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DOCUMENT 40C11-1

ENGINE MANUAL
AUXILIARY POWER UNIT (APU)
MODEL NUMBER T-62T-40C11
PART NUMBER 4501966
1993, 1995, 1997, 2001 - 2004, 2007 Hamilton Sundstrand Corporation

NOTICE
THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION (HSC). RECIPIENT
AGREES TO HOLD ALL SUCH INFORMATION IN CONFIDENCE AND AGREES IT SHALL BE USED ONLY FOR RECIPIENTS INTERNAL PURPOSES TO
MAINTAIN RECIPIENTS EQUIPMENT OR AS MAY OTHERWISE BE PERMITTED IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND HSC. THIS
DOCUMENT AND THE INFORMATION CONTAINED HEREIN SHALL NOT BE USED FOR ANY OTHER PURPOSE, INCLUDING THE CREATION,
MANUFACTURE, DEVELOPMENT, OR DERIVATION OF ANY REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGN, OR CONFIGURATION CHANGES, OR
TO OBTAIN FAA OR ANY OTHER GOVERNMENT OR REGULATORY APPROVAL FOR SAME. RECIPIENT AGREES NOT TO DISCLOSE SUCH
INFORMATION TO ANY THIRD PARTY, EXCEPT AS MAY OTHERWISE BE PROVIDED FOR IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND
HSC. COPYING OR DISCLOSURE OF THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN BY ANYONE WITHOUT HSCS PRIOR WRITTEN
PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY.

INFORMATION SUBJECT TO EXPORT CONTROL LAWS


THE TECHNICAL DATA IN THIS DOCUMENT (OR FILE) IS CONTROLLED FOR EXPORT UNDER THE EXPORT ADMINISTRATION REGULATIONS (EAR),
15 SFR PARTS 730-774, 9A991, VIOLATIONS OF THESE LAWS MAY BE SUBJECT TO FINES AND PENALTIES UNDER THE EXPORT ADMINISTRATION
ACT.

NOTICE
THE DATA IN THIS DOCUMENT WERE DEVELOPED ONLY TO MAINTAIN SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON
SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. THE DATA MAY NOT BE APPLICABLE TO ANY OTHER SYSTEMS AND/OR PARTS,
REGARDLESS OF THEIR APPARENT SIMILARITY TO SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR
APPROVED BY HAMILTON SUNDSTRAND. DO NOT RELY IN ANY WAY ON DATA IN THIS DOCUMENT TO MAINTAIN OR OTHERWISE SUPPORT
SYSTEMS AND/OR PARTS THAT WERE NOT MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND
WITHOUT EVIDENCE THAT THE FEDERAL AVIATION ADMINISTRATION OR OTHER REGULATORY AGENCY HAS DETERMINED THAT THE DATA IN
THIS DOCUMENT IS VALID FOR SUCH USE.

TITLE PAGE, 1
ORIGINAL ISSUE
JUN 30/99
REVISION 11
NOV 15/07

THIS PAGE INTENTIONALLY LEFT BLANK

TITLE PAGE
Page 2
MAY 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
TO:

Holders of Document 40C11-1 (Engine Manual), Hamilton Sundstrand Auxiliary Power Unit
(APU), Part Number 4501966, Model Number T-62T-40C11, used on Embraer ERJ 145 and
135 aircraft.
Revision 11, dated November 15, 2007
HIGHLIGHTS

Shown below are highlights of the significant changes and the affected pages contained in this
revision. Remove the used affected pages and put the new affected pages into the manual as
shown in the List of Effective Pages.
We recommend that you put this revision into your manual without delay. Mark the Record of
Revisions sheet with the new revision number and date, and write your initials on the Record of
Revisions sheet in the appropriate spaces after you have put the revised pages in your manual.
If you have any questions about this revision, please contact Technical Publications by telephoning
(858) 627-6000, FAX: (858) 627-6677, or write Hamilton Sundstrand Power Systems, Technical
Publications Department 374-S-1, 4400 Ruffin Road, P.O. Box 85757, San Diego, California 921865757.
Page Number

Description of Change

Title,
Page 1

Revised for Revision 11.

