GTP 5341-2D
Operation and
Maintenance
Manual
Allison Engine Company
MODEL 501-KB5
DIGITAL ELECTRICAL CONTROL SYSTEM
#iillJiilJ@f&/
mm@
mm
INITIAL ISSUE :
Printed in U.S.A.
1 JANUARY 1991
JAN/91
..
WP-1
.
IT IS YOUR RESPONSIBILITY to be
WP-2
JAN/91
JAN/91
WP-3
JANUARY 1991
200
LIST OF PAGES
PAGE NO.
WP1 TO WP3
TITLE PAGE
A
i to xxxi
1-1 to 1-18
2-1 to 2-38
3-1 to 3-28
4-1 to 4-156
5-1 to 5-9
6-1 to 6-39
7-1 to 7-33
8-1 to 8-25
9-1 to 9-8
10-1 to 10-25
11-1 to 11-17
12-1 to 12-21
13-1 to 13-60
14-1 to 14-23
Appendix-1 to Appendix-38
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The engine can be operated on dual (gaseous or liquid) fuel, liquid fuel, or
gaseous fuel, and utilizes an axial inlet housing.
The information in this manual applies only to the 501-KB5 DEC engines.
Part numbers are rarely used in the maintenance manual because design
improvements often change them. Specific components, parts, part description,
and vendors can be identified by the GTP 5010-4, 501-KA, 501-KB, and 501-KB5
Parts Catalog which is an illustrated parts breakdown manual used at all levels
of maintenance. When repair must be expanded beyond this manual or not
contained in this manual, contact your Distributor and/or Major Repair Center
for assistance.
Additional manual(s) recommended by Allison Industrial Gas Turbine that may be
obtained and used by the customer at an additional cost are:
DIGICON IBM Communications Operator Manual, obtained from:
Hawker Siddeley Dynamics Engineering, LTD
2869 Higgins Road
Elk Grove, IL 60007-2618 (U.S.A.)
Telephone: (708) 956-6302
FA;e1:x708) 956-6304
: 4996095
The engine is a fourteen-stage axial flow compressor directly coupled to a
four-stage turbine. There are six combustion chambers of the through-flow type
within a single annular chamber. The power takeoff (PTO) shaft rotates
counterclockwise as viewed from the rear.
Where applicable, metric equivalents are added in parentheses after the U.S.
Standard values.
JAN/91
A list of Abbreviations.
An Owner Assistance sheet of suggested procedures to be
followed if a problem occurs.
Table of Contents.
List of Figures.
List of Tables.
ii
Drawinq No.
23037500
JAN/91
Distrints are
ved by
with
Step Two--When it appears that your problem cannot readily be resolved at this
level without additional assistance, contact Allison Gas Turbine Division
at the address listed below. If outside the United States, contact the
applicable international office. Prior to this call, please have the
following information available:
Name and location of Distributor or Major Repair Center.
All information requested and what information that was not
Nature of problem(s).
given.
JAN/91
iii
DISTRIBUTORS
CENTRAX LIMITED
GAS TURBINE DIVISION
Shaldon Road, Newton Abbot
Devon, England TQ124SA
Mr. R.E. Whelband
General Manager, Product support
Telephone: 44-626-5-2251
Telex: 42935
Telecopier: 44-626-5-2250
iv
JAN/91
JAN/91
vi
JAN/91
gaseous
Gas
GENSET generator set
gallons per minute
;~m
gas producer
HI
high
high pressure
HP
horse power
hp
mercury
Hg
HSDE
Hawker Siddeley Dynamics
Engineering, LTD.
hertz
hz
inside diameter
ID
inch
in.
Incorporated
INC.
International Organization
I so
for Standardization
isochronous
ISOL
Industrial Engine
-K
Industrial Engine,
-KB5
Generator Set
kilograms
kg
kPa
kilopascals
kPaa
kilopascals absolute
kPad
kilopascals differential
kPag
kilopascals gage
kw
kilowatt or power
length or liter
;b
pound
lb ft
pound-force foot
lb in
pound-force inch
left hand
LH
LHV
Lower Heating Valve
Liq.
liquid
LO
1 Ow
LP
low pressure
liters per minute
Lpm
lubrication
Lube
linear variable
LVDT
differential transformer
milliampere
ma
maximum
max
Monochrome Display Adapter
MDA
manager
Mgr
MIL
military
minimum or minute
min
mL
milliliter
mm
millimeter
MS
military standard
N
newton or engine
JAN/91
vii
viii
Normal Closed
newton meter
Engine
Driven Equipment
Normal Open
number
National Pipe Thread
Non Volatile Memory
Initialization
Non Volatile Memory
oil
outside air temperature
outside diameter
Original Equipment
Manufacturer
ounce
personal computer
part number
positive
position
potentiometer
pounds per hour
parts per million
pressure
pressure
Pressure Switch
pounds per square inch
pounds per square inch
absolute
pounds per square inch
differential
pounds per square inch gage
power takeoff
compressor inlet pressure
compressor discharge pressure
point
R
Rc
Ref
RH
rpm
s
sec
SHP
S/N
s/o
SOAP
Ssu
T/C
TCP
temp
thd
TIT
TOT
Ttz
UNC
UNF
U.S.A.
v
vdc
WP
>
<
-u
#
P
0
JAN/91
JAN/91
ix
TABLE OF CONTENTS
Section
LIST OF WARNINGS
TITLE PAGE
LIST OF EFFECTIVE PAGES
INTRODUCTION
OWNER ASSISTANCE
ABBREVIATIONS
REFERENCE DESIGNATORS
TABLE OF CONTENTS
LIST OF FIGURES
LIST OF TABLES
A
i
iii
vii
ix
x
xxvi
xxx
ENGINE DESCRIPTION
1-1
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
General Definitions
;:::
Weights and Dimension
1-5.
Engine Description
1-8.
Compressor Section
1-1o.
Accessory Drive Gearbox
1-12.
Combustion Section
1-14.
Turbine Unit Assembly
1-16.
Turbine Outlet Temperature (TOT)
1-18.
Lubrication (Lube) System
1-20.
Ignition System
1-22.
Fuel and Control System
1-24.
Power Takeoff Assembly
1-26.
Engine Mounting
1-27.
Cooling
1-29.
Engine Configuration Options
1-30.
Operating and Maintenance Precautions
1-1
1-2
1-2
1-3
1-3
1-4
1-5
1-5
1-5
1-5
1-6
1-6
1-6
1-6
1-6
1-9
1-11
1-11
1-11
WP-1
JAN/91
Section
1
JAN/91
1-12
1-12
1-16
1-16
1-18
2-1
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
2-1.
General Engine Operation and Checks
2-2.
Operating Parameters and Limits
2-3.
Engine Operation
Normal Engine Starting
2-4.
2-5.
Continuous Normal Operation
2-6.
Normal Shutdown
2-7.
Emergency Shutdown
2-8.
Stalled or Stagnated Starts
2-9.
Start-Run Monitoring Equipment
2-1o.
Troubleshooting
2-11.
Special Inspections
2-12.
Performance Evaluation
2-13.
Records
2-1
2-2
2-2
2-3
2-4
2-7
2-7
2-9
2-1o
2-1o
2-11
2-12
2-13
2-18
2-20
2-28
3-1
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
3-1.
Inspections
3-2.
Inspection Condition Definitions
3-3.
Routine Engine Inspections
3-4.
Special Inspections
3-5.
Borescope Information
Borescope Inspection Locations
;:;:
Borescope Inspection of Combustion Liners
3-8.
Borescope Inspection of Engine lst Stage Turbine
3-9.
Borescope Inspection of Engine 4th Stage Turbine
3-1o.
General Engine Preservation
3-11.
Preservation of Installed Engine
3-12.
Engine Shipping Container
Driven Equipment Shipping Container
3-13.
3-14.
Fuel System Preservation
Engine Removal and Installation
3-15,
3-1
3-2
3-2
3-3
3-3
3-5
3-8
3-8
3-9
3-9
3-12
3-16
3-18
3-19
3-19
3-27
3-28
3-28
xi
Section
4
xii
FUEL SYSTEM
4-1
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
4-1.
Fuel Systems
4-2.
Gaseous Fuel System
Description and Operation
4-3.
Fuel Metering Valve (FMV)
Description and Operation
u:
Removal
4-6.
Cleaning
4-7.
Inspection and Test
4-8.
Repair
4-9.
Installation
4-1o.
Installed Test and Adjustment
4-11.
Fuel Nozzle
4-12.
Description and Operation
4-13.
Troubleshooting
4-14.
4-15.
Removal
4-16.
Inspection
4-17.
Cleaning
4-18.
Installation
4-19.
Final Filter
4-20.
Description and Operation
4-21.
Removal
4-22.
Installation
Fuel Manifold and Hoses
4-23
4-24.
Description and Operation
4-25.
Removal
4-26.
Installation
4-27.
Gaseous Fuel Water Injection
4-28.
Description and Operation
4-29.
Dual Fuel Nozzle
4-30.
Description and Operation
4-31.
Troubleshooting
4-32.
Removal
4-33.
Inspection
4-34.
Cleaning
4-35.
Installation
4-36.
Single Entry Liquid Fuel System
4-37.
Description
4-38.
Operation
4-39.
Fuel Pump
4-40.
Description and Operation
4-41.
Removal
4-42.
Installation
4-43.
Troubleshooting
4-1
4-8
4-1o
4-11
4-11
4-11
4-12
4-12
4-14
4-14
4-15
4-15
4-16
4-16
4-17
4-17
4-17
4-17
4-18
4-18
4-20
4-20
4-20
4-20
4-22
4-22
4-22
4-22
4-23
4-23
4-23
4-23
4-23
4-24
4-25
4-26
4-26
4-27
4-27
4-27
4-28
4-28
4-28
4-33
4-35
4-36
JAN/91
Section
4
JAN/91
4-36
4-36
4-36
4-37
4-37
4-38
4-41
4-41
4-41
4-42
4-42
4-43
4-43
4-44
4-44
4-47
4-48
4-50
4-51
4-53
4-53
4-53
4-54
4-56
4-56
4-56
4-57
4-60
4-60
4-60
4-61
4-62
4-63
4-63
4-63
4-63
4-64
4-65
4-65
4-65
4-65
4-66
4-67
4-67
xiii
Section
4
xiv
4-67
4-67
4-68
4-70
4-70
4-72
4-73
4-73
4-73
4-73
4-74
4-74
4-77
4-77
4-77
4-80
4-80
4-81
4-82
4-82
4-82
4-83
4-84
4-84
4-86
4-86
4-86
4-87
4-87
4-87
4-88
4-88
4-88
4-91
4-91
4-91
4-91
4-91
4-91
4-91
4-92
4-92
4-92
4-92
4-93
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JAN/91
Inspection
Cleaning
Installation
Manifold Drain Valves
Description and Operation
Removal
Installation
Dual Entry Fuel Water Injection System
Description and Operation
Dual Fuel System
Description and Operation
Low Pressure (LP) Fuel Filter Assembly
Description and Operation
Filter Element Removal
Filter Element Installation
Removal
Installation
High Pressure (HP) Fuel Filter Assembly
Description and Operation
Filter Element Removal
Cleaning
Filter Element Installation
Removal
Installation
Liquid Fuel Pump
Description and Operation
Removal
Installation
Liquid Fuel Metering Valve (FMV)
Description and Operation
Removal
Installation
Liquid Fuel Shutoff Valve
Description and Operation
Removal
Installation
Liquid Fuel Shutoff Valve (Ball Type)
Description and Operation
Removal
Installation
Flow Divider Valve
Description and Operation
Removal
Installation
Manifold Drain Valves (Pilot and Main)
Description and Operation
4-94
4-95
4-96
4-97
4-97
4-98
4-98
4-98
4-98
4-98
4-98
4-99
4-99
4-99
4-1oo
4-103
4-103
4-106
4-106
4-106
4-106
4-106
4-106
4-107
4-107
4-107
4-107
4-108
4-109
4-109
4-109
4-114
4-115
4-115
4-115
4-116
4-116
4-116
4-117
4-118
4-118
4-118
4-119
4-122
4-123
4-123
xv
xvi
4-124
4-124
4-125
4-126
4-126
4-126
4-127
4-127
4-127
4-128
4-129
4-130
4-131
4-132
4-132
4-132
4-133
4-133
4-133
4-133
4-133
4-134
4-134
4-135
4-135,
4-135
4-136
4-136
4-136
4-137
4-137
4-138
4-138
4-138
4-139
4-139
4-139
4-139
4-139
4-140
4-140
4-141
4-141
4-141
4-142
4-142
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4-143
4-143
4-144
4-144
4-145
4-145
4-146
4-146
4-147
4-147
4-147
4-148
4-150
4-150
4-150
4-150
4 - 1 5 0
5-1
TABLE OF CONTENTS
INDEX TO FIGURES
5-1.
Description and Operation
5-2.
System Components
5-3.
System Inspections and Checks
5-4.
I%;i%;gouples (T/C)
5-5.
5-1
5-1
5-2
5-3
5-3
5-5
5-8
CONTROL SYSTEM
6-1
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
6-1.
Description
6-2.
Caution
6-3.
Front Handles
6-4.
Removing Connector and Cables
Electrostatic Discharge (ESD)
::2:
Power Source Grounding
6-7.
Description of DCA Modules
6-8.
Central Processing Unit (CPU) Module
6-9.
Interface Unit Module
6-10.
Interface Extension Unit Modu e
6-11.
16-Way Relay Output Unit Modu e
6-12.
Status Lights
6-1
6-2
6-2
6-3
6-16
6-16
6-16
6-16
6-17
6-17
6-17
6-18
6-22
6-22
6-25
xvii
xviii
6-27
6-27
6-30
6-30
6-30
6-30
6-30
6-31
6-32
6-34
6-35
6-35
6-35
6-36
6-39
6-39
6-39
7-1
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
7-1.
Description and Operation
7-2.
Lubricating Oils
Oil Leaks and Troubleshooting
Oil System Cleaning
;:::
Servicing
7-5.
Oil System Components
7-6.
7-7.
Main Pressure and Scavenge Oil Pump
(Main Oil Pump)
7-8.
Description and Operation
7-9.
Removal
7-1o.
Cleaning
7-11.
Installation
7-12.
Pressure Regulating Valve Assembly Removal
7-13.
Pressure Regulating Valve Assembly
Installation
7-14.
Adjustment and Test
7-15.
Magnetic Chip Detector
7-16.
Description and Operation
7-170
Removal
7-18.
Installation
7-19.
Magnetic Drain Plug
7-20.
Description and Operation
7-1
7-2
7-2
7-3
7-4
7-1o
7-15
7-16
7-18
7-18
7-18
7-18
7-21
7-21
7-21
7-21
7-22
7-22
7-22
7-23
7-23
7-23
7-23
JAN/91
Section
7
JAN/91
Removal
Installation
Oil Filter Assembly
Description and Operation
Removal
Oil Filter Element Rep acement
Installation
External Scavenge Oil Pump Assembly
(Scavenge Pump)
Description and Operat on
Removal
Installation
Turbine Rear Scavenge Oil Pump
Description and Operation
Removal
Inspection
Installation
7-23
7-24
7-24
7-24
7-24
7-25
7-26
7-27
7-27
7-27
7-29
7-29
7-29
7-30
7-30
7-31
8-1
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
Description and Operation
8-1.
Speed Sensor Pickup
8-2
Description and Operation
8-3.
Removal
8-4.
Inspection
8-5.
8-6.
Installation
Oil Nozzle
8-7.
Description and Operation
8-8.
Removal
8-9.
Installation
8-10.
Power Takeoff (PTO) Housing
8-11.
Description and Operation
8-12.
Removal
8-13.
Installation
8-14.
8-15.
Power Takeoff (PTO) Shaft
Description and Operation
8-16.
Removal
8-17.
Installation
8-18.
8-19.
Adapter Housing
8-20.
Description and Operation
8-21.
Removal
Installation
8-22.
8-1
8-2
8-2
8-3
8-3
8-3
8-5
8-6
8-6
8-9
8-9
8-9
8-9
8-10
8-10
8-10
8-13
8-16
8-16
8-17
8-17
8-17
8-17
8-19
8-19
xix
Section
8
10
xx
8-19
8-19
8-20
8-22
9-1
TABLE OF CONTENTS
INDEX TO FIGURES
9-1.
Description
9-2.
Removal
9-3.
Installation
9-4.
Repairs
9-5.
Liquid Fuel Pump Oil Seal Replacement
9-6.
Magnetic Drain Plug and Chip Detector
9-7.
Corrosion Treatment and Painting
9-1
9-1
9-2
9-2
9-4
9-5
9-5
9-7
9-7
COMPRESSOR
1o-1
TABLE OF CONTENTS
INDEX TO FIGURES
1o-1.
Description and Operation
10-2.
Air Inlet Housing
10-3.
Description and Operation
10-4.
Maintenance and Inspection
10-5.
Casing Assembly
10-6.
Description and Operation
10-7.
Maintenance and Inspection
10-8.
Engine No. 2 Speed Pickup
10-9.
Removal
1o-1o.
Installation
10-11. Rotor Assembly
10-12.
Description and Operation
10-13.
Maintenance and Inspection
10-14. Diffuser Assembly
10-15.
Description and Operation
10-16.
Maintenance and Inspection
10-17.
Internal Compressor Inspection
10-18. Compressor Cleaning
10-19.
Water Rinse
10-20.
Chemical Wash
10-21.
Abrasive (Ground Shell) Cleaning
10-22.
Special Cleaning Process
10-1
10-2
10-3
10-3
10-3
10-4
10-4
10-4
10-5
10-5
10-5
10-6
10-7
10-7
10-7
10-7
10-7
10-7
10-8
10-11
10-13
10-15
10-17
10-20
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12
JAN/91
11-1
11-2
11-3
11-3
11-6
11-6
11-7
11-7
11-7
11-7
11-11
11-11
11-11
11-12
11-12
11-14
11-14
11-14
11-15
11-15
11-16
11-16
11-16
12-1
TABLE OF CONTENTS
INDEX TO FIGURES
Combustion Section
12-1.
12-2.
Description and Operation
Combustion Outer Case
12-3.
Description and Operation
12-4.
Removal
12-5.
12-6.
Inspection
12-7.
Installation
Combustion Liners
12-8.
12-9.
Removal
12-10.
Inspection
12-11.
Installation
12-12.
Other Combustion Section Components
Crossover Clamps
12-13.
12-14.
Combustion Inner Case
12-15.
Combustion Inner Case Liner
12-16. Engine Ignition System
12-17.
Description and Operation
12-1
12-2
12-3
12-3
12-5
12-5
12-5
12-8
12-8
12-9
12-9
12-10
12-10
12-12
12-12
12-12
12-12
12-12
12-12
xxi
13
xxii
Exciter
Description and Operation
Removal
Inspection
Installation
Igniter, Liner Supports, and Liner
Body Supports
Description and Operation
Removal
Inspection
Installation
Lead Assemblies
Removal
Inspection
Installation
12-13
12-13
12-13
12-14
12-16
12-17
12-17
12-17
12-18
12-19
12-20
12-20
12-21
12-21
13-1
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
13-1.
Description and Operation
13-2.
Maintenance and Inspection
13-3.
Turbine Unit Assembly Removal
13-4.
Combustion Inner Casing and Combustion
Inner Casing Liner Removal
13-5.
Front Bearing, Front Bearing Support,
Front Bearing Cage, and Front
Bearing Labyrinth Seal Removal
13-6.
Inlet Casing Removal
Vane Casing and 2nd, 3rd, and 4th Vanes
13-7.
Removal
13-8.
Rotor Assembly Removal
13-9.
Rear Bearing Support Disassemble
13-10. Cleaning
13-11.
Diffuser Sump Area
13-12.
Turbine Unit Assembly Components
13-13.
Bearing (No. 3 and No. 4)
13-14.
Inlet Casing, Vane Casing, Vanes,
and Rear Bearing Support
13-15. Turbine Unit Assembly Inspection
13-16. Assemble Rear Bearing Support
13-17. Rotor Assembly and 2nd, 3rd, and 4th Vane Installation
13-18.
Inlet Casing and 1st Stage Vane Installation
13-19. Front Bearing Support and Front Bearing Cage
Installation
13-1
13-2
13-4
13-5
13-6
13-6
13-18
13-19
13-24
13-27
13-29
13-32
13-34
13-34
13-37
13-37
13-38
13-39
13-40
13-42
13-45
13-47
JAN/91
14
TABLE OF CONTENTS
INDEX TO FIGURES
INDEX TO TABLES
14-1.
Introduction
14-3.
General Maintenance Practices
14-4.
Cotter Pin Installation
14-5.
Standard Torque Limits
14-6.
Lockwiring
14-7.
Universal Fittings
14-8.
Installing Universal Fitting Without
Back-up Rings
Rigid Tube Installation
14-9.
Flared Tubes
14-11.
Flanged Tubes
14-12.
Use of Torque Wrenches
14-13.
Corrosion Treatment and Painting
14-14.
Dye Penetrant Inspection
14-15.
Foreign Object Damage (FOD)
14-16.
Recommended Markers
14-17.
DIGITAL COMMUNICATIONS OPERATOR MANUAL
TABLE OF CONTENTS
INDEX TO TEXT FIGURES
Introduction
1.0.
Installation Procedures
2.0.
Materials Required
2.1.
2.2.
Files Supplied on Your DCOMMS Disk
2.3.
Minimum Digital Operating System (DOS) Requirements
2.4.
Installation for a Floppy Disk System
RS232 Interconnect Cable Configuration
2.5.
JAN/91
13-52
13-53
13-55
13-60
14-1
GENERAL MAINTENANCE
APPENDIX A
13-48
13-50
13-51
......
14-1
14-2
14-2
14-3
14-3
14-4
14-4
14-12
14-13
14-13
14-17
14-17
14-17
14-18
14-19
14-21
14-22
14-23
A-1
A-1
A-2
A-3
A-4
A-4
A-4
A-4
A-6
A-7
xxiii
AllisonEngin eCompany
501-KB5 DEC OPERATION AND MAINTENANCE
TABLE OF CONTENTS (cent)
Section
APPENDIX A
3.0.
3.1.
3.2.
3.3.
3.4.
4.0.
4.1.
4.2.
4.3.
5.0.
5.1.
2:::
5.4.
;:::
5.6.1,
5.7.
5.7.1.
5.7.2.
5.7.3.
;:;:
;:!:
6.2.
6.3.
6.4.
6.5.
6.6.
6.7.
6.8.
::::10
6.9.2.
7.0.
;:;:
7.3.
%.
7.4.2.
7.4.3.
7.4.4.
xxiv
A-7
A-8
A-8
A-9
A-9
A-n
A-n
A-12
A-12
A-12
A-12
A-13
A-14
A-14
A-15
A-16
A-17
A-18
A-18
A-18
A-18
A-19
A-19
A-19
A-20
A-20
A-22
A-23
A-23
A-24
A-25
A-25
A-27
A-27
A-27
A-27
A-27
A-28
A-28
A-29
A-29
A-30
A-30
A-30
JAN/91
JAN/91
A-31
A-31
A-31
A-31
A-32
A-32
A-33
A-33
A-35
A-35
A-38
EmE
1-1.
1-20
1-3.
1-4.
1-5.
1-6.
2-1.
2-2.
2-3.
2-4,
2-5.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
1;:
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-1o.
4-11.
4-12.
4-13.
4-14.
4-15.
4-16.
4-17.
xxvi
Title
Engine Assembly
Engine Cross Section
Engine Mounting
Engine Lifting Adapter, 6796871
Engine Forward Attaching Details
Engine Stand, 6799609
Gas Turbine Engine Operating Theory
Operating Lines of Compressor Pressure
Ratio vs. Compressor Inlet Temperature
for 1750F CTIT
Operating Lines of Compressor Pressure
Ratio vs. Compressor Inlet Temperature
for 1700F CTIT
Operating Lines of Compressor Pressure
Ratio vs. Compressor Inlet Temperature
for 1600F CTIT
Shaft Horsepower Decrease Due to Dirty Compressor
Borescope Inspection of Combustion Liner
Unacceptable (Not Allowed) Sulfidation of
Turbine Blades and Vanes Examples
1st Stage Vane Airfoil Leading Edge
Damage Examples
Unacceptable (Not Allowed) 1st Stage
Vane Damage Examples
Acceptable (Allowed) 1st Stage Vane Damage Examples
4th Stage Vane Burn Through Example
4th Stage Vane with Unacceptable (Not Allowed)
Peripheral Cracking Example
Engine Shipping Container
Gaseous Fuel System Schematic
Gaseous Fuel System Components
Gaseous Fuel Nozzle
Gaseous Fuel Water Injection System
Gaseous Fuel Nozzle Water Injection System
Single Entry Liquid Fuel System Schematic
Liquid Fuel Pump and HP Fuel Filter
High Pressure Fuel Filter
High Pressure (HP) Fuel Filter Element
Cross Section
Paralleling Valve O-ring and Valve Seat Installation
Low Pressure Fuel Filter Assembly
Use of Spring Depressor, 6796975
Use of Pliers, 6796974
Differential Pressure Switch and LP Fuel Filter
Pressure Relief Valve, Fuel Shutoff Valve,
and Manifold Drain Valve
Fuel Metering Valve (FMV)
Burner Drain Valves
1-4
1-7
1-1o
1-14
1-15
1-17
2-8
2-23
2-25
2-27
2-29
3-11
3-13
3-14
3-14
3-15
3-17
3-17
3-23
4-13
4-19
4-21
4-24
4-25
4-31
4-34
4-39
4-41
4-43
4-45
4-46
4-46
4-49
4-55
4-59
4-66
JAN/91
ml!m
4-18.
4-19.
4-20.
4-21.
4-22.
4-23.
4-24.
4-25.
4-26.
4-27.
4-28.
4-29.
4-30.
4-31.
4-32.
4-33.
4-34,
4-35.
5-1.
5-2.
5-3.
5-4.
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
JAN/91
Title
Single Entry Liquid Fuel Nozzle Schematic
Single Entry Liquid Fuel Nozzle
Liquid Fuel Water Injection Schematic
Flow Divider and Manifold Drain Valves
Liquid Fuel Water Injection Fuel Nozzle
Dual Entry Fuel System Schematic
Dual Entry Fuel Nozzle
Removal and Installation of Dual Entry Fuel Nozzle
Dual Fuel System Schematic
Off-Engine Mounted Fuel Pump and Filter Assemblies
RAFT Mounted Components
RAFT Junction Box Terminals
Flow Divider and Manifold Drain Valves
Dual Fuel Nozzle
Gaseous Fuel Manifold and Hoses
Dual Fuel Water Injection System
Dual Fuel Heating System
Single or Dual Entry Fuel Heating Systems
Thermocouple
Thermocouple Harness Terminal Block Connections
Thermocouple Harness Terminal Block Schematic
Thermocouple Circuits
Digital Electronic Control System
Digital Electronic Control Schematic
Digital Control Assembly (Front View)
Digital Control Assembly (Rear View)
Central Processing Unit (CPU) Module
Interface Unit Module
Interface Extension Unit Module
16-Way Relay Output Unit Module
4-Way D-to-A Output Unit Module
Servo Driver Park Unit Module
Engine Oil System Schematic
Engine Oil System Block Diagram
Hairlike Metal Particles
Main Oil Pump and Filter
Pressure Regulating Valve and Magnetic Chip Detector
Oil Filter Assembly
External Scavenge Pump
Turbine Rear Scavenge Oil Pump
Inner Rear Exhaust Cone Puller, 6799754
Power Takeoff Assembly
Power Takeoff Assembly and Adapter Coupling Details
System to Prevent Oil Mix Between
PTO and Driven Equipment
Speed Sensor Pickup
Use of Depth Gage, 6797571
PTO Housing and Adapter Housing
&
4-69
4-71
4-75
4-79
4-83
4-89
4-93
4-96
4-101
4-105
4-111
4-113
4-121
4-129
4-149
4-151
4-153
4-155
5-3
5-4
5-4
5-6
6-12
6-13
6-19
6-20
6-21
6-23
6-24
6-26
6-28
6-29
7-5
7-7
7-17
7-19
7-20
7-26
7-28
7-32
7-33
8-4
8-4
8-5
8-8
8-8
8-11
xxvi i
EmrE
8-7.
8-8.
8-9.
8-10.
8-11.
8-12.
8-13.
8-14.
9-1.
9-2.
9-3.
9-4.
1o-1.
10-2.
10-3.
10-4.
10-5.
10-6.
10-7.
11-1.
11-2.
11-3.
11-4.
11-5.
12-1.
12-2.
12-3.
12-4.
12-5.
13-1.
13-2.
13-3.
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
13-10.
13-11.
13-12.
xxviii
Title
Midbearing Fuide Tool, 6797753
Roller Retainer Tool, 6797881
Assembled PTO Shaft Assembly
Installation Measurement
Bearing Pulling Fixture, 6797754
Bearing Inner Race Pusher, 6797756
Use of Main Drive Coupling Tool, 6798754
Tapered Coupling and Input Shaft
Dimension B Measurement
Accessory Drive Gearbox
Accessory Drive Gearbox Drive Pads
Fuel Pump Drive Oil Seal Puller No. 6796461
Fuel Pump Drive Shaft Oil Seal Installation
No. 2 Engine Speed Pickup Locations
Compressor Rotor Blade Damage Limits,
Leading and Trailing Edges
Compressor Rotor Blade Damage Limits,
Convex and Concave Faces
Compressor Blade Corrosion Limits
Ground Shell Cleaner Dispenser
Typical Plenum (Plan - View)
Steam and Chemical Cleaning System
Compressor Air Bleed System Schematic
Troubleshooting Chart
Compressor Air Bleed Systems and Components
Compressor Bleed and Speed Sensitive Valves
Screen and Shield Installation
Cross Section of Combustion Section
Splitline Locations
Combustion Liner Crossover Clamping
Engine Ignition System
Lockwiring of Igniter, Igniter Lead,
and Liner Support
Turbine Unit Assembly Cross Section
Compressor Holder, 3755
Turbine to Compressor Tie Bolt
Removal of Tie Bolt Retaining Nut
Removal of Tie Bolt
Loosening Rear Bearing Clamp Nut
Removal and Installation of Turbine
Unit Assembly
Lifting Adapter, 6799620
Engine Turnover Stand, 6796643, and
Stand Adapter, 6796644
Positioning Turbine Rotor Wrench, 6796569
Rotor Clearance Adjusting Jack, 6797484
Removing Combustion Liners
&
8-13
8-14
8-16
8-18
8-18
8-21
8-22
8-24
9-3
9-4
9-6
9-6
10-6
1o-1o
1o-1o
10-12
10-23
10-24
10-25
11-4
11-5
11-9
11-13
11-17
12-4
12-7
12-11
12-15
12-21
13-7
13-9
13-10
13-11
13-12
13-12
13-14
13-16
13-16
13-17
13-17
13-18
JAN/91
EWE
13-13.
13-14.
13-15.
13-16.
13-17.
13-18.
13-19.
13-20.
13-21.
13-22.
13-23.
13-24.
13-25.
13-26.
13-27.
13-28.
13-29.
13-30.
13-31.
13-32.
13-33.
13-34.
13-35.
13-36.
13-37.
13-38.
13-39.
13-40.
14-1.
14-2.
14-3.
14-4.
14-5.
JAN/91
Title
Combustion Inner Casing, Combustion Inner
Casing Liner, and Front Bearing Support
Removing Combustion Liner Casing
Removing Combustion Liner Casing Liner
Removing Turbine Clamping Nut
Removing Bearing Inner Race and Rollers
Removing Front Bearing Support
Removing Front Bearing Outer Race
Removing Front Bearing Labyrinth Seal
Inlet Casing, Vane Casing, and Rear
Bearing Support
Removing Front Bearing Labyrinth Seal
Removing Vane Casing
2nd, 3rd, and 4th Stage Vane Locations
Removal of Rotor Assembly
Removing Rear Bearing Inner Race and
Labyrinth Seal
Rotor Assembly Installed in Rotor
Transportation and Storage Stand
Removing Rear Bearing Cage
Removing Rear Bearing Outer Race
Removing Metallic O-ring Seals
Diffuser Sump Carbon Deposit Buildup Location
Rear Bearing Retainer Bolt Torque Sequence
Rear Bearing Rollers Retainer, 6798242
Installing Rotor Assembly
1st Stage Vane and Saddle Positions
Seating Front Bearing and Labyrinth Seal
Rear Bearing Clamp Nut Installation
Rotor Assembly Axial Clearance Measurement
Combustion Liner Crossover Clamping
Scavenge Oil Tube and Tube and Nozzle
Assembly Alignment
Cotter Pin Installation
Step-by-Step Example of Lockwiring
Examples of Lockwiring
Universal Fittings
Torque Wrench and Extension
13-20
13-22
13-22
13-23
13-23
13-24
13-25
13-26
13-28
13-30
13-30
13-31
13-31
13-32
13-33
13-34
13-35
13-35
13-36
13-43
13-43
13-44
13-46
13-49
13-50
13-51
13-54
13-56
14-5
14-14
14-15
14-16
14-19
xxix
14-2.
14-3.
14-4.
14-5.
14-6.
14-70
14-8.
14-9.
14-10.
A-1.
A-2.
A-3.
A-4.
xxx
Title
Engine Weight and Dimensions
Operating Parameters
Operating Limits
Troubleshooting
Start, Run, and Stop Report
Engine Trouble Report
Installation Inspection Report
Control System Static Test and Instrument Calibration
Start-up and Adjustment Runs
Performance Estimate Date Record
Inspection Tasks
Engine Shipping Container Air Pressure
Requirements Versus Temperature
Approved Liquid Fuels
Dumb Terminal Access Adjustments
Lubrication Oils
Oil Leaks
Speed Sensor Pickup Shim Requirements
Turbine Unit Assembly Inspection
Standard Torque Limits to Either the Nut
or Bolt, When a Steel Tension Type Nut
is Used in the Combination. Values
also Apply to Bolts Torqued into
Steel Tapped Hobs or Steel Inserts.
Standard Torque Limits to be Applied to
Either Nut or Bolt When a Steel Shear
Type is Used in the Combination.
Standard Torque Limits for Bolts
Torqued into Aluminum Tapped Holes
With or Without Inserts.
Standard Torque Limits for Screws
into Aluminum Tapped Holes With
or Without Inserts.
Standard Torque Limits for Screws Torqued
into Tension or Shear Type Nuts With or
Without Self-1ocking Feature. Value also
Applies to Screw Torqued into Steel
Tapped Holes With or Without Inserts.
Steel Coupling Nuts on Steel Fitting
Steel With Aluminum or Aluminum With
Aluminum Coupling Nuts on Fitting
Aluminum or Steel Unions
Plugs and Bleeders
Recommended Markers
Test Table
Test Table
Test Table
Test Table
1-4
2-4
2-5
2-15
2-30
2-32
2-35
2-36
2-37
2-38
3-6
3-27
4-29
6-37
7-9
7-11
8-7
13-39
14-6
14-7
14-8
14-8
14-9
14-10
14-10
14-11
14-11
14-23
A-8
A-10
A-n
A-13
JAN/91
Title
A-5.
A-6.
A-7.
A-8.
A-9.
A-10.
A-n.
A-12.
A-13.
A-14.
A-15.
A-16.
A-17.
A-18.
A-19.
A-20.
Test
Test
Test
Test
Test
Test
Test
Test
Test
Test
Test
Test
Test
Test
Test
Test
JAN/91
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
A-14
A-16
A-20
A-21
A-22
A-23
A-24
A-25
A-26
A-29
A-33
A-34
A-34
A-36
A-37
A-37
xxxi
JAN/91
Descri~tion
Paqe No.
1-1
General Definitions
1-3
1-3
1-3
1-5
Engine Description
1-4
1-8
Compressor Section
1-5
1-10
1-5
1-12
Combustion Section
1-5
1-14
1-5
1-16
1-6
1-18
1-6
1-20
Ignition System
1-6
1-22
1-6
1-24
1-6
1-26
Engine Mounting
1-9
1-27
Cool ing
1-11
1-29
1-11
1-30
1-11
1-31
1-12
1-32
Removal
1-12
1-33
1-16
1-34
1-16
1-35
Installation
1-18
1-1
Fiqure No.
1-1
Engine Assembly
1-4
1-2
1-7
1-3
Engine Mounting
1-10
1-4
1-14
1-5
1-15
1-6
1-17
INDEX TO TABLES
Table No.
1-1
1-2
Title
Engine Weight and Dimensions
Paqe No.
1-4
GENERAL DEFINITIONS.
1-2.
1-3.
1-4.
The weights and dimensions for the engine are shown in Table 1-1.
JAN/91
1-3
ENGINE DESCRIPTION.
1-6.
The gas turbine engine with a digital electrical control (DEC) system
is divided into a compressor section, a combustion section, a turbine
unit assembly (coupled to the compressor), and an accessory drive
gearbox (Ref. Figures 1-1 and 1-2).
Table 1-1.
Weight
Width
Height
I
I
COMPRESSOR
ANDINLET
60MBusTi0N
ANDTURBINE
SECTION
ACCESSORY
DRIVE
GEARBOX
Figure 1-1.
.
1-4
QHA018XD
Engine Assembly,
JAN/91
COMPRESSOR SECTION.
1-9.
1-1o.
1-11.
The accessory drive gearbox is mounted to the bottom of the air inlet
housing and receives its drive from the compressor rotor via the side
gear meshed to the compressor extension shaft. The main pressure and
scavenge oil pump assembly is mounted on the front and the external
scavenge oil pump assembly on the rear. Driven accessories are mounted
on the front and rear sides as required. Refer to Section 9, Accessory
Drive Gearbox, for details and discussion.
1-12.
COMBUSTION SECTION.
1-13.
1-14.
1-15.
The turbine unit assembly, mounted to the rear of the outer combustion
casing, consists of a four stage rotor and vane assembly (stages 1, 2,
3, and 4), a inlet casing, a vane casing, and a rear bearing support.
The 1st stage blades and vanes are air cooled. The rotor assembly
absorbs the necessary energy from the expanding gases to drive the
compressor rotor, the engine driven accessories, and the driven
equipment through the PTO assembly. The turbine unit assembly also
provides the mounting flange for attaching the inner exhaust cone and
the rear scavenge oil pump. Refer to Section 13, Turbine Unit Assembly,
for details and discussion.
JAN/91
1-5
1-17.
The engine control system receives turbine temperature signals from TOT
systems thermocouples. The twelve thermocouples (T/C) are installed in
the turbine unit assemblys rear bearing support. Refer to Section 5,
Turbine Outlet Temperature (TOT) System, for details and discussion.
1-18.
1-19.
The lube oil system provide pressure oil to the engine shafts, gears and
bearings for lubrication and cooling. The oil system is a dry-sump type
which includes one combination pressure and scavenge oil pump, an
external scavenge pump, and an rear scavenge oil pump. Refer to Section
7, Engine Lubrication System, for details and discussion.
1-20.
IGNITION SYSTEM.
1-210
1-22.
1-23.
The fuel and control systems includes pumps, filters, metering and
shutoff valves, manifolds, fuel nozzles and the control assemblies and
input devices. Refer to Section 4. Fuel Systems. and Section 6., Control
System, for details and discussion.
1-24.
1-25.
1-6
JAN/91
{/ , \ .,
&
\~
=2
AIR INLET
I ////+
-pOwEROuTpuT
m
SEAL AIRFLOW
* OPTIONAL STANDBY ()ER (SEE TABLE 2.2 FOR NORMAL OPERATING LIMITS)
TURBINE SECTION
A
Y/
u-
0
0
d
SPECIFICATIONS
CONTINUOUS
MAXIMUM
RATED TURBINE
lHII~fRATURE (CTIT)
1895 (1035)
*.2(JO()(~()93.3)
RATED RPM
**14,200
15,800
ENGINE DRY
WEIGHT
QHA020XK
Figure 1-2.
1-8
JAN/91
ENGINE MOUNTING.
