare kilometerssquare hectometerscubic meterscubic metersmilliliterslitersliterslitersgramskilogramsmetric tons

Temperature (Exact)

5/9 (after Celsiussubtracting 32) temperature

To

newton. metersinchesfeetyardsmilessquare inchessquare feetsquare yardssquare milesacrescubic feetcubic yardsfluid ouncespintsquartsgallonsouncespoundsshort tons

oc

Multiply by

.3943.2801.094

.621

.15510.764

1.196.386

2.47135.315

1.308.034

2.1131.057

.264

.0352.2051.102

P I N : 0 4 8 1 2 5 - 0 0 0

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