Safety Advisory,
Page 7

Updated.

Record of Temporary
Revisions, Page 1

Updated.

Service Bulletin List,


Pages, 1, 3, 4, 5, 6, 7, 8

Updated.

List of Effective Pages,


Pages 1, 2, 3, 4, 5

Updated.

Introduction, Page 1

Revised reference to Standard Practices Manual.

Page 5

Corrected specification for dry cleaning solvent.

49-00-00
Operational Check,
Page 202

Incorporated TR 49-4.

Removal/Installation,
302

Corrected specification for isopropyl alcohol.

Page 318

Added removal/installation instructions (SB-49-189).

Pages 319 to 329

Text moved (no technical changes).


HIGHLIGHTS
Page 1
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Page Number

Description of Change

Pages 330 and 331

Added removal/installation instructions for start fuel nozzle holder


assemblies (SB-49-181 and SB-49-191).

Pages 332 to 344

Text moved (no technical changes).

Cleaning, Page 601

Corrected specification for isopropyl alcohol and dry cleaning


solvent.

Pages 605 and 606

Correct metric equivalent of pressure in the compressed air


warnings.

Inspection/Check,
Pages 803, 804, and
806

Added new inspections to Figure 801 (SOH99086R4)


(RDE06011R1) (RDE07036).

Page 805

Text moved (no technical changes).

Pages 806A and 806B

Added pages.

49-20-00
Disassembly, Page 504

Added disassembly instructions related to clamps and attaching


parts (SB-49-181 and SB-49-191).

Page 505

Added disassembly instructions for start fuel nozzle tube assemblies


(SB-49-181 and SB-49-191).

Pages 506 to 509

Text moved (no technical changes).

Page 510

Added disassembly instructions for start fuel nozzle holder


assemblies (SB-49-181 and SB-49-191).

Pages 511 and 512

Text moved (no technical changes).

Assembly, Page 1001

Corrected specification for isopropyl alcohol.

Page 1010

Text moved (no technical changes).

Pages 1011 and 1012

Added assembly instructions for start fuel nozzle holder assemblies


(SB-49-181 and SB-49-191).

Pages 1013 to 1022

Text moved (no technical changes).

Page 1023

Added assembly instructions for start fuel nozzle tube assemblies,


related clamps, and attaching parts (SB-49-181 and SB-49-191).

Pages 1024 to 1032

Text moved (no technical changes).

Storage, Page 1201


Page 1206

Revised paragraphs 1. and 2. to include depreservation.


Added a procedure for depreservation of the APU from storage
(TOH04004).

Testing, Page 1301

Added an alternate fuel (SOH06128R1).

Page 1317

Corrected equation in step 7.C.(4) (PAR SM062005) (SOH05163).

HIGHLIGHTS
Page 2
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Page Number

Description of Change

49-23-00
Assembly, Page 1001

Corrected specification for isopropyl alcohol.

The following Action Items (AIs) have been incorporated into this revision:
AIs

Location

RDE06011R1

49-00-00, Inspection/Check

RDE07036

49-00-00, Inspection/Check

SOH05163

49-20-00, Testing

SOH06128R1

49-20-00, Testing

SOH99086R4

49-00-00, Inspection/Check

TOH04004

49-20-00, Storage

HIGHLIGHTS
Page 3
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

HIGHLIGHTS
Page 4
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
SAFETY ADVISORY
1.

Scope
A.

2.

3.

This publication describes processes that may require the use of chemicals, solvents,
paints, or other materials that can affect a persons health or safety. It may also cover
high energy procedures that can affect a persons health or safety. Warnings are
placed just ahead of these procedures to bring attention to the existence of a
procedure or material that can be dangerous.

Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS
WARNING:

BEFORE USING ANY OF THE MATERIALS SPECIFIED IN HAMILTON


SUNDSTRAND MAINTENANCE PUBLICATIONS, BE AWARE OF ALL
HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED
BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH
MANUFACTURER'S OR SUPPLIER'S RECOMMENDATIONS MAY
RESULT IN PERSONAL INJURY OR DISEASE.