NOTE
There are various mounting systems for the 501-KB5 engine. The high
shock mount system is the one most frequently used, refer to the OEM
manual for the fixed mounting system.
A. The various types of the eng ne mounting systems are shown in Fgure
1-3.
B. The engine mounting systems:
1. Maintains engine position and alignment.
2. Supports weight, inertial, shock loads, and torque loads of the
engine.
3. Allows for thermal expansion.
4. Supports external air inlet and exhaust connection loads.
5. Dampens induced engine vibration.
NOTE
External loading caused by the inlet, exhaust, or other engine
connections is additive to weight and inertial loads.
c. The engine mounting system is designed to distribute the load through
the high shock mount which is located below the diffuser and connected to the two diffuser flanges. The high shock mount supports
vertical loads, limited side loads and no fore-and-aft loads. Loads
are transferred to the skid structure. Supplied linkage supporting
the lower mount accommodates the axial and radial growth of the
engine while maintaining the location of the engine axial center
line.
D. The engine bottom mounting bracket and plate are designed to
accommodate the following loads:
1. Vertical direction--20,000 pound force (88 964 N)
2. Lateral direction--3OOO pound force (13 345 N)
3. Axial direction--5O5O pound force (O N)
JAN/91
1-9
\: ,,
i\, !
f ([:.
,,
J-q
:Wc,,<jq
-<=
_/
~ AFT SUPPORT
MOUNT ~
PLATE
A{ri
-=4!0
PORTABLE
ENGINE
,MOUNT
SHOCK
MOUNT
ENGINE HANDLING
AND
SHIPPINGBRACKET~
Ih(ik;
)1/1
*@
/w
DAMPER
MOUNT
= PLATE
- ---
1-10
JAN/91
COOLING.
1-28.
The engine requires external cooling. OEM provisions for cooling the
engine room or engine enclosure and control components are necessary and
must be maintained. It is important that the cooling air have a uniform
flow over the engine hot section to avoid any case warpage. The
combustion section and parts of the turbine are air cooled by internal
secondary air (air not required for combustion).
1-29.
.
NOTE
1-30.
NOTE
Refer to OEMs Manual for a complete Operating and Maintenance
Precaution.
The following are the Operating and Maintenance Precautions
required by Allison Gas Turbine.
A. Establish a daily thorough installation and walk around visual
inspection (Refer to Section 3).
B. Maintain clean gaseous and/or liquid fuel filters. Check the
pressure drops of the fuel filters regularly. A dirty fuel filter
system with resulting high pressure losses can reduce the power of
the engine (Refer to Sections 2 and/or 3).
NOTE
Allison
JAN/91
1-11
I
Allison Engine Company
501-KB5 DEC OPERATION AND MAINTENANCE
c. Take an oil sample every six months or as recommended by the oil
Inspect the oil sample for contamination and have the
manufacturer.
sample analyzed to determine total acid number (TAN) and viscosity,
(refer to Industrial Engine Bulletin 8-GT-84). Additionally, on an
annual basis, or as recommended by the oil manufacturer, the oil
sample should be analyzed for the quality and integrity of the oil
additive packages used in the base lubricant.
D. Before the engine is started, accomplish prestart check. The use of
check lists,such as those included in the Maintenance Practices is
strongly encouraged by Al ison Gas Turbine.
E. Prior to starting the eng ne, clear the engine room (area) of all
unnecessary personnel.
F. Monitor starting and running operations with correctly calibrated
instrumentation and with well trained personnel.
G. Do not rely wholly on automatic devices to handle an emergency. Both
automation and human manual control should be available to accomplish
an operational task.
H. Do not stabilize at speeds below engine idle, at least 13,000 rpm.
The control system is designed to prevent such operation.
I. When engine running is simulated, regardless of method and kind,
check for any ancillary control circuitry which may be activated
(fuel, lube, air, high voltage systems) but should not be operated
during the test. Conversely, check that those devices and systems,
which are required for a proper test, installation well being and
human safety, are activated.
J. When increasing power, power should be increased in a steadv.
conservative m;nner to the required level.
Increasing engi;e turbine
temperature more rapidly and to a higher level than necessary will
shorten the turbine life.
1-31.
1-32.
REMOVAL.
A. Make sure all electrical, fuel, and oil systems are OFF and remain
OFF until installation is completed.
CAUTION
CAP ALL HOSES, HARNESS ENDS, AND OPENINGS TO PREVENT CONTAMINATION. IF
REQUIRED, RECORD OR IDENTIFY ALL HOSES, HARNESS ENDS, AND OPENINGS FOR
INSTALLATION.
1-12
JAN/91
JAN/91
1-13
ENGINE LIFTING
ADAPTER
(P/N 6797690)
ENGINE ASSY
QHT023XA
Figure 1-4.
1-14
JAN/91
3\
/6
\
./. , /,,
uL_J
wJ
1.
2.
3.
4.
NUT (16)
POWER TAKEOFF HOUSING
POWER TAKEOFF SHAFT
PACKING (O-RING)
5.
6.
7.
8.
PACKING (O-RING)
COMPRESSOR EXTENSION SHAFT
OIL NOZZLE
COMPRESSOR AIR INLET HOUSING
QHC023XA
Figure 1-5.
JAN/91
1-15
1-34.
1-16
JAN/91
ENGINE
ASSY
. -----
-1
~.. ..
1
,,
>
~.;
-..
:_.. _.,
:.1
1,
- - - -
11
i.. .j
~.J
t
-L. ... J
I
,/ !\
,,
. .
J..
..
-J
CG
\+
/
-----4&-
!5
cJ-
--. -- -
L-.
P]
--. _..
I
~.,
~_-.=..F-.- ..4
f-.
. ..>
\
J--
I
{..;z;
+-=
-!
,_. . . -1
. ~<
l.V. J
la
I
#-
6
I
,--
ENGINE STAND
P/N 6799609
1.
2.
3.
4.
5.
6.
BOLT (2)
MOUNTING BRACKET (2)
BOLT (8)
BOLT
WASHER
NUT
7.
8.
9.
10.
11.
BRACKET
JACKSCREW
BOLT
NUT
RETAINING NUT
QHT024XA
Figure 1-6.
1-17
INSTALLATION.
NOTE
Het O-rings with clean engine oil.
A. Install O-ring (4, Figure 1-5) to power takeoff shaft (3) and O-ring
(5) to power takeoff housing (2).
CAUTION
DURING INSTALLATION, MAINTAIN ENGINE POWER TAKEOFF SHAFT AND COMPRESSOR
EXTENSION SHAFT ALIGNMENT HORIZONTALLY AND VERTICALLY, MAKING SURE
SPLINES ARE ALSO ALIGNED, OR DAMAGE MAY OCCUR.
B. Slowly hoist engine into place, aligning both horizontally and
vertically, carefully move engine forward engaging power takeoff
shaft (2) and compressor extension shaft (6) splines.
C. After checking alignment, install nuts (1) securing power takeoff
housing (2) to compressor air inlet housing (8). Torque nuts to
140-170 lb in. (15.9-19.6 Nom).
D. Install mounting bolts and nuts securing mounting bracket(s) to fixed
engine support and torque (Refer to OEM manual).
E. Install air inlet bell and secure with clamp (Refer to OEM manual).
F. Install augmenter to engine exhaust diffuser (Refer to OEM manual).
G. Install all hose and electrical harness connections (Refer to OEM
manual).
H. Service engine lubrication and fuel systems.
I. Perform engine operation and inspect for leaks.
1-18
JAN/91
Description
Paqe No.
2-1
2-3
2-2
2-4
2-3
Engine Operation
2-7
2-4
2-7
2-5
2-9
2-6
Normal Shutdown
2-1o
2-7
Emergency Shutdowns
2-1o
2-8
2-11
2-9
2-12
2-1o
Troubleshooting
2-13
2-11
Special Inspections
2-18
2-12
Performance Evaluation
2-20
2-13
Records
2-28
JAN/91
2-1
INDEX TO FIGURES
Fiqure No.
Title
Paqe No.
2-1
2-8
2-2
2-23
2-25
2-27
2-29
2-3
2-4
2-5
INDEX TO TABLES
Table No.
2-2
Paqe No.
2-1
Operating Parameters
2-4
2-2
Operating Limits
2-5
2-3
Troubleshooting
2-15
2-4
2-30
2-5
2-32
2-6
2-35
2-7
2-36
2-8
2-37
2-9
2-38
JAN/91
2-1.
NOTE
JAN/91
2-3
arameter
Operating Parameters.
*Control Limit
Setting
(Continous O~eration)
Warning
*Shutdown
Settinq
Settinq
:ngine speed
13,800 to
14,600 rpm
At 15,400 rpm
and above
15,800 rpm
:alculate
turbine
nlet temperature
CTIT)
1895F
(1035C)
1925F
(1052C)
1945F (1063)
for 10 sec or
1995F (1091C)
for 100 minisecond (MSEC).
uel System
Fuel metering
valve mistrack
more than plus
or minus 0.5 v
for 1.0 sec.
These are maximum settings established by Allison. The OEM may have
stablished lower settings, but cannot exceed the Allison maximum settings, for
Particular units.
2-4
JAN/91
Operating Limits.
ALCULATED TURBINE
NLET TEMPERATURE
(CTIT) F (C)
ENGINE (Nl)
SPEED - RPM
DRIVEN
EQUIPMENT
DE) SPEED - RPM
OIL PRE
PSIG
N1
<1570 (854).
>1570(854).
-U)
>1600(871).
<600 (316) WITHIN
10 SEC (LIQUID FUEL)
OR 3SEC (GASEOUS
FUEL) AND N1
>7200 RPM.
NOTE 1.
<1895 (1035).
13,800 TO 14,600
50 TO 60
(345 TO
414).
>1925 (1052).
>15,400.
<40 (276),
>15,800.
<20 (138).
<13,000 AHER GG
HAS BEEN >13,000
FOR 3 SEC.
NOTE 2.
JAN/91
2-5
.PRESSURE(PAG)
*DE
OIL TEMPERATURE F 0 c)
N1
*DE
VIBRATION - lN/SEC
(MM/SEC)
N1
*DE
NOTE 1:
tiRBINEOtJTLET
TEMPERATURE (TOT)
OVER TEMPERATLIRE
BACKUP, > 1400F
(760C) AND NI
<13,000 RPM.
NOTE 2:
-40 T0160
(-40 TO 71).
jO
<160 (71).
6).
w),
>180 (82).
>3MILS
(0.07MM) FOR
>3 SEC.
ENGINE OPERATION.
A. Ouring starting, fuel and ignition are programmed by the control
system. Refer to the particular control system section for a
description of how this is accomplished. Overspeed, underspeed and
temperature protection is provided to the engine to initiate a
shutdown. Other safety circuits connected to safety devices such as
low oil pressure or high vibration sensors can also initiate a
shutdown in order to protect the engine (Ref. Tables 2-1 and 2-2).
B. Many safety circuits remain active during normal operation.
c. The gas turbine engine is essentially a heat engine using air as a
working fluid. Air-passing through the engine ii accelerated which
means that the kinetic energy of the air is increased. To obtain
this, the pressure energy is first increased and then heat energy is
added with the final conversion back to kinetic energy in the form of
a high velocity, high energy gas stream which is impinged on the
turbine rotor assembly. Refer to the working cycle pressure volume
diagram in Figure 2-1 with the following explanation:
1. Point X represents air at atmospheric pressure which is compressed
along line XY, which adds some heat.
2. From Y to Z more heat is added to the air by introducing and
burning fuel at constant pressure; this increases the temperature
and volume of air. Some pressure losses occur in the combustion
chamber as indicated by the drop between Y and Z.
3. From Z to Xthe hot gases expand through the turbine nozzle (jei
pipe or augmenter) and exhaust system to atmosphere. The kinet c
(gas) energy is converted to mechanical work in the turbine and
manifested as torque at the PTO shaft output spline.
2-4.
JAN/91
2-7
COMPRESSOR
TURBINE
AIR
OUTPUT
SHAFT
TORQUE
EXHAUST
px
POWER-TAKEOFF
ASSEMBLY
I
4I
3
l-u
a
z
Cn
2
u
2
Yd
FUEL
NOZZLE
/coMBusTloN(ADDsH~TENERGyt
\r-N
1
\
VVnn,
nI
PRESSURE-VOLUME
DIAGRAM
w-w,w.:vr-,rn,,.
lu 1, , LLL
(THROUGH EXHAUST
COMPRESSION
1 (ADDS PRESSURE
ENERGY)
----- ----- ----- -
A
AMBIENT AIR
x
o
1
1
-,- - x
W
7
6
VOLUME
Figure 2-1.
2-8
JAN/91
JAN/91
2-9
NORMAL SHUTDOWN.
CAUTION
STABILIZED RUNNING IS PROHIBITED AT SPEEDS BELOW THE IDLE SPEED. THE
CONTROL SYSTEM IS DESIGNED TO PREVENT ENGINE OPERATION BELOW 13,000
RPM .
NOTE
. Safeguards built into the engine control system to prevent engine
damage are listed and explained in the applicable control system
section.
. Compare starting difficulty symptoms with descriptions tabulated in
the control system section; refer there for details in order to
determine the malfunctioning item.
. Normal shutdown should include a minimum of 5 minutes operation at
idle rpm after operation at more than 1450F (788C) CTIT.
A. A signal is initiated which closes the fuel shutoff valve.
B. As fuel is completely shutoff, the flame extinguishes, and the engine
coasts down to zero rpm in a smooth manner.
c. Engine oil pressure declines to O psig (O kPag) as the engine comes
to a stop.
2-7.
EMERGENCY SHUTDOWNS.
NOTE
During an emergency shutdown, all functions associated with a normal
shutdown occur except for the time at idle and that they occur in rapid
sequence. An emergency shutdown will be initiated by the control system
or should be manually initiated if any of the following limiting
conditions occur:
A. CTIT is more than 1945F (1063C) for more than 10 seconds or 1995eF
(1091C) for 100 milliseconds. Automatic shutdown will occur.
2-1o
JAN/91
JAN/91
2-11
2-12
JAN/91
JAN/91
2-13
10.
-,..
JAN/91
Troubleshooting
Probable Cause(s)
Fuel manifold pressure and/or fuel flow is normal,
suspect an ignition fault:
(1) Exciter not energized or low input voltage.
(2) Exciter output weak.
(3) Igniter plug spark weak.
(4) Igniter lead open or shorted to ground.
NOTE
Liquid fuel manifold pressure should be 150 to 155
psig (1035 to 1069 kPag) for proper fuel atomization. Gaseous fuel manifold pressure should be 4
to 6 psig (28 to 41 kPag).
Fuel flow and manifold pressure is low, suspect a
faulty fuel shutoff valve or electronic control
system.
Fuel flow is normal but no fuel manifold pressure,
suspect a manifold drain valve or fuel bypass valve
not closed (Liquid Fuel Only).
No fuel flow or fuel manifold pressure, suspect fuel
shutoff valve(s) (automatic or manual) not open.
NOTE
Ambient temperature is cold and below the fuel 10
centistokes temperature, fuel heating is required
(Liquid Fuel Only).
Engine inlet air temperature too low for fuel being
used.
Fuel temperature too low.
Poor fuel quality.
Fuel metering valve (FMV) position mistrack above
2300 engine rpm.
Starter too strong and accelerates engine too rapidly
through lightoff speed range.
JAN/91
2-15
Trouble Indication(s)
Late lightoff. . .
Liquid fuel engine
in cold ambient
temperature. ..no
CTIT rise until 10
seconds after fuel
and ignition ON
No lightoff. . .
Gaseous fuel engine
. ..no CTIT rise 3
seconds after fuel
and ignition ON
No engine rpm
indication
Starter failure.
PTO shaft failure.
Acceleration slow or
stagnated and CTIT
appears normal
Stagnated (stalled)
start, i.e. . . .
acceleration slow or
stagnated with low
CTIT (less than 1300F
or 704C) and engine
rpm in the 3500-6500
range; Iightoff may be
normal or late
2-16
Probable Cause(s)
Inadequate starter assist.
A manifold drain valve or bypass valve not closed
(Liquid Fuel Only)
Late lightoff
JAN/91
2-17
Consumption Troubleshooting.
NOTE
SPECIAL INSPECTIONS.
A. Special inspections are usually those which come about because of a
malfunction or a pending malfunction as indicated by a warning.
Refer to appropriate manual sections.
B. Vibration limit is exceeded and a shutdown may or may not have
resulted:
1. Check for loose pickup, mounting plate or connector. Check the
wiring to the pickup connector.
2. Check magnetic chip detector for debris accumulation.
3. Restart engine. If the limits are exceeded again, check compressor
and turbine for damage.
c. Automatic shutdown occurs during engine start:
1. If three consecutive start attempts are unsatisfactory, determine
cause.
2. Inspect fuel and electronic control systems.
3. Inspect for fuel metering valve mistrack and electronic control
system.
4. Inspect engine oil system (Ref. Section 7).
5. Inspect turbine and compressor by the use of a borescope
Section 3).
Ref.
JAN/91
JAN/91
2-19
PERFORMANCE EVALUATION .
A. General.
NOTE
In most applications there is no way to obtain complete data necessary
to exactly calculate engine performance. However decreased compressor
efficiency often due to ingested oil vapors, dirt, or other airborne
contaminates can be determined by a comparative performance method.
This method requires that a complete engine baseline of data is recorded
and kept whenever a new and/or a replacement engine is installed, or
whenever an engine has undergone a major on-site repair, such as turbine
unit change. Future data, such as the Performance Estimate Data Record,
Gas Turbine Trouble Report, etc, will use the engine baseline data for
estimating a decrease in performance.
1. Use the engine baseline to estimate performance of the engine(s).
NOTE
If compressor damage such as blade erosion or vane erosion or foreign
object damage (FOD) has not occurred, the performance can normally be
recovered by cleaning the compressor.
2. Cleaning or other maintenance is highly recommended by Allison
when performance depreciates 5 percent below the baseline.
CAUTION
ENGINE PERFORMANCE THAT DECREASE IN EXCESS OF 5 PERCENT IS TO BE
AVOIDED, SINCE THE ACCOMPANYING INCREASE IN CTIT LEVEL REDUCES TURBINE
LIFE.
3. The compressor cleaning methods, described in Section 10, are the
conditions and times to accomplish cleaning recommended by
Allison. The gas turbine engine owner may modify these clean ng
methods to suit the particular type operating conditions.
Excessive performance depreciation (5 percent below the basel ne)
can lead to starting difficulties and turbine damage.
NOTE
Since the calculated turbine inlet temperature (CTIT) is held constant
for the baseline and the subsequent performance checks, it is advisable
to inspect the thermocouples for integrity as well as all the thermocouple indicating circuitry prior to running a performance check.
2-20
JAN/91
---1
I
I
JAN/91
2-21
2-22
JAN/91
(-34)
(-29)
(-23)
(-18)
(-12)
(-7)
(-1)
(4)
Figure 2-2.
JAN/91
2-23
1. BASELINE DATA
WHILE
IG STEADILY
CTIT.
50
(lo)
60
(16)
ENGINE IN
70
80
90
(21)
(27)
(32)
100
(38)
Il(j
(43]
120
(49)
(54)
QHSO08XA
Figure 2-2.
2-24
JAN/91
11.0
10.5
10,0
Id
o
i=
u
a
9.5
!3
u)
fJ
9.0
n
a
51
fIJ
8.5
s
o
8.0
7.5
7.0
-10
(-23)
(-:8)
(::2)
&
(::)
TOTAL COMPRESSOR I
Figure 2-3. Operating Lines of Compressor Pressure Ratio Versus
Compressor Inlet Temperature for 1700F (927C) ClIT.
JAN/91
2-25
Ui
40
(4)
(%)
&
(%)
0
&
0
?2)
100
1 1 0
(38)
(43)
QttSO09XK
JAN/91 -
--
F
w-%
I
1 I
-10
(-23)
(-:8)
!,
(!:2)
(~?)
(~:)
;,
(%)
(%
1
1
:,
I
I
($
I
,
?2)
2-27
RECORDS.
NOTE
The importance of keeping accurate records cannot be over emphasized
and is strongly recommended by Allison.
A. Records are used as an aid to locate problems as well as to determine
when maintenance is required.
B. This data can be useful in anal.yzinq oPeratin9 costs. Several kinds
of technical records should be ~ons~dered: 1. Those when the gas turbine engine and the driven equipment are
operating normally and efficiently.
2. Those when conditions indicate trouble or a when a malfunction
actually occurs (The Trouble Report).
3. A third set of records, eauall.y as important to the troubleshooter
as well as for record purposes; are those which cover prestart
checks and proper adjustments.
C. The following data forms are recommended by Allison. Samples of
these recommended forms follow.
1. Start, Run, and Stop Report (Ref. Table 2-4).
2. The Trouble Report is used as a supplement the Start, Run, and
Stop Report when a malfunction occurs (Ref. Table 2-5).
30 Installation Inspection Report (Ref. Table 2-6).
4. Control System Static Test and Instrument Calibration (Ref. Table
2-7).
5. Start-up and Adjustment Runs (Ref. Table 2-8).
6. Performance Estimate Data Record (Ref. Table 2-9).
2-28
JAN/91
10
15
20
100
90
95
BASELINERC
85
-pERcE~
QHSO1lXA
Figure 2-5.
JAN/91
Date
PLACE:
Country
Location No.
Other Location Ident.
Owner/Operator
Report Recorded by
Misc. Ident. Info.
Gas Turbine Engine Model - 501-KB5 DEC
Driven Equipment
Name
Model
START :
Take fuel sample and record condition, as required.
Lower Heating Valve (LHV)
Fuel
If applicable, prestart check list number
Record kind of instrumentation if different or unusual from normal, such as,
Start-Run Monitoring Test Set.
NOTE: This report assumes that prestart checks and startup and adjustment
runs have been done. If a separate record is not required, then
this information should be put here in this report.
Check and Record the Following: Starting Time: (2200 rpm
Compressor Inlet Temperature (CIT):
F (
F
Outside Air Temperature (OAT):
Fuel Supply Pressure:
Minimum Fuel Flow Manifold Pressure:
Initial CTIT:
Ignition RPM:
Peak light-off Calculate Turbine Inlet Temperature
Acceleration Time (start-to-crank to lightoff)
2-30
to 3,000 rpm)
c)
( c)
psig ( kPag)
ps:: (
(
(CTIT)
I
kPag )
c)
F
Or\
JAN/91
kPag)
psig(
mm)
mm)
kPag)
roils (
roils (
psig (
rpm
STOP:
Date
Time of day
Describe shutdown:
Record Engine coast-down time:
Listen for and record unusual noises (scraping, bumping, knocking, etc.) and
record:
Peak Vibration:
Enf <*F..
Dr ven Equipment:
F (
CIT
C). CTIT:
Engine Drain Oil Temperature:
Driven Equipment Drain Oil Temperature:
Take oil samples & record condition:
F (
F (
F (
c).
c)
c)
JAN/91
2-31
TROUBLE REPORT.
Owner/Operator
Location Number
Country
Reported by
Contacted
FAX/Teletype No.
Telephone No.
City
Date
State
Unit Starts
2.
3.
4.
Start-up Date
5.
Unit Location
6.
Telephone/Telex No.
7.
Description of problem:
(record data) .
8.
9.
10.
2-32
No
JAN/91
12.
13.
Starting Problem
a.
b.
c.
d.
e.
f.
9
h.
JAN/91
mil m
Vibration Level at Time of Problem
mm
mil
Previous to Problem
Rundown Time of Engine after Shutdown from Idle:
Seconds
Minutes
Oil Consumption
::
c.
d.
e.
f.
9
15.
14.
Compressor Inlet
Turbine Vanes & Blading
Combustion Area
Fuel Nozzles
Magnetic Plug(s)
30 minutes, check again.
2-33
16.
psig
psig
kPag
kPag
Collapsed
Other
vdc .
Controlling Problem
;:
17.
Power Problem
;:
c.
d.
e.
f.
:.
.
i.
Notes:
2-34
JAN/91
2.
Inlet air bellmouth to plenum seal has snug fit with no air
leakage (static or running)
3.
4.
5.
Inlet air plenum area doors (hatches) closed and properly secured
6.
7.
8.
9.
ALL CONDITIONS HAVE BEEN CHECKED AND MEET THE APPLICABLE SPECIFICATIONS
INSPECTOR
JAN/91
SUPERVISOR
2-35
d.
ALL STATIC TESTS AND MOTORING OPERATIONS COMPLETED AND ENGINE READY FOR
STARTUP
.
INSPECTOR
2-36
SUPERVISOR
JAN/91
2.
3.
a.
.
Lightoff rpm
Lightoff peak CTIT
Minimum fuel manifold pressure (If ~sed, close gage shutoff
valve before pressure exceeds gage limit).
Acceleration rate and temperature characteristics. (Time
.
lapse from lightoff to idle setting)
Record the following final settings.
(1)
(2)
(3)
(4)
b.
.
.
.
JAN/91
SUPERVISOR
2-37
OPERATOR:
1.
2.
* 1700F
(927C)
CTIT
F
F
F
c
c
c
3.
4.
5.
6.
7.
Ad.iusted c
Comparative Rc
x 100 =
8.
Enter Shaft HP Decrease Due to Dirty Compressor graph with the percentbaseline Rc
and determine percent of decrease of engine shaft
horse power is
.
9.
2-38
JAN/91
Inspections
Paqe No.
3-3
3-2
3-3
3-3
3-5
3-4
Special Inspections
3-8
3-5
Borescope Information
3-8
3-6
3-9
3-7
3-9
3-8
3-12
3-16
3-9
3-1o
JAN/91
Descri~tion
3-18
3-11
3-19
3-12
3-19
3-13
3-27
3-14
3-28
3-15
3-28
3-1
Fiaure No.
3-1
3-11
3-2
3-13
3-14
3-14
3-15
3-6
3-17
3-7
3-17
3-23
3-3
3-4
3-5
3-8
INDEX TO TABLES
Table No.
3-2
Title
Paae No.
3-1
Inspection Tasks
3-6
3-2
3-27
JAN/91
INSPECTIONS.
3-2.
JAN/91
3-3
3-4
JAN/91
JAN/91
3-5
NOTE
The inspections list does not contain detailed maintenance instructions
on how to perform the inspection. Refer to the specific section of the
manual dealing with the component.
c.
D.
Example:
The frequency interval for Igniters are 2000 hours. The igniters can
be inspected between 1800 to 2200 hours.
E. The operators and their maintenance personnel must use sound
judgement based on experience to adjust inspection frequency
intervals.
NOTE
If the operator and their maintenance personnel delete an inspection
task (item) or extends inspection frequency interval over the 10 percent
leeway, this will relieve Allison of its warranty obligations, while the
engine is within the warranty period.
F.
Item
Inspection Tasks.
Action
Interval
Check quantity
Daily
Engine
Daily
Compressor
Weekly or
Note A
As required
500 hrs or
Note A
Electrical leads,
cables and
connectors.
3-6
JAN/91
Action
Interval
500 hrs or
Note A
Daily or
Note A
500 hrs or
Note A
Compressor bleed
valves
500 hrs or
Note A
Fuel nozzles
500 hrs
(First time)
and then 2000
hrs thereafter
Igniters
2000 hrs or
Note A
Combustion liners
2000 hrs or
Note A
Turbines
2000 hrs or
Note A
Engine oil
filter
500 hrs or
Note A
Refer to
driven equipment OEM.
Fuel quality
Daily or as
required to
ensure
quality.
Fuel filter
2000 hrs
(Visual
Inspection)
Thermocouples
500 hrs or
Note A
JAN/91
3-7
Action
8000 hrs or
Note A
Control system
(DEC and B1 eed
valve systems)
8000 hrs or
Note A
Engine mounting
2000 hrs or
Note A
Note A.
3-4.
SPECIAL INSPECTIONS.
NOTE
Special inspections are usually those which are necessary as the result
of a malfunction or a pending malfunction as indicated by a warning.
Refer to appropriate manual sections and the troubleshooting section.
3-5.
BORESCOPE INFORMATION.
A. A borescope inspection instrument is necessary to inspect internal
areas of the engine without major disassembly. There are many sizes
and types of borescopes available for purchase. Some considerations
are:
1. Probe diameter:
2. View angle:
3. Magnification:
3-8
JAN/91
3-7.
JAN/91
3-9
JAN/91
2,
11
12
13
14
15
17
//
/
/
10
u:,
0
0
o
0
0
~:
TRANSITION ASSEMBLY
12,
13.
14.
15.
16.
17.
18.
QHPOOIXA
Figure 3-1.
JAN/91
3-11
3-8.
3-12
JAN/91
1
Allison Engine Company
501-KB5 DEC OPERATION AND MAINTENANCE
240743
Figure 3-2.
JAN/91
3-13
Figure 3-3.
.----
-., .
Figure 3-4.
3-14
JAN/91
-m
Figure 3-5.
JAN/91
3-15
3-16
JAN/91
$*-
ACCEPTABLE
UNACCEPTABLE
CRACKING
3-17
3-18
JAN/91
A. Description.
1. The engine shipping container has been designed and tested to
protect the engine from shock and vibration resulting from
shipping (by any mode) and handling to a shock limit resulting
from a drop from height of 18 inches (457.2 mm).
JAN/91
3-19
WARN ING
USE CARE IN REMOVAL OF AIR VALVE STEM TO PREVENT IT FROM BLOWING OFF
AND CAUSING INJURY TO PERSONNEL.
WARNING
MAKE SURE ALL PRESSURE IS RELEASED BEFORE REMOVING PIPE PLUG OR
CONTAINER COVER. INJURY OR DAMAGE MAY OCCUR.
2. Release pressure by removing stem from air valve (5), when
pressure has been released, remove pipe plug (6).
3. Remove nuts (7) and bolts (8). Attach lift hooks to container
cover (9) and lift container cover up and away from base assembly
(10). Allow closure seal (11) to remain with base assembly.
Place container cover on wooden mounts (boards) to prevent damage
to the flange.
4. Attach engine lifting adapter to engine as outlined in Section 1.
Lift engine sufficiently to remove weight from the base assembly
(lo).
5. Remove yoke (12) from base assembly (10), by removing nuts (13),
washers (14), and bolts (15).
6. Remove LH bracket (16) from base assembly (10) by removing washers
(17) and bolts (18).
3-20
JAN/91
JAN/91
3-21
WARN ING
MAKE SURE ALL PRESSURE IS RELEASED BEFORE REMOVING PIPE PLUG OR
CONTAINER COVER. DAMAGE OR INJURY MAY OCCUR.
2. If required, release any pressure by removing stem from air valve
(5), when all pressure has been released, remove pipe plug (6).
3. If required, remove nuts (7) and bolts (8), attach lift hooks to
container cover (9) and lift container cover up and away from base
assembly (10). Place container cover on wooden mounts (boards) to
prevent damage to the flange. Allow closure seal (11) to remain
with base assembly.
4. If required, remove yoke (12) from base assembly (10) by removing
nuts (13), washers (14), and bolts (15).
5. If required, remove LH bracket (16) from base assembly (10) by
removing washers (17) and bolts (18).
6. If required, remove RH bracket (19) from base assembly (10) by
removing washers (20) and bolts (21).
7. If required, remove loose items from storage box (44) and place on
work bench.
8. Install yoke (12) to engine upper rear mounting bracket by
installing bolts (36), washers (35) and nuts (34). Torque nuts to
135-155 lb in. (15.3-17.5 Nm).
9. Attach engine lifting adapter to engine and remove engine from
engine stand, 6799609, or equivalent, as outlined in Section 1.
10. If required, install RH mount (28) to RH bracket (19), secure with
bolt (33), washer (32), and nut (33). Tighten nut to seat firmly
and then back nut off one complete turn.
11. Install assembled RH mount (28) and RH bracket (19) to lower RH
mounting pad on engine air inlet, secure with washers (29) and
bolts (30). Torque bolts to 240-300 lb in. (27.1-33.8 Nm).
Lockwire bolt heads in pairs.
12. If required, install LH mount (22) and LH bracket (16), secure
with bolt (27), washer (26), and nut (25). Tighten nut to seat
firmly and then back nut off one complete turn.
13. Install assembled LH mount (22) and LH bracket (16), to lower LH
mounting pad on engine air inlet, secure with washers (23) and
bolts (24). Torque bolts to.240-300 lb in. (27.1-33.8 Nm).
Lockwire bolt heads in pairs.
3-22
JAN/91
2.
3.
4.
5.
6.
7.
8.
1::
11.
12.
13.
;;:
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
29.
40.
41.
42.
;::
NUTS (2)
LOCKWASHER (2)
SERVICE COVER
DOUBLE END BOLT (2)
AIR VALVE
PIPE PLUG
NUT (56)
BOLT (56)
CONTAINER COVER
BASE ASSY
CLOSURE SEAL
YOKE
NUT (4)
W&lE~4~4)
9
/
LH BRACKET
WASHER (3)
.-,
BOLT (3)
RH BRACKET
:~l~E: 313 )
LH MOUNT
h&U~E~4~4)
NUT
WASHER
BOLT
RH MOUNT
WASHER (4)
BOLT (4)
NUT
WASHER
BOLT
NUT (Z)
l1:l;E~2\2)
RECORD RECEPTACLE
NUT (2)
WASHER (2)
RECEPTACLE COVER
HUMIDITY INDICATOR
INSPECTION PORT (2)
DESICCANT RECEPTACLE
STORAGE BOX
Figure 3-8.
JAN/9 1,
Allison Engine
501-KB5 DEC OPERATION
\ d
10
:.
Figure 3-8.
3-24
3-25
At 37 to
humidity
pink. If
the
3-26
JAN/91
PRESSURE
~ ~
TEMPERATURE
~
~
PRESSURE
&
J2QJ2
+140
+130
+120
+110
+100
+90
+80
+70
+60
+50
7.6
52.4
4.4
3.9
;:;
6.5
6.1
5.8
5.4
5.0
4.6
4.3
:;::
44.8
42.1
40.0
37.2
34.5
31.7
29.6
+40
+30
+20
+10
-::;
-12.2
-18
-23
-29
-34
-40
::;
60
54
:;
38
32
27
21
16
10
-!0
-20
-30
-40
;::
2.0
26.9
24.1
22.1
19.3
16.5
13.8
;:;
0.9
;!07
6.2
NOTE
The temperature and pressure values are base on the requirement of 5.0
psig (34.5 kPag) air pressure at 70F (21-C) temperature, a ~ 0.5 psig
(3.45 kPag) from the correct pressure is allowable.
NOTE
If engine is not shipped within 24 hours after container is
pressurized, pressure shall be rechecked. Check pressure again
immediately prior to shipment.
3-15.
3-28
JAN/91
Pacie No.
4-1
Fuel Systems
4-11
4-2
4-11
4-3
4-11
4-4
4-12
4-5
4-12
4-6
Removal
4-14
4-7
Cleaning
4-14
4-8
4-15
4-9
Repair
4-15
4-1o
Installation
4-16
4-11
4-16
4-12
Fuel Nozzle
4-17
4-13
4-17
4-14
Troubleshooting
4-17
4-15
Removal
4-17
4-16
Inspection
4-18
4-17
Cleaning
4-18
4-18
Installation
4-20
4-19
Final Filter
4-20
4-20
4-20
4-21
Removal
4-20
4-22
Installation
4-22
4-23
Fue
4-22
4-24
4-22
4-25
Removal
4-22
4-26
Installation
4-23
4-27
JAN/91
Descri~tion
4-23
4-28
4-23
4-29
4-23
4-1
Paqe No.
4-30
4-23
4-31
Troubleshooting
4-24
4-32
Removal
4-25
4-33
Inspection
4-26
4-34
Cleaning
4-26
4-35
Installation
4-27
4-36
4-27
4-37
Description
4-27
4-38
Operation
4-28
4-39
Fuel Pump
4-28
4-40
4-28
4-41
Removal
4-33
4-42
Installation
4-35
4-43
Troubleshooting
4-36
4-44
4-36
4-45
4-36
4-46
Removal
4-36
4-47
Installation
4-37
4-48
4-37
4-49
Cleaning
4-38
4-50
4-41
4-51
4-2
Description
Paralleling Valve
4-41
4-52
4-41
4-53
Removal
4-42
4-54
Installation
4-42
4-55
4-43
4-56
4-43
4-57
4-44
4-58
4-44
4-59
4-47
4-60
4-48
4-61
4-50
JAN/91
4-53
4-53
4-65
Removal
4-53
4-66
Installation
4-54
4-56
4-68
4-56
4-69
Removal
4-56
4-70
Installation
4-57
4-60
4-72
4-60
4-73
Inspection
4-60
4-74
Removal
4-61
4-75
Installation
4-62
4-76
4-63
4-77
4-63
4-78
Removal
4-63
4-79
Installation
4-63
4-80
4-64
4-81
4-51
4-71
JAN/91
Pacle No.
4-64
4-67
Descri~tion
4-65
4-82
4-65
4-83
Removal
4-65
4-84
4-65
4-85
Installation
4-66
4-86
Troubleshooting
4-67
4-87
4-67
4-88
4-67
4-89
4-67
4-90
Removal
4-68
4-91
Inspection
4-70
4-92
Cleaning
4-70
4-93
Installation
4-72
4-3
Descri~tion
Liquid Fuel Water Injection
4-73
4-95
4-73
4-96
4-73
4-97
4-73
4-98
Removal
4-74
4-99
Maintenance
4-74
4-1oo
Installation
4-77
4-101
4-77
4-102
4-77
4-103
4-80
4-104
4-80
4-105
4-81
4-106
4-107
4-82
4-82
4-108
4-82
4-109
Removal
4-83
4-110
Inspection
4-84
4-111
Cleaning
4-84
4-112
Installation
4-86
4-113
4-86
4-114
4-86
4-115
4-87
4-116
4-4
Paqe No.
4-87
4-117
Description
4-87
4-118
Operation
4-88
4-119
Fuel Pump
4-88
4-120
4-88
4-121
Paralleling Valve
4-91
4-122
4-91
4-123
4-91
JAN/91
Paqe No.
4-124
4-91
4-125
4-91
4-126
4-91
4-127
4-91
4-128
4-92
4-129
4-92
4-130
4-92
4-131
4-92
4-132
Removal
4-93
4-133
Inspection
4-94
4-134
Cleaning
4-95
4-135
Installation
4-96
4-136
4-97
4-137
4-97
4-138
Removal
4-98
4-139
Installation
4-98
4-140
4-141
4-142
4-98
4-98
4-98
4-143
4-98
4-144
4-99
4-145
4-99
4-146
4-99
4-147
4-1oo
4-148
Removal
4-103
4-149
Installation
4-103
4-150
JAN/91
Descri~tion
4-106
4-151
4-106
4-152
4-106
4-153
Cleaning
4-106
4-154
4-106
4-155
Removal
4-106
4-5
Paqe No.
4-156
Installation
4-107
4-157
4-107
4-158
4-107
4-159
Removal
4-107
4-160
Installation
4-108
4-161
4-109
4-162
4-109
4-163
Removal
4-109
4-164
Installation
4-114
4-165
4-115
4-166
4-115
4-167
Removal
4-115
4-168
Installation
4-116
4-169
4-116
4-170
4-116
4-171
Removal
4-117
4-172
Installation
4-118
4-173
4-118
4-174
4 - 1 1 8
4-175
Removal
4-119
4-176
Installation
4-122
4-177
4-123
4-178
4-123
4-179
4-124
4-180
4-124
4-181
4-125
4-182
4-126
4-183
4-126
4-184
4-126
4-185
4-127
4-186
4-187
4-6
Descri~tion
4-127
4-127
JAN/91
Paqe No.