WARNING:

THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL


SAFETY DATA SHEETS (OCCUPATIONAL SAFETY AND HEALTH ACT
(OSHA) FORM 20 OR EQUIVALENT) FROM THE MANUFACTURERS OR
SUPPLIERS OF MATERIALS TO BE USED. THE USER MUST BECOME
COMPLETELY FAMILIAR WITH THE MANUFACTURER OR SUPPLIER
INFORMATION AND ADHERE TO THE PROCEDURES,
RECOMMENDATIONS, WARNINGS, AND CAUTIONS OF THE
MANUFACTURER OR SUPPLIER FOR THE SAFE USE, HANDLING,
STORAGE, AND DISPOSAL OF THESE MATERIALS.

A.

Refer to the materials list at the beginning of each section of this manual for materials
used to repair and maintain the covered equipment.

B.

If you do not have a copy of the manufacturers MSDS for the materials covered in the
materials list, contact the manufacturer and request that a MSDS be supplied before
you use the material.

Purpose
A.

The warnings bring your attention to the existence of a procedure that can affect a
persons health or safety.

B.

Short warnings are provided in this maintenance publication to alert operating and
maintenance personnel of potential hazards that could result in personal injury or
health hazards. The warnings do not replace the manufacturer's recommendations.
When there is a reference to the Warnings Registry 341-006, that publication will
provide more information about the dangers of the material. The information contained
in the Warnings Registry is a summary of the manufacturers MSDS. The full-length
warnings provide three principle parts of safety: (1) a listing of the known dangers, (2)
what is needed to do to protect you from the dangers, and (3) what to do if the dangers
occur.
New Safety Advisory for Sustaining Manuals
Figure 1 (Sheet 1 of 2)

SAFETY ADVISORY
Page 1
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

4.

5.

C.

The detailed warnings in Warnings Registry 341-006 are a summary of the


manufacturers MSDS and are not intended to replace the material on the sheet, but
are intended to supplement them.

D.

Cautions are provided in the maintenance publication or service bulletin to alert


operating and maintenance personnel to conditions that could result in equipment
damage.

Definitions Applying to Warnings


A.

Flammable: a material that can catch fire easily and can be explosive. These materials
are labeled according to the flash point of the material.

B.

Flash Point: the lowest temperature at which a flammable liquid gives off fumes that
can burn.

C.

Ignition Source: includes flames, sparks, or heat.


(1)

Flames: materials that are burning such as lit matches, propane torches, or pilot
lights.

(2)

Sparks: materials such as lighted cigarettes, electrical motors, or static electricity.

(3)

Heat: any source of energy that will raise the temperature of a flammable
material to its flash point and could include hot parts, heated tools, or direct
sunlight.

D.

Corrosive: acidic or alkaline material that will remove human tissue or create chemical
reactions with other materials.

E.

Toxic: material that is poisonous.

F.

Reactive: material that will make fumes, burn, or can be explosive when mixed with
certain other materials.

G.

Shock (Electrical): the result of any source of electricity more than 50 volts that causes
current to flow through a person and can result in dangerous burns to human tissues or
death.

H.

Exposure: contact with the material or physical process without protection. Contact
may be by the eyes, breathing, touch, skin absorption, or swallowing.

I.

Irritation: any sense of pain, soreness, rash, or general discomfort.

Reporting Materials or Processes Not Covered


A.

Please call (858) 627-6000, FAX (858) 627-6677, or write to Hamilton Sundstrand,
Technical Publications, Department 374, 4400 Ruffin Road, P.O. Box 85757, San
Diego, CA 92186-5757, if you find a material in a Hamilton Sundstrand maintenance
document that is known to be covered by a material data safety sheet (MSDS) but is
not covered by a warning in the procedure.
New Safety Advisory for Sustaining Manuals
Figure 1 (Sheet 2 of 2)