4-188
Removal
4-128
4-189
Inspection
4-129
4-190
Cleaning
4-130
4-191
Installation
4-131
4-192
4-132
4-193
4-132
4-194
Removal
4-132
4-195
Installation
4-133
4-196
4-197
4-198
4-133
4-133
4-133
4-199
4-133
4-200
Removal
4-134
4-201
Installation
4-134
4-202
4-135
4-203
4-135
4-204
Removal
4-135
4-205
Installation
4-136
4-206
4-136
4-207
4-136
4-208
Removal
4-137
4-209
Installation
4-137
4-210
4-138
4-211
4-138
4-212
R e m o v a l
4-138
4-213
Installation
4-139
4-214
4-215
4-216
JAN/91
Descri~tion
4-139
4-139
4-139
4-217
4-139
4-218
Removal
4-140
4-219
Installation
4-140
4-7
Descrir)tion
Gaseous Fuel Metering Valve
Paqe No.
4-141
4-221
4-141
4-222
Removal
4-141
4-223
4-142
4-224
Installation
4-142
4-225
4-143
4-226
4-143
4-227
Removal
4-144
4-228
Installation
4-144
4-229
4-145
4-230
4-145
4-231
Removal
4-146
4-232
Installation
4-146
4-233
4-147
4-234
4-147
4-235
4-147
4-236
4-148
4-237
4-150
4-238
4-150
4-239
4-150
4-240
4-241
4-150
4-150
INDEX TO FIGURES
Fiqure No.
4-8
Paqe No.
4-1
4-13
4-2
4-19
4-3
4-21
4-4
4-24
JAN/91
Title
4-5
4-25
4-6
4-31
4-7
4-34
4-8
4-39
4-9
4-1o
JAN/91
Paqe No.
4-41
4-43
4-11
4-45
4-12
4-46
4-13
4-46
4-14
4-49
4-15
4-55
4-16
4-59
4-17
4-66
4-18
4-69
4-19
4-71
4-20
4-75
4-21
4-79
4-22
4-83
4-23
4-89
4-24
4-93
4-25
4-96
4-26
4-101
4-27
4-105
4-28
4-111
4-29
4-113
4-30
4-121
4-9
Title
Paqe No.
4-31
4-129
4-32
4-149
4-33
4-151
4-34
4-153
4-35
4-155
INDEX TO TABLES
Table No.
4-1
4-1o
T i t l e
Approved Liquid Fuels
Paqe No.
4-29
JAN/91
FUEL SYSTEMS .
A. The following fuel systems may be installed on the 501-KB5 DEC
engine:
1. Gaseous Fuel.
Gaseous Fuel with Water Injection.
:: Liquid Fuel.
4. Liquid Fuel with Water Injection.
Dual Fuel (Gaseous and Liquid Fuels),
:: Dual Fuel with Water Injection.
7. Optional Liquid Fuel Heating Systems.
B. All these fuel systems will be covered in this Section.
C. Basically, the engine fuel system meters and distributes the required
fuel to the engine to maintain a selected engine speed under varying
loads.
D. Many fuel system components may be used in the different fuel systems
and will be identified.
4-2.
4-3.
Control System.
Fuel Metering Valve (FMV).
Fuel Nozzles (6).
Final Filter.
Fuel Manifold and Hoses.
Fuel Shutoff and Vent Valves (Ref. to OEMS).
NOTE
Some eng nes have an optional 200 + 5 psig (1380 + 34.5 kPag) fuel
metering valve (FMV). Normal FMV~s a 250~5 ps~g (1725 *34.5 kPag).
JAN/91
4-11
4-5.
4-12
JAN/91
IN LINE FILTER
(3 MICRONS)
GASEOUS FUEL
x-?
ENT+
FUEL
S SHUTOFF
VALVE
)--Q
FUEL
S SHUTOFF
VALVE
BASE MOUNTED
ENGINEMO~NTED
I
I
rl
PRESSURE
SWITCH
OPEN >20PSID
I ~NG l----fi:~:
r+ .
FUELMANIFOLDPRESSURE
GAGECONNECTION
FUEL
NOZZLES
F==l
Figure 4-1.
JAN/91
FINAL FILTER
::$;2 (2MICRONSNORMAL,
j{~~? 10 MICRONSABSOLUTE)
:,,#jj,##
FUELMETERINGVALVE
INLETPRESSUREGAGE
CONNECTION
;u/j, ;
PRESSURESWITCH
OPEN >10 PSI (69 KPA)
QWXA
Gaseous Fuel System Schematic.
4-13
Removal.
A. Make sure electrical power is OFF and remains OFF until installation
is completed.
B. Make sure gaseous fuel is OFF and no pressure is at the inlet to the
FMV .
CAUTION
DO NOT DISCONNECT FMV ELECTRICAL LEADS INSIDE THE FMV. DAMAGE TO THE
FMV WILL OCCUR.
C. Remove FMV electrical leads (1, Figure 4-2) at point of interface
with the control system.
D. Remove bolts (2), fuel manifold (3), and gasket (4). Discard gasket.
E. Remove FMV outlet gage pressure hose (5).
F. Remove FMV inlet gage pressure hose (6).
G. Remove bolts (7) and washers (8).
H. Move adapter assemble (9) and remove gasket (10). Discard gasket.
I. Remove nuts (11) and remove FMV (16) with bracket (13).
J. Remove bolts (12) and bracket (13) from FMV (16).
K. If required, remove unions (14) and O-rings (15) from FMV (16).
Discard O-rings.
4-7.
Cleaninq.
A. Because of the electrical circuits, do not submerge the FMV in
cleaning solvent.
4-14
JAN/91
4-9.
u
A. There is no disassembly, parts fix, or parts replacement allowed.
Repair consists of installing a known good, new or overhauled FMV.
JAN/91
4-15
Installation.
A. Wet O-rings (15, Figure 4-2) with clean engine oil.
B. Install an O-ring (15) on each union (14). Install unions in FMV
(16). Torque unions to 55-80 lb in. (6.3 -9.0 N-m).
C. Install bracket (13) on FMV (16) and secure with bolts (12). Torque
bolts to 120-150 lb in. (13.6-16.9 Nom) and lockwire.
D. Install assemble bracket and FMV to engine and secure with nuts
(11). Torque nuts to 74-89 lb in. (8.4-10.0 N-m).
E. Install gasket (10) and adapter assembly (9) to FMV (16) and secure
with washers (8) and bolts (7). Torque bolts to 70-85 lb in.
(8.0-9.6 N-m) and lockwire.
F. Install FMV inlet gage pressure hose (6) to union (14). Retain union
(14) from turning and torque hoses coupling nut to 80-120 lb in.
(9.0 -13.5 Nm).
G. Install FMV outlet gage pressure hose (5) to union (14). Retain
union (14) from turning and torque hoses coupling nut to 80-120 lb
in. (9.0 -13.5 Nm).
H. Install gasket (4) and manifold (3) to FMV (16) and secure with bolts
(2). Torque bolts to 70-85 lb in. (8.0-9.6 N*m) and lockwire.
WARNING
MAKE SURE ELECTRICAL POWER IS OFF. DAMAGE OR INJURY MAY OCCUR.
I. Connect FMV leads (1) per color coding on FMVS (16) identification
tag to the control system to complete the interface.
4-11.
4-16
JAN/91
FUEL NOZZLE.
4-13.
4-14.
Troubleshootinq.
NOTE
Although the following trouble indications may be traceable to
malfunctioning fuel nozzle(s), other devices, and/or a combination of
things can cause the same troubles.
A. Some symptoms which can lead to a fuel nozzle inspection:
1. Frequent fail-to-start or slow or stagnated starts.
2. Excessive and frequent torching and/or smoking.
3. High incidence of thermocouple failures such as burned-off probe
tips and/or open thermocouple junctions.
4. Appearance of hot spots on the outer combustion case.
5. Excessive engine vibration which may result in erosion and/or
cracking of the fuel nozzle bodies.-
4-15.
Removal.
NOTE
Individual gaseous fuel nozzles may be replaced.
A. Remove the fuel manifold hose (20, Figure 4-2) from the fuel nozzle
(19).
B. Cap the hose to keep out contamination.
C. Remove bolts (17) and carefully remove fuel nozzle (19) and gasket
(18). Discard gasket.
D. Repeat Steps A., B., and C. to required fuel nozzle(s) to be removed.
JAN/91
4-17
1.
2.
3.
4.
4-16.
Inspection.
A. Inspect for obvious physical damage such as metal deterioration
(burns, erosion, corrosion) and cracks in the fuel nozzle body holder
and body. Damage which affects the structural integrity of the fuel
nozzle and/or which disturbs gas flow, is unacceptable.
B. Cracks between the jet holes or erosion of the holes is unacceptable.
co Inspect the flame plated coating on the wear surface of the fuel
nozzle body. Wear is permitted if the coating is not worn through to
the base metal at any place along the axial wear surface of the body.
D. Inspect for clogged passages and jet holes.
E. Inspect for carbon deposits. If they disturb the gas path in anyway,
they wi11 need to be removed.
4-17.
Cleaninq.
CAUTION
DO NOT USE A METHOD WHICH WILL REMOVE THE FLAME-PLATED ALUMINUM OXIDE
COATING. AVOID CAUSTIC (BASE/HYDROXIDE) CLEANING SOLUTIONS.
4-18
JAN/91
22 \
Figure 4-2.
JAN/91
Installation.
A. Install gasket (18, Figure 4-2).
B. Apply Ablube, MIL-L-25681, on the bolts (17) threads.
C. Carefully install the fuel nozzle (19) and secure with bolts (17).
Torque bolts to 70-85 lb in. (7.9-9.6 Nom). Lockwire bolts.
D. Connect the fuel manifold hose (20) to the fuel nozzle. Torque hose
coupling nut to 325-400 lb in. (36.8-45.1 Nm) and lockwire.
4-19.
FINAL FILTER.
Removal.
A. Remove fuel supply hose (21, Figure 4-2) from elbow (22).
4-20
JAN/91
<0
NOZZLE
BODY
HOLDER
QHH078XD
Figure 4-3.
B. Remove bolts (7), washers (8), adapter assembly (9), and gasket (10)
from FMV (16). Discard gasket.
C. Remove bolt (23), nut (24), and assemble final filter (31) from
bracket (26).
D. If required, remove clamp (25).
E. If required, loosen nut (27) and remove elbow (22), nut (22), and
O-ring (28) from final filter (31). Remove and discard O-ring.
F. If required, loosen nut (29) and remove adapter assembly (9), nut
(29), and O-ring (30) from final filter (31).
JAN/91
4-21
Installation.
A. If required, install nut (29, Figure 4-2) and O-ring (30) on adapter
assembly (9). Install adapter assembly in final filter (31). Do not
tighten nut (29).
B. If required, install nut (27) and O-ring (28) on elbow (22). Insta 1
elbow in final filter (31). Do not tighten nut (27).
c. Install assembled final filter (31) and clamp (25) to bracket (26)
and secure with nut (24) and bolt (23). Do not tighten nut (24).
D. Install gasket (10) and adapter assembly (9) to FMV (16). Secure
with bolts (7) and washers (8). Torque bolts to 70-85 lb in.
(8.0-9.6 Nm) and lockwire bolts.
E. Torque nut (24) to37-42 lb in. (4.2-4.7 N-m) and tighten nut (29).
F. Install fuel supply hose (21) to elbow (22), aligning elbow as
required. Torque hose coupling nut to 1200-1500-lb in. or 100 -125
lbft. (135.6-169.4 Nm). Tighten nut (27).
4-23.
4-24.
4-25.
Removal.
NOTE
Record position of each fuel manifold hose for installation.
A. Remove fuel manifold hoses (20, Figure 4-2) from fuel nozzles (19)
and fuel manifold (3).
B. Remove fuel manifold (3) as follows:
1. Remove bolts (2) and gasket (4) from FMV (16). Discard gasket.
2. Remove manifold test cap (32).
3. Remove nut (33), nut (34), bolt (35), clamp (36), and bracket
(37) .
4-22
JAN/91
Installation.
A. If required, install gaskets (40, Figure 4-2),burner dra n valve
covers (39), and secure with bolts (38) with Ablube, MIL L-25681,
applied. Torque bolts to 70-85 lb in. (8.0-9.6 Nom) and lockwire
bolts.
B. If required, install fuel manifold (3) as follows:
1. Install clamD (36) on fuel manifold (31 and secure to bracket {371
with bolt (3S) and nut (34). Torquenbt to 37-42 lb in. (4.2-4.7
Nom).
2. Install manifold test cap (32) and torque to 105-115 lb in,
(11.9 -12.9 N-m).
3. Install fuel manifold (3) and gasket (4) to FMV (16) and secure
with bolts (2). Torque bolts to 70-75 lb in. (8.0-9.6 Nom) and
lockwire bolts.
4. Install bracket (37) to engine and secure with nut (33). Torque
nut to 74-89 lb in. (8.4-10.0 Nom).
4-27.
JAN/91
4-23
WATER
SUPPLY IN
=+
FUEL
METERING
VALVE
I
-----
y:;;
~1 FUELMETERINGVALVE
OUTLET PRESSUREGAGE
CONNECTION
FUELMANIFOLDPRESSURE
GAGECONNECTION
FUEL
NOZZLES
1
I
k
QHS041XD
Figure 4-4.
B. The engine has six (6) dual fuel nozzles. Each dual fuel nozzle is
secured to the diffuser and extends into the forward end of the
combustion liner.
c. Disassembling the dual fuel nozzle is not permitted at this level of
maintenance.
4-31.
Troubleshooting.
NOTE
Although the following trouble indications may be traceable to
malfunction fuel nozzle(s), other devices, and/or a combination of
things can cause the same troubles.
A. Some symptoms which can lead to a fuel nozzle inspection:
1. Frequer,t fail-to-start or slow or stagnated starts.
4-24
JAN/91
Removal.
NOTE
Cap all hoses and openings to prevent contamination.
A. Remove fuel manifold hose (1, Figure 4-5) from fuel nozzle (6).
QHH095XD
1.
2.
3.
JAN/91
4.
5.
6.
BOLT (4)
GASKET
FUEL NOZZLE
4-25
Inspection.
A. Inspect for obvious physical damage such as metal deterioration
(burns, erosion, corrosion) and cracks in the fuel nozzle body holder
and body, Damage which affects the structural integrity of the fuel
nozzle and/or which disturbs gas flow, is unacceptable.
B. Cracks between the jet holes or erosion of the holes is unacceptable.
c. Inspect the flame plated coating on the wear surface of the fuel
nozzle body. Wear is permitted if the coating is not worn through to
the base metal at any place along the axial wear surface of the body.
D. Inspect for clogged passages and jet holes.
E. Inspect for carbon deposits. If they disturb the gas path in anyway,
they will need to be removed.
4-34.
Cleaning.
CAUTION
DO NOT USE A METHOD WHICH WILL REMOVE THE FLAME-PLATED ALUMINUM OXIDE
COATING. AVOID CAUSTIC (BASE/HYDROXIDE) CLEANING SOLUTIONS.
NOTE
In order to ascertain the amount of damage, cleaning may have to
precede inspection.
A. Use light pressure with a soft cloth and petroleum solvent. If
necessary, use a carbon solvent.
B. Dry with filtered compressed air.
CAUTION
DO NOTHING WHICH WOULD INCREASE THE HOLE SIZE. IF HOSE SIZE IS
INCREASED, REPLACE THE FUEL NOZZLE.
4-26
JAN/91
Installation.
A. Apply Ablube, MIL-L-25681, to threads of bolts (4, Figure 4-5).
B. Install gasket (5) and carefully install fuel nozzle (6) and secure
with bolts (4). Torque bolts to 70-85 lb in. (7.9-9.6 Nom).
Lockwire bolts.
c. Install water injection inlet hose (2) to fuel nozzle (6). Torque
hose coupling nut to 200-250 lb in. (22.6-28.2 Nom) and lockwire.
D. Install fuel manifold hose (1) to fuel nozzle (6). Torque hose
coupling nut to 325-400 lb in. (36.72-45.19 N-m) and lockwire.
E. If required, install cap (3) and torque to 80-120 lb in. (9.0-13.5
N-m). Lockwire cap.
4-36.
4-37.
DESCRIPTION.
A. The single entry fuel system consists of all the components necessary
to receive fuel, boost it to the necessary pressure, and supply it in
the necessary metered volume and pressure to the combustion section
of the engine.
B. Components of the fuel system are mounted in various locations on or
near the engine. The components are:
Fuel pump.
;: Low pressure (LP) fuel filter with differential pressure switch.
JAN/91
4-27
FUEL PUMP.
4-40.
4-28
JAN/91
Product Name
Atlantic #1 Diesel
CITGO
CITGO
CITGO
CITGO
Gulf Kerosene
Enco
Enco
Enco
Enco
Enco
Enco
Enco
Esso
Phillips
Phillips
PhilliDs
Phil ips
Shel
Shel
Shel
Shel
Kerosene
Stove Oil
Kerosene C
Light Diesel Fuel
4-29
Product Name
76 Division Products
76 Turbine Fuel
76 Turbine Fuel
JP-5 Union Jet Fuel
76 Uniflame 1
76 Uniflame 1
Union Kerosene
J-1
J31
JS-51
M-2
M-31
M-1
0805
0820
1051
1500
1601
1001
B. The fuel entering the fuel pump passes through the boost section then
flows externally through the LP fuel filter. The bypass valve opens
only in the event of boost pump failure.
c. The fuel returns to the dual element gear section through internal
passages in the HP fuel filter. The primary and secondary gear elements normally operate in series, i.e., the output of the secondary
pump is delivered to the inlet of the primary pump. Parallel
operation of the fuel pump primary and secondary elements is provided
during engine starting to ensure a sufficient volume of fuel flow.
During start (between 2200 and 8400 engine rpm), the paralleling
valve in the HP fuel filter is energized to parallel operation.
4-30
JAN/91
DRIVE
TO DRAIN
J
1
BOOST
PUMP
(F+)
DUAL ELEMENT
GEAR PUMP
I l
II
II H I G H
I I PRESSURE
II FILTER
>
OPTIONAL
DIFFERENTIAL
PRESSURE
GAGE
(F-1)1
0-50 Psl
(O-345 KPA)
( F - 7 ) t
LOW
PRESSURE
FILTER
(F+
PARALLELING
VALVE
/ ~
[
RELIEF
VALVE
BYPASS
R=l--------------
Figure 4-6.
JAN/91
ME
I
SYMBOLS
SINGLE ENTRY
FUEL NOZZLES
F-1
F-2
F-3
F-4
F-5
F-6
F-7
F+
F-47
MANIFOLD
- - - -
PRESSURE
(F-2)~
ELECITllCAL
1
FUEL
:TERING
VALVE
FUEL
SHUTOFF
VALVE
I
METERED
e
MANIFOLD
DRAIN VALVE
@--
Uu
rt
(F-48) (F-47)
i
TO DRAIN =
COLLECTOR TANK
Figure 4-6.
JAN/91
Removal.
NOTE
The fuel pump with the HP fuel filter is removed and installed as a
complete assembly.
A. Provide containers to catch fuel drainage.
NOTE
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
B. Remove inlet fuel hose (Ref. OEMS Manual).
c. Remove LP filter return hose (6, Figure 4-7) and bypass return hose
(7) from tee (22).
D. Remove HP outlet hose (8) from elbow (21).
E. Remove LP filter outlet hose (9) from union (14).
F, Remove fuel pump seal drain hose (10) from elbow (11).
G. Cap all openings to prevent contamination.
H. Remove paralleling valve electrical connector.
I. Remove the washers (3) and nuts (2), and slide the assembled fuel
pump and HP fuel filter rearward and off as a complete assembly.
J. Remove and discard the gasket (4) and O-ring (5).
K. If fuel pump (1) and/or HP fuel filter (16) need to be separated,
remove the short bolts (17), long bolts (18) and washers (19).
Separate fuel pump and HP fuel filter. Remove and discard O-rings
(20) .
NOTE
Record position of elbow for installation.
L. If the fuel pump is to be replaced, remove union (14), elbow (11),
nut (13), and O-rings (12 and 15) for installation on the replacement
unit. Discard O-rings.
JAN/91
4-33
QHHO1OEA
1.
2.
3.
4.
5.
6.
7.
FUEL PUMP
NUT (4)
WASHiR (4)
GASKET
PACKING (O-RING)
LP FILTER RETURN IOSE
BYPASS AND RELIEF
RETURN HOSE
8. HP OUTLET HOSE
Figure 4-7.
L-34
9. LP FILTER OUTLET
HOSE
10. FUEL PUMP SEAL
DRAIN HOSE
11. ELBOW
12. PACKING (O-RING)
13. NUT
14. UNION
15. PACKING (O-RING)
16.
17.
18.
19.
20.
21.
22.
23.
24.
HP FUEL FILTER
SHORT BOLT (3)
LONG BOLT (3)
WASHER (6)
PACKING (O-RING) (4)
ELBOW
TEE
PACKING (O-RING) (2)
NUT (2)
JAN/91
Installation.
A. If fuel pump was replaced, do the following:
1. Install O-ring (15, Figure 4-7) on union (14). Install union on
fuel pump (l). Torque union to 300-450 lb in. (33.9-50.0 Nm).
2. Install nut (13) and O-ring (12) on elbow (11). Install elbow on
fuel pump (1) to position recorded on removal, do not tighten nut
(13) now.
B. If fuel pump (1) and HP fuel filter (16) are separated, do the
following:
1. Install O-rings (20).
2. Connect HP fuel filter (16) to fuel pump (1) with short bolts
(17), long bolts (18), and washers (19). Torque all bolts to 70-85
lb in. (8.0-9.6 Nm). Lockwire bolts.
c. Install a gasket (4) on the mounting flange and an O-ring (5) on the
shaft of the fuel pump (l).
D. Install the assembled fuel pump and HP fuel filter as an assembly on
the mounting studs engaging the spline drive. Secure the assembly
with washers (3) and nuts (2). Torque nuts to 140-170 lb in.
(15.9 -19.6 Nom).
E. Remove all caps.
F. Install fuel pump seal drain hose (10) to elbow (11). Torque hoses
coupling nut to 80-120 lb in. (9.0-13.5 Nm). Tighten nut (13).
G. Install LP filter outlet hose (9) to union (14). Retain union from
turning and torque hoses coupling nut to 475-575 lb in. (53.7-64.9
Nom).
H. Install HP outlet hose (8) to elbow (21). Torque hoses coupling nut
to 475-575 lb in. (53.7-64.9 Nom). If required, tighten nut (24).
I. Install LP filter return hose (6) and bypass return hose (7) to tee
(22). Torque hoses coupling nuts to 475-575 lb in. (57.7 -64.9
N-m).
If required, tighten nut (24).
J. Install inlet fuel hose (Ref. OEM Manual).
K. Install paralleling valve electrical connector and lockwire.
L. Perform an operational and leakage check.
JAN/91
4-35
-1
Troubleshootinq.
NOTE
There is no repair allowed for the fuel pump at this maintenance level.
A. Drainage of fuel from the fuel pump seal drain line indicates the
fuel pump shaft seal is leaking. Remove and replace the fuel pump.
B. Oil drainage from the seal drain indicates the seal in the accessory
drive gearbox for the fuel pump shaft is leaking. Refer to Section
9, Starter and Accessory Drive Gearbox, for replacement of the oil
seal.
C. Internal failure of one of the gear elements in the fuel pump is
indicated by slow cool starting without a temperature spike when the
fuel pump flow is shifted from parallel to series at about 9200 GG
rpm. Remove and replace the fuel pump.
4-44.
4-45.
4-46.
Removal.
NOTE
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
A. Remove the fuel pump and HP fuel filter as an assembly. Refer to
Paragraph 4-41.
4-36
JAN/91
Installation.
A. If required, install nut (24, Figure 4-7) and O-ring (23) on elbow
Install elbow on HP fuel filter (16) to position recorded on
(21).
removal. Do not tighten nut (24) now.
B. If required, install nut (24) and O-ring (23) on tee (22). Install
tee on HP fuel filter (16) to position recorded on removal. Do not
tighten nut (24) now.
CAUTION
MAKE SURE O-RINGS REMAIN IN PLACE WHEN INSTALLING HP FUEL FILTER TO
FUEL PUMP.
C. Install O-rings (20) on the fuel pump (1) to HP fuel filter (16)
mounting face and then install the HP fuel filter on the fuel pump
housing. Secure with washers (19), short bolts (17), and long bolts
(18) . Torque bolts to 70-85 lb in. (8.0-9.6 Nom). Lockwire bolts.
D. Install the assembled fuel pump and HP fuel filter as an assembly on
the accessory drive gearbox. Refer to Paragraph 4-42.
4-48.
JAN/91
4-37
Cleaning.
A. Remove special nut (10, Figure 4-8), spring clip (11), filter pack
disks (12), and washer spacers (13) from perforated tube (14).
NOTE
If contamination is found, investigate and find source of
contamination.
B. Inspect filter pack disks (12) for contamination.
CAUTION
DO NOT USE A CLOTH TO CLEAN FILTER PACK DISKS. LINT NAY CONTAMINATE
THE FILTER PACK DISKS.
NOTE
Ultrasonic
Follow
JAN/91
~HH025DA
1.
2.
3.
4.
5.
6.
7.
8.
Figure 4-8.
15.
16.
17.
18.
19.
20.
21.
PLUG
PACKING (O-RING)
SCREW (4)
PACKING (O-RING)
PACKING (O-RING)
PARALLELING VALVE
FILTER BODY
DO NOT USE A CLOTH TO DRY FILTER PACK DISKS. LINT MAY CONTAMINATE THE
FILTER PACK DISK.
F. Use filtered air in reverse direction from normal fuel flow to dry
filter pack disks (12), washer spacers (13), and perforated tube
(14).
JAN/91
4-39
4-40
JAN/91
4-51.
PARALLELING VALVE.
5-52.
S-IL
0.0151N(0.38MM)NUT
FACETOSHOULDER
MINIMUMCLEARANCE
QHH038XD
Figure 4-9.
JAN/91
4-41
Removal.
NOTE
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
A. Remove the electrical connection.
B. Remove plug (15, Figure 4-8) and allow fuel to drain. Remove and
discard
O-~ing
(16): C. Remove the solenoid coil portion from the paralleling valve (20)
D. Remove the screws (17) and the paralleling valve (20) from the f 1 ter
body (21).
E. Remove and discard the O-rings (18 and 19).
4-54.
Installation.
A. If installed, unscrew the solenoid coil portion from the paralleling
valve (20, Figure 4-8).
B. Place the smaller diameter O-ring (18) in the groove on the end of
the paralleling valve (20) seat and the larger diameter O-ring (19)
on the outer diameter of the paralleling valve seat (Ref. Figure
4-lo).
CAUTION
USE EXTREME CARE WHEN INSTALLING THE PARALLELING VALVE TO PREVENT
DAMAGE TO THE PARALLELING VALVE SEAT AND MAKE SURE THAT O-RINGS REMAIN
IN PLACE.
NOTE
The paralleling valve mounting flange will not be flush against the
filter body after final torque of screws.
c. Install the paralleling valve (20, Figure 4-8) into filter body (21)
with a paralleling valve web positioned as shown in Figure 4-10.
Install and torque the screws (17, Figure 4-8) alterna~ely in 5 lb
in. (0.6 N-m) increments until a torque of 15 lb in. (1.7 N-m) is
obtained.
4-42
JAN/91
WEB
FUEL PASSAGE
SMALL
O-RING
LARGE
O-RING
QHH047XD
Figure 4-10. Paralleling Valve O-ring
and Valve Seat Installation.
D. Install solenoid coil portion to the paralleling valve (20, Figure
4-8) and tighten the electrical connector with the index in the up
position. Lockwire solenoid coil portion to one of the screws (17).
Lockwire remaining screws together.
E. Install O-ring (16) on plug (15). Install plug and torque to 80-120
lb in. (9.3-13.5 mm). Lockwire plug.
F. Connect and lockwire electrical connector.
G. Perform an operational and leakage check.
4-55.
4-56.
JAN/91
4-43
4-58.
4-44
JAN/91
5
I
10
3 2
12 13 14
16
11
H
WI!@
1.
2.
3.
4.
5.
HEAD ASSEMBLY
DRAIN PLUG
PACKING (O-RING)
PACKING (O-RING)
FILTER ELEMENT,
10 MICRON (2)
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
PACKING (O-RING)
PACKING (O-RING)
GASKET
BAR
CASE
QHH019CA
Figure 4-11.
4-45
IJ
,y,.:
SPRING
L DEPRESSOR
(6796975)
\
= FUEL FILTER
QHT016XE
Figure 4-12. Use of Spr ng Depressor, 6796975.
DEPRESSOR
(6796975)
b. .z . . . . . . . . . . . . . . . . . ..z . . . .
PLIERS
(6796974)
.E.
..r,. . . . . . . ...rr.r. . . . . . .
7?4
FUELFILTER
QHT017XE
Figure 4-13.
C. Apply a light coat of clean engine lubricating oil to O-ring (4) and
mating diameters and install O-ring in head assembly (l).
D. Apply a light coat of clean engine lubricating oil to bar threads.
Secure case and bar assembly to head assembly with bar. Torque bar
to 200-225 lb in. (23-25 Nm). .Lockwire case and bar assembly to
head assembly.
4-46
JAN/91
4-47
28. UNION
29. PACKING (O-RING)
30. FUEL HEATING PRESSURE
REGULATOR SUPPLY HOSE
31. CONNECTOR TEE
32. NUT
33. PACKING (O-RING)
34. REDUCER
35. PACKING (O-RING)
36. ELBOW
37. NUT
38. PACKING (O-RING)
39. REDUCER (3)
40. PACKING (O-RING)
41. LF FUEL FILTER
E. Remove tee (5), nut (6), and O-ring (7). Discard O-ring.
F. Remove union (9) and O-ring (10). Discard O-ring.
4-60.
4-48
JAN/91
21
10
i?
/::
[/
-~ Ii :. >.,
/ -. ,! -<-I
=-...
&
I
28\
29\
<
30
fjii+--25
11
23
24
y=
41
31
J+--+!!?!!
, 5/
QHHO08A
Figure 4-14.
JAN/91
4-49
4-50
JAN/91
JAN/91
4-51
JAN/91
4-64.
4-65.
Removal.
NOTE
Cap
Make
sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
A. Remove pressure relief valve inlet hose assembly (1, Figure 4-15)
from adapter (4).
NOTE
If required, remove pressure relief valve outlet hose assembly (2,
Figure 4-15) from tee (3).
B. Remove pressure relief valve outlet hose assembly (2) from elbow (5).
c. Remove bolts (6), nuts (7), and pressure relief valve (10) from
mounting bracket (8).
D. Remove adapter (4) from pressure relief valve (10).
E. Remove elbow (5) from pressure relief valve (10).
F. Remove clamps (9) from pressure relief valve (10).
JAN/91
4-53
4-66.
Installation.
A. Install elbow (5, Figure 4-15) in pressure relief valve (10).
B. Install adapter (4) in pressure relief valve (10). Torque adapter to
75-110 lb in. (8.5-12.4 N+m).
C. Install clamps (9) onto pressure relief valve (10).
4-54
JAN/91
34
12
28
QHH083XA
Figure 4-15.
JAN/91
4-55
4-68.
4-69.
Removal.
CAUTION
NO FIELD ADJUSTMENTS TO THE FMV IS ALLOWED. DAMAGE MAY OCCUR FROM A
MALFUNCTION, AND/ORMISADJUSTED FMV.
4-56
JAN/91
sure fuel and electrical systems are OFF and remains OFF until
installation is completed.
Have
Installation.
NOTE
Uet O-rings with clean engine oil.
A. If required, install O-ring (19) on reducer (18) and install
assembled reducer in FMV (20). Torque reducer to 300-450 lb in.
(33.9 -50.8 Nom).
JAN/91
4-57
ELECTRICAL CONNECTOR
PRESSURE RELIEF VALVE INLET HOSE ASSY
FMV PRESSURE INLET HOSE ASSY
FMV BYPASS HOSE ASSY
METERED FUEL TO FUEL SHUTOFF VALVE HOSE ASSY
NUT (4)
[~M7E~3j4)
MOUNTING BRACKET
NUT
PACKING (O-RING)
ELBOW
NUT
PACKING (O-RING)
REDUCER
PACKING (O-RING)
TEE
REDUCER
PACKING (O-RING)
FUEL METERING VALVE (FMV)
JAN/91
Y-----
)! -y#
k+
Q&
/
Figure 4-16.
JAN/91
\*
/7
4-59
4-72.
4-73.
Inspection.
A. Remove fuel shutoff valve to manifold drain valve hose assembly (13,
Figure 4-15) from union (18).
4-60
JAN/91
Removal.
NOTE
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
A. Remove the fuel shutoff valve electrical connector (11, Figure 4-15).
B. Remove meter fuel to fuel shutoff valve hose assembly (12) and fuel
shutoff valve to manifold drain valve hose assembly (13).
NOTE
JAN/91
4-61
Installation.
NOTE
Wet O-ring with clean engine oil.
A. Install O-rings (25, Figure 4-15) and nut (24) on union (26).
B. Install union (26) in fitting (23).
C. Install pipe plug (22) in fitting (23). Tighten pipe plug.
D. Install O-rings (21) on Unions (20).
E. Install unions (20) in fitting (23).
in. (22.6 -33.8 Nom).
NOTE
If optional fuel heating system is not installed, install caps on the
recorded two unions.
F. If required, install caps on two unions (20) recorded on removal,
G. Install fitting (23) and union (26) on fuel shutoff valve to position
mark on removal. Tighten nut (24).
H. Install O-ring (19) on union (18) and install union on fuel shutoff
valve (27). Torque union to 200-300 lbs in. (22.6-33.8 N+m).
I. Install assembled fuel shutoff valve (27) to mounting bracket (8) and
secure with bolts (15), washers (16), and nuts (17). Torque nuts to
74-89 lb in. (8.4-10.0 Nom).
J. Install meter fuel to fuel shutoff valve hose (12) to union (20).
Torque hoses coupling nut to 325-400 lb in. (36.8-45.1 Nom).
K. If required, install optional heating hose assemblies (14) to unions
(20). Torque hoses coupling nuts to 325-400 lb in. (36.8-45.1
Nm).
L. Install fuel shutoff valve electrical connector (11) to fuel shutoff
valve (27). Lockwire connector.
4-62
JAN/91
4-77.
4-78.
Removal.
A. Remove manifold drain valve electrical connector (28, Figure 4-15).
B. Remove fuel shutoff valve to manifold drain valve hose assembly (13),
drain line (37), and fuel manifold (29).
c. Remove bolts (30). washers (311. nuts (32). and manifold drain valve
(33) from mounting bracket ~8)~
4-79.
Installation.
A. Install manifold drain valve (33, Figure 4-15) to mounting bracket
(8) and secure w th bolts (30), washers (31), and nuts (32). Torque
nuts to 74-89 lb in. (8.4 -10.0 N-m).
JAN/91
4-63
4-64
JAN/91
4-82.
Removal.
CAUTION
AN ATTEMPT TO REMOVE THE BOLTS WITHOUT USING A PENETRATING OIL MAY
CAUSE THE THREADS TO STRIP DURING REMOVAL.
PROVIDE ADEQUATE
C. Clean all the parts with Fed. Spec P-D-680-2 cleaning solvent
(mineral spirits), using a wire brush. If required, polish body (1)
with crocus cloth.
JAN/91
4-65
OUTER
-COMBUSTION
CASE
D
. .i
J@@
/
*~z
J6
&
$~ 3
=
& 4
6
-----+3
L--
BODY
VALVE
:: SPRING
4. GASKET
5. ADAPTER
6. BOLT (20)
7. GASKET
8. BURNER DRAIN VALVE
1.
f?
5
QHH039XD
D. Make sure that the spring (3) can move the burner drain valve freely
in the adapter (5).
E. Lightly coat the threads of the body (1) and adapter (5) lightly with
silicone (Ablube), MIL-L-25681, or antiseize compound, MIL-L-15719.
F. Light coat valve (2) and spring (3) with silicone (Adlube),
MIL-L-25681, or antiseize compound, MIL-L-15719.
G. Install gasket (4), spring (3), and valve (2) on adapter (5).
Install adapter (5) in body (1). Torque adapter to 300-350 lb in.
(34-40 N-m).
Lockwire
adapter;
4-85.
Installation.
A. Apply a light coat of antiseize compound, MIL-L-15719, or silicone
(Ablube), MIL-L-25681, to bolts (6, Figure 4-17) threads.
B. Clean the combustion outer casing to burner drain valve mounting
flange.
4-66
JAN/91
Troubleshootinq.
WARN ING
BURNING DRAIN LINES MAY BE HOT IF BURNER DRAIN VALVES ARE STUCK OPEN.
INJURY MAY OCCUR.
A. While the engine is running, feel the lower end of the burner drain
line(s).
B. If the line(s) are hot, a burner drain valve(s) is leaking and must
be cleaned, repaired, or replaced.
4-87.
Leaks
Chaffing
Wear
Damage coupling nuts (connectors)
Kinks
Twisting
Swelling
Crushing
4-88.
4-89.
JAN/91
4-67
Removal.
NOTE
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
A. Remove fuel manifold (1, Figure 4-19) from fuel nozzle (4).
CAUTION
PARTICULAR CARE MUST BE TAKEN DURING FUEL NOZZLE REMOVAL TO PREVENT
DAMAGE TO THE FUEL NOZZLE. CARBON DEPOSITS ON THE FUEL NOZZLE TIP ARE
ABRASIVE AND CAN DAMAGE THE ORIFICES IF HANDLING IS CARELESS.
B. Remove bolts (2), fuel nozzle (4), and gasket (3), using care to
avoid damage to the fuel nozzle orifices. Discard gasket.
C. Install protective caps on the inlet and outlet fittings and place
removed fuel nozzle in a protective storage case.
D. Repeat Steps 1., 2., and 3. to remaining fuel nozzles.
4-68
JAN/91
AIR SHROUD
MAINJETS
INLET A
FUELA
i
LOC~UT
%
PRIMARY SPRAY
TIP ORIFICE
AIR SHROUD
FILTER
SCRFFN
SPRING
SEAT
SPRING
PRIMARY SPRAY
TIP ORIFICE
NOZZLE TIP
ASSEMB[Y
----- . . .
/
PISTON AND
SLEEVE ASSEMBLY
I
VALVE
BODY
11SPACER
SPRING
SEAT
QHH069XA
Figure 4-18.
JAN/91
Insl)ection.
CAUTION
DO NOT DISASSEMBLE FUEL NOZZLES FOR INSPECTION. DISASSEMBLY IS NOT
ALLOWEDAT THIS MAINTENANCE LEVEL.
NOTE
Carbon deposits anywhere except around the tip and shroud indicates
leakage, which is allowed.
A. Visually inspect for excessive carbon accumulation on the fuel
nozzles.
NOTE
Some carbon deposited around the pilot spray tip and the main jets is
normal . If there is no visible damage or hot spots in the associated
combustion liners or turbine vanes as seen by borescope inspection, and
if there are no startinq ~roblems or dark exhaust smoke, the carbon is
not interfering with th~ operation of the fuel nozzle and should not be
disturbed.
B. Replace or clean the fuel nozzles if excessive smoking occurs from
the exhaust or if carbon buildup appears to be restricting or
distorting the fuel flow.
C. Warpage of the fuel nozzle air shroud or worn places through the wear
coating to the bare metal along the axial Portion of the air shroud
the fuel nozzle must be replac~d.
D. Any damage to the spray tip orifice or main jets which changes fue
flow characteristics or to the air shroud which changes air flow
characteristics or to the internal screen which is suspected of be ng
clogged the fuel nozzle must be replaced.
E. Replacement of individual liquid fuel nozzles is not allowed. A
complete bench test is necessary to accurately determine which fuel
nozzle(s) of the six are deficient. The fuel nozzles are changed in
sets of six (6).
4-92.
Cleaning.
CAUTION
DO NOT DISASSEMBLE FUEL NOZZLES FOR CLEANING. DISASSEMBLY IS NOT
ALLOWED AT THIS MAINTENANCE LEVEL.
4-70
JAN/91
;:
3.
4.
FUEL MANIFOLD
BOLT (4)
GASKET
FUEL NOZZLE
QHH084XD
Figure 4-19.
CAUTION
4-71
Installation.
CAUTION
FUEL NOZZLES MUST BE REPLACED IN A MATCHED SET. DO NOT MIX FUEL
NOZZLES WITH DIFFERENT FLOW CHARACTERISTICS SUCH AS NEW AND USED FUEL
NOZZLES OR THOSE OF DIFFERENT PART NUMBER EVEN THOUGH THEY PHYSICALLY
FIT. UNBALANCED FLOWS CAN CAUSE EXTENSIVE TURBINE DAMAGE.
A. Apply a light coat of antiseize compound, MIL-L-15719, or Adlube,
MIL-L-25681, to the threads of the bolts (2, Figure 4-19).
B. Carefully install gasket (3) and fuel nozzle (4) and secure with
bolts (2). Torque bolts to 70-85 lb in. (7-9-9.6 Nm). Lockwire
bolts.
c. Install fuel manifold (1) and torque coupling nut to 200-250 lb in.
(22.6 -28.2 Nom).
D. Repeat Steps 1. thru 3. for remaining fuel nozzles.
E. Preform an operational and leakage check.
4-72
JAN/91
4-97.
JAN/91
4-73
Removal.
NOTE
Cap
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
A. Remove flow divider inlet hose assembly (1, Figure 4-21) from flow
divider union (9).
B. Remove flow divider to pilot manifo d drain hose assembly (2) from
flow dividers tee (13).
C. Remove pilot fuel manifold (3) from tee (13).
D. Remove main fuel manifold (4) from tee (16).
E. Remove flow divider to main manifold drain valve hose assembly (5)
from tee (16).
F. Remove bolts (6), washers (7), nuts (8), and assemble mounting flow
divider valve (17) from mounting bracket (18).
NOTE
Record positions of tees for installation..
G. Remove union (9) and O-ring (10) from flow divider valve (17).
Remove and discard O-ring (10).
H. Loosen nut (11), remove tee (13), nut (11), and O-ring (12) from flow
divider valve (17). Remove and discard O-ring (12).
I. Loosen nut (14) and remove tee (16), nut (14), and O-ring (15) from
flow divider valve (17). Remove and discard O-ring (15).
4-99.
Maintenance.
A. The flow divider valve requires flow bench calibration, therefore
operator maintenance is limited to replacement.
B. When reDair or calibration is reauired. the six fuel nozzles and flow
divider valve should be calibrated andreplaced as a set.
co The most common problem with the flow divider valve is contamination
of the internal metering valve. This usually results from sticking
causing low or no main manifold fuel flow and aborted, stagnated, or
slow starts.
4-74
JAN/91
FUEL SUPPLY
Cjjl
0-50 Psl
(O-345 KPA)
}
t
TO DRAIN
1
,
1300ST
PUMP
DUAL ELEMENT
GEAR PUMP
II
ml
I
Ii
HIGH
II
PRESSURE! ;
FILTER II
COLLECTOR~
TANK
Ii
PARALLELING
VALVE
.-
PRESS ~
RELIEF
VALVE
OPTIONAL
DIFFERENTIAL
PRESSURE
GAGE
1 1 - - -
~ y+)
11~
ow
PRESSURE:
FILTER
(F-7)
I
t
(F+ I
~
BYPASS
m--
FUEL
METERING
VALVE
~
PRESSURE
METERED
(F-48) (F-47)
Figure 4-20.
JAN/91
a
v
I
I
FUEL
SHUTOFF
VALVE
(N.C.)
4-75
WATER
INJECTION
SUPPLY
SYMBOLS
CHECK
T VALVE
F-1
F-2
F-3
F-4
F-7
F-6
F+!6
F-47
F-48
w-1
F-6
NOZZLE CONNECTION
{
[
----
ELECTRICAL
1
I
MAIN
FUEL
MANIFOLD
0.061-0.063 IN.
(1.55-1.60 MM)
ORIFICE, 6 REOUIRED
/
t
j
FLOW
DIVIDER
VALVE
MANIFOLD
DRAIN
VALVE
(F-8)
l
y
e
<
4,-76
JANf 91
4-77
BOLT (3)
:;: [ll:H:~)(3)
23.
24. MOUNTING BLOCK
25. REDUCER
PACKING (O-RING)
;!: UNION
28. PACKING (O-RING)
29. NUT
30. PACKING (O-RING)
TEE
:;: PILOT MANIFOLD DRAIN VALVE
BOLT (3)
;:: WASHER (3)
35. NUT (3)
36. NUT
37. PACKING (O-RING)
38. E L B O W
NUT
:;: PACKING (O-RING)
41. ELBOW
42. MAIN MANIFOLD DRAIN VALVE
B. The pilot manifold drain valve inlet tees into the pilot fuel
manifold. The main manifold drain valve connects to the main fuel
manifold. Both manifold drain valve outlets are connected to a drain
tube which has a single outlet fitting. The drain tube outlet should
be connected to a drain collector tank. The manifold drain valves are
spring-loaded to the closed position and solenoid actuated to open by
command of the control system.
C. The control system opens the manifold drain valves immediately upon
any shutdown signal. Combustion section pressure then forces fuel
remaining in the fuel nozzles and manifolds to the drain tank through
the manifold drain valves. During starts, the manifold drain valves
are held open until engine 2200 rpm. After shutdown, the manifold
drain valves are held open by a timer for 30 seconds.
D. It is essential that the fuel manifold drains have little or no back
pressure. For this reason, the drain line must not have kinks or
other restrictions. The fluid in the drain tank(s) must not create a
head pressure causing a back pressure on the drain system.
4-78
JAN/91
QHH086XA
Figure 4-21.
JAN/91
4-79
JAN/91
manifold
NOTE
Record position of elbows for installation.
E. Loosen nut (36) and remove nut (36), O-ring (37), and e bow (38) from
main manifold drain valve (42). Remove and discard O-r ng.
JAN/91
4-81
JAN/91
sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
;:
3.
4.
5.
6.
Figure 4-22.
JAN/91
4-83
JAN/91
4-85
4-86
JAN/91
Fuel pump.
Low pressure (LP) fuel filter with differential pressure switch.
High pressure (HP) fuel filter.
Fuel pump paralleling valve.
Pressure relief valve.
Fuel metering valve.
Fuel shutoff valve.
Flow divider valve.
Pilot and main fuel man folds.
Fuel nozzles.
Manifold drain valves.
Burner drain valves.
Lines and hoses.
4-87
4-88
JAN/91
=J~~7ELuMAssEMBLy
DUAL ELEMENT
GEAR PUMP
BOOST
PUMP
+
()
(F4)
TO DRAIN
COLLECTOR
TANK
Ei%uRl EFELNGls
--
II
PRESS
RELIEF
VALVE
Unul-
1
(F+ I
EEF----
FUEL
METERING
VALVE
BYPASS
.
PRESSURE
METERED
e
UU
/t
(F+) (F-47)
I
I
Figure 4-23.
JAN/91
4-89
SYMBOLS
F-1
F-2
F-3
F-4
F-6
F-7
F-B
F-46
F-47
F-48
----
It
ELECTRICAL
PILOT
K iiRiFoL13
FLOW
DIVIDER
VALVE
MANIFOLD
DRAIN
VALVE
(F-$)
<
I 1
Figure 4-23.
4-90
JAN/91
501-KB5 DEc
OPERATION
AND
MAINTENANCE
4-91
I
Allison Engine Company
501-KB5 DEC OPERATION AND MAINTENANCE
4-128. FUEL LINES AND HOSES.
A. All flexible fuel lines furnished with the engine have an inner core
of teflon, protected by one or more layers of protective material and
a braided metal sheath. These hoses are very durable and not prone
to deterioration, however they are susceptible to damage from sharp
bends, kinks, twists and crushing. Evidence of such damage to the
teflon core is difficult to detect. If damage is suspected, the hose
must be replaced or pressure tested.
B. All fuel lines and hoses should be inspected regularly for:
1.
2.
3.
4.
5.
6.
7.
8.
Leaks
Chaffing
Wear Damage coupling nuts (connectors)
Kinks
Twisting
Swelling
Crushing
JAN/91
Make
sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
A. Remove the pilot and main fuel manifolds (1 and 2, Figure 4-25) from
the fuel nozzles.
MAINFUELINLET
/
JET
SHROUD
MAINJET1
QHHO09AD
Figure 4-24. Dual Entry Fuel Nozzle.
CAUTION
PARTICULAR CARE MUST BE TAKEN DURING FUEL NOZZLE REMOVAL TO PREVENT
DAMAGE TO THE FUEL NOZZLE. CARBON DEPOSITS ON THE FUEL NOZZLE TIP ARE
ABRASIVE AND CAN DAMAGE THE ORIFICES IF HANDLING IS CARELESS.
JAN/91
4-93
4-133. Inspection.
CAUTION
DO NOT DISASSEMBLE FUEL NOZZLES FOR INSPECTION. DISASSEMBLY IS NOT
ALLOWED AT THIS MAINTENANCE LEVEL.
NOTE
Carbon deposits anywhere except around the tip and shroud indicates
leakage, which is allowed.
A. Visually inspect for excessive carbon accumulat on on the fuel
nozzles.
B. Replacement of individual fuel nozzles is not allowed. A complete
bench test is necessary to accurately determine which fuel nozzle(s)
of the six are deficient. The fuel nozzles are changed in sets of six
(6). The flow divider valve should be replaced and sent with the
fuel nozzles for repair and calibration.
NOTE
Some carbon deposited around the pilot spray tip and the main jets is
normal.
If there is no visible damage or hot spots in the associated
combustion liners or turbine vanes as seen by borescope inspection, and
if there are no starting problems or dark exhaust smoke, the carbon is
not interfering with the operation of the fuel nozzle and should not be
disturbed.
C. Replace or clean the fuel nozzles if excessive smokincl occurs from
the exhaust or if carbon buildup appears to be restri~ting or
distorting the fuel flow.
D. Warpage of the fuel nozzle air shroud or worn places through the wear
coating to the bare metal along the axia portion of the air shroud
the fuel nozzle must be replaced.
4-94
JAN/91
4-95
/1
ill
i
f
\
6
0
b
Figure 4-25.
4-96
QHH088XD
JAN/91
JAN/91
4-97
4-139.
Installation.
NOTE
Refer to OEM Manual for installation.
4-140.
JAN/91
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
JAN/91
4-99
R- 1
R- 2
R- 3
R- 4
R- 5
R- 6
R- 7
R- 8
R- 9
R-10
R-n
R-12
R-13
R-14
R-15
R-16
R-17
4-1oo
JAN/91
m
LJOUID FUEL
SUPPLY TANK
_~17
CHECK
VALVE
El
El
..
/
FUEL
PUMP
wL&
_
FILlsn
WIl
-El
SYMEOLS
N.C.
NORMAL CLOSED
N.O.
NORMA OPEN
P/s
PREsSURE SWITCH
SIo
SHUTOFF
c1
PG >
d
R-14
<
LESS THAN
>
MORE 11w
OPSN
10 PSIG
(69 $7AGl
---{+5?
OPEN
>20P9G
(136
KPAGl
~y
P/s
LIOUID FUEL
GASEOUS FUEL
CONTROL AIR
GAGE CONNECTION POINT
Figure
4-26.
4-101
JAN/91
WEL
FILTER
- ~
LIOIAD
PAOT
MAJN
0-
1
:-
r*&.
/=
fmspp
r-
[
t
IQ
--l
, J,=. rl
N.C.
NC.
?
t
t
1 ~~
I
~Eal
SNUTOFF VAMS
I
I
El
---
If
%7-
-1
F.15
i
--0---
s
IG
1
-------
-m
4
i /:/.
t
+-&---------- d--.. ------4.. - . . ..---.-. A\
I
R.15
w+
h
-t=
El-\
I
I
a--
J
ow FUEL
RAFT
DRAW
VALVE
QHS037AK
Wl VALVE
Figure 4-26.
4-102
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
JAN/91
4-103
AllisonEngi neCompany
PACKING (O-RING)
i;: UNION
28. PACKING (O-RING)
29. HP FILTER ASSY
B
O
W
L
:;:
FILTER ELEMENT
PACKING (O-RING)
HEAD ASSY
34. INDICATOR
35. BOLT (6)
36. LOCKWASHER (6)
37. WASHER (6)
38. SCREW (2)
39. FLEXIBLE COUPLING
KEY
:;: UNION
42. PACKING (O-RING)
UNION
::: PACKING (O-RING)
45. FUEL PUMP ASSY
KEY
:!: BOLT (4)
48. LOCKWASHER (4)
49. WASHER (4)
50. MOUNT ASSY
51. MOTOR ASSY
:$
JAN/91
/ n /
9
+
11
1,>>$13
10
12
L2
QHH089XA
Figure 4-27.
JAN/91
4-105
JAN/91
I
Allison Engine Company
501-KB5 DEC OPERATION AND MAINTENANCE
NOTE
Record position of HP filter assembly for installation.
B. Loosen nut (25) and remove HP filter assembly (29) from union (41).
Remove and discard O-ring (26).
C. If required, remove union (27) and O-ring (28) from HP filter
assembly. Discard O-ring.
4-156. Installation.
A. Install O-ring (28, Figure 4-27) on union (27) and install union in
HP filter assembly (29) outlet. Torque union to 200-300 lb in.
(22.6 -33.8 Nom).
B. If required, install nut (25) and O-ring (26) on union (41).
c. Install HP filter assembly (29) on union (41) to position recorded on
removal. Tighten nut (25).
D. Install liquid fuel HP filter outlet hose (5) to union (27). Torque
hoses coupling nut to 200-300 lb in. (22.6-33.8 Nm).
E. Perform operation and leakage test.
4-157. LIQUID FUEL PUMP.
4-158. Descri~tion and ODeration.
A. The electric motor driven liquid fuel pump is the main fuel pump for
the liquid fuel system.
B. The minimum flow rate is 12 gpm (45.4 Lpm) at 500 psig (3450 kPag)
and 80F (26.7C) fuel inlet temperature at 1800 rpm electric motor
speed.
4-159. Removal.
A. Remove LP filter assembly (16, Figure 4-27) and filter to pump tube
(24) per Paragraph 4-148.
B. Remove HP filter assembly (29) per Paragraph 4-155.
C. On fuel pump side, loosen screw (38) through bottom slot on mount
assembly (50).
D. Remove bolts (35), lockwashers (36), washers (37), and assembled fuel
pump assembly (45).
JAN/91
4-107
4-108
JAN/91
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed. -
JAN/91
4-109
3.
4.
::
;:
9.
10.
11.
12.
13.
k
16.
17.
18.
LOCKWASHER (4)
;:: FUEL SHUTOFF VALVE
ELECTRICAL LEAD (2)
& METERED FUEL TO
ENGINE TUBE
23. AIR SUPPLY TUBE
24. BOLT (3)
25. LOCKWASHER (3)
26. ADAPTER (2)
27. AIR ADAPTER
28. BALL TYPE FUEL
SHUTOFF VALVE
29. ELECTRICAL JUNCTION
BOX
30. RELIEF VALVE TUBE
31. RELIEF AND BYPASS
RETURN TUBE
32. SOCKET HEAD
SCREW (2)
33. RETAINER
ADAPTER
% TEE
36. PRESSURE RELIEF
VALVE
37. PARALLEL AIR CONTROL
VALVE
38. GASEOUS PURGE
TUBE (2)
39. GASEOUS U TUBE
40. SOCKET HEAD SCREW
(8)
41. LOCKWASHER (8)
4-110
42.
43.
44.
45.
:!:
48.
49.
50.
51.
52.
53.
54.
55.
:!:
58.
59.
60.
61.
62.
63.
64.
:;:
67.
:::
70.
;;:
73.
;::
76.
77.
78.
79.
80.
CROSSOVER TUBE
TEE (3)
ADAPTER
GASEOUS FUEL PURGE
VALVE (2)
OUTLET BYPASS TUBE
SOCKET HEAD SCREW
(4)
LOCKWASHER (4)
ADAPTER (2)
OUTLET BYPASS VALVE
TEE
INCOMING FUEL SUPPLY
TUBE
HEATING BYPASS TUBE
SOCKET HEAD SCREW
(4)
LOCKWASHER (4)
ADAPTER
ADAPTER
HEATING BYPASS VALVE
LIQUID FUEL PRESSURE
SWITCH
GASEOUS FUEL SUPPLY
HOSE
ELBOW
GASEOUS FUEL FILTER
INLET PRESSURE TUBE
BOLT (4)
LOCKWASHER (4)
GASKET
NUT
PACKING (O-RING)
ADAPTER ASSEMBLY
HEX HEAD SCREW (2)
LOCKWASHER (2)
RETAINER
NUT
PACKING (O-RING)
GASEOUS FUEL FILTER
GASEOUS FUEL
MANIFOLD HOSE
ELBOW
GASEOUS FUEL TO TEE
TUBE
GASEOUS FUEL FILTER
OUTLET PRESSURE TUBE
PRESSURE SWITCH AND
GAGE TUBE
HEX HEAD SCREWS (3)
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
;!:
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
LOCKWASHERS (3)
HEX HEAD SCREWS (4)
LOCKWASHERS (4)
FLANGE
GASKET
OUTLET ADAPTER
HEX HEAD SCREW (4)
LOCKWASHER (4)
GASKET
CHECK VALVE
HEX HEAD SCREW (4)
LOCKWASHER (4)
GASKET
GASEOUS FMV
HEX HEAD SCREW (2)
LOCKWASHER (2)
ADAPTER (2)
DIFFERENTIAL
PRESSURE SWITCH
GASEOUS - PRESSURE
SWITCH TUBE
GASEOUS FUEL
PRESSURE SWITCH
HOSE CONNECTIONS
LIQUID FUEL BYPASS
AND RELIEF
AIR TO PARALLEL
VALVE (NORMALLY
CAPPED)
AIR SUPPLY
LIQUID FUEL PRESSURE
GAGE
GASEOUS FUEL PURGE
PRESSURE GAGE
GASEOUS FUEL PURGE
GASEOUS FUEL PURGE
LIQUID FUEL SUPPLY
LIQUID FUEL SUPPLY
PRESSURE GAGE
LIQUID FUEL TO
ENGINE PRESSURE GAGE
LIQUID FUEL TO HEAT
EXCHANGE OR PUMP
INLET
LIQUID FUEL TO PUMP
INLET
LIQUID FUEL TO
ENGINE
GASEOUS FUEL
PRESSURE GAGE
JAN/91
o
1
&
r015
&iiiFr6
,9,
/3 6FGfkl
El===
1
13-
3 0 \
15-
3 4 \
43
[F,
42
!5 40
A 41 /43
A/
32
33 1=
3 6 _
35
53
I
I
Cl+
101 102
r+
103 104
105
106
107
108 109
Figure 4-28.
JAN/91
4-111
11[
(CJ
\\
Q
c)
100
\
79
II
22
59
\
66 I
7A
169
70
71 72
73 61
rn
I*
1,
C)
::
ti
d4!lwh? 2T
. --- - 1
i
6
60
-.- 3---:
.+?)
*!-!
Iil
li2
li3
,
94
i
99
lb+
I
li4
Figure 4-28.
95
96
7CJ
I
75
f%
SPARES
:1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
(~
BLUE
BROWN
RED
1-
LtQUIDFUELSHUTOFF VALVES(2)POWER(+)
LIOUIDFUELBYPASS ANDUNLOADVALVES POWER(+)
GAS FUELPURGEVALVES (2)POWER(+)
LIQUID FUEL PARALLEL VALVE POWER (+)
PRESSURE SWITCHES (3) GROUND (-)
LKIUID FUEL SHUT OFF VALVES (2) RETURN (-)
L~UID FUEL BYPASS AND UNLOAD VALVES RETURN (-)
GAS FUEL PURGE VALVES (2) RETURN (-)
LK)UID FUEL PARALLEL VALVE RETURN (-)
34 *
35
36
37
38
39
1
40 [
41 ~+
42
43
44
45
46
47
48V
49
50
51
B-
BROWN
YELLOW
GREEN
VIOLET
BLUE
RED
ORANGE
BROWN
YELLOW
GREEN
VIOLET
. BLUE
--.
BLUE
BROWN
RED
Figure 4-29.
JAN/91
LIQUIDFUELSHUTOFF VALVEINLET
PRESSURESWITCHPOWER (+)
1
1\
LK2UID FMV
GAS FMV
4-113
4-114
JAN/91
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
A. Remove the two electrical leads (11, Figure 4-28) at the electrical
junction box terminals 25 and 30 (Ref. Figure 4-29).
B. Remove metered fuel tube (4, Figure 4-28) at tee (12).
C. Remove pressure gage tube (13) at tee (12).
D. Remove pressure switch tube (14) at tee (12).
E. Remove bypass valve tube (15) at tee (12).
F. Remove shutoff valves tube (16) from fuel shutoff valve adapter (17).
G. Remove bolts (18), lockwashers (19), and assembled fuel shutoff valve
(20) from RAFT bracket.
JAN/91
4-115
JAN/91
Make
sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
JAN/91
4-117
JAN/91
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
JAN/91
4-119
24.
25.
26.
27.
28.
29,
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
PACKING (O-RING) 2)
UNION
NUT
PACKING (O-RING)
TEE
NUT
PACKING (O-RING)
TEE
FLOW DIVIDER VALVE
MANIFOLD DRAIN HOSE
DRAIN VALVES CROSSOVER
DRAIN TUBE
BOLT (4)
NUTS (4)
UNION (2)
PACKING (O-RING) (2)
MAIN MANIFOLD DRAIN VALVE
BOLT (4)
NUT (4)
UNION
PACKING (O-RING)
REDUCER
PACKING (O-RING)
PILOT MANIFOLD DRAIN VALVE
NUT (4)
MOUNTING BRACKET
L. Remove union (22) and check valve (20) as an assembly from flow
divider valve (32). Discard O-ring (21). If required, remove union
(22) from check valve (20). Discard O-ring (21).
M. Loosen nut (29) and remove assembled tees (28 and 31) from flow
divider valve (32). Remove and discard O-ring (30).
N. If required, loosen nut (13) and remove nut (13), O-ring (14), and
elbow (15) from check valve (16). Discard O-ring.
O. If required, loosen nut (26) and remove nut (26), O-ring (27) and
assembled tee (28) from tee (31). Discard O-ring.
P. If required, remove check valve (23) from union (25). Remove and
discard O-ring (24).
Q. If required, remove union (25) and O-ring (24) from tee (28).
Discard O-ring.
4-120
JAN/91
8
111111/1 )
4
45 44
;-= -*=I
7
t).
JAN/91
4 0
F4?T!3
b,
**
Ii
Figure 4-3o.
JAN/91
JAN/91
The control system opens the manifold drain valves immediately upon
any shutdown signal. Combustion section pressure then forces fuel
remaining in the fuel nozzles and manifolds to the drain tank through
the manifold drain valves. During starts, the manifold drain valves
are held open until 2200 engine rpm. After shutdown, the manifold
4-123
Make sure fuel and electrical systems are OFF and remain OFF until
Installation is completed.
JAN/91
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
JAN/91
4-125
JAN/91
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
4-127
_ Make sure fuel and electrical svstems are OFF and remain OFF until
installation is completed.
A. Remove gaseous fuel manifold (1, Figure 4 31) from the dual fuel
nozzle (6).
B. Remove the liquid fuel pilot and main fue manifolds (2 and 3) from
the dual fuel nozzles (6).
CAUTION
PARTICULAR CARE MUST BE TAKEN DURING FUEL NOZZLE REMOVAL TO PREVENT
DAMAGE TO THE DUAL FUEL NOZZLE. CARBON DEPOSITS ON THE FUEL NOZZLE TIP
ARE ABRASIVE AND CAN DAMAGE THE ORIFICES IF HANDLING IS CARELESS.
C. Remove bolts (4), dual fuel nozzle (6), and gasket (5), using care to
avoid damage to the dual fuel nozzle orifices. Discard gasket.
D. Install protective caps on the gaseous pilot, and main inlet fittinqs
and place removed duai fuel noz;le in a- protective storage case. E. Repeat Steps A., B., C., and D. to rema ning dual fuel nozzles.
4-128
JAN/91
(+
2
/
QHH089XD
1. GASEOUS FUEL MAN I FOLD
2. LIQUID MAIN FUEL MANIFOLD
3. LIQUID PILOT FUEL MANIFOLD
4. BOLT (4)
5. GASKET
6. DUAL FUEL NOZZLE
4-129
DISASSEMBLY IS NOT
CAUTION
INTERNAL CLEANING OF THE FUEL FUEL NOZZLES EXCEPT AT A REPAIR CENTER IS
IMPRACTICAL BECAUSE OF THE NEED FOR A QUALIFIED TECHNICIAN SPECIALIZED
EQUIPMENT AND A FLOW BENCH TEST.
NOTE
If carbon is excessive, especially that of the hard type or if air will
not flow freely from the pilot and main passages, a faulty fuel nozzle
is indicated. Replacement of all six dual fuel nozzles are required.
External carbon buildup, especially that of the soft type, can be
cleaned, and the dual fuel nozzles can continue in service.
A. Connect clean, dry shop air to each fuel inlet fitting (gaseous,
pilot, and main). Maintain a steady flow of air while cleaning.
B. Hold the dual fuel nozzle at an attitude so that carbon, when
removed, will fall clear of the dual fuel nozzle.
C. Initially attempt to clean the tip with a cotton swab.
4-130
JAN/91
4-131
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
4-132
JAN/91
JAN/91
4-133
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
4-201.
Installation.
A. If required, install adapter (44, Figure 4-28) and tee(s) (43) on
gaseous fuel purge valve (45), to position recorded on removal.
Torque tee and/or adapter to 200-300 lb in. (22.6-33.8 N-m).
4-134
JAN/91
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
JAN/91
4-135
JAN/91
sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
4-137
4-138
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
4-139
JAN/91
Make sure fuel and electrical svstems are OFF and remain OFF until
installation is completed. -
JAN/91
4-141
4-224. Installation.
NOTE
Make sure check valve is installed to prevent reverse flow.
A. If required, install gasket (93, Figure 4-28) and check valve (90) to
gaseous FMV (94) outlet port and secure with lockwashers (92) and hex
head screws. Torque screws to 70-85 lb in. (8.0-9.6 Nom).
B. If required, install gasket (89) and outlet adapter (86) to check
valve (90) and secure with lockwashers (88) and hex head screws
(87) . Torque screws to 70-85 lb in. (8.0-9.6 N-m).
C. If required, install gasket (85), elbow (76), and flange (84) to
outlet adapter (86) and secure with lockwashers (83) and hex head
4-142
JAN/91
JAN/91
4-143
4-144
JAN/91
JAN/91
4-145
sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
Cap
JAN/91
Make sure fuel and electrical systems are OFF and remain OFF until
installation is completed.
JAN/91
4-147
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
NUT
BRACKET 90
GASEOUS MANIFOLD BRACKET
BOLT (3)
WASHER (3)
NUT (3)
ENGINE BRACKET
NUT (3)
WASHER (3)
BOLT
NUT
CLAMP
BRACKET
JAN/91
d
10
11
12
13
14
5
~ +4
lh-
8
9
h-l
I__ -
I
9
BOTTOM
VIEW
QHH091XA
Figure 4-32.
JAN/91
4-149
JAN/91
r--l
I
1
I
I
TOW R-13
J4zl
CNECK
VALVE
O-i
s
I
I
I
-9
I
I
MANIFOLODR41N
VPMISNC
-!
F-15
1
TO llA~ %
- - - - ---- 9-- ---.
R-7
-O-----TO RAW
- 1-
L .
*
Figure 4-33.
JAN/91
4-151
DRAIN
wvE
* CHECK
ORIFICES
I
I
1
I
t
:-1.9
1
$
I
t t
I
1
SYMBOLS
F-18
*
IN.IECT!ON SYSTEM
--
F-52
G
QHS042AK
Figure 4-33.
4-152
:;::;
~
syw~Y
BREATHER
.~ C A P
--l
FUEL HEATING T/C
MAINTAIN 130-1500 F
(54.4=65.63 c)
PRIOR TO START
+
1
. -
FUEL
HEATER
LIQUID FUEL T
HEATING BYPASS
VALVE
N.O. i
I
I
.- --
El
HIGH
PRE;:IRE
R+ ##iDN~~h
In
/
1
1 /
~~\!$&!kIEL
~
1
FUEL
PUMP
/
n.
F-6
DIFFERENTIAL
PRESSURE SWITCH
>5 PSID (34.5 KPAD)
m
F-7
JAN/91
4-153
t
---
R-1
R-6
R-II
R-1 2
R-13
R = RAH
LIQUID FUEL BYPASS AND RELIEF RETURN
LIQUID FUEL SUPPLY PRESSURE (FROM FUEL PUMP)
LIQUID FUEL HEATING BYPASS VALVE OUTLET
LIQUID FUEL OUTLET BYPASS VALVE OUTLET
LIQUID FUEL TO ENGINE
SYMBOLS
)-HI
- -- --
-4I
R
s
F-1
F-6
F-7
F-6
F-16
F-17
1
I
I
LIQUID FUEL
OU;~W;3Y~ASS
..
t
t
I
/mF
?&
s
N.C.
BALL
V A L V E
N.C.
v
LIQUID FUEL
1
SHUTOFF VALVES I
FLOW
DIVIDER
fl-11-l;(
TO MAIN
MANIFOLD
QHif082XK
Figure 4-34.
4-154
* BREATHER
. . . CAP
k 4
-J /
*FUEL
HEATER
*RELIEF VALVE
1 40-50 PSI (276345 KPA)
TO DRAIN
COUEECJOR
*GAGE
OPTIONAL ~
DIFFERENTIAL
PRES::RE
(FL
*GAGE
*BACK PRESSURE
REGULATOR
20-30 PSI (13B-207 KPA)
\
F,
~.
OPENFORCIRCl
PRIORTOSTART
CLOSEDDURING
STARTINGANDF
*OPTIONALFUELHEATING COMPONENTS
JAN/91
of
2).
4-155
DIJAJ:LflvlJvlpJT
II
1!
(F-7)
q
(F-46)1
1- -
BYPASS
FUEL
- METERING
VALVE
METERE[
(F-46)
VES
KIJLATION
~RT.
NG ENGINE
DRUNNING
~
P R E S S U R E , ,
MAINTAIN131.IOF I
J-L
s
+
VALVE
,hl n ,
. . . . . . . ..- I FUELSYSld I
TO 150F (54.5 C
TO~6W~~P10R
.
(F-47) I
(JHS044XK
Figure 4-35.
4-156
Description
Paqe No.
5-1
5-2
5-2
System Components
5-3
5-3
5-3
5-4
Thermocouples (T/C)
5-5
5-5
Harness
5-8
INDEX TO FIGURES
Fiqure No.
Paqe No.
5-1
Thermocouple
5-3
5-2
5-4
5-4
Thermocouple Circuits
5-6
5-3
5-4
JAN/91
Title
5-1
5-2
JAN/91
1.
THERMOCOUPLE ASSEMBLY
2. CHROMEL NUTS
3. ALUMEL NUTS
4.
SENSING PROBES
QHI025CD
Figure 5-1.
5-2.
Thermocouple.
SYSTEM COMPONENTS.
A. Thermocouples (12).
B. Inner thermocouple averaging harness.
c. Outer thermocouple averaging harness.
D. Thermocouple harness terminal block and bracket.
E. Associated brackets and clamps.
5-3.
CAUTION
EXERCISE CARE AS THE THERMOCOUPLE STUDS ARE OF ALUMEL AND CHROMEL
MATERIAL AND LOW STRENGTH, DAMAGE TO STUDS MAY OCCUR.
JAN/91
5-3
1,
6.
Figure 5-2.
QHI027XD
Figure 5-3.
5-4
JAN/91
THERMOCOUPLES (T/C~.
A. Description.
1. The twelve (12) thermocouples (T/Cs) have bas tally alumel (AL)
and chromel (CR), ISA type K junctions. The T/C probes are
exposed to the hot exhaust gasses.
2. The design of the T/C is such that it holds and protects the
sensing probes while it controls and directs the hot exhaust
JAN/91
5-5
&(&y~
LEFTHAND4
TERMINALS
L REAR
RIGHTHAND
TERMINALS
QHI029XD
JAN/91
5-7
2. Instal
T/C in support.
HARNESS.
A. Description.
1. Terminal connectors for the T/Cs, 12 pair of chromel (CR) and
alumel (AL) (CR and AL terminals are of different hole size with
the CR being the smaller).
2. Internal Type K wiring to connect the 12 inputs in parallel thus
providing an average output signal.
3. An output connection pair of CR and AL terminals.
4. The wires are sheathed in a wrapping shield with inconel wire
braid on the exterior.
B. Removal.
CAUTION
EXERCISE CARE AS THE T/C STUDS ARE OF A LOW STRENGTH ALUMEL AND CHROMEL
MATERIAL. DAMAGE TO STUDS MAY OCCUR.
1. Disconnect the harness from the T/C terminal block (located on the
engine at the diffuser aft flange) and from individual T/Cs studs
per Paragraph 5-4, Step C. (Ref. Figures 5-1 and 5-2).
2. Remove or loosen the clamps holding the harness.
C. Inspection and Checks.
1. Check for outer braid for evidence of wear. Replace if areas are
worn through.
2. Check for deteriorated or missing insulation at the breakouts
(near connections to T/C studs and to terminal block studs).
5-8
JAN/91
JAN/91
5-9
Paqe No.
6-1
Description
6-3
6-2
Caution
6-16
6-3
Front Handles
6-16
6-4
6-16
6-5
6-16
6-6
6-17
6-7
6-17
6-8
6-17
6-9
6-18
6-10
6-22
6-11
6-22
6-12
Status Lamps
6-25
6-13
6-27
6-14
6-27
6-15
JAN/91
Descri~tion
6-30
6-16
Motoring
6-30
6-17
Starting Engine
6-30
6-18
Stopping Engine
6-30
6-19
6-30
6-20
6-31
6-21
6-32
6-22
Fault Log
6-34
6-1
Description
Paqe No.
6-23
Dumb Terminal
6-35
6-24
6-35
6-25
6-35
6-26
6-36
6-27
6-39
6-28
6-39
6-29
6-39
INDEX TO FIGURES
Fiqure No.
Title
Paqe No.
6-1
6-12
6-2
6-13
6-3
6-19
6-4
6-20
6-5
6-21
6-6
6-23
6-7
6-24
6-8
6-26
6-9
6-28
6-10
6-29
INDEX TO TABLES
Table No.
6-1
6-2
Title
Dumb Terminal Access Adjustments
Paqe No.
6-37
JAN/91
CONTROL SYSTEMS
6-1.
6-3
6-4
JAN/91
JAN/91
6-5
START switch.
STOP switch.
MOTOR switch.
GOVERNOR switch.
FUEL SELECT switch.
AUTOSHUTDOWN Reset Input.
5. Sequencing Relays.
NOTE
. The DCA will operate seven (7) sequencing relays to control the
ignition, starter, and liquid and/or gaseous fuel systems.
. The outputs are provided by the 16 Way Output Relay Module. The 7
relays are:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
JAN/91
I
Allison Engine Company
JAN/91
6-7
6-8
JAN/91
6-9
JAN/91
6-11
MANUAL OPERATING
SWITCHES
STATUS
LAMP
SIGNALS
SETPOINT POT
INPUTS
DIGITAL
CONTROL
ASSEMBLY
(DCA)
PROCESS
CONTROL
INPUT
FUEL METERING
VALVE(S)
z~ : SEQUENCING
RELAYS
ENGINESENSORS
LOADSENSORS
SEQUENCING
RELAYS
DIGITAlfSERIAL
INTERFACE
Fwv
I
CONTROL
ADJUSTMENTS
MODE
SELECTIONS
OPERATION
ANDFAULT
MONITORING
QHI053AA
Figure 6-1.
6-12
JAN/91
FUEL DIFFERENTIAL
PRESSURE SWITCH
LOW PRESSURE
F~ELFILTER
-----q
PARALLELING VALVE
DIRECTLY DRIVEN BY DCA
LIC2UID FUEL
P#;L&:
PRESSURE
WITCHES
IL
CIT
11
POSITION. Ov
DEMAND .15 V-15VOV
THERMIXOUPLE ~~) s
J7 ~1
If
u:
J6 J5
Figure 6-2.
Ji
J3
Jz
DIGITAL CONTROtASSEMBLY (DGA)
L
~
v
I
gital E l e c t r o n i c C o n t r o l S y s t e m S c h e m a t i c .
6-13
VIMATIC+4
Cl-l SENSOR
PILOT
M AIN
MANIFOLO
DRAIN VALVE
MANIFOLO
DRAIN V A L V E ,
-cd
_.
FUEL
, Cb
) METERING
VMVES(S) ~Q
TOT
THERMOCOUPLES
FUEL
SHv;;;~F
-...
:J~
Q
Ssracmxm
l?
~mw
II
iv
MONITORING
CWER OUTPUT
To
ACTIVATE
ACCESSORIES
SWITCHES INPUT
u u
vmRATlcl
SIGNAL
: (-m) SIGNAL
WARNING
LIGHTS
CONTROL
PANEL
CONTROL
RELAYS
$D $T ,:,
L1
START
.
wIsoc
ADJUSTMENT
POTS
lr
OPTIONAL
THERMOCOUPLE
SPREAD
MONITOR
VIBIIATION
AMPLIFIER
t.&iSTER
SWTTCH
S P E E D CAITIT W
CONTROL CONSOLE
Figu e 6-2.
6-14
QHI045XK
JAN/91
JAN/91
6-15
CAUTIONS.
NOTE
The following cautions must be observed.
6-3.
FRONT HANDLES. The front mounted handles on the card frame were not
designed for carrying the DCA. They are intended for extending the DCA
from a rack which uses slide rail mounting.
6-4.
6-5.
6-16
JAN/91
POWER SOURCE GROUNDING. The DCA must be properly grounded for safe and
reliable operation. It is necessary to maintain the DCA ground at the
same potential as earth ground. This is achieved by connecting the OV
terminal on the rear of the DCA to a suitable earth ground, e.g. utility
power neutral.
6-7.
DESCRIPTION OF DCA.
A. The DCA is mounted in a nineteen (19) inch rack and consists of six
(6) individual modules which slide into the card frame. Five (5)
unused module slots exist on the DCA for the 501-KB5 engine.
B. The front and rear views are shown in Figures 6-3 and 6-4. It is
important to note that each module has one or more cable connectors
installed on the front. These cables then enter the lower front of
the chassis and are internally connected to the electrical connectors
on the back of the DCA.
c. The Power ON and OFF switch is found on the front of the DCA, on the
lower right of the front panel. This is a protective circuit
breaker, as well as the control power ON and OFF switch. The nearby
red lamp (Input Supply) is not affected by the operation of this
switch. This lamp indicates that 24 volts dc power is provided to
the DCA from the external power source.
D. When the Power switch is in the ON position the electrical power is
provided to the DCA power supply regulation unit located at the back
of the DCA. There are two additional power supply lamps on the DCA
that are found on this power supply regulation unit and an additional
circuit breaker. The red 24V Input lamp and the yellow POWER SUPPLY
ON lamp will be ON (illuminated) when the front panel power switch is
ON. The yellow lamp will not be ON (illuminated) if the power supply
circuit breaker trips open.
E. There is one potentiometer (POT) on the lower left of the card frame
that is marked Trim A, This adjustment POT is not used in this
application.
F. All lamps (LEDs) on the front of each module are red in color.
Although this manual notes that some lamps will not be used, it is
not unusual to observe a brief illumination of any lamp. This
flickering may occur due to switching transients as the DCA is first
powered.
6-8.
JAN/91
6-17
6-18
JAN/91
Figure 6-3.
JAN/91
6-19
MAGNETIC
CIRCUIT BREAKER
WARNING
ISOLATE24V DC
I SUPPLY EMWHERE
c
\(
\
BACK PLANE
POWER SUPPLY
DCAPOWER
INPUT
CONNECTOW
QHI059XA
Figure 6-4.