SAFETY ADVISORY
Page 2
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
This Safety Advisory has all the WARNINGS included in this manual.
WARNING: MAKE SURE YOU FOLLOW ALL OF THE MANUFACTURER'S OR SUPPLIER'S
INSTRUCTIONS WHEN YOU USE THE MATERIALS SPECIFIED IN THIS MANUAL.
FAILURE TO OBEY MANUFACTURE'S OR SUPPLIER'S INSTRUCTIONS CAN
CAUSE INJURY OR DISEASE.
WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR AROUND
ELECTRICAL COMPONENTS. TO AVOID INJURY, BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.
WARNING: MAKE SURE ELECTRICAL POWER SUPPLY IS REMOVED FROM THE APU.
ENERGIZED CIRCUITS CAN CAUSE INJURY TO PERSONS.
WARNING:

DO NOT TOUCH THE COMPONENTS OF THE OIL SYSTEM IF THE APU IS HOT.
THESE COMPONENTS STAY HOTTER THAN OTHER COMPONENTS. HOT
COMPONENTS CAN BURN YOU.

WARNING: HOT OIL MAY CAUSE BURNS TO EYES AND SKIN. PUT ON SPLASH GOGGLES,
INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE OR
SKIN CONTACT, SEEK MEDICAL ATTENTION.
WARNING: DO NOT LET THE OIL STAY ON YOUR SKIN. YOU CAN ABSORB POISONOUS
MATERIALS FROM THE OIL THROUGH YOUR SKIN.
WARNING: OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN USING
CONSUMABLES. TO AVOID INJURY, WEAR NECESSARY PROTECTIVE GEAR
DURING HANDLING AND USE. MAKE CERTAIN CONSUMABLES AND THEIR
VAPORS ARE KEPT AWAY FROM HEAT, SPARK, AND FLAME.
WARNING: USE LOCQUIC PRIMER GRADE N OR T, CORRECTLY. THE PRIMER IS
FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE PRIMER, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0135SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
PRIMER, PUT ON CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT
GLOVES (BUTYL RUBBER). MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE PRIMER FUMES BELOW THE MATERIAL SAFETY DATA
SHEET LIMIT.
WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE) CORRECTLY. THE
DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE DRY ICE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0088SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE DRY
ICE, PUT ON INSULATED GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY
DATA SHEET LIMIT.
SAFETY ADVISORY
Page 3
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
WARNING: LIQUID NITROGEN WILL FREEZE SKIN INSTANTLY. USE IN WELL-VENTILATED
AREA. PREVENT EYE AND SKIN CONTACT. PUT ON SPLASH GOGGLES AND
INSULATED GLOVES. IN CASE OF SKIN CONTACT SEEK MEDICAL ATTENTION.
IN CASE OF EYE CONTACT, SEEK MEDICAL ATTENTION.
WARNING: TO AVOID INJURY, STAY CLEAR OF ENERPAC RAM DURING STRETCHING
PROCEDURE. DO NOT USE STRETCH ROD (ST78693-02) IF THE 400 CYCLE
LIMIT IS ACHIEVED.
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT HIGH
TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE A BAD EFFECT
ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ANTI-SEIZE
COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY.
READ THE DETAILED WARNING, W0200SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICALSPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING EXHAUST
DEPOSITS INTO OPEN WOUNDS.
WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN
WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES.
PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER
PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH
WITH SOAP AND WATER.
WARNING: NYCOTE 7-11, NYLON VARNISH IS TOXIC AND FLAMMABLE. DO NOT BREATHE
VAPORS. USE IN WELL VENTILATED AREA FREE FROM SPARKS, FLAME OR
HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES
AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH
WATER AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH
WITH SOAP AND WATER.