6-20
JAN/91
ENGINE
SPEED
INPUT
, /
UVPROMS \
SERIAL
INTERFACE
RS232C124V ~
AM
LINKCH
EEPROM
MICRO
PROCESSOR
GiD-
D
-01
MEMORY
LINKS
~ TIME
LINK
QHI060XA
Figure 6-5.
JAN/91
6-21
6-11.
6-22
JAN/91
LIGHTS
(NOT USED)
PLUGS
+ 12 VISOL CDT
-2vsL~
m
RELAY AND
INDICATOR
LAMPS
DRIVE OUTPUT
- SYSTEM HEALTHY
- WARNING
-AUTOSHUTDOWN
{15 PINS)
E
T
12i-1-FiB
1=
Pm
L~
1-
1-
1-
11-
CONDITIONED
ENGINEANALoG
SIGNALS INPUT
(64 PINS)
,/
/=
,-
u
T
1=
[
I
NOT usED
LATCH
Figure 6-6.
JAN/91
6-23
L!l
UP TO 3 FUELVALVE DRIVE
CONTROL OUTPUTS
ON LINE
LIGHT
Kc
lNPLJl
CONNECTORS
m
THERMOCOUPLES
HARNESS INPUT ~
QHI062XA
Figure 6-7.
6-24
Status Lamps.
A. The 16 Status Lamps are all red in color and when illuminated
indicate that the related relay has been act vated. These lamps are:
Al
;:
;:
:!
A8
;;
::
B5
B6
B7
B8
6-25
11111=J2?!?
Al
A2
A3
A4
A5
A6
A7
A6
B1
B2
B3
B4
B5
B6
B7
B8
ouTPur
CONNECTOf
P
D
y
m
cl-!!
.$
.
.
.
;>:
.*,
>
:, ,
.,
.:,
. ,,
,
:>:
OUTPUTS
TO RELAYS AND DCA
STATUS INDICATOR LAMPS
IN CONTROL CONSOLE
..
,.
>
QHI055XA
Figure 6-8.
6-26
6-27
CHANNEL
LINK
CHANNEL 2
LINK
Dm
Our!=ur
XWNECTOR
4 ANALOG SIGNALS TO
DRIVE N METER, CALTIT METER,
TOT METER, AND A SPARE ~
(6-20mA OR O-1OV)
II
CHANNEL 3
LINK
CHANNEL 4
LINK
II.
*
o
000
do
F
Figure 6-9.
6-28
JAN/91
1QHI063XA
Figure 6-10.
JAN/91
6-16. MOTORING.
A. Motoring the engine may be desired for purging the air intake,
engine,-and exhaust system of residual natural gas, for low speed
mechanical tests, or for compressor cleaning. The Motoring Switch
must be held closed to facilitate motoring. When motoring, the
starter circuit is allowed to be energized, but the fuel and ignition
systems are not energized. Motoring will continue until terminated
by the motoring timer or the Motoring Switch is released (opened).
The motoring timer is adjustable. The Motoring Output status light
(B6) on the 16-Way Relay Output Unit will be ON (illuminated).
B. The engine can be started from the Motoring mode if the engine speed
is not above 2200 rpm. If above engine 2200 rpm, the start signal is
ignored.
c. Following any automatic shutoff by the motoring timer, the Motoring
Switch must be reset to OFF to permit additional motoring.
6-17.
STARTING ENGINE.
A. The engine is started by momentarily closing the Start Switch. A
start is allowed if the Rundown Timer has expired, if the engine
speed is below 2200 rpm, and if no autoshutdown or malfunction
signals are present.
B. The Reset Switch will reset any autoshutdown or malfunction signals.
6-18.
STOPPING ENGINE.
A. The engine is stopped by momentarily closing the Stop Sw tch. This
command supersedes all other commands and initiates fuel shutoff.
The Rundown Timer is then activated.
B. The, engine may also be stopped by an Autoshutdown, in which the
operator has no control. An Autoshutdown signal would be generated.
Any Autoshutdown will require pressing Reset before a restart.
6-19. OPERATING MODES AND MODULATION OF ENGINE POWER. The DCA can allow
engine operation in these modes: isochronous (ISOL) speed governing,
droop speed governing, process control, temperature control, KW (power)
control. Since each engine installation is different, not all of these
modes will be used.
A. ISOCHRONOUS SPEED GOVERNING. Isochronous mode is used where constant
speed and variable load is encountered, as in a stand alone or stand
by generator set. The Governor Selection Switch must be in the
6-30
JAN/91
6-31
ndicates an
JAN/91
JAN/91
6-33
FAULT LOG.
A. The DCA ncludes a running Fault Log storage in the computer memory
that can be examined to determine the specific faults detected that
produced a Warninq indication or an Autoshutdown. The loq is keyed
to a start event ~nd records all Warnings that have occur~ed fro~ the
start to a shutdown. The fault log also indicates whether the
shutdown was a normal shutdown or if it was an Autoshutdown, it
records which one occurred.
B. The Fault Log can be accessed while the engine is running or
stopped. Approximately 10 start and stop log events will be
available for viewing.
c. The Fault Loq is accessed via the RS232 V24 serial data Dort of the
DCA or CPU. Either the connector on the back of the DCA(J1) or the
connector on the front of the CPU Unit (V24) may be used for
connection to appropriate digital monitoring equipment.
D. Two types of digital monitoring equipment which may be used are:
6-34
JAN/91
DUMB TERMINAL.
A. The following is an exp- anation of the procedure to follow for
accessing the Fault Log with a dumb terminal connected to the serial
data port.
B. The log is displayed by simply pressing L (uppercase only). The CRT
will then display the log of the most recent start. It may look like
this:
********** ALLISON 501-KB5 EVENT LOG START #0056
WARNINGS
CIT PROBE FAILURE
N1 PROBE FAILURE
SHUTDOWN
NORMAL STOP
be
SHUTDOWN
OVERTEMP AT START
6-25.
JAN/91
6-35
Baud Rate:
Parity:
Data Bits:
Stop Bits:
Data Type:
9600
None
8
1
ASCII
c. With the dumb terminal connected to the RS232 port, power up the
DCA . After any power up, fault reset, or operation of the return
key, hereafter referred to as (RET), the following sign on message
should appear on the screen:
COMMAND >H>
D. Before any parameter adjustment can be done, the correct access code
must be entered by typing AC PAS] followed by a return.
E. A parameter adjustment is performed by entering CR ###=XXXX. Where
### represents a register number given on the following table, and
XXXX is the hexadecimal representation of the desired new value.
6-36
JAN/91
.Parameter
Name
20
10
;:
27
29
35
36
JAN/91
. . . . . .
. . . . . .
. . . . . .
. . . . . .
. . . . . .
. , . . . .
.,...,. .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
18432
24725
13672
23400
20211
32767
768
1908
160
4096
218
166
-87
1299
2899
279
5799
307
307
500
8
-154:
-2454
512
366
3316
1
-22;:
524
373
3376
3
102
1
-327
-327
-327
1
1
1024
4
0
0
4096
21:
154
32i~
3277
3277
307
307
6-37
6-38
3. s =
4. /
JAN/91
ADJUSTMENTS WITH A HAND HELD UNIT. A portable hand held unit can also
be used to perform control adjustments. The procedure to be followed is
identical to that described above for a dumb terminal unit.
6-28.
6-29.
JAN/91
6-39
Description
7-1
7-3
7-2
Lubricating Oils
7-4
7-3
7-1o
7-4
7-15
7-5
Servicing
7-16
7-6
7-18
7-7
7-18
7-8
7-18
7-9
Removal
7-18
7-1o
Cleaning
7-21
7-11
Installation
7-21
7-12
7-13
7-14
7-15
7-21
7-21
7-22
7-22
7-16
7-22
7-17
Removal
7-23
7-18
Installation
7-23
7-19
7-23
7-20
7-23
7-21
Removal
7-23
7-22
Installation
7-24
7-23
JAN/91
Paqe No.
7-24
7-24
7-24
7-25
Removal
7-24
7-26
7-25
7-1
Description
Installation
7-27
7-28
Paqe No.
7-26
7-27
(Scavenge Pump)
7-29
7-27
7-30
Removal
7-27
7-31
Installation
7-29
7-32
7-29
7-33
7-29
7-34
Removal
7-30
7-35
Inspection
7-30
7-36
Installation
7-31
INDEX TO FIGURES
Fiqure No.
Paqe No.
7-1
7-5
7-2
7-7
7-3
7-17
7-4
7-19
7-5
7-20
Chip Detector
7-6
7-26
7-7
7-28
7-8
7-32
7-9
7-33
INDEX TO TABLES
Table No.
7-2
Pacie No.
7-1
Lubrication Oils
7-9
7-2
Oil Leaks
7-11
JAN/91
501-KB5
DEC
OPERATION
AND
MAINTENANCE
SECTION 7
ENGINE LUBRICATION SYS EM
7-1.
JAN/91
7-3
LUBRICATING OILS.
A. The engine and engine driven components are sometimes supplied by
different oil systems. Other times they are suDDlied bv a common oil
system. Oils m~st conform to one of th; following specifications for
the engine.
1. MIL-L-23699
2. Allison Gas Turbine Specification EMS-53
Synthetic
Synthetic
CAUTION
MINERAL OIL MUST NOT BE USED IN THE ENGINE. DAMAGE TO THE ENGINE WILL
OCCUR.
CAUTION
LUBE OILS WHICH MEET THE REQUIREMENTS OF ANY ONE OF THE OIL
SPECIFICATIONS MAY NOT NECESSARILY PERFORM SATISFACTORILY IN THE
ENGINE. THEY MAY CAUSE SEVERE COKING IN THE ENGINE AND RESULT IN
BEARING FAILURE. TO BE FULLY QUALIFIED, THE OIL MUST MEET REQUIREMENTS
OF THE SPECIFICATION AND HAVE COMPLETED A SATISFACTORY SERVICE
EVALUATION IN THE ENGINE (REFER TO INDUSTRIAL ENGINE BULLETIN 8-GT-84).
B. Lubricants which are fully qualified for use in the engine are listed
by oil brand name and vendor (Ref. Table 7-l).
7-4
JAN/91
MAGNETIC
CHIP
DETECTOR
RE:~JING
PRESSURE PUMP J
PRESSURE OIL
Figure 7-1.
JAN/91
7-5
~TRBINE FRONTSIJMP
TURBINE REAR SUMP 1
L TURBINE REAR
SCAVENGE PUMP
B, SCAVENGE OIL
QHJO16XK
Figure 7-1.
7-6
JAN/91
SYMBOLS
A-2
0-1
o-2
o-3
o-7
o-8
CHIP
PUMP
1?
D3 fl
PSIG
KPAG
GPM
34.5
89.7
124.2
379.5
1.0
4.5
6.0
13
18
55
LPM
DRAIN-PLUG
3.8
17.0
22.7
PRESSURE
PUMP
3
>-Q
A
/
{
/
f
HI
.
3
PF
PI
MOUNTED
ENGINE
. .
-- --
BASE MOUNTED
CHECK
VALVE
/
REWIRED IF OIL COOLER IS
HIGHERTHANSCAVENGE OIL
RETURNPORT
Figure 7-2.
JAN/91
7-7
2
\
<
TURBINE
SCAVENGE
PUMP
A
COMPRESSOR
REAR SUMP
&
S C A V E N G E -- ;
PRESSURE
:ENGE
ELEF
/l\
EXTERNAL
SCAVENGEPUMP
TURBINE
FRONT
SUMP
SUMP
TOCOMPRESSOR
REARBEARING
TOCOMPRESSOR
INLETHOUSING
L:~:::sORyL&l%rRrNG
1
!
1
n
o-1
PRESSUREREGULATOR
(55 PSIG)
SHAFT
-i. .----- --
.. -- - -- - -
--
--
ENGINE MOUNTED
-- --
--
BASE MOUNTED
L
SYSTEM
ENGINE OIL SUPPLY (O-5 PSIG, 4.S-6.0 GPM)
I
+
Figure 7-2.
7-8
OKRnnac
JAN/91
Lubrication Oils.
Iroup
lumber Oil Brand Name
Vendor Name
CAUTION
OILS WITH DIFFERENT GROUP NUMBERS SHOULD NOT BE MIXED. SYNTHETIC AND
MINERAL OIL SHOULD NEVER BE MIXED. DAMAGE TO THE ENGINE WILL OCCUR.
NOTE
Oils within any one group number may be mixed. Oil from different vendors
with same group numbers are rebrands of the same oil and can therefore be
mixed. Oils from different group numbers should not be mixed.
9
9
9
10
11
;:
Castrol 5000
Castrol 580
Burmah-Castrol Company
Castrol Research Laboratories
Whitchurch Hill, Pangbourne
Reading, Berkshire RG8 7QR
Engl and
JAN/91
7-9
7-1o
JAN/91
Probable Source
1.
Replace gasket.
2.
Vent assembly to
air inlet splitline
Main oil
.pump-to-accessory
gearbox splitline
JAN/91
7-11
Leakaqe
Probable Source
3.
4.
5.
Accessory gearbox
cover-to-accessory
gearbox body
splitline
6.
Puddle of oil in
bottom of inlet
housing
7.
8.
External scavenge
pump oil tube
splitlines
Pump connection
Diffuser connection
O-ring
9.
7-12
External scavenge
pump spl itline -
JAN/91
Probable Source
Check compressor
seal vent system. See
No. 6 Leakage above.
NOTE
If oil leakage is enough to coat the compressor bleed valves with oil,
then the engine instruments should be monitored to detect low power
level . Refer to operating limits, Table 1-1, and clean the compressor
when the compression ratio decreases below recommendation. Refer to
Section 10, Compressor Section.
No external repair.
Remove enaine for rei)air.
11.
Diffuser side
vents (can have
breather spew
also). Engine
running should be
continued unti
repaired.
12.
Bottom turbine
inlet casing
struts. En~ine
running should be
discontinued until
repair is done.
Indicates malfunction
Remove engine or turb ne
at front turbine posifor repair.
tion of one of the
following:
(1) Metal O-ring gasket
between inner combustion
casing and turbine
bearing support.
(2) Turbine scavenge tube
out of diffuser connection.
(3) Front turbine bearing cage
vent holes plugged with carbon.
(4) Excessive clearance
in labyrinth seal(s).
(5) Blockage of breather
system.
13.
JAN/91
7-13
Leakaqe
Probable Source
14.
Power takeoff
housing-to-gearbox
splitline
15.
Power takeoff
housing-to-speed
sensor pickup
splitline
16.
Power takeoff
housing-to-engine
inlet housing
splitline
17.
Speed sensitive
valve drain holes
(located immediately forward of
mounting flange,
90 apakt.
18.
19.
Compressor bleeds
5th, 10th stage
20.
7-14
JAN/91
20.
7-4.
Leakaqe
Probable Source
JAN/91
If the external oil system filter failed in such a way that the
contaminant has passed through, then the entire exter~al oil system will
require cleaning. This could include such things as the heat exchanger,
oil cooler, valves, fittings, hoses, piping and oil tank. (Ref. OEMs
Manual.)
7-15
SERVICING.
NOTE
In addition to the instructions of this manual regarding the servicing
of the engine oil system, refer to the OEMs Manual for servicing the
oil system external to the engine.
A. Drain all oil from the engine system. Remove magnetic drain plug
from fitting in bottom of accessory drive gearbox to drain the sump.
Remove scavenge line from lower left of diffuser to drain diffuser
sump.
B. Service the main oil tank with the required amount of oil conforming
to Allison Specifications for Synthetic Oils. (Ref. OEMs Manual.)
NOTE
When excessive oil consumption is suspected, refer to Paragraph 7-3 for
oil leaks and reps rs.
7-16
JAN/91
CLEAN
Figure 7-3.
JAN/91
HAIR LIKEACCUMULATION
QHJO08XD
Hairlike Metal Particles.
7-17
7-7.
7-8.
7-9.
Removal.
A. Disconnect electrical connector from the magnetic chip detector.
WARN ING
TRICRESYLPHOSPHATE (TCP) AND SOME OF THE OTHER ORGANIC ADDITIVES IN THE
SYNTHETIC OILS ARE READILY ABSORBED BY THE SKIN AND ARE HIGHLY TOXIC.
ANY PART OF THE BODY THAT COMES IN CONTACT WITH THESE OILS SHOULD BE
CLEANSED AS SOON AS POSSIBLE.
B. Remove the nuts (11, Figure 7-4) and washers (12) securing the oil
inlet and oil lines (14 and 15) to the main oil pump (7) and remove
the oil lines. Remove and discard gaskets (13). Cap all openings to
prevent contamination.
7-18
JAN/91
\ -i2
11
1. NUT (6)
9.
PACKING (O-RING)
2. WASHER (6)
4. PACKING (O-RING)
5. NUT (8)
6. WASHER (8)
8. GASKET
QHJ018XD
Figure 7-4.
JAN/91
1. VALVE CAP
6. VALVE STEM
2. PACKING (O-RING)
7. VALVE POPPET
90 PACKING (O-RING)
5. VALVE SPRING
QHJO06XD
Figure 7-5.
7-20
7-1o.
Cleaning.
A. Use mineral spirits, AMS 3160, or equivalent and allow to air dry.
B. Visually inspect for damage.
7-11.
Installation.
NOTE
Het O-ring and gasket with clean engine oil before installing.
A. Install O-ring (9, Figure 7-4) on the main oil pump (7) and gasket
(8) on the accessory drive gearbox (10) cover mounting flange. .Then,
install the main oil pump (7) and secure with nuts (5) and washers
(6). Torque nuts to 74-89 lb in. (8.4 -10.0 Nm).
B. Install oil inlet and outlet gaskets (13). Install the outlet and
inlet lines (14 and 15) to the main oil pump and secure with nuts
(11) and washers (12). Torque nuts to 74-89 lb in. (8.4-10.0 Nom).
C. Install magnetic chip detector electrical connector and lockwire.
7-12.
7-13.
JAN/91
7-21
7-22
JAN/91
Installation.
A. Install O-ring (9, Figure 7-5) onto magnetic chip detector (8).
B. Install magnetic chip detector and O-ring into main oil pump. Torque
to 240-300 lb in. (27.1 to 33.9 N*m) and lockwire.
7-19.
7-20.
7-21.
Removal.
A. Remove magnetic drain plug and O-ring. Discard O-ring.
B. Clean with clean cloth.
C. Inspect (Ref. Paragraph 7-5, Step C.).
JAN/91
7-23
Installation.
A. Install O-ring onto magnetic drain plug.
B. Install magnetic drain plug and O-ring into accessory gearbox
housing. Torque to 240-300 lb in. (27-34 N-m) and lockwire.
7-23.
7-24.
7-25. Removal.
A. Remove nuts (1, Figure 7-4) and washers (2).
NOTE
If oil filter assembly will not come out of accessory drive gearbox, use
jackscrews in the jackscrew holes (9, Figure 7-6).
B. Remove oil filter assembly (3, Figure 7-4) and O-r ng (4) from the
front of the accessory drive housing (10).
7-24
JAN/91
WARNING
MINERAL SPIRITS ARE TOXIC. ANY PART OF THE BODY THAT COMES IN CONTACT
WITH THESE MINERAL SPIRITS SHOULD BE CLEANSEDAS SOON AS POSSIBLE.
INJURY MAY OCCUR.
E. Clean the perforated tube (6) and cover (3) with mineral spirits,
AMS-3160, and allow to air dry.
NOTE
Wet O-rings and gasket with clean engine oil before installing.
F. Install O-ring (7) on the perforated tube (6).
G. Install check valve (8) on the perforated tube (6).
!
JAN/91
7-25
1 2
7\n
5\
\ \
@ill@
..
. . ..
~;) ;
-b
1. BOLT
6. PERFORATED TUBE
2. PACKING (O-RING)
7. PACKING (O-RING,
3. COVER
8. CHECK VALVE
4. PACKING (O-RING)
9. JACKSCREW HOLE 3)
5. FILTER ELEMENT
QHJO07AD
Figure 7-6.
7-27.
Installation.
A. Make sure the filter cavity is clean and free of coke and carbon
deposits.
If not, clean the filter cavity using a lint-free cloth
and mineral spirits, AMS-3160, and allow to dry before installing the
filter.
NOTE
Wet O-rings and gasket with clean engine oil before installing.
B. Install O-ring (4, Figure 7-4) in the oil filter (3) cover.
C. Install oil filter (3), in the accessory drive gearbox cover (10) and
secure with washers (2) and nuts (l). Torque nuts to 74-89 lb in.
(8.4 -10.0 Nm),
7-26
JAN/91
7-29.
7-30.
Removal.
WARNING
TRICRESYLPHOSPHATE (TCP) AND SOME OF THE OTHER ORGANIC ADDITIVES IN THE
SYNTHETIC OILS ARE READILY ABSORBED BY THE SKIN AND ARE HIGHLY TOXIC.
ANY PART OF THE BODY THAT COMES IN CONTACT WITH THESE OILS SHOULD BE
CLEANSED AS SOON AS POSSIBLE.
A. Remove outlet tube (2, Figure 7-7).
B. Disconnect tubes (3 and 4) at the scavenge pump (11).
C. Remove the nuts (10) securing scavenge pump (11,
gearbox (1) and remove the scavenge pump.
to accessory drive
JAN/91
7-27
8. UNION (2)
3. PUMP RH TUBE
4. PUMP LH TUBE
5, UNION
6. ELBOW
7. NUT
QHJO08XD
Figure 7-7.
7-28
Installation.
NOTE
Apply clean engine oil to the O-rings and threads of unions and elbow.
A. Install O-rings (9, Figure 7-7) on unions (5 and8) and elbow (6).
B. Install the short union (5) with O-ring in scavenge pump bottom
intake port.
C. Install a long union (8) with O-ring in scavenge pump top intake port
and in scavenge pump outlet port.
D. Install elbow (6) in the scavenge pump outlet port. Do not tighten
nut at this time.
NOTE
If leaks are experienced through the O-ring (12), install an O-ring in
the groove and fill the groove with RTV or Permatex.
E. Apply clean engine oil to scavenge pump drive shaft splines and
O-rings.
F. Install O-rings (12 and 13) on scavenge pump.
G. Carefully install the scavenge pump (11) on the accessory drive
gearbox (l), turning scavenge pump shaft as necessary to permit
spline engagement. Secure the scavenge pump with nuts (10) and
torque nuts to 140-170 lb in. (15.8-19.2 N-m).
H. Install tubes (3 and 4).
I. Install tube (2) and tighten nut (7). Lockwire the tube to the nut.
7-32. TURBINE REAR SCAVENGE OIL PUMP.
7-33.
JAN/91
7-29
Removal.
A. Remove sleeve nut (1, Figure 7-8) and discard sleeve nut.
NOTE
Normally an inner rear exhaust cone puller (cone puller), 6799754, is
used to remove the cone assembly due to heat exposure.
B. Remove cone assembly (2) using cone puller, 6799754, as follows (Ref.
Figure 7-9):
10 Use penetrating oil, VV-P-216, at forward end slots of the cone
assembly (2, Figure 7-8), as required.
2. Install cone puller, 6799754, aligning guide with the rear stud of
the support assembly (5) and tighten the thumb screws into forward
end slots of the cone assembly, (2).
3. Slowly tighten the tee handle of cone puller and remove cone
assembly (2).
co Remove insulation blanket (3).
D. Remove bolts (4) and carefully remove assembled support assembly (5)
from the rear bearing support. Remove and discard gasket (6).
E. Remove gearshaft (11), shaftgear (10), and O-ring (12) from pump
assembly (13). Discard O-ring.
F. Remove bolts (7), gasket (8), bushing (9), and pump assembly (13)
from support assembly (5). Discard gasket.
G. Remove bushing (9) from pump assembly (13).
7-35.
Inspection.
NOTE
7-30
The oil flow rate to the rear turbine bearing is 4.7 ppm (2.13 kpm),
with oil weight figure at 8.0 ppg (0.96 KpL) a 12 gallon (45 liters)
tank would be emptied in approximately 20-25 minutes of engine
operation, with no scavenging from turbine rear sump.
JAN/91
Installation.
NOTE
Wet gaskets and O-ring with clean engine oil.
A. Install bushing (9, Figure 7-8) and gasket (8) in pump assembly (13).
B. Apply Ablube, MIL-L-25681, to the threads of bolts (4 and 7).
c. Install pump assembly (13) on support assembly (5) and secure with
bolts (7). Torque bolts to 70-85 lb in. (8.0-9.6 Nom) and lockwire
bolts in pairs.
D. Install shaftgear (10) into pump assembly (13) gears. Inspect for
freedom of movement.
E, Install O-ring (12) on gearshaft (11) and install gearshaft into pump
assembly (13) meshing the gears of shaftgear (10). Inspect for
freedom of movement.
F. Install gasket (6) on mounting flange of support assembly (5).
G. Carefully install assembled support assembly (5) on rear bearing
support, aligning the gearshaft (11) with the splines in the tie
bolt. Secure with bolts (4). Tighten bolts in circumferential
pattern until a torque of 100-110 lb in. (11.3-12.4 Nom) is
obtained.
Lockwire bolts.
H. Install insulation blanket (3) aligning the forward end with clips on
the support assembly (5).
I. Install cone assembly (2) and secure with sleeve nut (l). Torque
sleeve nut to 140-170 lb in. (15.9-19.6 N-m).
J. Install high temperature lockwire, MS9226-04, into support assemb Y
(5) stud holes in figure 8 pattern.
JAN/91
7-31
1. SLEEVE NUT
2. CONE ASSY
8. GASKET
3. INSULATION BLANKET
9. BUSHING
4. BOLT (12)
10. SHAFTGEAR
5. SUPPORT ASSY
11. GEARSHAFT
6. GASKET
7. BOLT (4)
Figure 7-8.
7-32
JAN/91
SUPPORT
ASSYISTUD
TEE HANDLE
CONE ASSY
I
THUMB
SCREW
___JL _____
la
GUIDE
QHT015XA
Figure 7-9.
JAN/91
7-33
Paqe No,
8-1
8-3
8-2
8-3
8-3
8-3
8-4
Removal
8-5
8-5
Inspection
8-6
8-6
Installation
8-6
8-7
Oil Nozzle
8-9
8-8
8-9
8-9
Removal
8-9
8-10
Installation
8-9
8-11
8-10
8-12
8-10
8-13
Removal
8-10
8-14
Installation
8-13
8-15
8-16
8-16
8-16
8-17
Removal
8-17
8-18
Installation
8-17
8-19
Adapter Housing
8-17
8-20
8-17
8-21
Removal
8-19
8-22
Installation
8-19
8-23
JAN/91
Descrir)tion
8-19
8-24
8-19
8-25
Removal
8-20
8-26
Installation
8-22
8-1
INDEX TO FIGURES
Fiqure No.
Title
8-1
8-2
8-3
Paqe No.
8-4
8-4
8-5
8-4
8-8
8-5
8-8
8-6
8-11
8-7
8-13
8-8
8-14
8-9
8-16
8-10
8-18
8-11
8-18
8-12
8-21
8-13
8-22
8-14
Dimension B Measurement
8-24
INDEX TO TABLES
Table No.
8-1
8-2
Paqe No.
.$~eed Sensor pickut) Shim Requirements
-,
8-7
JAN/91
8-2.
8-3.
JAN/91
8-3
/- SHAH COUPLING
%~6HnlRp
~ TUBE LOCATING KEY
OIL
MIDBEARING
+11~
&
L ADAPTER HOUSING
QHY023XF
Figure 8-1.
15
14
13
12 11
POWER
TAKEOFF
~ HOUSING
1*
10
\
/
17
.z-
,..
w\
1 2 3
\
4
1. NUT (16)
INTERNAL RETAINING RING (2)
:: PTO SHAFT ADAPTER
4. INTERNAL RETAINING RING
5. BEARING LOCK RING
6, PTO SHAFT
7. PTO HOUSING
8. MIDBEARING
9. LOCK KEY
Figure 8-2.
8-4
QHY024XF
:!:
12.
:::
150
16.
17.
JAN/91
t,---
1
NEEDLE VALVE
PRESSURE GAGE
COMPRESSOR
DISCHARGE
PRESSURE
PRESSURE
REGULATINGVALVE
20 PSIG (138 KPAG)
FINNED
LOOP COOLER
PTO SHAFT
FILTER
ORIFICE (
T
TO DRAIN
COLLECTOR
TANK
QHJ020XF
REMOVAL .
A. Disconnect electrical connector (1, Figure 8-4) from speed sensor
pickup (7).
NOTE
Tee handle pullers, 6797000, may also be used to remove speed sensor
pickup.
B. Remove bolts (2) and washers (3), then carefully remove speed sensor
pickup (7) from PTO housing (6) and if required use two tee handle
pullers, 6797000, in the jackscrew holes (8) as jackscrews to remove
speed sensor pickup (7) evenly. ,
JAN/91
8-5
INSPECTION.
A. Clean the speed sensor pickup by wiping with a clean cloth dampened
with mineral spirits, AMS3160, and allow to air dry.
B. Inspect to ensure continuity between pins A and B. No continuity,
replace speed sensor pickup.
C. Inspect for no continuity between pins and pickup hous ng. If
continuity exists, replace speed sensor pickup.
s
INSTALLATION.
A. If required, install pickup block assembly (9, Figure 8-4) per
Paragraph 8-14, Step D.
B. If required, clean pickup block assembly (9) and speed sensor pickup
(7) mounting flanges.
NOTE
Make sure the pickup block assemblys dowel pin is inserted into the
depth gages dowel pin hole or clearance measurement will be a high
inaccurate reading.
8-6
JAN/91
ASSEMBLY
Table 8-1.
Clearance Distance
0.017
0.022
0.027
0.031
0.036
0.041
JAN/91
to
to
to
to
to
to
0.021
0.026
0.030
0.035
0.040
0.046
in
in
in
in
in
in
(0.432
(0.559
(0.686
(0.788
(0.915
(1.042
Shims Reauired
to
to
to
to
to
to
0.533
0.660
0.762
0.889
1.016
1.168
mm)
mm)
mm)
mm)
mm)
mm)
;
3
4
5
6
8-7
1.
2.
3.
4.
5.
QHY025XD
ELECTRICAL CONNECTOR
BOLT (4)
WASHER (4)
SHIM(S) (AR)
PACKING (O-RING)
6.
7.
8.
9.
Figure 8-4.
PTO HOUSING
SPEED SENSOR PICKUP
JACKSCREW HOSE (2)
PICKUP BLOCK ASSY
00WELPINHOLE
/
PICKUPBLOCKASSY
GAGE
DEPTH
(679757
QHT018XD
Figure 8-5,
8-8
JAN/91
OIL NOZZLE.
8-8.
8-9.
REMOVAL.
A. Remove pressure hose (1, Figure 8-6) from oil nozzle union (2). If
required, remove union and O-ring (3). Discard O-ring.
B. Remove bolts (4), O-ring (5), and oil nozzle (6) from adapter housing
(37). Remove and discard O-ring (5).
c. Remove wire mesh filter (7) from oil nozzle (6) using care not to
damage wire mesh filter. Inspect for contamination.
D. If required, clean wire mesh filter (7) with a clean cloth damr)ened
with mineral oil, AMS3160, and allow-to dry. Inspect wire mesh
filter for damage.
8-10.
INSTALLATION.
NOTE
Het O-rings with clean engine oil.
A. Carefully install wire mesh filter (7, Figure 8-6) into oil nozzle
(6) with taper end down.
B. Install O-ring (5) on oil nozzle (6) and install assembled oil nozzle
in adapter housing (37), secure with bolts (4). Torque bolts to
60-65 lb in. (6.8-7.3 Nom) and lockwire,
C. Install O-ring (3) on union (2) and install union with O-ring side in
oil nozzle (6). Torque union to 55-80 lb in. (6.3-9.0 Nom).
D. Install pressure hose (1) to union (2). Retain union from turning
and torque hoses coupling nut to 80-120 lb in. (9.0-13.5 N-m).
JAN/91
8-9
REMOVAL.
A. Remove speed sensor pickup per Paragraph 8-4.
B. Remove nuts (9, Figure 8-6) securing PTO housing (8) to the engine.
C. Remove engine per Section 1.
8-10
JAN/91
l~
,,
,5
//
23
I
//
25
./
QHY027XA
Figure 8-6.
JAN/91
8-11
The midbearings inner race will remain with the PTO shaft when the
PTO housing is removed. The midbearing guide, 6797753, is required to
protect the midbearings rollers during PTO housing removal and holds
the midbearings rollers in place during PTO housing installation.
8-12
JAN/91
~ MIDBEARING
KNURL KNOB J
%y
VIEW
A-A
QHT019XA
Figure 8-7.
8-14.
INSTALLATION.
CAUTION
THE BEARING ASSEMBLY IS SERIALIZE SET CONSIST OF INNER RACE, OUTER RACE,
ROLLERS, AND SEPARATOR. THE INNER RING IS INSTALLED ON THE PTO SHAFT
PER PARAGRAPH 8-18.
A. If required, make sure roller retainer tool, 6797881, is installed to
retain rollers (Ref. Figure 8-8).
JAN/91
8-13
PTO HOUSING -
\\
=z- ,=-- I
,
=
\\
-
NIDBEARING
QHT020XD
Figure 8-8.
JAN/91
8-15
la
td
Figure 8-9 .
8-16
QHY026XD
JAN/91
REMOVAL .
A. Remove PTO housing (8, Figure 8-6) per Paragraph 8-13.
B. Remove aft retaining ring (25) and PTO shaft (24) from shaft coupling
(26).
CAUTION
DO NOT REMOVE SHAFT ADAPTER FROM SOLID STEEL SHAFT. THE SHAFT ADAPTER
AND SOLID STEEL ARE A BALANCED ASSEMBLY AND MUST REMAIN BOLTED TOGETHER.
C. If required, remove inner race (21) from PTO shaft (24) using bearing
pulling fixture, 6797754, turn tee handle to push off inner race
(Ref. Figure 8-10). Inspect PTO shaft for damage.
8-18.
INSTALLATION.
CAUTION
THE PTO SHAFT IS A BALANCED ASSEMBLY, THE SOLID STEEL SHAFT AND SHAFT
ADAPTER MUST REMAIN BOLTED TOGETHER. IF SEPARATED, THE PTO SHAFT MUST
BE RETURNED TO A MAJOR REPAIR CENTER FOR BALANCING.
A. If required, press inner race (21, Figure 8-6) onto PTO shaft (24)
using bearing inner race pusher, 6797756 (Ref. Figure 8-11) to seat
inner race on PTO shaft.
B. Thread retaining ring (25, Figure 8-6) on the forward end of the
shaft adapter of the PTO shaft (24).
c. Install forward external splines of the PTO shaft (24) to the
internal splines of the shaft coupling (26) and secure with retaining
ring (25).
D. Install PTO housing per Paragraph 8-14.
8-17
EAR NG NNERRACE
/-f
3
I
,,
,,
I
/
TEE HANDLE /
BEARING PULLING J
FIXTURE (6797754)
Figure 8-10.
~ MIDBEARING INNERRACE
QHT022XD
Figure 8-11.
8-18
JAN/91
REMOVAL .
A. Remove PTO shaft (24, Figure 8-6) per Paragraph 8-17.
B. Remove oil nozzle (6) per Paragraph 8-9.
C. Remove drain hose (33) from union (34).
D. Remove bolts (35) and adapter housing (37) from driven equipment.
Remove and discard O-ring (36).
E. If required, remove union and O-ring (34). Discard O-ring.
8-22.
INSTALLATION.
NOTE
Het O-rings with clean engine oil.
A. If required, install O-ring on union (34, Figure 8-6) and install
union and O-ring into housing adapter (37). Torque union to 50-70 lb
ft. (67.8-94.9 Nom).
B. Install O-ring (36) to adapter housing (37).
C. Install adapter housing (37) to driven equipment and secure with
bolts (35). Torque bolts to 400-470 lb in. (45.2-53.1 Nom).
Lockwire bolts.
D. Install drain hose (33) to union (34) and torque hoses coupling nut
as outlined in Section 15, General Maintenance.
E. Install oil nozzle per Paragraph 8-10.
F. Install PTO shaft (24) per Paragraph 8-18.
8-23.
8-24.
8-19
REMOVAL .
A. Remove adapter housing (37, Figure 8-6) per Paragraph 8-21.
B. Remove retaining ring (27) and shaft coupling (26) from tapered
coupling (28).
c. Remove tapered coupling (28) as follows:
1. Make sure O-ring (1, Figure 8-12) is serviceable and installed in
stud (2).
2. Install
stud (2) in the threaded portion of input shaft (6, Figure
.-.
8-13).
NOTE
Make sure bearing races (5, Figure 8-12) and bearing (6) are properly
installed in the nut (7) and sleeve(3).
3. Install sleeve (3, Figure 8-12), bearing assembly (4), and nut
on stud (2). Position nut until sleeve is approximately 0.125
(1/8) inch (3.2 mm) from taper coupling (3, Figure 8-13).
7)
4. Install elbow (8) in end of stud (2) while retaining stud from
moving, torque elbow per Section 15, General Maintenance.
5. Connect tube (9) to elbow (8) and to pump and gage assembly (10).
Torque tubes coupling nuts per Section 15, General Maintenance.
NOTE
If required, service and bleed main drive coupling tool, 6798754, by
loosening tubes coupling nut at elbow and slowly activating the pump
and gage assembly until air free oil leaves connection. Torque tubes
coupling nut per Section 14, General Maintenance.
6. Build up pressure with pump and gage assembly (10) until tapered
coupling (3, Figure 8-13) moves in contact with the sleeve (3,
Figure 8-12). Back off nut (7) while retaining stud (2) from
turning and continue building up pressure until tapered coupling
(3, Figure 8-13) is free of driven equipment input shaft (6).
7. Remove tube (9, Figure 8-12) from elbow (8).
8. Remove remaining coupling tools and tapered coupling (3, Figure
8-13) by removing (screw out) stud (2, Figure 8-12) and removing
sleeve (3), bearing assembly (4), nut (7), and elbow (8).
8-20
JAN/91
;:
3.
4.
5.
PACKING (O-RING)
STUD
SLEEVE
BEARING ASSY
BEARING RACE (2)
6.
BEARING
NUT
:: ELBOW
9. TUBE
10. PUMP AND GAGE ASSY
QHT013AD
Figure 8-12.
JAN/91
8-21
3
BACKUP RING
PACKING (O-RING)
TAPERED COUPLING
5
4. PACKING (O-RING)
5. BACKUP RING
6. DRIVEN EQUIPMENT INPUT SHAFT
QHY028XD
Figure 8-13.
9. Remove backup ring (1, Figure 8-13) and O-ring (2) from tapered
coupling (3). Discard backup ring and O-ring.
10. Remove backup ring (5) and O-ring (4) from driven equipment input
shaft (6). Discard backup ring and O-ring.
11. Clean and inspect mating surfaces of tapered coupling (3) and
driven equipment input shaft (6) for damage.
8-26.
INSTALLATION.
A. Inspect driven equipment input shaft (6, Figure 8-13) end play per
OEM manual.
NOTE
Do not install backup rings and O-rings on tapered coupling and driven
equipment input shaft until told to do so.
B. Make sure driven equipment input shaft (6) and tapered coupling (3)
mating surfaces are clean and lightly lubricated with clean engine
oil and install tapered coupling on the driven equipment input shaft
as far as it will go by hand without backup rings (1 and 5) and
O-rings (2 and 4) installed.
8-22
JAN/91
The
8-23
DRIVEN
EQUIPMENT
QHYO09AD
II
Figure 8-14.
Dimension B Measurement.
5. Connect tube (9) to elbow (8) and to pump and gage assembly (10).
Torque tubes coupling nuts per Section 15, General Maintenance.
NOTE
If required, service and bleed main drive coupling tool, 6798754, by
loosening tubes coupling nut at elbow and slowly activating the pump
and gage assembly until air free oil leaves the connection. Torque
tubes coupling nut per Section 14, General Maintenance.
6. Subtract 0.350 in. (8.89 mm) from recorded Dimension B. Build up
pressure with pump and gage assembly (10) and continue tightening
nut (7), while retaining stud (2) from turning, until the new
Dimension B measurement is reached (Ref. Figure 8-14). A plus
I
I
8-24
JAN/91
I
Allison Engine Company
8-25
Description
Paqe No.