SAFETY ADVISORY
Page 4
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE CLEANING SOLVENT (ALSO KNOWN AS DRY CLEANING SOLVENT,
STODDARD SOLVENT, MINERAL SPIRITS, NAPHTHA, PETROLEUM SPIRITS,
MIL-PRF-680 TYPE II, ASTM D235 TYPE II, OR AMS3160) CORRECTLY. THE
SOLVENT IS FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE SOLVENT, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0158SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE SOLVENT, PUT ON
CHEMICALSPLASH GOGGLES, AND SOLVENT-RESISTANT GLOVES (BUTYL
RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE SOLVENT FUMES BELOW THE MATERIAL SAFETY
DATA SHEET LIMIT.
WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL
IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT
ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE
MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: LOCTITE 404 OR 480 ADHESIVE CAUSES INSTANT BONDING OF
SKIN OR OTHER HUMAN TISSUE. USE CARE WHEN HANDLING
THE ADHESIVE. USE THE ADHESIVE CORRECTLY. IT IS
FLAMMABLE AT HIGH TEMPERATURES. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
ADHESIVE, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0013SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ADHESIVE,
REMOVE YOUR CONTACT LENSES. PUT ON NITRILE OR
POLYETHYLENE GLOVES AND SAFETY GLASSES OR CHEMICAL
SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ADHESIVE FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: USE LOCTITE RC640 PRIMER, CORRECTLY. THE COMPOUND IS
FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH
OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE
MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ
THE DETAILED WARNING, W0067SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY
GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE
COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

SAFETY ADVISORY
Page 5
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE ANAEROBIC RETAINING COMPOUND, MIL-R-46082
CORRECTLY. THE COMPOUND IS COMBUSTIBLE. IT CAN HAVE A
BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE COMPOUND, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL
AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0069SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU
USE THE COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES
AND NEOPRENE, RUBBER, OR BUTYL RUBBER GLOVES.
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO
BECOME A PROJECTILE. THE FORCE CAN CAUSE THE
LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF
YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT
BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR
INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDESHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO
YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE
HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY
TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED
MEDICAL PERSON REMOVES THE LOCKWIRE.
WARNING: USE SILICONE ADHESIVE/SEALANT, DOW CORNING 3145,
CORRECTLY. KEEP THE SEALANT AWAY FROM WATER OR
MOIST AIR. THE SEALANT CAN REACT WITH WATER OR MOIST
AIR TO MAKE METHYL ALCOHOL GAS. METHYL ALCOHOL GAS IS
VERY FLAMMABLE AND CAN BE EXPLOSIVE. DO NOT SWALLOW
THE SEALANT, IT CAN MAKE METHYL ALCOHOL THAT CAN
CAUSE DEATH OR BLINDNESS. BEFORE YOU USE THE SEALANT,
GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0202SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE SEALANT,
PUT ON SAFETY GLASSES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: USE ANAEROBIC SEALANT AND LOCKING COMPOUND, MIL-S22473, CORRECTLY. THE COMPOUND IS FLAMMABLE. IT CAN
HAVE A BAD EFFECT ONYOUR HEALTH OR SAFETY. BEFORE
YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING W0068SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE COMPOUND PUT ON SAFETY GLASSES
OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

SAFETY ADVISORY
Page 6
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE MANGANESE DIOXIDE-CURED POLYSULFIDE RUBBER
SEALANT PR1440 B-2, CORRECTLY. THE SEALANT CONTAINS
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE SEALANT, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0189SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES
OR CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT
GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO
KEEP THE SEALANT FUMES BELOW THE MATERIAL SAFETY
DATA SHEET LIMIT.
WARNING: USE PIPE SEALANT COMPOUND CORRECTLY. THE COMPOUND
IS COMBUSTIBLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH
OR SAFETY. BEFORE YOU USE THE COMPOUND, GET THE
MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ
THE DETAILED WARNING, W0069SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY
GLASSES OR GOGGLES AND NEOPRENE, RUBBER, OR BUTYL
RUBBER GLOVES.
WARNING: LUBRICANT, DRY FILM, IS TOXIC AND FLAMMABLE. DO NOT
BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM
SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH
GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER
PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN
CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN
AND EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.
WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS,
MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30
POUNDS PER SQUARE INCH (207 KILOPASCALS). DO NOT
DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS.
PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES.
THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR
DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET
MEDICAL ATTENTION.

SAFETY ADVISORY
Page 7
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

SAFETY ADVISORY
Page 8
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
RECORD OF REVISIONS
REV
NO.