9-1
Description
9-2
9-2
Removal
9-2
9-3
Installation
9-4
9-4
Repairs
9-5
9-5
9-5
9-6
9-7
9-7
9-7
INDEX TO FIGURES
Fiqure No.
JAN/91
Paqe No.
9-1
9-3
9-2
9-4
9-3
9-6
9-4
9-6
DESCRIPTION.
A. The accessory drive gearbox is mounted to the bottom of the
compressor air inlet housing as shown in Figure 9-1. It is driven by
a right angle drive from the compressor extension shaft. There are a
set of bevel gears inside the accessory drive gearbox to provide the
drive to the accessories. The center line of these drives are
parallel to the engine main shafts. There are accessory drive pads on
the front and rear face as shown in Figure 9-2.
B. There is no recommended operator performed internal maintenance of
the accessory drive gearbox. The recommended maintenance tasks are
performed from the outside of the accessory drive gearbox as covered
in this Section.
9-2.
REMOVAL.
A. Remove magnetic drain plug and allow oil to drain from accessory
drive gearbox per Section 7.
B. Remove oil inlet and outlet hoses per Section 7.
C. Remove external scavenge oil pump per Section 7.
D. If required, remove liquid fuel pump and HP fuel filter per Section
4.
E. Remove bleed valve control hoses and speed sensitive valve per
Section 11.
NOTE
If any more components are installed on accessory drive gearbox, refer
to their OEM Manual(s) for removal.
F. Remove cotter pins (1, Figure 9-l), castellated nuts (2), and washers
(3). Discard cotter pins.
G. Remove long bolts (4), washers (5), short bolts (6), and washers (7).
H. Support the accessory drive gearbox (11). Remove nuts (8), washers
(9), and carefully lower accessory drive gearbox (11), and accessory
drive shaft (12) away from compressor air intake.
9-2
JAN/91
;:
3.
4.
5.
6.
7,
8.
9.
10.
11.
12.
QHFO1OXF
Figure 9-1.
JAN/91
OIL
FILTER
OIL PUMP
/
COVER
QHDO08BD
Figure 9-2.
INSTALLATION.
A. Apply a light coat of permatex, No. 1372 (EMS-2771O), to the
accessory drive gearbox and air inlet housing spl itline, using care
not to get permatex in oil passages.
B. Coat O-ring (10, Figure 9-1) with clean engine oil and install O-ring
and accessory drive shaft (12) .in accessory drive gearbox (11).
9-4
JAN/91
REPAIR.
9-5.
JAN/91
9-5
QHTOOIXD
Figure 9-3.
L....2..
1
\
+- Y
q
3
1. SHA!7
2. SEAL
3. SEAL EXPANDER6796355 ;
~...
~-
--
,:
ji
&
Figure 9-4.
9-6
9-7.
JAN/91
9-7
WARNING
THIS SOLUTION IS INJURIOUS TO THE SKIN AND CLOTHING: OPERATORS MUST BE
ADEQUATELY PROTECTED BY GOGGLES, RUBBER GLOVES, APRONS, ETC.
B. Swab area to be treated with clean water. While still wet, coat area
with the following aqueous solution using a nylon bristle brush:
Alodine No. 1200* 3 oz per gal
1/2 fluid oz per gal
Nitric Acid (HN03)
* American Chemical Paint Co., Ambler, Pa.
C. Both part and solution must be maintained at room temperature. Allow
solution to remain on area from one to five minutes, but in no case
should it be allowed to dry on the part.
D. Rinse or swab the coated area thoroughly with clean water to
completely remove all remaining solution.
CAUTION
ALL BRUSHES AND SWABS MUST BE WATER RINSED TO MINIMIZE FIRE HAZARD.
E. Blow surface dry with clean, dry air.
F. ADDIV Daint, consisting of a mixture, by volume, of two parts
A~ti~hane WC1OO (produ~t of Saren Chemical Co. ,Detroit, Michigan),
and one part special lacquer reducer No. 9012 (product of Gliden CO.,
Cleveland, Ohio).
G. Brush part with two coats; allow first coat to air dry for at least
20 minutes. Localize heat cure after the second coat.
9-8
JAN/91
Paqe No.
1o-1
10-3
10-2
10-3
10-3
10-3
10-4
10-4
10-5
Casing Assembly
10-4
10-6
10-4
10-7
10-5
10-8
10-5
10-9
Removal
10-5
1o-1o
Installation
10-6
10-11
Rotor Assembly
10-7
10-12
10-7
10-13
10-7
10-14
JAN/91
Description
Diffuser Assembly
10-7
10-15
10-7
10-16
10-7
10-17
10-8
10-18
Compressor Cleaning
10-11
10-19
Water Rinse
10-13
10-20
Chemical Wash
10-15
10-21
10-17
10-22
10-20
1o-1
10-2
Title
Paqe No.
1o-1
10-6
10-2
1o-1o
10-3
1o-1o
10-4
10-12
10-5
10-23
10-6
10-24
10-7
10-25
JAN/91
1o-1.
10-2.
10-3.
JAN/91
10-3
C. The air inlet housing assembly has internal cored passages for lube
oil supply and scavenge, venting, and passage of the accessory drive
shafts. It has the forward attachment points for engine handling and
mounting of external components as needed.
I
10-4.
1. Thoroughly swab damaged areas with trichloroethy ene and air dry
for five to ten minutes.
2. Abrade the damaged area into a slightly larger area with feathered
edges.
3. Clean abraded areas with solvent and dry with clean compressed air.
4. Apply aluminum coating SermeTel 196 (a product of Teleflex Inc.,
North Wales, PA) in two coats w th a 30 to 60 minute air dry
period between coats.
10-5.
CASING ASSEMBLY.
10-6.
10-4
JAN/91
10-9.
Removal.
A. Remove the electrical connector at the engine No. 2 speed pickup.
B. Loosen the locknut and remove.
JAN/91
10-5
ENGINE NO. 2
SPEED PICKUP
LOCKNUT
R
RS
QHI064X
Figure 10-1.
1o-1o.
Installation.
A. Turn the compressor rotor to align a 5th stage blade directly
across the engine No. 2 speed pickup hole in the 5th stage bleed
adapter.
B. Apply a light coating of Permatex sealant No. 1372 (EMS 27710) to
the engine No. 2 speed pickup threads which go into the 5th stage
bleed cover.
C. Carefully, using finger pressure only, thread the engine No. 2
speed pickup into the bleed adapter until it touches the 5th stage
blade (positioned in preceding Step a.), then back it Out 180 t
10 (about 1/2 turn).
D. Retain the engine No. 2 speed pickup to prevent it from turning
and tighten the locknut to 100-150 lb in. (11-17 Nom). Measure
and record the resistance of the engine No. 2 speed pickup winding
for troubleshooting comparison in the future.
E. Connect the electrical connector to the engine No. 2 speed pickup
and lockwire.
10-6
JAN/91
ROTOR ASSEMBLY.
10-12.
10-13.
10-14.
DIFFUSER ASSEMBLY.
10-15.
10-16.
JAN/91
10-7
10-8
JAN/91
WARNING
THE TEMPERATURE RISE THROUGH THE COMPRESSOR CAN BE MORE THAN 500F
(260C). SEVERE BURNS CAN OCCUR.
F. Inspect for air leaks. While the engine is runri ng, check splitlines,
bleed adapters and manifolds for air leakage. Rt pair as necessary.
G. Evidence that indicates the engine has operated with air inlet
blockage or partial blockage for more than 5 minutes is cause for
engine removal for major repair.
1. Blockage, or partial blockage, of the engine air inlet at the air
inlet housing or the air inlet guide vanes causes a harmonic
excitation of some compressor blade stages which can quickly
reduce blade strength and life due to high cycle fatigue.
2. Blockage is considered to be material found to cover the area of
two or more air inlet guide vanes or sufficient to cause a
noticeable reduction of power.
H. InsDect for mechanical damage: evidence of foreign object damage
(FOD), cracks, nicks, dents; bent, or otherwise damaged parts.
Remove the eng ne for repair if any of the following condt ions are
seen.
NOTE
Damaaed vanes or blades exceeding inspection limits may be only
reworked or replaced during engi~e major repair.
1. Any missing, cracked, or broken stator vane or rotor blade.
2. Any rotor blade with a nick, or dent in a blade, in the area from
the base to 1/3 of the distance to the tip, if the damage is deep
enough to feel.
3. Any rotor blade with damage in the outer 2/3 of blade length and
the damage exceeds the limits shown in Figure 10-2 and 10-3.
Sharp nicks or dents are not allowed.
4. Any rotor blade bent enough to make contact with a stator vane.
5. Damage to ten or more stator vanes or rotor blades in the 1st
stage.
6. Any rotor blade with corrosion exceed ng the limits shown in
Figure 10-4.
JAN/91
10-9
(NO CRACKS)
?wL )- I
A
OUTI
WHEEL STAGES
MAX DEPTH
1 THRU 5
6THRU14
/3 -
OUTI 2/3
I--#
WHEEL
STAGES
1 THRU 5
6 THRU 14
LOWE
DENT DAMAGE
MAX DEPTH
0.100 IN (2.5 MM)
0.050 IN (1 .3 MM)
Figure 10-2.
OUTER 2/3
0+
/ NICKS
/
MAXDEPTH
1 THRU5
6THRU 14
0.0321N(0.81 MM)
0.010 IN (0.25 MM)
\
QHC014XD
Figure 10-3.
1o-1o
1
\
WHEEL STAGES
BLENDEDEDGES
1
LOWER 1/3
JAN/91
COMPRESSOR CLEANING.
A. A compressor cleaning program is necessary to maintain compressor
efficiency for optimum power, fuel consumption, and service life.
Contamination of the compressor reduces the mass of air supplied to
the combustion section. Reduced air mass results in either:
1. Higher turbine temperature for the same fuel flow, with lower
power output.
2. Even higher turbine temperature with the increased fuel
consumption necessary to achieve the same power output.
B. Power losses that cannot be blamed to contamination of the compressor
must be further investigated. Dirt or other contaminates in the
compressor are the most common cause of gradual loss of engine performance. As a general rule, for each percent of loss in compressor
efficiency, approximately two percent of power is lost at the driven
equipment output shaft.
c. Engines operating in a salt laden environment requires extra attention to avoid corrosion. Corrosion in the compressor reduces air
mass flow and can weaken the components.
D. Compressor approved methods of cleaning compressor:
1. Water rinse with fresh pottable water while motoring, for rinsing
corrosive contaminates from the gas path and/or rinse the engine
after chemical wash (Ref. Paragraph 10-19).
2. Chemical wash while motoring, for washing contaminates from the
compressor (Ref. Paragraph 10-20).
3. Abrasive (walnut shell) cleaning, for removing dry or baked on
contaminates when other methods are not effective (Ref. Paragraph
10-21).
JAN/91
10-11
rlrlnll
1ST STAGE
2ND STAGE
3RD STAGE
4TH STAGE
/5%TEwDP77-l
5TH STAGE
il
6TH STAGE
BQ
7TH STAGE
8TH STAGE
Ii i i i i i l I)IIIB4 Jiiiiiia
10TH STAGE
9TH STAGE
Ifz%ll
11TH STAGE
12TH STAGE
CRITICAL AREA
A. SLIGHT PITTING (NO. 1 ) IS ACCEPTABLE. PIT DEPTH MUST
NOT EXCEED 0.W4 INCH (0.1 MM)
B. PITTING CLUSTERS (NO. 2) ARE NOT ACCEPTABLE IN THIS
14TH STAGE
.n. -. . . .
.,;. .. ..,
AREA
1(3
SEMI-CRITICAL AREA
A. SCATTERED PITTING (NO. 3) IS ACCEPTABLE, PROVIDED
THE PITS DO NOT FORMA DEFINITE LINE ACROSS THE bLADE
WIDTH.
B. PITTING CLUSTERS (NO.2) ARE NOf ACCEPTABLE IN THIS
AREA
NON-CRITICAL AREA
m A. SCATTERED PIITING [NO.3) IS ACCEPTABLE, PROVIDED
I
I
THE PITS DO NOT FORMA DEFINITE LINE ACROSS THE BIADE
WIDTH.
B. PrTTING CLUSTERS (NO. 2) ARE ACCEPTABLE IF NOT EXCEEDING:
(1.) STAGES 1-5: TWO PITTING CLUSTERS PER SIDE AND
DEPTH DOES NOT EXCEED 0.010 INCH (0.25 MM).
(2.) STAGES 6-14: ONE PITTING CLUSTER PER SIDE AND
DEPTH DOES NOT EXCEED 0.CQ5 INCH (0.13 MM).
c. PITTING CLUSTERS (NO. 2) ARE ONLY ACCEPTABLE IN THE
CENTER 1/3 OF BLADE WIDTH AND THEY MUST NOT OPPOSE
EACH OTHER FROM OPPOSITE SIDES
Jiuil
13TH STAGE
s ,..;. .,
., :,.,.:.
.- .:..
,.. .
. .
,
1
+
-&
PllllNG EXAMPLES
QHC015XA
Figure 10-4.
10-12
JAN/91
WATER RINSE.
A. Water rinse is done by spraying fresh, pottable, filtered water into
the compressor air inlet while the engine is being motored by the
starter. The purpose is to remove water soluble contaminates from
the gas path of the engine. It is also used to rinse out residues
after chemical wash of the engine.
1. Frequency of Water Rinse.
a. An engine which has ingested salt water or mist directly into
the compressor air inlet shall receive a motoring water rinse
wash after each days use.
b. An engine in a salt laden environment which has not been
operated for a period of three days shall receive a water rinse
wash prior to operation.
c. An engine which has received a water wash immediately prior to
becoming inactive may remain inactive for a period of fourteen
(14) days. If inactivity is to continue, the water wash application must be reapplied at the end of the 14th day unless an
inspection indicates that the need does not exist.
d. Engines which have visually observable compressor blade and
vane contamination and/or which show a trend of deteriorating
performance should receive a water rinse wash and/or liquid
cleaner chemical wash.
2. Materials for Water Rinse.
a. Water: Use pottable water if possible. Fresh, drinkable, filtered water is the lowest acceptable quality. The flow rate is 3.5
gallons (13.25 liters) per minute for a total of 10 gallons (38
liters). Flow can be continuous or divided into equal motoring
time intervals, as required, depending on starter limitations.
JAN/91
10-13
JAN/91
CHEMICAL WASH.
A. Chemical Wash the compressor internally with a chemical wash agent
and water mixture is the ~referred method of cleaning. Chem cal Wash
is done by spraying a chemical and water mixture into the engine
inlet while the engine is being motored by the starter. The purpose
is to clean the gas path of the compressor to maintain optimum
performance and reduce corrosive damage. Chemical Wash is effective,
convenient, and does not damage the engine.
B. Frequency of Chemical Wash. Engines which have visually observable
compressor blade and vane. contamination or which show a trend of
deteriorating performance should be chemical washed
c. Materials for Chemical Wash.
1. Water used in the chemical wash mixture must meet the same
requirements as discussed for Materials for Water Rinse, Paragraph
10-19, Step A-2.
2. Listed below are chemical wash agents that have been tested and
approved for compatibility with the materials within the engine.
The cleaninq effectiveness of cleaners may differ with the type of
contamination present. Comply with the chemical cleaner
manufacturers instructions for mixture concentrations.
NOTE
Do not exceed the chemical manufacturers recommendations for the
chemical concentration.
JAN/91
10-15
Product
Uresco Ardrox
Ardrox 624
Brulin Chemical
B & B 3100
McGean Rohco
Cee Bee R674
Rochem
G. T. E.
Penetone Corp.
Penair M5704
Penetone Corp.
Penetone 19
*RMC
Ivar Rivenaes
Rochestor Midland
S E 310
Aeromarine
T C 200
Kent Chemical Ltd.
Turboclean
Purex Div. of Turco
Turco 5884
*ZOK 27
Airworthy Ltd.
Racascan
512M
*May also be used as an online compressor cleaner.
D. Equipment for Chemical Wash.
NOTE
Refer to Equipment for Water Rinse, Paragraph 10-19, Step B.
E. Precautions.
1. Do not inject chemical wash mixture into the compressor air inlet
if the CTIT is above 150F (66C). The flash (kindling) point of
some cleaning chemicals is quite low. Make sure the engine
temperature is below this point before chemical wash is initiated.
2. A water rinse and a drying cycle are required after a chemical
wash per Paragraph 10-19, Step D.
3. If the ambient temperature is below the freezing point of the
chemical solution, refer to the chemical manufacturers
recommendations to prevent freezing.
CAUTION
USE OF UNAPPROVED ENGINE CHEMICAL CLEANERS MAY DAMAGE ENGINE AND/OR ITS
COMPONENTS.
4. Do not use unapproved engine chemical cleaners. The approved
chemical cleaners have been tested for compatibility with the
materials in the engine.
5. Make sure the oil supply to the engine is ON and the fuel and
ignition systems are OFF while the engine is motoring.
6. Obey any starter restrictions recommended by the manufacturer or
damage may occur to the starter (Refer to OEMs Manual).
10-16
JAN/91
JAN/91
10-17
JAN/91
10-19
10-20
JAN/91
10-21
10-22
JAN/91
ADJUSTMENT
SECTliN B-B
1- B
NPT
PIPE COUPLING
1.0 (25.4)
-1.13(22,6)
k 1.75(44.5)
GAS GENERATOR
VERTICLE
$
(It!!)fi
-.0W5-16BOLT
?,~.\~w~/pLENuM16.0(
+6wwg
-r--t
.l
45T.2)-~0(5566)
(APPROX)
TT ol-l-r
--i-+
-o
1(!
---I
.
A_
G-N GENERATOR-~iZWTAL ~
Figure 10-5.
JAN/91
QHCO1lXA
AND MAINTENANLt
SAFETY SCREEN
\
L/
/-2
INLET BELL
Ik /
4=
SE
--
A-M
ENGINE
QHC016XD
Figure 10-6.
10-24
JAN/91
PRESS.
nAr2c
UAUL
11-~ as DC I
PRESS.
REG.
0
SPRAY
YOKEIN
COMPRESSOR
0 INLET
0
PRESS.
RELIEF
VALVE
125 Psl
CHECK
VALVE
ON-OFF
AIR VALVE
GRADUATED
LOADING AND
MEASURING TANK
ON-OFF
PRESS. ~
%
AIR VALVE
SWITCH
Q -*~
PRESSURE
TAP
SPRAY
.(-. . 1
TAAM
,ru .,.
NULLLC3
1
II
II
+
I
It
II
II
A
I
--h-l+
Ill
~1
lKzl-.fY
~%#OhOES_C_~BE Ill
AGITATION
ON-OFF u
II
PIPE PLUGS. I
CIRCIJTAND
AIR VALVE
DRILL INVHPEPLUGS
-YOKE AND
10-30 GAL
0.0S25 H{OLESTOHELP
TANK CLEANB&B,BRULIN,
MIXINGTEE
VAPORLZEANDSPREAD
r]
OR OTHER
THEMIXTURE.
MIXTURES
al./. k
ra
I1
0
%% hi :.-4
\7 ~
.,
\T
YOKE
-,,
G.,-
0.5CQ IN.
ON-off
WATER
VAIVE
WATER
CONTROL
H
D.750 IN.
ON-OFF
WATER VALVE
VALVE
..,,.-,,
>
f).k25
IN,
I
CHECK
VALVE
SOLENOID
VALVE
PURE CLEAN
WATER INPUT
WATER
Md4-&
STEAM
REGULATOR
45=
ON-OFF
STEAM
VALVE
METRIC CHART
INCH
0.0625 (1/16)
0.5000 (1/2)
0.7500 (3/4)
MILLIMETER
1.6
12.7
19.05
Psl
125
kPa
862.5
GAL
:
LITERS
38
114
QHCO1OXA
Figure 10-7.
JAN/91
10-25
AllisonEngin eCompany
Description
Paqe No.
11-1
11-3
11-2
Troubleshooting
11-3
11-3
11-6
11-4
Bleed Valves
11-6
11-5
Air Filter
11-7
11-6
11-7
11-7
Removal
11-7
11-8
Cleaning
11-7
11-9
Installation
11-11
11-10
11-11
11-11
11-11
11-12
Removal
11-12
11-13
Installation
11-12
11-14
11-14
11-15
11-14
11-16
Removal
11-14
11-17
11-15
11-15
11-2
Title
Paqe No.
11-1
11-4
11-2
Troubleshooting Chart
11-5
11-3
11-9
11-4
11-13
11-5
11-17
JAN/91
TROUBLESHOOTING.
NOTE
Troubleshoot compressor air bleed system per Troubleshooting Chart,
Figure 11-2.
JAN/91
11-3
ATMOSPHERIC
VENT
.VENT OPENED
BLEED
VALVE
OPEN
TO 5TH STAGE
BLEED VALVES
r MANIFOLD
.. .. .. ..
,:..:..
........
~:... .
U
L1
..........................................................
w TO 10TH STAGE
BLEED VALVES
ABOVE 12,750 ENGINE RPM
SYMBOLS:
...........
... ... ... ... . .. . .. . ... ... ... . . . . .
14TH STAGE PRESSURE
. . . . . . . .. . .. . .. . .. . .. . .. . .. . .~..
m
.. : .. .. .. .. ... .. . ... .... ..
..........
..$ . . .::::::..:
.........
o
c1
ATMOSPHERIC PRESSURE
F gure 11-1 .
11-4
QHC029XA
w
BAD
REPAIRORREPLACE COMPRESSOR
> AIR BLEEDHOSES,TUBES, AND/OR
FITTINGS PER PARA 11-21
BAD
BAD
BAD
>
INSPECTCOMPRESSOR AIRBLEED
HOSES,TUBES,AND FITTINGSFOR
LEAKAGE DURINGENGINE OPERATION
OK
1
INSPECT 5TH OR 10TH STAGE
BLEED VALVE PER PARA 11-4
OK
1
PERFORM ENGINE OPERATION
AND LEAKAGE TEST RUN
QHS048XA
Figure 11-2.
JAN/91
Troubleshooting Chart.
11-5
BLEED VALVES.
A. Remove air hoses (4 and 5, Figure 11-3) from tee (6) on the upper
right side of the compressor.
NOTE
Hose (4, Figure 11-3) controls the top (12 oclock) and left (9
oclock) side 4 bleed valves. Hose (5) controls the right (3 oclock)
and bottom (6 oclock) side 4 bleed valves.
B. Inspect bleed valve
close and vacuum to
the set of 4 should
screens surrounding
11-6
JAN/91
REMOVAL.
A. Remove inlet hose (2, Figure 11-3) and inlet tube (10) from filter
(13).
B. Remove bolt (11) retaining filter clamp (12) to CIT sensor and remove
filter (13) and clamp (13).
C. If required, remove clamp (12) from filter.
11-8. CLEANING.
Note
If required, disassemble filter for cleaning.
A. Remove housing (14, Figure 11-3) and seal (15) from filter element
(16). Discard seal.
CAUTION
DO NOT USE A CLOTH TO DRY FILTER ELEMENT. LINT NAY BE INTRODUCED INTO
THE SPEED SENSITIVE VALVE ANDA MALFUNCTION MAY OCCUR.
Note
If an ultrasonic cleaner is not available, clean filter element and
housing Per Step C.
JAN/91
11-7
11-8
OUTLET HOSE
INLET HOSE
SPEED SENSITIVE VALVE
TEE TO TOP HOSE
TEE TO RH HOSE
TEE
NUT
NUT (2)
BRACKET
INLET TUBE
BOLT
CLAMP
FILTER
HOUSE
SEAL
FILTER ELEMENT
NUT
WASHER
BOLT
CLAMP (2)
NUT
BOLT (2)
GASKET
14TH STAGE TUBE
CDP HOSE
TEE
NUT
WASHER
BOLT
CLAMP (2)
PACKING (O-RING)
NUT
ELBOW
PACKING (O-RING)
NUT
TEE
LH HOSE, 5TH TO 10TH
STAGE
TOP TO LH HOSE
NUT
WASHER
BOLT
CLAMP
BRACKET
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
NUT
PACKING (O-RING)
NUT
SPECIAL TEE
NUT
WASHER
BOLT
CLAMP
BRACKET
PACKING (O-RING)
UNION
NUT
WASHER
BOLT
CLAMP
BRACKET
NUT
TOP HOSE, 5TH TO 10TH STAGE
PACKING (O-RING)
UNION
RH HOSE, 5TH TO 10TH STAGE
NUT
WASHER
BOLT
CLAMP
BOLT
BRACKET
PACKING (O-RING)
NUT
SPECIAL TEE
RH TO BOTTOM HOSE
PACKING (O-RING)
NUT
SPECIAL ELBOW
NUT
WASHER
BOLT
CLAMP
BRACKET
NUT
BOTTOM HOSE, 5TH TO 10TH STAGE
PACKING (O-RING)
NUT
ELBOW
JAN/91
4:
481
46
47t
24
& +yp!iiii
TrT
16
15
33
32
31
14
Figure 11-3.
JAN/91
148
62
63
J-b
5
I
64
/--
27
28
29
30
71
:1
85A
86 -----@+
87
78
79
81
80
82
84
BOITOM VIEW
QHC030XK
Figure 11-3.
11-10
INSTALLATION.
A. Apply a thin film of Ablube, MIL-L-25681, to filter (13, Figure 11-3)
hose and tube threads.
B. If required, install clamp (12) on filter (13).
c. install filter (13) and clamp (12) to CIT sensor and secure with bolt
(11). Torque bolt to 70-85 lb in. (8.0-9.6 Nm) and lockwire bolt.
D. Install inlet hose (2) and inlet tube (10) to filter (13). Torque
both coupling nuts to 200-250 lb in. (22.6-28.2 Nom).
11-10.
11-11.
JAN/91
11-11
REMOVAL.
A. If, Required, remove air inlet bell (Ref. to OEM Manual).
B. Remove outlet hose (1, Figure 11-3) and inlet hose (2) from speed
sensitive valve.
C. Remove nuts (1, Figure 11-4), washers (2), gasket (3), and speed
sensitive valve (4) from accessory drive gearbox. Discard gasket.
11-13.
INSTALLATION.
A. Make sure mounting pads on accessory drive gearbox and speed
sensitive valve (4, Figure 11-4) are clean and free of foreign
material.
B. Apply a thin film of Permatex, No. 1372, to both sides of the gasket
(3) and install on the accessory drive gearbox mounting pad for the
speed sensitive valve.
CAUTION
IF A NEW SPEED SENSITIVE VALVE IS INSTALLED, MAKE SURE THAT THE VENT
SHIPPING CAP IS REMOVED OR DAMAGE MAY OCCUR.
NOTE
It may be required to rotate the speed sensitive valves drive shaft
slightly to align the splines of the accessory drive gearbox and speed
sensitive valve.
c. Install speed sensitive valve (4) on accessory drive gearbox and
secure with washers (2) and nuts (1). Torque nuts to 74-89 lb in.
(8.4 -10.0 N.m).
D. Apply thin film of Ablube, MIL-L-25681, to inlet and outlet port
threads of the speed sensitive valve.
E. Install inlet hose (2, Figure 11-3) to speed sensitive valve inlet
port. Torque hoses coupling to 200-250 lb in. (22.6-28,2 N.m).
11-12
JAN/91
1.
2.
3.
4.
5.
6.
7.
8.
NUT (4)
WASHER (4)
GASKET
SPEED SENSITIVE VALVE
BOLT (3)
\,
WASHERS (3)
VALVE ASSY
PISTON
9.
10.
11.
12.
13.
14.
15.
QHC031XF
Figure 11-4.
JAN/91
11-13
11-15.
The top (12 oclock) 2 bleed valve screens do not have shields where
the remaining 6 screens do have shields.
6. A screen,
11-16.
REMOVAL.
NOTE
Due to different types of hose and fitting (elbow, tee, special tee,
etc.) connections, refer to Figure 11-3 and locate the correct type of
hose and fitting connection.
A. Remove the required hose(s) (Ref. Figure 11-3).
11-14
JAN/91
11-18.
INSTALLATION.
NOTE
Due to different types of hose and fitting connections, Ref. to Figure
11-3 and locate correct type of hose and fitting connections.
JAN/91
11-15
The 2 top (12 oclock) position screens do not have shields, but the
remaining 6 screens do have shields and must be installed to position
recorded on removal. If shield position(s) were not recorded on
removal, refer to Figure 11-5 for correct shield position(s).
11-19.
11-20.
11-21.
MAINTENANCE.
A. Leakage may occur from a hose, tube, gasket, O-ring, and/or fitting
(elbow, union, tee, etc.) and should be inspected for leakage while
the engine is in the normal operation mode.
B. Remove and install hoses, tubes, fittings, O-rings, and gaskets using
Figure 11-3 and General Maintenance procedures, Section 14.
11-16
JAN/91
INSTALL SHIELD
IN THIS SEGMENT
BOTTOM VIEW
IN THIS SEGMENT
Wv
QHC032XA
Figure 11-5.
JAN/91
11-17
Combustion Section
Paqe No.
12-3
12-2
12-3
12-3
12-5
12-4
12-5
12-5
Removal
12-5
12-6
Inspection
12-8
12-7
Installation
12-8
12-8
Combustion Liners
12-9
12-9
Removal
12-9
12-10
Inspection
12-10
12-11
Installation
12-10
12-12
12-12
12-13
Crossover Clamps
12-12
12-14
12-12
12-15
12-12
12-16
JAN/91
Description
12-12
12-17
12-12
12-18
Exciter
12-13
12-19
12-13
12-20
Removal
12-13
12-21
Inspection
12-14
12-22
Installation
12-16
12-1
Description
Igniter, Liner Supports,
and Liner Body Supports
Paqe No.
12-17
12-24
12-17
12-25
Removal
12-17
12-26
Inspection
12-18
12-27
Installation
12-19
12-28
Lead Assemblies
12-20
12-29
Removal
12-20
12-30
Inspection
12-21
12-31
Installation
12-21
INDEX TO FIGURES
Fiqure No.
12-2
Paqe No.
12-1
12-4
12-2
Splitline Locations
12-7
12-3
12-11
12-4
12-15
12-5
12-21
JAN/91
COMBUSTION SECTION .
12-2.
JAN/91
12-3
(%0
LINERS ~
3
COMBUSTION INNER CASING
CROSSOVERTUBES(6 PLACES)
A17LOOKINGFORWARD
Figure 12-1.
QMPOOIXD
12-4
JAN/91
Combustion
Combustion
Combustion
Combustion
Combustion
12-3.
12-4.
12-5.
Removal.
CAUTION
THE ENGINE MUST BE SUPPORTED AT THE DIFFUSER AND THE TURBINE UNIT
ASSEMBLY WHILE ONE OF THE OUTER COMBUSTION CASE HALVES IS LOOSE OR
REMOVED.
NOTE
To remove and install the one piece combustion outer case the turbine
unit assembly must be removed, refer to Section 13.
A. Either half of the outer combustion case may be removed. The upper
left half (referred to as the upper) will expose combustion liners 1,
5, and 6. The lower right half (referred to as the lower) will
expose combustion liners 2, 3, and 4. The position of the axial
JAN/91
12-5
c. Remove the nuts and bolts from both horizontal splitline flanges and
from the splitlines with the diffuser and with the turbine inlet case
as necessary to release the particular case half (Ref. Figure 12-2).
D. Loosen the nuts two full turns in the splitlines of the diffuser and
the turbine inlet case on the casing half not being removed.
CAUTION
DO NOT PRY OR INSERT TOOLS BETWEEN ANY OF THE SPLITLINE FLANGES. DAMAGE
TO THE SEALING SURFACES MAY OCCUR.
E. Use jackscrews in the threaded holes in the lower case half splitline
flanges to separate the case halves. Varying the tension on the
support at the diffuser may help free the case half. Do not pry or
use tooling between any splitlines (Ref. Figure 12-2).
F. Remove the case half and place it where it will not be damaged.
12-6
JAN/91
JACKSCREW
JACKSCREW
UPPER CASE
0.3125-24 UNJF-3B)
(0.31 25-24 UNJF-3B)
\
345678910111213
1415161718192021222324
25
mmm. .mmmm
mm m. Un m.m, m.m.mun. mm.
HORIZONTAL SPLITLINE
48
40
40
10
10
,30
30
An SPLITLINE
LOOKING FORWARD
FRONT SPLITLINE
LOOKING FORWARD
QHPO03XA
Figure 12-2.
JAN/91
12-7
Installation.
A. Prior to placing the removed outer combustion case half in position,
coat sealing surfaces of horizontal flanges with EMS-27700 sealant
(Plastiseal F).
B. Place the removed outer combustion case half in position. Loosely
install the combustion liner support assemblies and igniter with new
gaskets to ensure axial positioning of the combustion liners.
co Use a soft drift to achieve hole alignment and loosely install the
close tolerance bolts (hex head) in the proper holes. Loosely install
the remaining bolts and nuts in the splitlines with the diffuser and
with the turbine inlet case.
D. In the horizontal splitline flanges, loosely install the close
tolerance bolts (hex head) in holes 2, 8, 14, 20 and 26 numbered from
the diffuser end. Loosely install the remaining bolts and nuts (Ref.
Figure 12-2).
E. Torque the horizontal splitline flange bolts as follows:
1. On one horizontal splitline flange, torque to 140 lb in. (15.8
Nm) above prevailing nut torque in the following sequence:
Bolt position numbers 14, 15, 13, 16, 12, 17, 11, 18, 10, 19, 9,
20, 8, 21, 7, 22, 6, 23, 5, 24, 4, 25, 3, 26, 2, 27 and 1.
2. Repeat Step 1. for the opposite horizontal splitline.
12-8
JAN/91
Removal.
NOTE
The combustion liners can be removed by two methods; (1) With the engine
in a shop with the engines turbine unit assembly removed and (2) with
the engine installed by removing one of the outer combustion case
halves. The instructions contained here are for method (2) only. The
instructions for method (1) are contained in Section 13, which if
possible, is the recommended way.
A. Remove the outer combustion case half (Ref. Paragraph 12-5).
NOTE
If more than one combustion liner is to be removed, complete the removal
of each one before proceeding to the next combustion liner.
B. Remove the nut and bolt from the crossover clamp on both sides of the
combustion liner (Ref. Figure 12-3).
JAN/91
12-9
F. Lift the nozzle end of the combustion liner forward and out to
remove. Record the position of the combustion liner for
troubleshooting and/or installation.
12-10. Inspection.
NOTE
Refer to Section 3, Engine Inspection and Maintenance Tasks, Paragraph
3-6 for inspection and damage limits for combustion liners whether installed or removed. The limits are the most severe conditions that are
allowed to continue operation. If combustion liners are either removed
or accessible with an outer combustion casing half removed, consideration should be given to replacing marginally serviceable liners, or
individual liner sections (front liner section and/or transition
section).
12-11. Installation.
A. Place the combustion liner in position with the transition section
opening over the first stage turbine vanes. Work the liner rearward
until it is in position. The axial position of the liner is
determined by the liner support and the liner support ferrule.
Measuring the distance may help position the liner for easier
installation.
B. Install the fuel nozzle with gasket. Tighten bolts finger tight.
C. Use a small drift, punch or screwdriver to align the grommets, and
install the three associated borescope port plugs with gaskets per
Section 13.
12-10
JAN/91
AND
IZUNTENANCE
v
QHPO05XD
Figure 12-3.
12-11
12-13.
Crossover Clamps.
A. The six crossover clamps with spacers connect the crossover ferrules
of adjacent combustion liners.
B. The crossover clamps should be inspected whenever the engine is
disassembled enough to expose them.
12-14.
12-15.
12-16.
12-17.
12-12
JAN/91
EXCITER.
12-19.
12-20.
Removal.
WARNING
THE IGNITION SYSTEM MUST BE OFF FORAT LEAST 5 MINUTES BEFORE HANDLING
THE EXCITER. THIS PERIOD OF TIME PERMITS BLEED RESISTORS WITHIN THE
EXCITER TO DISSIPATE ENERGY STORED IN THE CONDENSERS. SEVERE INJURY OR
DEATH MAY OCCUR, IFAN ENERGIZED EXCITER IS HANDLED.
JAN/91
12-13
Inspection.
WARN ING
THE EXCITER TEST MUST NOT BE PERFORMED IN AN AREA WHERE THERE IS THE
POSSIBILITY OF A FUEL LEAK OR ANY OTHER EXPLOSIVE MATERIAL WHICH COULD
BE IGNITED. INJURY OR DAMAGE MAY OCCUR.
A. Connect two known good lead assemblies (8, Figure 12-4) and igniters
(29) to exciter (l).
WARN ING
NEVER HANDLE ENERGIZED IGNITER. SERIOUS PERSONAL INJURY MAY OCCUR FROM
CONTACT WITH AN ENERGIZED IGNITER.
B. Clip a jumper from the igniter (29) case and to the ground of the
power supply.
CAUTION
CONNECT 24 VOLT POSITIVE LEAD TO THE EXCITER INPUT PIN AND NEGATIVE
LEAD TO EXCITER CASE. REVERSING POLARITY CAN CAUSE INTERNAL DAMAGE TO
THE EXCITER.
C. Apply 24 volts dc to input terminal of the exciter (l), using a
minimum wire size of 16 gage, and observe firing, of the igniter.
12-14
JAN/91
13
14
15
1. EXCITER
2. BOLT (4)
3. WASHER (4)
4. NUT (4)
5. L.H. BRACKET
6. R.H. BRACKET
7. NUT (4)
8. LEAD ASSY (2)
9. BOLT
10. LONG BOLT
11. CLAMP (4)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
NUT (2)
BOLT(Z)
CLAMP (2)
NUT (2)
LEAD FLANGE (2
TERMINAL ASSY 2)
TERMINAL ASSY 2)
WASHER (4)
WASHER (4)
SOCKET (4)
CONNECTOR (4)
Figure 12-4.
JAN/91
f-l
23.
24.
25.
26.
CAUTION
THE IGNITION SYSTEM HAS A MAXIMUM CONTINUOUS RATING OF THREE MINUTES.
HOWEVER, TO PREVENT OVERHEATING OF THE EXCITER, THE OPERATING CYCLE
SHOULD NOT BE MORE SEVERE THAN TWO MINUTES ON, THREE MINUTES OFF, TWO
MINUTES ON AND 23 MINUTES OFF. DAMAGE WILL OCCUR, WHEN THE EXCITER
OVERHEATS.
D. Determine whether the observed spark is the initial (trigger) spark,
or the actual ignition spark. The trigger spark is a continuous,
flowing spark, while the ignition spark is instantaneous, very
brilliant, and accompanied by a sharp report. This latter spark
observed at each igniter is repetitive with a rate of approximately
six to eight sparks per second. If either igniter fails to fire,
fires at a greatly reduced rate, fires intermittently, or fires only
the trigger spark, replace the exciter.
E. If there is a question about the exciter after the above tests, check
the unit at 20 volts dc input voltage measured at the input terminals
to the exciter. The minimum acceptable spark rate at 20 volts dc
input voltage is four sparks per second.
12-22.
Installation.
A. If removed, install LH support (5, Figure 12-4) and/or RH support
(6), secure with nuts (7). Torque nuts to 74-89 lb in. (8.4-10.0
Nom).
B. Install exciter (1) to LH and RH supports (5 and 6), secure with
bolts (2), washers (3), and nuts (4). Torque nuts to 74-89 lb in.
(8.4 -10.0 N-m).
NOTE
Hold terminal to prevent lead assembly from turning.
C. Install terminal assemblies (18) to exciter (l). Torque terminal
nuts (24) to 100-120 lb in. (11.3-13.6 Nom) and lockwire nuts to
each other.
12-16
JAN/91
12-24.
12-25.
Removal.