ISSUE
DATE

DATE
REV ISSUE
INSERTED BY NO. DATE

Jan 15/97

Jun 30/99

HS

Oct 15/97

Jun 30/99

HS

Jul 15/98

Jun 30/99

HS

Mar 1/99

Jun 30/99

HS

Jun30/99

Jun 30/99

HS

Jul 1/00

Jul 1/00

HS

Aug 1/01

Aug 1/01

HS

May 1/02

May 1/02

HS

Jan 15/03

Jan 15/03

HS

10

Mar 15/04

Mar 15/04

HS

11

Nov 15/07

Nov 15/07

HS

DATE
REV
INSERTED BY NO.

ISSUE
DATE

DATE
INSERTED BY

RECORD OF REVISIONS
Page 1
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

RECORD OF REVISIONS
Page 2
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV. NO.
49-1

PAGE NUMBER
Servicing 603

ISSUE
DATE
Apr 9/99

BY
HS

DATE REMOVED
Jun 30/99

BY
HS

49-2

Assembly 1023

Sep 2/99

HS

Jul 1/00

HS

49-3

See below

Sep 15/03

HS

Mar 15/04

HS

Removal/
Installation
Disassembly

302-305, 309, 311, 312,


318-320, 322-324
503, 505

Assembly

1001, 1016, 1019

49-4

Operational Check
202

Jul 14/04

HS

Nov 15/07

HS

RECORD OF TEMPORARY REVISIONS


Page 1
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

RECORD OF TEMPORARY REVISIONS


Page 2
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
SERVICE BULLETIN LIST
SB NO.

Description

Parts Added or
Changed

MOD
Symbol

Serial No.
Effectivity

SB-T-62T-49-58
Rev 1

Magnetic Chip
Detector Inspection
Procedure

All fielded
Units

SB-T-62T-49-124
Rev 3

Improved
Combustor Housing
and Start Fuel
System

924-10,
4502885B,
4502433C,
4503257,
4503258,
4503259,
MS21045C3,
MS51853-1SS or
MS51853-2SS,
115352-1,
MS21919WCJ4,
MS21919WCJ2
MS21279-06

SB-T-62T-49-126

Replacement of
Electronic Sequence
Unit

4501973D

None

All fielded
units

SB-T-62T-49-133

Introduction of
Electrical Wire
Harness

4502160B

Mod Dot 3

All fielded
units up to
S/N SPE974051

SB-T-62T-49-139

Introduction of
Electrical Wire
Harness
Improvements

4951334-1

Mod Dot 4

All fielded
units up to
S/N SPE974060

SB-T-62T-49-147
Rev 1

Replacement of
V-Band Clamp
(Superseded by
SB-T-62T-49-199)

4951327

Mod Dot 5

SP-E954001
through
SP-E984134

SB-T-62T-49-149
Rev 2

Introduction of
Resized Turbine
Nozzle and Revised
Rotor Clearances

4503900,
4502089-152

Mod Dot 6

SP-E954001
through
SP-E974116

Mod Dot 1

SP-E954001
through
SP-E954033

SERVICE BULLETIN LIST


Page 1
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
SB NO.

Description

Parts Added or
Changed

MOD
Symbol

Serial No.
Effectivity

SB-T-62T-49-150

Performance
Upgrade

115352-4,
4503958,
4950745,
4504051,
4503552,
4503551,
4504270,
4504050,
4501984B

Mod Dot 7

SP-E954001
through
SP-E984116

SB-T-62T-49-151

Introduction of New
Reduction Drive
Assembly

4501979,
4501979B,
4503225,
4950254,
4951153,
4503363-1,
4951154,
4503293,
4503226

Mod Dot 8

SP-E954001
through
SP-E984129

SB-T-62T-49-152
Rev 1

Improves High
Altitude Starting

4503259,
4504160,
4504270,
4504401,
4951439,
924-019,
MS21279-06,
MS21279-08,
MS21919WCJ2,
MS51853-2SS

Mod Dot 9

SP-E954001
through
SP-E994215

SB-T-62T-49-155

Introduction of
Improved
Acceleration Control
Assembly

4504015

Mod Dot 14

SP-E954001
through
SP-E994234

SB-T-62T-49-156
Rev 1

Introduction of New
Fuel Pump

4951545

Mod Dot 15

SP-E954001
through
SP-E994231

SB-T-62T-49-157

Reinforced
Combustor Liner
with Improved
Airflow and Lower
Operating
Temperatures

4503552A

Mod Dot 12

SP-E954001
through SPE994215

SERVICE BULLETIN LIST


Page 2
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
SB NO.

Description

Parts Added or
Changed

MOD
Symbol

Serial No.
Effectivity

SB-T-62T-49-158

Introduction of
Improved Turbine
Wheel Tie-Bolt Nut

4504439

Mod Dot 13

SP-E954001
through
SP-E994215

SB-T-62T-49-159

Turbine Wheel
Assembly with
Rolled Tie-Bolt
Threads

4503776,
4501993,
4501989B,
4501989C

Mod Dot 11

SP-E954001
through
SP-E984129

SB-T-62T-49-160

Introduction of
Turbine Assembly to
Combustor Housing
Flex Seal

4951556

Mod Dot 10

SP-E954001
through
SP-E994271

SB-T-62T-49-161

Turbine Wheel with


Improved Tie Bolt
Material and
Increased Tie Bolt
Stretch

4504574,
M4501993,
M4503776,
M4501989B,
4501989E,
4504439

Mod Dot 16

SP-E954001
through
SP-E994289

SB-T-62T-49-162
Rev 1

Air Inlet Screen


Assembly
Replacement

4504583

Mod Dot 17

SP-E954001
through
SP-E994241

SB-T-62T-49-166

Wrapping Control
Harness Assembly
Exciter and Bleed
Valve with SelfBonding Silcone
Tape

SB-T-62T-49-167
Rev 4

Improved Turbine
Assembly

4504497,
4504692,
4951644,
4504838,
4505325,
M172268-100,
172268-100A,
4501987,

Mod Dot 19

SP-E954001
through
SP-E004320

SERVICE BULLETIN LIST


Page 3
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

SB NO.

Description

SB-T-62T-49-168

Turbine Roller
Bearing and
Labyrinth Seal AntiRotation Features,
Increased-Clearance
Thrust-Bearing,
Thrust-Bearing
Retainer Plate with
Sealing Feature, and
Increased ThrustBearing Retainer Nut
Torque

SB-T-62T-49-169
Rev 1

Effusion Cooled
Combustor Liner
and Recalibrated
Acceleration Control

SB-T-62T-49-170
Rev 2

Altitude Start
Improvement Modified Start Fuel
Injection
(Superseded by
SB-49-181)

SB-T-62T-49-173

Grounding Stud

SB-T-62T-49-177

SB-T-62T-49-179

Parts Added or
Changed

MOD
Symbol

Serial No.
Effectivity

1809-4-3,
4504497A,
M4501987A,
4504794,
4951647,
4951648,
4951649,
4951645,
4951646,
4505445

Mod Dot 20

SP-E954001
through
SP-E004329

4504015,
4504015A,
4500874,
4503552A,
4504694A,
4504694B,
M4504694,
M4504694A

Mod Dot 21

SP-E954001
through
SP-E004343
and
SP-E004343
through
SP-E014499

Mod Dot 22

Serial number
SP-E954003

4503930,
NAS1149D0316J

Mod Dot 23

All APUs
through
SP-E004271

Replacement of
Engine Control
Harness Assembly
part number
45041051 with part
number 4504051A

4504051,
4504051A,
4502160,
4502160A,
4502160B

Mod Dot 24

SP-E954001
through
SP-E004363

Introduction of
Support Clamps for
Maximum Fuel
Solenoid Valve

0335702760,
MS21919WCJ18,
MS21919WCJ6,
MS21279-06,
MS21045C3

Mod Dot 30

SP-E954001
through
SP-E014506

SERVICE BULLETIN LIST


Page 4
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
SB NO.