WARN ING
NEVER HANDLE AN ENERGIZED IGNITER. MAKE SURE THAT IGNITION SYSTEM HAS
BEEN OFF FORAT LEAST FIVE MINUTES BEFORE REMOVING AN IGNITER. THIS
TIME WILL ALLOW THE EXCITER BLEED RESISTORS TO DISSIPATE ALL ENERGY
STORED IN THE CONDENSERS. SEVERE INJURY OR DEATH MAY OCCUR IF AN
ENERGIZED IGNITER IS HANDLED.
NOTE
Removal of the igniters and liner body supports are the same
procedures, except for the lead assemblies. Delete following Step 1.,
if only removing the liner body supports.
NOTE
Hold lead assembly to prevent from turning when removing nut.
A. Disconnect terminal assembly (17, Figure 12-4) from igniter (29).
Hold lead assembly (8) to prevent any twisting damage when removing
nut (24). Remove lead assembly from igniter by pulling straight
outward with no rotational movement.
B. Apply penetrating oil, VV-P-216, to bolts (25 and/or 26) and allow
sufficient time for penetrating oil to penetrate the threads.
JAN/91
12-17
Insr)ection.
NOTE
If liner support is worn on one side and not worn through, the liner
support may be used again, but will have to be rotated 180 degrees on
installation.
A. Inspect liner support (32, Figure 12-4) for wear and/or burning.
Wear over 0.03125 (1/32) inch (0.8 mm) deep on both sides or if liner
support is worn through is cause for replacement of the liner
support.
NOTE
During engine operation, the electrodes erode (or burn away) becoming
rounded. This is a natural condition and does not affect igniter
performance unless the electrode becomes shorter than the ceramic, when
this condition occurs, replace the igniter.
B. Inspect the igniter center electrode length. If electrode is shorter
than the ceramic, replace the igniter.
C. Inspect the igniter ceramic tips for cracks. If any cracks are
visible through the carbon coating, replace the igniter.
D. Clean igniters carbon deposits using a bristle brush or a clean dry
cloth.
E. Inspect igniter firing.
WARNING
NEVER HANDLE AN ENERGIZED IGNITER. SERIOUS PERSONAL INJURY MAY OCCUR
FROM CONTACT WITHAN ENERGIZED IGNITER.
12-18
JAN/91
WARNING
THE IGNITER TEST SHOULD NOT BE PERFORMED IN AN AREA WHERE THERE IS THE
POSSIBILITY OF A FUEL LEAK OR ANY OTHER EXPLOSIVE NATERIAL WHICH COULD
BE IGNITED. INJURY OR DAMAGE MAY OCCUR.
1. Connect a known good exciter (1, Figure 12-4) and a lead assembly
(8) to the igniter (29) being tested. 2. Clip a jumper from the igniter (29) case and to the ground of the
power supply.
CAUTION
CONNECT 24 VOLT POSITIVE LEAD TO THE EXCITER INPUT PIN AND NEGATIVE
LEAD TO EXCITER CASE. REVERSING POLARITY CAN CAUSE INTERNAL DAMAGE TO
THE EXCITER.
NOTE
Difference n spark rate between the two igniters is not cause for
replacement unless the spark rate is intermittent.
3. Apply 24 volts dc to the input terminal of the exciter, usinq
minimum wire size of 16 gage, and observe the firing. If sp~rk
rate is intermittent, replace the igniter.
F. Shut off 24 volts dc power to exciter, short the igniters with
insulated tool.
G. Remove igniter from test equipments.
12-27.
Installation.
A. Apply Ablube, MIL-L-25681, to the bolts (25 and/or 26, Fiwre 12-4)
threads.
NOTE
. If line support wear is 0.03125 (1/32) inch (0.8 mm) and not worn
through rotate 180 degree and install.
JAN/91
12-19
LEAD ASSEMBLIES.
12-29.
Removal.
WARNING
SERIOUS PERSONAL INJURY MAY OCCUR IF IGNITION SYSTEM IS ENERGIZED.
A. Make sure 24 volts dc is removed from exciter (1, Figure 12-4).
UARN ING
THE IGNITION SYSTEM SHOULD BE OFFAT LEAST 5 MINUTES BEFORE HANDLING
THE IGNITION SYSTEM COMPONENTS. SEVERE INJURY MAY OCCUR.
B. Disconnect terminal assemblies (18, Figure 12-4) from exciter (1)
while holding lead assembly (8) to prevent twisting. Remove terminal
from exciter by pulling straight outward with no rotational movement.
C. Disconnect terminal assemblies (17) from igniters (29) while holding
lead assembly (8) to prevent twisting. Remove terminal from igniter
by pulling straight outward with no rotational movement.
NOTE
Record location of clamps and long bolts for installation.
12-20
JAN/91
Inspection.
A. Inspect lead assemblies for cuts, kinks, and damage. Replace as
required.
B. Inspect terminal assemblies (17 and 18, Figure 12-4) for damage.
Replace washers (19 and 20), socket (21), connector (22), or spring
assemblies (23) as required.
12-31.
Installation.
A. Install lead assembly(ies) (8, Figure 12-4) to exciter (1) and
igniter (29). Tighten terminal nuts (24) finger tight only.
B. If required, install bolts (9, 10, and 13), clamp (11 and 14), nuts
(12 and 15), and lead flange(s) (16) to positions record on removal,
Torque all nuts to 37-42 lb in. (4.2-4.7 Nom).
CAUTION
HOLD LEAD ASSEMBLY TO PREVENT TURNING WHILE TIGHTENING OR TORQUING NUT
TO PREVENT DAMAGE TO THE LEAD ASSEMBLY.
C. Hold lead assembly (8) to prevent turning, torque nut (24) to 100-120
lb in. (11.3-13.6 N-m) and lockwire per Figure 12-5.
Figure 12-5.
JAN/91
QHI031XE
Lockwiring of Igniter, Igniter Lead, and Liner Support.
12-21
Paraara~h
JAN/91
Paae No.
13-1
13-5
13-2
13-6
13-3
13-6
13-4
13-18
13-5
13-19
13-6
13-24
13-7
13-27
13-8
13-29
13-9
13-32
13-10
Cleaning
13-34
13-11
13-34
13-12
13-37
13-13
13-37
13-14
13-38
13-15
13-39
13-16
13-40
13-17
13-42
13-18
13-45
13-19
13-47
13-1
t)escri Dtion
Paqe No.
13-20
13-48
13-21
13-50
13-22
13-51
13-23
13-52
13-24
13-53
13-25
13-55
13-26
Engine Installation
13-60
INDEX TO FIGURES
Fiqure No.
13-2
Paqe No.
13-1
13-7
13-2
13-9
13-3
13-10
13-4
13-11
13-5
13-12
13-6
13-12
13-7
13-14
13-8
13-16
13-9
13-16
13-10
13-17
13-11
13-17
13-12
13-18
JAN/91
1
Allison Engine Company
JAN/91
Title
Paqe No.
13-13
13-20
13-14
13-22
13-15
13-22
13-16
13-23
13-17
13-23
13-18
13-24
13-19
13-25
13-20
13-26
13-21
13-28
13-22
13-30
13-23
13-30
13-24
13-31
13-25
13-31
13-26
13-32
13-27
13-33
13-28
13-34
13-29
13-35
13-30
13-35
13-31
13-36
13-32
13-43
13-33
13-43
13-34
13-44
13-3
Title
Pacie No.
13-35
13-46
13-36
13-49
13-37
13-50
13-38
13-51
13-39
13-54
13-40
13-56
INDEX TO TABLES
Table No.
13-1
13-4
Title
Turbine Unit Assembly Inspection
Paqe No.
13-39
JAN/91
c. The combustion inlet casing and combustion inlet casing liner form a
heat shield and enclose the scavenge and pressure oil tubes and the
turbine shaft. The combustion inlet casing liner incorporates a
bellows type expansion joint at the rear end to allow for expansion,
contraction, and/or misalignment.
D. The inlet casing encloses the 1st stage vane assembly, front bearing
support, and bearing (No. 3). The inlet casing is bolted to the
combustion outer casing, at the forward end, and to the vane casing
at the rear end.
E. The vane casing encloses the rotor assembly and the 2nd, 3rd, and 4th
vane assemblies. The vane casing is bolted to the inlet casing, at
the forward end, and to the rear bearing support, at the rear end.
F. The rear bearing support houses the rear bearing (No. 4), rear
bearing labyrinth seal, provides a mount flange for the rear scavenge
oil pump, and for the turbine outlet temperature (TOT) thermocouples
(T/C) . The rear bearing support provides an outlet duct for the hot
exhaust gas.
Go The rotor assembly consists of four turbine wheels supported by
roller bearings at each end. The four stage turbine rotor assembly
provides the horsepower (HP) to drive the components.
H. Labyrinth seals are used at the front and rear bearing locat ens.
JAN/91
13-5
13-3.
13-6
JAN/91
mF
ROTOF
COMBUSTION
OUTERCASING
I
+
- - - - >.
t
I - - - 1 0 >
~+
3)
-TT---Tyy
COMBUSTION
.#--
ST;
STAGE
S%E
TURBINE TLK
TURBINE II
.Ai
,-
-/7\\
LKXIOiiEL
DRAIN VALVE
Figure 13-1.
JAN/91
13-7
~-.-r.>
----+
COOLING AIR
~ VENTEDAIR
~ EXHAUSTAIR
<....<=
d
%.
., .\ \
..:.:.,,
.
.......
.y,.:h
. . . -..:..... t
. .*. ../..;
~
b ., -.:.,.
*& . . . . . .;
~.s, .
.- --- :.. .
. . .1..c:;G
3RD
STAGE
VANES
TK\(12)
S;;E
VANES
Figure 13-1.
13-8
\
REhR BEARING
SUPPORT
QHFOISXK
JANf91
COMPRESSOR
HOLDER(3755)
QHT036XD
Figure 13-2.
JAN/91
13-9
/----
LOCKRING
TIE BOLT RETAINING NUT
LOCKPIN
DRIVE COUPLING
GASKET
;: TIE BOLT
7. HEADLESS PIN
8. PACKING (O-RING)
QHF012XA
Figure 13-3.
13-10
JAN/91
RETAINING NUT
WRENCH (6796S30)
WRENCH SUPPORT
(6796382)
T-HANDLE
QHT025XD
Figure 13-4. Removal of Tie Bolt Retaining Nut.
9.
10. Remove lockpin (3, Figure 13-3), drive coupl ng (4), and gasket
(5). Discard gasket.
CAUTION
IF DURING REMOVAL OF THE TIE BOLT, BREAKAWAY TORQUE EXCEEDS 5500 INCH
POUNDS (621 N-m). DO NOT REUSE TIE BOLT IF TIE BOLT IS DAMAGED,
TWISTED, BENT, AND/ORTHREAD STRESSED.
11. Remove tie bolt (6) usina a toraue wrench. wrench suDDort.
6796382, and tiebolt wr=nch, 6i96533 (Ref. Figure 13:5),if
breakaway torque exceeds 5500 lb in. 621 Nom), replace the tie
bolt. When tie bolt is loose, remove torque wrench, wrench
support, and tie bolt wrench. Remove tie bolt by hand. Remove
and discard O-ring (8, Figure 13-3). Do not remove headless pin
(7).
12. Only loosen, do not remove, rear bearing clamp nut (35, Figure
13-13) using rear bearing clamp nut wrench, 6796529, and wrench
support, 6796382 (Ref. Figure 13-6).
13. Remove the four top bolts (1, Figure 13-7) and nuts (3) at
positions 1, 2, 47, and 48, and install turbine lifting adapter,
6799620, to the turbine lift bracket and engage the lifting
JAN/91
13-11
TIE BOLT
WRENCH
\\%&k
*?.. \\\N\ \\ \\\\\\P
\\\\ \vlll/ 1
WRENCH
SUPPORT /
(6796382)
0
sL-
Figure 13-5.
REAR BEARING
CL&f#T , py-.i-.~
. . . .
\ \
%
7
.
- - -
-_
=*
K!!r
Figure 13-6.
13-12
ET
QHT037XD
JAN/91
Record positions of slab head bolts, hex head bolts, and brackets for
installation.
Hex head bolts are used for the two piece outer combustion casing.
If a one piece outer combustion casing is installed, all are slab head
bolts.
14. Remove slab head bolts (1, Figure 13-7), hex head bolts (2), nut
(3), and brackets (4), and slowly pull the turbine unit assembly
(22) to the rear to disengage it from the compressor, turbine
coupling shaft assembly (5), and to the outer combustion case (6).
15. Install the turbine unit assembly (22) horizontally in an engine
turnover stand, 6797352, with the attaching stand adapter,
6796644, clamping it to the forward rib of the turbine rear
bearing support (Ref. Figure 13-9).
NOTE
Removal of the turbine coupling shaft assembly for inspection is
allowed. Disassembly of the turbine coupling shaft assembly is not
allowed at this Maintenance Level. The turbine coupling shaft assembly
requires a high speed balance if it is disassembled.
16. If required, remove retaining ring (7, Figure 13-7) and turbine
coupling shaft assembly (5) from compressor diffuser for
inspection.
17. Remove and discard split seal rings (20) and O-rings (21).
CAUTION
USE CAUTION WHEN PULLING TURBINE ROTOR ASSEMBLY TO THE REAR, EXCESSIVE
FORCE MAY DAMAGE THE TURBINE ROTOR ASSEMBLY AND/OR VANES.
JAN/91
13-13
l-fl~
./
- 1
46
,1
/
30
21
SPLITLINE
BOLT POSITION
LOOKING FORWARD
22
>
b ./
e
c?
r\\2
15
QHF013XA
Figure 13-7.
13-14
JAN/91
4.
5.
6.
7.
8.
9.
10.
110
BRACKET (AR)
TURBINE COUPLING SHAFT ASSY
OUTER COMBUSTION CASING
RETAINING RING
NUT (36)
GASKET (18)
PORT PLUG (18)
COMBUSTION LINER (6)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
CROSSOVER CLAMP
BOLT
NUT
SPACER
BOLT (6)
NUT (6)
TRANSITION ASSY
FRONT LINER ASSY
SPLIT SEAL RING (2)
PACKING (O-RING) (3)
TURBINE UNIT ASSY
18. Insert positioning wrench, 6796569, into the turbine rear bearing
clamp nut and slowly pull the turbine rotor assembly to rear until
it has touched or seated (Ref. Figure 13-10).
19. Remove positioning wrench and install rotor clearance adjusting
jack, 6797484, by its two screws to the rear scavenge oil pump
mounting flange of the rear bearing support. Adjust the rotor
clearance adjusting jack until it seats against the rear of
turbine rotor assembly shaft (Ref. Figure 13-11).
20. Rotate the turbine unit assembly (22, Figure 13-7) in the engine
turnover stand until combustion liners are in the vertical
position (pointed straight up).
21. Remove all nuts (8), gaskets (9), and port plugs (10) from the
turbine unit assembly (22). Discard gaskets.
CAUTION
WHEN MARKING AND/OR IDENTIFYING ANY PART SUBJECTED TO HIGH TEMPERATURES
DO NOT USE ANY tiRKING MATERIAL (PEN, PENCIL, INK, ETC.) CONTAINING
GRAPHITE. GRAPHITE MAY CAUSE DAMAGE TO THE PARTS.
22. Mark combustion liners, positions 1 through 6, using the approved
marker. To select the approved marker, refer to Section 14,
General Maintenance.
23. Remove combustion liners as a unit, using a combustion liner
adjustment and lifting fixture, 23003623 (Ref. Figure 13-12).
24. To protect the turbine unit assembly during disassembling and/or
temporary storage, install cover, 6799717, over the turbine inlet
casing.
JAN/91
13-15
ADJ
AP TER
QHT027XD
Figure 13-8.
LIFTINGADAPTER
(6799620)
STAND ADAPTER
(6796644)
\
Q
@
Q
ENGINETURNOVER
STAND(679~52)
( d%QL
QHF017XD
Figure 13-9.
13-16
JAN/91
POSITIONING
WRENCH
(6796569)
JAN/91
Figure 13-10.
F gure 13-11.
13-17
.COMBUSTION LINER
LIFTING ADAPTER
(23003623)
MH
0
00
00
QHF020XD
Figure 13-12.
25. Remove combustion liner(s) (11, Figure 13-7) from the assembled
combustion liner unit by removing the required crossover clamps
(12), bolts (13), nuts (14), and spacers (15) per Combustion
Section, Section 12.
26. If required, disassemble combustion liner(s) (11) by removing
bolts (16), nuts (17) and separate the transition assembly (18)
from the front liner assembly (19). Inspect as outlined in Engine
Inspection and Maintenance, Section 3.
13-4.
13-18
JAN/91
FRONT BEARING, FRONT BEARING SUPPORT, FRONT BEARING CAGE, AND FRONT
BEARING LABYRINTH SEAL REMOVAL.
A. Remove lockring (20, Figure 13-13) from the turbine coupling clamp
nut (21) and inside of the turbine drive shaft.
B. Remove turbine coupling clamp nut (21) using a 0.750 (3/4) inch
T-handle and clamp nut wrench, 6799621 (Ref. Figure 13-16).
C. Remove assembled shaft coupling (22, Figure 13-13) and shaft adapter
(23) from turbine units drive shaft. Separate shaft COUPI ing and
shaft adapter by removing a retaining ring (24) and after separation
remove remaining retaining ring (24).
D. Remove bearings (25) inner race and rollers using bearing removal
tool, 6799902 (Ref. Figure 13-17).
E. Remove front bearing support (26, Figure 13-13) using three
T-handles, 6797000 (Ref. Figure 13-18).
JAN/91
13-19
/-
--- //
33
r+
13
QHG16XA
Figure 13-13.
13-20
JAN/91
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
B O L T 241
GANG NUT
GANG NUT (5)
COMBUSTION INNER CASING
PACKING (O-RING)
BOLT (24)
PACKING (O-RING)
SEAL
COMBUSTION INNER CASING LINER
BOLT (2)
SCAVENGE OIL TUBE
BOLT (2)
TUBE AND NOZZLE ASSY
TAB LOCKWASHER
OIL NOZZLE
TAB LOCKWASHER
TAPERED OIL NOZZLE
LOCKRING
TURBINE COUPLING CLAMP NUT
i SHAFT COUPLING
23. SHAFT ADAPTER
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39,
40,
41,
42.
43,
44.
45.
46.
13-21
,B
COMBUSTION
~ INNER CASING
HANDLE
(6797000)
COVER
(6799717)
Jf
QHP012XD
Figure 13-14.
COMBUSTION
INNERCASING
~ LINER
e
u
QHP013XD
Figure 13-15.
13-22
JAN/91
JT
QHG021XE
Figure 13-16.
ROLLERS
f
Figure 13-17.
JAN/91
I
\1
QHT038XD
13-23
QHF027XD
Figure 13-18.
NOTE
If difficulty is encountered in the following step, the front bearing
labyrinth can be removed after the inlet casing has been removed,
refer to Paragraph 13-6, Step D.
I. If required, remove front bearing labyrinth seal (33) using front
bearing labyrinth seal, 6799902 (Ref. Figure 13-20).
13-6.
13-24
JAN/91
s
BEARING
OUTER
RACE
FRONT
BEARING
CAGE
S P1. .ATE
BOLTS
13-25
QHT039XD
Figure 13-20.
NOTE
Record position of 1st stage vanes, saddles, and gang nuts for
installation.
B. Remove bolts (7), guide vane and seal support (8), 1st stage vanes
(9), saddles (10), 1st stage vane air seal ring (11), and gang nuts
(12 and 13).
C. Turn inlet casing (6), forward side up, on work bench and remove
screws (14), gang nuts (15 and 16), and insulation blanket (17).
NOTE
If removal of the front bearing labyrinth seal (33, Figure 13-13) is
required, remove per following step.
D. If required, remove front bearing labyrinth seal (33, Figure 13-13)
as follows:
1. Clean labyrinth seal (33) and surrounding area with solvent,
MIL-M-13999 and wipe with a clean cloth to remove all traces of
oil. Allow solvent to air dry.
13-26
JAN/91
WARNING
MAKE SURE SOLVENT IS DRY BEFORE HEAT IS APPLIED. INJURY TO PERSONNEL
AND/OR DAMAGE MAY OCCUR.
CAUTION
DO NOT CONCENTRATE HEAT IN ONE AREA, HEAT MUST BE KEPT MOVING OR DAMAGE
MAY OCCUR.
NOTE
Steps 2 and 3 should be done as quickly as possible, not allowing
labyrinth seal to cool.
2. Cover turbine rotor assembly with a suitable fire blanket. Heat
forward bearing labyrinth seal (33), using propane or butane
torch, moving the torch around the labyrinth seal. Heating should
require approximately three (3) minutes.
3. Install turbine front bearing labyrinth seal puller, 6799902,
engaging clam shell flange in a slot in the labyrinth seal.
Remove labyrinth seal (Ref. Figure 13-22).
4. Remove fire blanket.
NOTE
Use front labyrinth seal puller, 6799623, the same as front bearing
labyrinth seal puller, 6799902, refer to Figure 13-20.
13-7.
JAN/91
13-27
---
1
Allison Engine Company
501 -KB5 DEC OPERATION AND MAINTENANCE
231
i ___
18
19
I!fi
20--T
II
I-@
32
QHG019XA
Figure 13-21,
13-28
JAN/91
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
LIFT BRACKET
2ND STAGE VANE RETAINER (4)
REAR PILOTING KEY (4)
NUT (4)
VANE CASING
2ND STAGE VANE AIR SEAL RING
3RD STAGE VANE AIR SEAL RING
2ND STAGE VANE (12)
3RD STAGE VANE (6)
4TH STAGE VANE (6)
ROTOR ASSY
REAR LABYRINTH SEAL
OIL TUBE BRACKET
PACKING (O-RING)
REAR BEARING OIL TUBE
METALLIC O-RING SEAL
GASKET
REAR BEARING OIL SEAL
BOLT (13)
INNER FRONT EXHAUST CONE
REAR BEARING SUPPORT
C. Remove 3rd and 2nd stage vane air seal rings (27 and 28, Figure
13-21).
NOTE
Record and mark the 2nd, 3rd, and 4th vane positions to aid in
inspection location of burner problems. Refer to General Maintenance,
Section 14, for correct marking material.
D. Remove 2nd, 3rd, and 4th stage vanes (29, 30, and 31) from rotor
assembly (32). Be sure to number (mark) each vane in their
respective place for insta lation (Ref. Figure 13-24).
E. Remove rear piloting keys
13-8.
JAN/91
13-29
/7
QHT035XD
Figure 13-22.
/F--
QHT034XD
Figure 13-23.
13-30
JAN/91
QHG015XD
Figure 13-24.
4P
TRUNNION~ z
ADAPTER
;
(6799523)
pil!J
ROTORLIFFINGADAPTER
(6799619)
ROTORASSY
REARBEARING
SUPPORT
QHT033XD
Figure 13-25. Removal of Rotor Assembly.
JAN/91
13-31
1---
REARBEARINGAND
SEAL PULLER (23055344)
9
QHT032XD
Figure 13-26.
13-32
ER
QHF024XD
Figure 13-27. Rotor Assembly Installed in Rotor
Transportation and Storage Stand.
CAUTION
REMOVE REAR BEARING OIL TUBE BY USING A WRENCH ONLY ON THE HEX PORTION
DO NOT USE A WRENCH ON THE INNER OR OUTER FLANGE OF THE REAR BEARING O iL
TUBE OR DAMAGE MAY OCCUR.
c. Remove oil tube bracket (34) and rear bearing oil tube (36) by using
a wrench of hex portion. Remove and discard O-ring (35).
D. Remove the seven long bolts (37, Figure 13-13) rear bearing retainer
(38), and locking key (42).
E. If required, disassemble rear bearing retainer (38) as follows:
1. Bend locking tab down on tab lockwasher (40) and remove oil nozzle
(39) and tab Iockwasher from retainer (41). Discard lockwasher.
2. Repair, replace, or clear as required.
F. Remove two short bolts (36) and then remove rear bearina caae (46)
using rear bearing cage-puller, 6796531 (Ref. Figure 13~28)~
JAN/91
13-33
REAR BEARING
CAGE PULLER
(6796531)
QHF023XD
Figure 13-28.
G. Remove rear bearinqs (43, Fiqure 13-13) outer race from rear bearina
cage (46) using re~r outer ra;e puller,6796541 (Ref. Figure 13-29).
H. Remove metallic O-ring seals (44 and 45, Figure 13-13) from rear
bearing cage (46) and/or rear bearing support (42, Figure 13-21)
using pliers, 6796619 (Ref. Figure 13-30).
I. Remove bolts (40, Figure 13-21), inner front exhaust cone (41), rear
bearing oil seal (39), and gasket (38) from the rear bearing support
(42) . Discard gasket.
J. Remove and discard metallic O-rinq seal (37) from rear bearinq
support (42) using pliers, 6796613.
13-10. CLEANING.
13-11. DIFFUSER SUMP AREA.
CAUTION
IF A BAFFLE HAS NOT BEEN INSTALLED, CARBON DEPOSIT CAN ACCUMULATE JUST
OUTBOARD OF THE DIFFUSER SLEEVE AND BECOME DISLODGED CAUSING A BLOCKAGE
OF THE SUMP DRAIN. A THOROUGH INSPECTION AND CLEANING OF THIS AREA MUST
BE DONE WHENEVER THE TURBINE UNIT ASSEMBLY HAS BEEN REMOVED. LATER
UNITS HAVE A WELDED BAFFLE INSTALLED TO PREVENT THE CARBON BUILDUP.
13-34
JAN/91
AllisonEngin eCompany
-)
?
\
\
(
REARBEAI?ING
C)UTERRACEPULLER
(6796541)
CAGE
QHF021XD
Figure 13-30.
JAN/91
13-35
14TH STAGE
COMPRESSOR
WHEEL
BAFFLE
WELDEDAREA
BAFFLEINSTALLED
I
DIFFUSER
SCAVENGE
OIL TUBE
QHJ012AD
Figure 13-31.
13-36
JAN/91
BEARINGS INNER RACE, OUTER RACE, AND ROLLERS ARE A MATCHED SET. DAMAGE
TO ANY PART WILL REQUIRE COMPLETE BEARING REPLACEMENT. BEARING MUST BE
RETAINED AS A MATCHED SET.
A. Cleaning.
1. Immerse bearing in mineral spir ts, AMS-3160, or equivalent for 10
minutes.
CAUTION
DO NOT SPIN BEARINGS HITHAIR BLAST.
13-37
2. Immerse bearing in clean engine lube oil and wrap the bearing in
glassine paper with the waxed side against the bearing. Secure
glassine paper to ensure a dust-tight seal using tape. This
storage is also good for up to 30 days.
3. Storage more than 30 days:
a. Clean bearing prior to Step A.
b. Immerse bearing in clean corrosion preventive compound
petrolatum, MIL-C-11796A, Class 3, heated at 165-175F
(74-79C). Move bearing up and down to ensure the first
congealed coating melts off and the bearings have an oily
Allow bearing to cool to less than lOOF (38C).
appearance.
NOTE
Storage may be made using plastic bags or other protective wrappings.
c. Wrap bearing in glassine paper with the waxed side against the
bearing. Secure glassine paper to ensure a dust-tight seal.
13-14. Inlet Casinq, Vane Casinq, Vanes, and Rear Bearincl Support.
CAUTION
DO NOT CLEAN FLAME PLATED PARTS (SUCH AS THE BEARING CAGES) USING
ALKALINE RUST REMOVER SOLUTIONS. DAMAGE TO FLAME PLATED AREA MAY OCCUR.
13-38
JAN/91
Accet)tance Condition
1.
2.
Insulation B anket
(3, Figure 7 8)
3.
4.
Support Assembly
(5, Figure 7-8)
5.
6.
No visual damage.
7.
JAN/91
13-39
Part
Acceptance Condition
8.
Combustion Liners
9.
10.
No cracks allowed.
11.
13-40
JAN/91
13-41
JAN/91
MAINTENANCE
TOP
REAR BEARING
RETAINER
QHG017XD
REAR
BEARING ~=
RETAINER
A
II
ER
(6798242)
W&J& /
..tm n,l-rrn
ANU UUltll
L4
RACE
Figure 13-33. Rear Bearing Rollers Retainer, 6798242.
JAN/91
QHT040XD
13-43
E. Install rotor clearance ad.justincl jack (Ref. Figure 13-11) and adjust
until it supports the roto; asse;bly (32, Figure 13-21). Remove
hoist and rotor lifting adapter, 6799619.
F. Install 4th stage vanes (31) to positions recorded on removal (Ref.
Figure 13-24).
G. Install 3rd stage vanes (30, Figure 13-21), align number 1 position
between number 1 and six position of the 4th stage vanes position
locating tang at the top vertical center line (Ref. Figure 13-24).
H. Install 3rd stage vane air seal ring (28, figure 13-21) over 3rd
stage vanes. Align notches in the 3rd stage vane air seal with 3rd
stage vane tangs and slit in 3rd stage vane air seal ring shall be
aligned with the midpoint of the 3rd stage vane segment.
I. Install 2nd stage vanes (29) with key aligned into 3rd stage vanes
(30) and slot opening of 3rd stage vane air seal ring (28) (Ref.
Figure 13-24).
J. Install 2nd stage vane air seal ring (27, Figure 13-21) over 2nd
stage vanes and slit in 2nd stage vane air seal ring shall be aligned
~ROTORASSY
QHT033AD
Figure 13-34.. Installing Rotor Assembly.
13-44
JAN/91
13-45
FIAINTENANCE
B. Place guide vane and seal support (8) on a work bench and install 1st
stage vanes (9) and saddles (10) the correct positions (Ref. Figure
13-35) .
C. Install the 1st stage vane air seal (11, Figure 13-21) over the 1st
stage vanes (9).
D. Apply high temperature lubricant and anti-seize compound (SiliconeMolybdenum Disulfide), DC-550-R, to the threads of bolts (7).
QHG020XF
Figure 13-35.
13-46
JAN/91
ing keys at
12, 13, 24,
the two
Splitline A
H. Install the upper oil tube brackets (4) and the lower oi tube
bracket (5), secure Splitline A with the correct slab hei d bolts (1)
and nuts(2). Torque all nuts to 70-90 lb in. (7.91-10.17 N-m).
13-19. FRONT BEARING SUPPORT AND FRONT BEARING CAGE INSTALLATION.
A. Install rotor front labyrinth seal (19, Fi~ure 13-21) on rotor
assemblys (32) front shaft and sec;re witfi locking. The rotor
front labyrinth seal to rotor assembly front shaft fit shall be
0.000-0.001 in. (0.000-0.025 mm) L.
NOTE
When aluminum graphite seals are used, apply a light coat of anti-seize
compound, EMS-27627, to labyrinth seal mating surface, prior to
installation.
B. If required, apply clean engine oil to the mating surfaces of the
split seal rings (31 and 32, Figure 13-13) and the front bearing cage
(27). Install split seal rings on the front bearing cage.
JAN/91
13-47
JAN/91
*I
/:
.
FRONT BEARING
INNER RACE PUSHER
(6799641)
FRONT BEARING
QHT041XD
Figure 13-36.
puller lip forward, using front bearing inner race pusher, 6799641
(Ref. Figure 13-36). The bearings inner race to rotor shaft fit
shall be 0.0005 in. (0.0127 mm) T to 0.001 in. (0.025 mm) L.
D. Coat splines of shaft coupling (22, Figure 13-13), shaft adapter
(23), and turbine units (34) rotor shaft with clean engine oil.
E. Install shaft coupling (22) to shaft adapter (23) and secure with
retaining rings (24). Install assembled shaft coupling and adapter
to turbine units (34) rotor shaft.
F. Coat threads of turbine coupling clamp nut (21) with high temperature
lubricant and anti-seize compound (Silicone-Molybdenum Disulfide),
DC-550-R.
NOTE
Use a torque wrench instead a T-handle as shown in Figure 13-16.
G. ~;:~;ll turbine coupling clamp nut (21) to turbine units (34)
Torque turbine coupling clamp nut to 70-90 lb ft. (95-122
Nm), using torque wrench and clamp nut wrench, 6799621, aligning
the lockring (20) holes. Install lockring inside turbine unit rotor
shaft (Ref. Figure 13-16).
JAN/91
13-49
Figure 13-37.
13-50
I
I ---- .-
WRENCH
SUPPORT
JAN/91
MEASURING
GAGE(3856)
QHF015XD
Figure 13-38.
JAN/91
13-51
13-52
JAN/91
13-53
BOLT
IE al
NUT L
1
Figure 13-39.
13-54
t
I
FERRULE
Combustion, Liner Crossover Clamping.
QHPO05XD
JAN/91
JAN/91
13-55
--~--
..~-- -
1
GAGE PIN
Figure 13-40.
-. --
-. -- /
COmbUStiOn
INNERCASING
STOP RING
QHF016XD
NOTE
Hex head bolts are used for the two piece outer combustion casing at
splitline positions 3, 6, 13, 20, 27, 30, 37, and 44.
J. Coat the threads of slab head bolts (1) and hex head bolts (2)
with high temperature lubricant and anti-seize compound (SiliconeMolybdenum Disulfide), DC-550-R.
K. Install slab head bolts (l), hex head bolts (2), brackets (4), and
nuts (3), to positions recorded on disassembly, to secure the outer
combustion casing (6) and turbine unit assembly (22). Torque all
nuts to 200-220 lb in. (22.6-24.8 Nm).
13-56
JAN/91
JAN/91
13-57
JAN/91
13-59
13-60
JAN/91
Paqe No.
14-1
Introduction
14-3
14-3
14-3
14-4
14-4
14-5
14-4
14-6
Lockwiring
14-12
14-7
Universal Fittings
14-13
14-8
14-9
JAN/91
Descri~tion
Installing Universal
Fitting Without Back-up Rings
Rigid Tube Installation
14-13
14-17
14-11
Flared Tubes
14-17
14-12
Flanged Tubes
14-17
14-13
14-18
14-14
14-19
14-15
14-21
14-16
14-22
14-17
Recommended Markers
14-23
14-1
.. _..
Title
Paqe No.
14-1
14-5
14-2
14-14
14-3
Examples of Lockwiring
14-15
14-4
Universal Fittings
14-16
14-5
14-19
INDEX TO TABLES
Paqe No.
Fiaure No.
14-2
14-1
14-6
14-2
14-7
14-3
14-8
14-4
14-8
14-5
14-9
14-6
14-10
14-7
14-10
14-8
14-11
14-9
14-11
14-10
Recommended Markers
14-23
JAN/91
INTRODUCTION.
14-2.
14-3.
I
I
.
JAN/91
14-5.
14-4
JAN/91
2!!3
2!33
/SHORT PRONG
LONG PRONG
CUT
c
f!!!!
QHYO06XD
Figure 14-1.
14-5
14-6
Torque
Lb ln (N-m)
Lb Ft (Nom)
6-8 (0.7-0.9)
6-8 (0.7-0.9)
7-9 (0.8-1.0)
9-11 (1.1-1.2)
12-15 (1.4-1.7)
17-20 (2.0-2.2)
25-30 (2.9-3.9)
35-40 (4.0-4.5)
60-65 (6.8-7.3)
70-85 (8.0-9.6)
105-115 (11.9-12.9)
120-150 (13.6-16.9)
205-245 (23.6-27.6)
240-280 (27.1-31.6)
350-390 (39.6-44.0)
400-465 (45.2-52.5)
48-54 (65.1-73.2)
60-65 (81.4-88.1)
65-75 (88.2-101.6)
90-100 (122.0-135.5)
Torque
Lb In (Nm)
Lb Ft (Nom)
6-8 (0.7-0.9)
6-8 (0.7-0.9)
8-10 (0.9-1.1)
10-12 (1.2-1.3)
13-17 (1.5-1.9)
19-22 (2.2-2.4)
27-32 (3.1-3.6)
37-42 (4.2-4.7)
65-70 (7.4-7.9)
74-89 (8.4-10.0)
113-123 (12.8-13.8)
140-170 (15.9-19.6)
217-257 (24.6-29.0)
265-300 (30.0-33.8)
367-407 (41.5-45.9)
414-479 (46.8-54.1)
49-55 (66.5-74.5)
63-67 (88.5-90.8)
67-77 (90.9-104.3)
93-102 (126.1-138.2)
JAN/91
Torque
Lb In (Nm)
6-32
6-40
8-32
8-36
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/18-18
3/4-10
JAN/91
Lb Ft (Nom)
7-9 (0.8-1.0)
9-11 (1.1-1.2)
12-16 (1.4-1.8)
14-17 (1.6-1.9)
22-25 (2.5-2.8)
24-28 (2.7-3.1)
35-45 (4.0-5.0)
45-55 (5.0-6.2)
65-85 (7.4-9.6)
85-110 (9.6-12.4)
125-165 (14.1-18.6)
160-200 (18.1-22.5)
245-335 (27.7-37.8)
290-350 (32.8-39.5)
400-470 (45.2-53.1)
43-48
51-53
50-52
60-65
70-75
84-88
(58.3-65.0)
(69.1-71.8)
(67.8-70.5)
(81.4-88.1)
(95.0-101.6)
(113.9-119.3)
14-7
Torque
Lb In (Nm)
6-32
8-32
10-24
10-32
1/4-20
1/4-28
5/16-18
3/8-16
7/16-14
1/2-13
7-9 (0.8-1.0)
12-15 (1.4-1.7)
22-25 (2.5-2.8)
24-28 (2.7-3.1)
50-58 (5.7-6.5)
60-68 (6.8-7.6)
105-115 (11.9-12.9)
190-200 (21.5-22.5)
300-325 (33.9-36.7)
420-450 (47.5-50.8)
TABLE 14-4.
STANDARD TORQUE LIMITS FOR SCREWS TORQUED INTO ALUMINUM TAPPED
HOLES WITH OR WITHOUT INSERTS.
Thread Size
Torque
Lb In (Nom)
6-32
8-32
8-36
10-24
10-32
1/4-20
1/4-28
5/16-18
3/8-16
7/16-14
1/2-13
14-8
8-10 (0.9-1.1)
12-15 (1.4-1.7)
14-16 (1.6-1.8)
18-22 (2.0-2.4)
22-26 (2.5-2.9)
35-40 (4.0-4.5)
50-58 (5.7-6.5)
75-90 (8.5-10.1)
135-165 (15.3-18.6)
240-275 (27.1-31.0)
370-410 (41.8-46.3)
JAN/91
Thread Size
Lb In (Nm)
6-32
6-40
8-32
8-36
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
JAN/91
Lb Ft (Nom)
8-10 (0.9-1.1)
8-10 (0.9-1.1)
12-15 (1.4-1.7)
14-16 (1.6-1.8)
18-22 (2.0-2.4)
22-26 (2.5-2.9)
35-40 (4.0-4.5)
50-58 (5.7-6.5)
75-90 (8.5-10.1)
95-110 (10.8-12.4)
135-165 (15.3-18.6)
170-210 (19.2-23.7)
240-275 (27.1-31.0)
290-335 (32.8-37.8)
370-410 (41.8-46.3)
450-500 (50.9-56.4)
43-47
46-50
56-60
60-65
77-82
(58.3-63.7)
(62.4-67.7)
(76.0-81.3)
(81.4-88.1)
(104.4-111.1)
14-9
TORQUE
THREAD SIZE
Lb Ft (Nm)
Lb In (Nm)
3/8
7/16
9/16
5/8
11/16
7/8
1
1 1/4
1 1/2
2
5/16-24
3/8-24
7/16-20
1/2-20
9/16-18
3/4-16
7/8-14
1 1/16-12
1 5/16-12
1 5/8-12
35-40 (4.0-4.5)
65-100 (7.4-11.2)
80-120 (9.0-13.5)
150-200 (17.0-22.5)
200-250 (22.6-28.2)
325-400 (36.8-45.1)
475-575 (53.7-64.9)
55-65 (74.6-88.1)
60-80 (81.4-108.4)
100-125 (135.6-169.4)
TABLE 14-7.
STEEL WITH ALUMINUM OR ALUMINUM WITH ALUMINUM
COUPLING NUTS ON FITTINGS
WRENCH SIZE
THREAD SIZE
TORQUE
Lb In (Nom)
3/8
7/16
9/16
5/8
11/16
7/8
1
1 1/4
1 1/2
: 1/4
14-10
5/16-24
3/8-24
7/16-20
1/2-20
9/16-18
3/4-16
7/8-14
1 1/16-12
1 5/16-12
1 5/8-12
1 7/8-12
Lb Ft (Nom)
14-25 (1.7-2.8)
25-40 (2.9-4.5)
40-65 (4.6-7.3)
60-80 (6.8-9.0)
80-120 (9.0-13.5)
150-200 (17.0-22.5)
200-350 (22.6-39.5)
300-500 (33.9-56.4)
40-60 (54.3-81.3)
50-75 (67.8-101.6)
50-75 (67.8-101.6)
JAN/91
TORQUE
THREAD SIZE
Lb Ft (Nom)
Lb In (Nom)
9/16
5/8
11/16
3/4
13/16
1
1 1/8
1 3/8
1 5/8
1 7/8
1 15/16
5/16-24
3/8-24
7/16-20
1/2-20
9/16-18
3/4-16
7/8-14
1 1/16-12
1 5/16-12
1 5/8-12
1 5/8-12
18-25 (2.0-2.8)
50-75 (5.7-8.4)
55-80 (6.3-9.0)
75-110 (8.5-12.4)
100-150 (11.3-16:9)
200-300 (22.6-33.8)
300-450 (33.9-50.8)
420-600 (47.5-67.7)
50-70 (67.8-94.9)
65-85 (88.2-115.2)
65-85 (88.2-115.2)
TABLE 14-9.
PLUGS AND BLEEDERS
WRENCH SIZE
THREAD SIZE
TORQUE
Lb In (N-m)
9/16
5/8
1 1/16
3/4
13/16
1
1 1/8
1 3/8
JAN/91
5/16-24
3/8-24
7/16-20
1/2-20
9/16-18
3/4-16
7/8-14
1 1/16-12
10-16 (1.2-1.8)
30-40 (3.4-4.5)
40-65 (4.6-7.3)
60-80 (6.8-9.0)
80-120 (9.0-13.5)
150-200 (17.0-22.5)
200-350 (22.6-39.5)
300-500 (33.9-56.4)
14-11
JAN/91
UNIVERSAL FIllINGS.
NOTE
Installing universal fittings with back-up rings per Figure 14-4.
A. Install the nut on the fitting and run it back until the counterbore
of the nut aligns with the upper inner corner of the gasket groove.
B. Lubricate the seal and install it on the fitting.
c. Work the back-up ring into the counterbore of the nut.
D. Turn the nut down until the seal is pushed firmly against the lower
threaded section of the fitting.
E. Install the fitting into the boss, making certain the nut turns with
the fitting, until the seal touches the boss. Then tighten the
fitting one and one-half turns.
F. Put a wrench on the nut to prevent its turning, and position the
fitting by turning it not more than one turn.
G. Hold the fitting in its position and tighten the nut against the
boss.
14-8.
JAN/91
14-13
,
.
4
(9
QHYO07XA
Figure 14-2.
14-14
JAN/91
~lt!t!lb
.a-: :.
J
E,
.-
:.,c L_
,-
. /:
SEAL
Figure 14-3.
JAN/91
Examples of Lockwiring.
14-15
iii!!%
,.,,.
,+
(-T
lL-!r--sLEEvE
II
TUBI
Lk
O-RING OR-PACKING
,m
,
SEAL RING
f=d
CKNUT
OR PAC
POSIT
AND
LOCKNUT TIGHTENED
NOTES:
1. THREAD LOCKNUT ON BULKHEAD END OF FITTING PAST SEAL RING GROOVE.
2. PLACE SEAL RING AND/OR O-RING SEAL IN GROOVE.
3. SCREW FITTING INTO BOSS UNTIL SEAL RING Oi-&-RING SEAL CONTACTS
UPPER THREAD OF BOSS.
CAUTION
DO NOT BACK-UP FllllNG MORE
THAN 360 TO ALIGN CONNECTION.
4. ASSEMBLE CONNECTION; TIGHTEN LIGHTLY. TIGHTEN LOCKNUT LIGHTLY.
FINAL TIGHTEN.
QHYO09XA
Figure 14-4. Un versal Fittings.
14-16
JAN/91
14-10. Remove rigid tube assemblies from components that are to be replaced.
Remove all interfering tube assemblies to allow for easy removal of the
component. This precaution will help prevent damage to the tube
assemblies.
14-11. Flared Tubes.
A. Tube assemblies must fit and be aligned with the mating flare tube
fittings in a free state so that the nuts at each end of the assembly
will engage the mating tube fitting threads up to the final one-half
turn with light finger pressure. In the event a tube does not align
with the mating fittings, reposition the mating fittings to the
degree that proper alignment may be attained. Final tightening of
these fittings must be done before the tube assembly is connected.
B. If proper alignment cannot be attained by repositioning mating flare
tube fittings, bend the tube sufficiently to provide alignment in the
free state as specified. Accomplish all bending with the tube
removed from the engine. Adjustment of the fit may be accomplished
by bending by hand at principal bends. In the event the tube cannot
be bent by hand, the tube must be clamped in a fixture or device
which will not scratch, indent, crimp, or mark the surface of the
tube during the bending operation. The flattened effect of the cross
section of the tube as a result of the reforming operation must not
exceed 15 percent of the tube OD.
c. When Drot)er free state alianment is attained, complete the tubing
instaila~ion by simultaneously securing the coupling nuts and tightening them to proper torque.
14-12. Flanqed Tubes.
NOTE
The alignment of tube fittings with mating sealing surfaces and the
securing of tube clips must conform to the following steps.
A. Nut and Nipple Joints. With one end hand tightened, it must be
Dossible to locate the nipple at the free end in its conical seating,
by flexing the tube by hand, without causing a permanent set to the
assembly. The alignment of the joint must be such that the nut
readily engages with its mating thread.
B. Setscrew Retained Flanged Adapters. The clearance and parallelism
between flange and mating surface, with the opposite end secured,
JAN/91
14-17
14-18
JAN/91
L
E1 -,
+---E1+L~
t-
QHTO1OXG
Figure 14-5. Torque Wrench and Extension.
C. With the axes of the extension or adapter and the torque wrench in a
straight line, the actual torque applied will be greater than that
indicated by the torque wrench. To determine the torque wrench
reading required to produce a given torque, use the following
formula:
L
L+E
R = T x
where,
E =
L =
Distance between hand hold (or handle pivot point) to drive end of
torque wrench.
R =
T=
Example:
E=
10 in (254 mm)
10 in (254mm) +3 in (76.2 mm)
58 lb n 66 m)
14-19
JAN/91
14-21
14-22
JAN/91
RECOMMENDED MARKERS .
CAUTION
UHEN MARKING OR IDENTIFYING ANY PART SUBJECTED TO HIGH TEMPERATURES DO
NOT USE ANY tlARKING MATERIAL CONTAINING GRAPHITE. GRAPHITE MAY CAUSE
DAMAGE TO THE PART.
NOTE
The recommended markers are contained in Table 14-10.
Table 14-10.
MANUFACTURER
Recommended Markers.
COLOR
1.
Red
Dixon Ticonderoga Co.,
756 Beachland Blvd,
B1 ue
P.O. Box 3504
Vero Beach, FL 32964
White
Phone (800) 824-9430
Formerly:
Joseph Dixon Crucible Co.
Jersey City, N.J.
2.
3.
JAN/91
MODEL NO.
TYPE
940
1940
950
1950
1998
Anadel Pencils
White
Orange
B1 ack
169T
269T
365T
561
268T
551
556
557
273T
Red
B1 ue
Green
Yellow
---------
Liqua-Tip
Markers
Red
1803
Vita-Color
Red
B1 ue
14-23
TABLE OF CONTENTS
l)escrir)tion
Paqe No.
1.0
Introduction
2.0
2.1
2.2
;::
2.5
Installation Procedures
Materials Required
Files Supplied on Your DCOMMS Disk
Minimum Digital Operating System (DOS) Requirements
Installation for a Floppy Disk System
RS232 Interconnect Cable Configuration
4
4
4
4
6
7
3.0
3.1
3.2
3.3
3.4
7
8
8
9
9
4.0
4.1
4.2
4.3
Fault Log
Format
Warnings
Shutdowns
11
5.0
5.1
5.2
5.3
i::
5.6
5.6.1
::; .1
5.7.2
5.7.3
5.8
5.9
6.0
6.1
6.2
6.3
:::
6.6
6.7
6.8
6.9
JAN/91
;;
12
12
::
14
14
15
16
17
18
18
18
18
19
19
;:
20
22
23
23
;;
25
27
Appendix-1
Descrir)tion
Paae No.
Wrong Password
Invalid File Operation
27
27
7.0
7.1
7.2
7.3
7.4
7.4.1
7.4.2
7.4.3
7.4.4
8.0
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.2
8.2.1
8.2.2
8.2.3
Use of DCOMMS
System Summary
Monitoring Mode
Change Mode
Log Mode
NVINIT Mode
DCOMMS With Or Without DCA
Startina DCOMMS Without DCA
Startin~ DCOMMS With DCA
Terminating DCOMMS
31
31
31
31
32
32
33
33
35
35
9.0
Cautions
38
INDEX TO TEST TABLES
Table No.
1
:
4
5
6
7
8
9
10
;;
13
14
15
16
17
18
19
20
Appendix-2
Paqe No.
8
10
11
13
14
16
;;
;:
24
25
26
;:
34
34
36
37
37
JAN/91
INTRODUCTION .
A. This ar)~endix describes the Digital Communications (DCOMMS) package
as it is used with the Allison-501-KB5 engine using a Hawker Siddeley
Dynamics Engineering, LTD (HSDE) Digital Control Assembly (DCA).
DCOMMS utilizes the RS232C serial interface via an IBM compatible
personal computer (PC) setup.
B. The material herein is adapted from a HSDE document entitled, DIGICON
IBM Communications Operator Manual.
C. The DCOMMS package provides the following key features:
1. On line monitoring of engine parameters (both interfaced directly
to the DCA and computed by the DCA), with engineering unit display.
2
Appendix-3
INSTALLATION PROCEDURES.
2.1
MATERIALS REQUIRED.
A. To successfully use the DCOMMS package, you need:
1. The DCOMMS package: a single disk labeled, DCOMMS .
2. An IBM (or fully compatible) personal computer (PC) equipped with
a minimum of:
256K of RAM
;: Monochrome Display Adapter (MDA)
2.3
Appendix-4
JAN/91
DEVICE = KBUK.SYS
may be required if the keyboard driver is not a directly
executable program (e.g. .COM or .EXE file), refer to your
computer reference manual if in doubt.
2.4
JAN/91
Appendix-5
KEYBUK
DATE
TIME
MODE COM1:9600, n, 8, 1
DCOMMS
this will, when run either from system reset or by entering
AUTOEXEC (followed by pressing Return key), prompt you to enter
correct date and time, configure the serial port for 9600 baud
with no parity 8 bit data and 1 stop bit as required for DCA. If
DCA is configured for alternative serial port parameters then
modify the AUTOEXEC.BAT file as necessary. The DCOMMS program
will then be automatically entered.
Appendix-6
JAN/91
Personal Computer
(25-Way Socket)
TXD 2
RXD 3
GND 7
RTS 4
CTS 5
DSR 6
DTR 20
CR 8
3
2
7
6
8
Personal Computer
(9-Way Socket)
RXD
TXD
GND
DSR
CD
TXD 3
RXD 2
3 RXD
2 TXD
CAUTION
THE ABOVE IS FOR INFORMATION ONLY. IT IS HIGHLY RECOMMENDED THAT EACH OPERATOR
VERIFY THE PIN ASSIGNMENTS ON THEIR PERSONAL COMPUTER (PC) BEFORE CONNECTING
AND APPLYING POWER. NOT ALL PCS ARE ALIKE.
3.0
JAN/91
Appendix-7
SCREEN LAYOUT.
A. The screen will now appear as Table 1.
B. The screen is split into four fields. The top field depicts
application, page, mode, date, and time information. The center
field (most of the screen) shows parameter names, their values and
units. The bottom field shows actions associated with function keys
on the IBM keyboard (the functions are shown in cryptic form due to
the screen space available). The field above the function key
legends is reserved for DCOMMS prompts and error messages.
C. The screen fields will be referred to, from now on, as header.
parameter, prompt, and function key fields. Function keys will be
referred to as labeled on the keyboard, e.g. F2 or F1O.
Test Mode Table 1.
Station:Allison 501KB5
ENGINE
TEST MODE
PARAMETERS
Mode Monitor
Clock O1-18-89 09:17
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
17.8
35.6
53.4
71.2
ENGINE CIT
89.0 DEGF
ISOC=O DROOP>O
106.8
RPM
DEGF
DEGF
LBS/HR
Unitless
Page 1
Log OFF
GAS V DEMAND
GAS V POSITION
124.6 VDC
142.4 VDC
LIQ V DEMAND
LIQ V POSITION
160.2 VDC
178.0 VDC
LIQ=O
194.7 Unitless
GAS>O
212.4 Unitless
data fail
1
3.2
2Change 3Log
4NVinit
FUNCTION KEYS.
A. The function key field shows the functions associated with them, i.e.
F2 . . . . Change mode
F3 . . . . Historical Data Log mode
F4 . . . . NVM Initialization mode
Append x-8
JAN/91
PAGE SELECTION.
A, The mode of operation we are currently operating in is the Monitoring
mode, whereby parameters may be viewed (monitored) page by page, but
no changes can be made to them.
B. In order to view other pages, either page number may be entered
directly followed by pressing the return key,
- . or the Home, End, PgUp
or PgDn-keys may be-used: Home . . . . . . .
End . . . . . . .
PgUp . . . . . .
PgDn . . . . . . .
displays
disp ays
. disp ays
disp ays
the
the
the
the
first page
very last page
previous page
next page
NOTE
Try out these page movement keys a few times to familiarize operation.
In all cases, note that the page number display changes, and that the
page title changes to reflect the newly selected display page.
c. If pages are selected by page number, then the numbers appear in the
header field as they are typed in, and are removed on pressing the
return key. DCOMMS will limit you in a maximum number equivalent in
the number of pages available. The Del key may be used to edit the
page number in this direct page number entry mode.
D. Obviously it would be a tedious process to scan throuah pages using
the page selection keys until you came across the act~al page you are
interested in. In this case, an Index to pages may be called up
through use of function key F9. Press the F9 key. Immediately an
index is shown, similar to Table 2, depicting page numbers and the
associated page titles. (When more than 12 pages exist, the up and
down cursor keys may be used to scroll through the list.) Having
noted the page you are interested in, exit Index mode by pressing
F1O, then enter the page number directly as outlined above (page
number then Return).
3.4
SAVE PAGE.
A. A facility is provided for saving a currently selected Monitoring
mode display page to a logical file (e.g. disk).
JAN/91
Appendix-9
Mode Monitor
Clock 01-18-89 09:17
TEST MODE
Page 1
Log OFF
Index to pages
ENGINE PARAMETERS
; LIGHTOFF DETECTION
3 CONTROL MODES
4 CONTROL ADJUSTMENTS
SELECTORS/TIMERS/SDs
2 METER ADJUSTMENTS
7 FLT LOG PREV STRT 7
8 FLT LOG PREV STRT 6
FLT LOG PREV STRT 5
1? FLT LOG PREV STRT 4
11 FLT LOG PREV STRT 3
12 FLT LOG PREV STRT 2
use cursor keys to scroll, F1O to quit
data fail
1
Station:Allison 501KB5
Mode Monitor
Clock 01-18-89 09:17
TEST MODE
OQuit
Page 1
Log OFF
Index to pages
LIGHTOFF DETECTION
: CONTROL MODES
4 CONTROL ADJUSTMENTS
5 SELECTORS/TIMERS/SDs
6 METER ADJUSTMENTS
7 FLT LOG PREV STRT 7
8 FLT LOG PREV STRT 6
9 FLT LOG PREV STRT 5
10 FLT LOG PREV STRT 4
11 FLT LOG PREV STRT 3
12 FLT LOG PREV STRT 2
13 FAULT LOG-CURRENT
use cursor keys to scroll, F1O to quit
data fail
1
OQuit
I
Appendix-10
JAN/91
FAULT LOG.
4.1
FORMAT .
A. The DCOMMS Fault Log consists of two segments: warnings and shutdowns. Also, some engine parameters are included for easy monitoring
convenience (Ref. Table 3). The fault log is viewed in the
monitoring mode and consists of seven (7) pages. Each page contains
information of one (1) start and is updated as the next start is
made. Hence, the most recent seven (7) starts are always available.
B. The seven (7) pages of fault log have been numbered backwards so that
the most recent start is the last page of DCOMMS (Ref. Table 2).
This configuration allows for the easiest access to the current start
fault log from any other page in the monitoring mode by simply
pressing the end key.
Test Mode Table 3.
Station:Allison 501KB5
FAULT LOG-CURRENT
TEST MODE
START NO.
ALARMS/WARNINGS
N1 DIFF.
T/C
T/C
T/C
CIT
CIT
CIT
687.5
0000001010110100
START O/TMP
RUN O/TMP yes
yes OVERSPEED
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
DIFF.
1 FAULT
2 FAULT yes
DIFF
yes
1 FAULT
2 FAULT yes
SHUTDOWN
Mode Monitor
Clock 01-18-89 09:17
704.0
709.5
715.0
720.5
Page 16
Log OFF
RPM
DEGF
DEGF
LBS/HR
LIQ, FUEL
data fail
JAN/91
2Change 3Log
4NVinit 5
7SavePg
8Reset
91ndex OQuit
Appendix-n
WARNINGS.
A. The portion of the fault log for warnings is set up such that
multiple warnings may be displayed as they occur in operation. When
a warning signal is transmitted to the PC from the DCA, a YES will
appear to the side of the warning designator.
4.3
SHUTDOWNS.
A. The portion of the fault log for shutdowns is set up such that no
message is given until a shutdown occurs. When a shutdown does
occur, the cryptic response will be displayed near the bottom of the
screen.
B. Both the warnings and the shutdown messages are reset as a new start
This moves the data to the next page of fault log for
is attempted.
later evaluation.
5.0
5.1
Appendix-12
Maximum
Minimum
Nominal
120.000
120.000
50.000
560.000
5.000
3000.000
1251.800
3997.600
1014.910
607.630
871.880
707.480
3.000
3.000
0.391
0.391
-60.000
14.000
0.296
1500.000
751.100
1709.300
156.260
188.640
312.500
314.600
1.000
1.000
85.200
64.800
-8.700
140.000
3.432
2236.000
934.700
2465.700
600.000
400.000
500.000
499.700
3.000
1.000
JAN/91
Maximum
Minimum
Nominal
29.812
1800.000
15,800.000
636.380
1000.000
6396.500
1000.000
4529.500
1000.000
3.720
0.120
14,358.000
0.188
-100.000
12.207
-100.000
12.143
-100.000
11.200
180.000
15,800.000
625.000
0.000
6250.000
0.000
4444.000
0.000
Station:Allison 501KB5
ENGINE PARAMETERS
TEST MODE
ENGINE SPEEN
37.5
T/C TOT
75.0
CALCULATED TIT 112.5
FUEL FLOW RQST
150.0
ENGINE CIT
ISOC=O DROOP>O
RPM
DEGF
DEGF
LBS/HR
187.5 DEGF
225.0
Unitless
Mode Monitor
Clock 01-18-89 09:17
Page 1
Log OFF
GAS V DEMAND
GAS V POSITION
262.5 VDC
300.0 VDC
LIQ V DEMAND
LIQ V POSITION
337.5 VDC
375.0 VDC
LIQ=O
412.5 Unitless
GAS>O
450.0 Unitless
password?
data fail
1
dAN/91
2Change 3Log
4NVinit 5
7SavePg
8Reset
91ndex OQuit
Appendix-13
SCREEN LAYOUT.
A. The screen layout will be very similar to that of Monitor mode (Ref.
Table 5) with the exceptions being that the mode displayed (in header
field) will be CHANGE, and that the first parameter on the page will
be highlighted.
Test Mode Table 5.
Station:Allison 501KB5
~ENGINE SPEED I
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
ENGINE CIT
46.1
92.2
138.3
184.4
RPM
DEGF
DEGF
LBS/HR
230.5 DEGF
ISOC=O DROOP>O
276.6
Unitless
Page 1
Log OFF
Mode CHANGE
Clock 01-18-89 09:17
ENGINE PARAMETERS
TEST MODE
GAS V DEMAND
GAS V POSITION
322.7 VDC
368.8 VDC
LIQ V DEMAND
LIQ V POSITION
414.9 VDC
461.0 VDC
LIQ=O
507.1 Unitless
GAS>O
553.2
Unitless
~
data fail
1
5.4
2Mon
3Change
4Trim
8Reset
91ndex OQuit
PARAMETER SELECTION.
A. To select the parameter required for changing, highlight that
parameter using the cursor keys:
(up-arrow) . . . . . . . . . . move to previous parameter
(dn-arrow) . . . . . . . . . . move to next parameter
Appendix-14
JAN/91
JAN/91
Appendix-15
Mode CHANGE
CONTROL ADJUSTMENTS
Clock 01-18-89 09:17
TEST MODE
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
418.5
434.0
449.5
465.0
RPM
DEGF
DEGF
LBS/HR
Page 4
Log OFF
N ISOC PROP
36.0 ---
N ISOC INTEGRAL
37.0 ---
31.0 Unitless
N DROOP PROP
38.0 ---
32.0 Unitless
TIT PROP
39.0 ---
33.0 Unitless
TIT INTEGRAL
40.0 ---
34.0 Unitless
KW PROPORTIONAL
41.0 ---
KW INTEGRAL
42.0 ---
IK-TRIM
35.0 DEGF
K-TRIM
NVM value = ????=
1
5.6
2Mon
3Change
Ram/Nvm/Both
40.0
?
data fail
4Trim
8Reset
91ndex OQuit
TRIMMING.
A. Sometimes it is necessary to alter a value in small continuous finite
steps analogous to a potentiometer adjustment, while observing the
effects on other parameters without having to repeatedly enter exact
values on the keyboard. For example, it may be required to establish
a control loop gain term by continuous adjustment while observing the
measured input value, such as changing speed loop proportional gain
and observing the stability effects on speed. This may be achieved
via the Trim function selected by function key F4 from Change mode.
B. With the required parameter highlighted, press the F4 key. The
parameter name and value will now be transferred into the prompt
field, and the associated NVM (default value) will also be
displayed. In test mode the statement:
NVM value = ????
will be displayed, as the DCA is not on-line, and a communication
error has been detected, ignore this.
C. The display will continue to be a dynamically updating screen.
Appendix-16
JAN/91
Appendix-17
ERROR MESSAGES.
A. It may become apparent through experimentation that several different
types of error messages can be displayed, these being described as
follows.
Appendix-18
JAN/91
5.9
CAUTIONS.
A. It is not wise to leave the system unattended while operating in
Change mode as it would be possible for unauthorized changes to be
made. Until Monitor mode is reestablished, the system remains in an
unlocked state, as password entry is required only to change mode,
not for each and every discrete alteration.
6.0
JAN/91
Appendix-19
6.2
INITIAL SETUP.
A. Enter the required password as prompted. The password is ALLIGT (an
acronym for Allison Industrial Gas Turbines).
B. Enter the time interval You want subseauentl.y selected parameters to
be logged against, in units of seconds: For-example, enter 5 (for
every 5 seconds) or 120 (for every 2 minutes) or 3600 (for every
hour) (Ref. Table 7).
Test Mode Table 7.
Station:Allison 501KB5
CONTROL ADJUSTMENTS
Mode Log set_up
TEST MODE
Clock 01-18-89 09:17
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
526.5
546.0
565.5
585.0
RPM
DEGF
DEGF
LBS/HR
Page 4
Log OFF
N ISOC PROP
36.0 ---
N ISOC INTEGRAL
37.0 ---
31.0 Unitless
N DROOP PROP
38.0 ---
32.0 Unitless
TIT PROP
39.0 ---
33.0 Unitless
TIT INTEGRAL
40.0 ---
34.0 Unitless
KW PROPORTIONAL
41.0 ---
K-TRIM
40.0 DEGF
KW INTEGRAL
42.0 ---
I 1
2Mon
Appendix-20
8Reset 9
OQuit
JAN/91
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
526.5
546.0
565.5
585.0
Page 4
Log OFF
RPM
DEGF
DEGF
LBS/HR
N ISOC PROP
36.0 ---
N ISOC INTEGRAL
37.0 ---
31.0
Unitless
N DROOP PROP
38.0 ---
32.0
Unitless
TIT PROP
39.0 ---
33.0
Unitless
TIT INTEGRAL
40.0 ---
34.0
Unitless
KW PROPORTIONAL
41.0 ---
K-TRIM
40.0
DEGF
KW INTEGRAL
42.0 ---
Enter no of records 20
data fail
1
2Mon
8Reset 9
OQuit
D. The next DromDt is for the filename of the lociical device that YOU
want the iogged data to be sent (stored) (Ref~ Table 9). This must
be a valid DOS filename, but cannot be the screen display. It may
typically be a disk filename or perhaps a connected printer (in which
case enter PRN:).
If the selected filename already exists, then this
will be over-written with new data, else a new file will be opened.
Be careful in that if a printer is selected (i.e., PRN:) and a
printer is not actually connected to the computer, then the system
will fail (due to DOS).
E. Having entered valid responses to the above prompts, the mode
automatically changes to Log set-up in the header field, and
parameter names associated with the current page appear on the
display; parameter values and units are not shown as they are not
relevant to parameter selection for logging.
F. To abort log mode at any of the above points, enter a non-valid
response (which will be followed by associated error message) or use
the quit (F1O) function, returning back to Monitor mode.
JAN/91
Appendix-21
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
526.5
546.0
565.5
585.0
RPM
DEGF
DEGF
LBS/HR
Page 4
Log OFF
N ISOC PROP
36.0 ---
N ISOC INTEGRAL
37.0 ---
N DROOP PROP
38.0 ---
TIT PROP
39.0 ---
TIT INTEGRAL
40.0 ---
34.0 Unitless
KW PROPORTIONAL
41.0 ---
K-TRIM
40.0 DEGF
KW INTEGRAL
42.0 ---
31.0 Unitless
6.3
2Mon
8Reset 9
OQuit
Append x-22
JAN/91
ENGINE PARAMETERS
TEST MODE
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
LOG
LOG
LOG
LOG
LIQ=O
ISOC=O
DROOP>O
GAS>O
30FF
LOG
LOG
LIQ V DEMAND
KIQ V POSITION
ENGINE CIT
Page 1
Log OFF
6CANCEL 7
data fail
8Reset
91ndex OQuit
RETURN KEY.
A. On having finalized your log selection, press the Return key. This
signifies to DCOMMS that you have completed the log selection.
B. Now a summary of your chosen parameters will be displayed (Ref. Table
11). If you are not happy with this, then press the N key, in which
case you will be prompted for all parameters again, else DCOMMS will
quit Log set-up mode withthe parameters that you have chosen.
C. Familiarize yourself with operation by entering N (for No) to the
above summary response, and changing your selection. DCOMMS will
re-prompt you for time, record and file information and re-display
the current parameter page with the associated log attributes.
6.5
LOGGING.
A. On exiting Log, set up mode with valid selections, DCOMMS will return
to Monitor mode with the Log status in the header field initially
JAN/91
Appendix-23
TEST MODE
Page 1
Log OFF
data fail
6
OQuit
showing ON, soon followed by a count of the number of records currently Logged (i.e., O, 1, 2, and so on until the Log terminates).
This is initiated by entering Y (for Yes) at the prompt described in
6.4.
B. It will also be seen that any parameter that has been selected for
Logging has a blinking asterisk (*) to the right of the parameter
data field (Ref. Table 12).
C. Normal monitoring mode is in operation, with Logging occurring in the
background (actually interleaved with Monitoring mode functions).
D. If another mode is selected from Monitoring mode, however, for
example Change or NVinit, then the Logging function will be suspended
until Monitor mode is re-invoked.
6.6
TERMINATING LOGGING.
A. Unless otherwise demanded, the Logging function will carry on until
its natural termination; that is, when the selected number of records
have been logged.
Appendix-24
JAN/91
ENGINE PARAMETERS
TEST MODE
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
61.3
122.6
183.9
245.2
ENGINE CIT
306.5 DEGF
ISOC=O DROOP>O
367.8
*RPM
*DEGF
*DEGF
*LBS/HR
Unitless
Mode Monitor
Clock 01-18-89 09:17
Page 1
Log 5
GAS V DEMAND
GAS V POSITION
429.1 *VDC
490.4 *VDC
LIQ V DEMAND
LIQ V POSITION
551.7 VDC
613.0 VDC
LIQ=O
674.3 Unitless
GAS>O
735.6 Unitless
data fail
1
2Change 3Log
4NVinit
7SavePg
8Reset
91ndex OQuit
6.8
JAN/91
Appendix-25
logging . . .
units
RPM
DEGF
DEGF
LBS/HR
VDC
VDC
Time
P2
09:37:58
09:38:03
09:38:09
09:38:14
09:38:19
09:39:01
09:39:06
09:39:11
09:39:16
09:39:21
09:39:26
09:39:32
09:39:37
09:39:42
09:39:47
09:39:52
09:39:57
09:40:02
09:40:07
09:40:12
PI
59.5
59.5
59.5
59.6
61.1
61.5
63.0
64.5
66.0
67.5
69.0
70.5
72.0
73.5
75.0
76.6
78.1
79.6
81.1
82.6
119.0
119.0
119.0
119.2
122.2
123.0
126.0
129.0
132.0
135.0
138.0
141.0
144.0
147.0
150.0
153.2
156.2
159.2
162.2
165.2
P3
178.5
178.5
178.5
178.8
183.3
184.5
189.0
193.5
198.0
202.5
207.0
211.5
216.0
220.5
225.0
229.8
234.3
238.8
243.3
247.8
P4
238.0
238.0
238.0
238.4
244.4
246.0
252.0
258.0
264.0
270.0
276.0
282.0
288.0
294.0
300.0
306.4
312.4
318.4
324.4
330.4
P5
416.5
416.5
416.5
417.2
427.7
430.5
441.0
451.5
462.0
472.5
483.0
493.5
504.0
514.5
525.0
536.2
546.7
557.2
567.7
578.2
P6
476.0
476.0
476.0
476.8
488.8
492.0
504.0
516.0
528.0
540.0
552.0
564.0
576.0
588.0
600.0
612.8
624.8
636.8
648.8
660.8
B. The log file will show engineering unit information for the following
monitoring parameters. (All found on page 1 of the DCOMMS program. )
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
Appendix-26
GAS V DEMAND
GAS V POSITION
JAN/91
ERROR MESSAGES .
A. The following error messages may be encountered in Log set-up mode:
7.1
GENERAL.
A. The DCOMMS package allows access to the DCAS NVM based parameters,
these generally being used for default settings of adjustments. The
operations described in this section refer to the adjustable
parameters as defined in Paragraph 5.1. Where the phrase DIGICON NVM
parameters is used, the adjustable parameters are inferred. This
function allows block transfer of information from one memory station
to another.
B. While the Change mode allows discrete alteration of NVM based
parameters, the NVinit mode allows block transfer of all DCA NVM
parameters to and from the personal computer (PC).
C. This mode allows block read and write of the DCA NVM values as well
as examination of both the DCA based parameters and the internal IBM
default values (as defined in the DCOMMS configuration file).
D. The block read and write functions are particularly useful in:
1. (Block read) Keeping a record of currently stored information
within the DCA system.
2. (Block write) Performing a complete default value initialization
on the DCA system.
JAN/91
Appendix-27
7.3
NVINIT MENU.
A. The screen layout will now appear as shown in Table 14.
B. The menu shown depicts the functions that are supported, i.e.:
1. F3 Read all DCA based NVM values into IBM internal default
database. This will overwrite the default settings that were
previously present and loaded in via the DCOMMS configuration
file. This is the inverse function to F4 below.
2. F4 Write all default settings as currently stored in the IBM
internal default database to DCA NVM. This will overwrite all
DCA NVM parameters associated with those parameters declared in
the DCOMMS configuration file. This is the inverse function of
F3 above.
3. F5 Examine (view) the current DCA NVM based parameter values.
This reads the DCA NVM parameters into the IBM, page by page as
required, and allows examination only of those parameters.
4. F6 Examine (view) the IBM current default database settings, page
by page as required. These values will reflect the DCOMMS
configuration file default settings plus any subsequent changes
Appendix-28
JAN/91
Page 1
Log OFF
Selection Menu
Read NVM values into IBM memory . . . . . . . . . . . .
Download Configuration file values to NVM . .
View NVM values page by page . . . . . . . . . . . . . . .
View IBM default values page by page . . . . . .
Return to Monitor mode . . . . . . . . . . . . . . . . . . . . .
F3
F4
. ;:
F1O
8Reset
91ndex OQuit
OPERATION.
A. Any of the aforementioned operations may be performed from the NVinit
menu. To return to the menu from any of these operations, use the
Quit (F1O) key, and to return back to Monitoring-mode, do this from
the NVinit menu using again the Quit (F1O) key.
Appendix-29
JAN/91
USE OF DCOMMS.
8.1
8.1.1
Monitoring Mode.
A. Monitoring mode is the primary operating mode, and it is from this
mode that others (e.g. Historical data logging, Change) are entered.
B. DisDlay r)aqes may be selected either via the page selection keys
(Horne,-End~ PgUp~ PgDn) or direct entry. c. An Index facility (F8) provides a list of display pages available
within the system.
D. A Save Paqe facility (F7) stores the currently selected Pa9e to a
selected logical file:
8.1.2
Chanae Mode.
A. Change mode is entered via Monitoring mode, after entry of a valid
password. The password is ALLIGT (an acronym for Allison Industrial
Gas Turbines).
B. Operator password access is to operator definable adjustable
parameters, and subsequent parameter changes are limit protected.
c. The required parameter for adjustment is selected through use of page
selection and cursor movement keys.
D. Page Indexing (via F9) is available.
JAN/91
Appendix-31
F3 .
F4 .
F5 .
F6 .
.
.
.
.
.
.
.
.
JAN/91
Ref.
Appendix-33
E. The prompt will now appear abort, retry, test mode. Ref. Table 17.
Abort returns to normal DOS system, retry may be used if a
configuration file was on a floppy disk not inserted and a wrong name
error message was given. Test will display the DCOMMS package in
Monitoring mode.
Test Mode Table 17.
DIGICON (DCA) IBM PC Communications facility
DCOMMS V2.03
Designed by: Bill Harlow
Copyright (C) 1987 Hawker Siddeley Dynamics Engineering Inc
2869 Higgins Road
Elk Grove
Chicago Illinois 60007
tel 312-956-6302 fax 312-956-6304
Enter comm port number [1-4] 1
enter station a:xxxxxxxx.kb5
downloading configuration file. ..wait
lines read = 562
all lines read
Digicon not on line, abort, retry, or test mode?
Appendix-34
JAN/91
B. Install the RS232 (P/N EX-157395) cable to the rear serial port of
the PC. Do not install this cable to the DCA until later.
c. Turn the PC ON. The computer will go through its initial sequence
and display the prompt C.
D. Change the PCs CPU speed from 12 to 8 MHz.
E. Install the RS232 cable to the front CPUs V24 connector of the DCA.
F. Type MODE COM1 9600,N,8,1 at the C prompt. Follow this by a RETURN.
This command establishes the communication parameters, i.e., baud
rate, parity, etc.
G. If the DCA is not turned ON yet, do so.
H. Type DCOMMS and the program should operate correctly.
I. Enter the numeral 1 at the comport prompt (Ref. Table 15).
J. .-.
Enter the configuration file name at the station prompt (Ref. Table
lb).
JAN/91
Appendix-35
ENGINE PARAMETERS
TEST MODE
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
100.9
201.8
302.7
403.6
ENGINE CIT
504.5 DEGF
ISOC=O DROOP>O
605.4
RPM
DEGF
DEGF
LBS/HR
Mode Monitor
Clock O1-18-89 09:17
Page 1
Log OFF
GAS V DEMAND
GAS V POSITION
706.3 VDC
807.2 VDC
LIQ V DEMAND
LIQ V POSITION
908.1 VDC
1009.0 VDC
LIQ=O
1109.9 Unitless
GAS>O
Unitless
Terminate session ?
data fail
I 1
2Change 3Log
4NVinit
7SavePg
8Reset
91ndex OQuit
3. If YOU enter Y to the ~rom~t, then DCOMMS will prompt YOU for a
con~iguration filename; At this point, you should enter a different filename to the one entered at the very start of DCOMMS
invocation (from the Enter station prompt) if you want to maintain
the previous configuration; else if you do want to overwrite the
existing configuration file then enter the same filename as the
one you started with.
4. In response to entering a valid filename, DCOMMS will reconstruct
a configuration file, writing to it all parameter and screen
information.
This file can at a subsequent time be used as the
starting filename for DCOMMS at the Enter station prompt. As the
file is written, an indication of progress is indicated by a
parameter counter in the prompt field. This may take a little
time, as DCOMMS will be performing quite a bit of data manipulation, data conversion and file manipulation, be patient.
5. DCOMMS will then prompt, Do You want another run?. An Y response
will return you to the DCOMMS-monitor mode. An N response will
abort DCOMMS and return the system to DOS prompt (see Table 20).
dcomms aborted
c>
CAUTION
DO NOT TERMINATE DCOMMS BY ANY OTHER TECHNIQUE (E.G., Ctrl-C OR CtrlBreak OR Ctrl-Alt-Del) AS DCOMMS DATA (internal to IBM) WILL BE LOST.
Appendix-36
JAN/91
ENGINE PARAMETERS
TEST MODE
100.9 RPM
ENGINE SPEED
T/C TOT
201.8 DEGF
CALCULATED TIT 302.7 DEGF
FUEL FLOW RQST
403.6 LBS/HR
504.5 DEGF
ENGINE CIT
ISOC=O DROOP>O
605.4
Mode Monitor
Clock O1-18-89 09:17
GAS V DEMAND
GAS V POSITION
706.3 VDC
807.2 VDC
LIQ V DEMAND
LIQ V POSITION
908.1 VDC
1009.0 VDC
LIQ=O
1109.9 Unitless
FUEL
Unitless
Page 1
Log OFF
GAS>O
2Change 3Log
4NVinit 5
7SavePg
8Reset
91ndex OQuit
ENGINE PARAMETERS
TEST MODE
ENGINE SPEED
T/C TOT
CALCULATED TIT
FUEL FLOW RQST
100.9
201.8
302.7
403.6
ENGINE CIT
504.5 DEGF
ISOC=O DROOP>O
605.4
RPM
DEGF
DEGF
LBS/HR
Mode Monitor
Clock O1-18-89 09:17
Page 1
Log OFF
GAS V DEMAND
GAS V POSITION
706.3 VDC
807.2 VDC
LIQ V DEMAND
LIQ V POSITION
908.1 VDC
1009.0 VDC
LIQ=O
GAS>O
1109.9 Unitless
Unitless
JAN/91
2Change 3Log
4NVinit
Appendix-37
1,
.-
9.0
CAUTIONS.
A. The following is a list of CAUTIONS that may tend to interfere with
the system operation:
1. Depressing Ctrl-Alt-Del resets the computer and aborts everything
(standard IBM/DOS).
2. Pressing Ctrl-S suspends screen update (standard DOS).
3. Pressing Ctrl-P sends subsequent screen data to assigned printer
port until Ctrl-P is pressed again. Note that if printer is not
connected then standard DOS will print screen error message and
ruin the DCOMMS display.
4. Ctrl-NumLock suspends system operation until any other character
key is pressed (standard DOS). Thus, if used, this will freeze
the DCOMMS operation.
5. Shift-PrtSc sends a copy of what is currently displayed on the
screen to the printer. If printer is not attached, the system
will eventually (many seconds) timeout and resume operation,
though in intervening period, all system activity is suspended.
Appendix-38
JAN/91