Description

SB-T-62T-49-180

Introduction of Hour
Meter/Event Counter
part number
4951559

4950077,
4950135,
4504051B,
M4504051

SB-T-62T-49-181

Altitude Start
Improvement Modified Start Fuel
Injector

4503259B,
4504270,
MS51852-2SS,
MS21919WCJ2,
MS21279-08
AN960C10

Mod Dot 33

All APUs with


three start
fuel nozzles
4504401
series

SB-T-62T-49-183
Rev 2

Effusion-Cooled
Combustor Liner
with Enlarged
Dilution Holes

4505344,
4504694,
4504694A
4504694B
MS51852-2SS,
4503259,
4504270,
M4504694
M4504694A,
M4504694B

Mod Dot 26

SP-E004344
through
SP-E004431

4950745,
4503958,
4505587,
4951861,
NAS1160-3-6H,
AN960C416L

Mod Dot 25

SB-T-62T-49-185

Introduction of
Exciter Mounting
Bracket Assembly
with Isolation Pads

Parts Added or
Changed

SB-T-62T-49-186

Incorporation of
Modification Plate

0335702760

SB-T-62T-49-187

Containment Ring
Inspection/
Replacement and
Modification of
Containment Ring
Notches

M168404-200

MOD
Symbol

Serial No.
Effectivity
SP-E954001
through
SP-E014513

SP-E954001
through
SP-E004343

SP-E954001
through SPE984116
(Post SB-T62T-49-150)
SP-E954117
through
SP-E004470

None

Mod Dot 22

SP-E954001
through
SP-E04470
All fielded
units

SERVICE BULLETIN LIST


Page 5
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

SB NO.

Description

SB-T-62T-49-189

Modification of
Engine Control
Harness Assembly
for Oxley Hour
Meter/Event Counter
to Curtis Meters

SB-T-62T-49-190

Parts Added or
Changed

MOD
Symbol

Serial No.
Effectivity

4504051,
4504051A,
4950077,
4950135,
4951334-1,
4501991,
MS16995-10,
AN960C4,
MS21045C04,
M39029-4-110

Mod Dot 34

SP-E014514
and
subsequent.
SP-E954001
through
SP-E14513
with
SB-T-62T-49180
incorporated.

Introduction of Start
Fuel Nozzle Holder
Assembly with
Tabbed Lock
Washer

4504401,
4503259,
4504401A,
4503259A

Mod Dot 27

SP-E954001
through
SP-E014483

SB-T-62T-49-191

Modification from
Two High-Flow to
Three Low-Flow
Start Fuel Nozzles

4504401A,
4504050,
MS51853-2SS,
MS21919WCJ4,
MS21919WCJ2,
MS21279-06,
MS21045C3

Mod Dot 32

SP-E014515
SP-E014516
SP-E014521

SB-T-62T-49-192

Engine Harness
Assembly
Relocation to
Eliminate Bleed
Valve Contact

Mod Dot 28

SP-E954001
through
SP-E014474

SB-T-62T-49-193

Introduction of
Acceleration Control
Assembly part
number 4505716

4504015,
4504015A,
4505716

Mod Dot 29

SP-E014500
through
Subsequent

SB-T-62T-49-194

De-Icing Fluid
Resistant Fuel
Solenoid Valve

4952316-1,
4952316-2

Mod Dot 35

All fielded
units through
SP-E014521

SERVICE BULLETIN LIST


Page 6
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

SB NO.

Description

Parts Added or
Changed

MOD
Symbol

Serial No.
Effectivity

SB-T-62T-49-197

Introduction of High
Oil Temperature
Switch with
Improved OverTemperature
Protection

4952459-2

Mod Dot 37

All fielded
units through
serial number
SP-E044522

SB-T-62T-49-198

Introduction of Air
Inlet Housing with
Features to Improve
Roller Bearing
Longevity

M4504497A
4507007A

Mod Dot 38

All fielded
units through
serial number
SP-E04522

SB-T-62T-49-199
(Supercedes
SB-T-62T-49-147)

Introduction of
V-Band Clamp with
an Improved Clamp

4952538
4951556

Mod Dot 39

All fielded
units through
serial number
SP-E014522

SB-T-62T-49-200

Introduction of Air
Inlet Housing
Assembly with
Improved Moisture
and Corrosion
Resistance

4507007B
or
M4504497B

Mod Dot 40

All fielded
units through
serial number
SP-E054523

SERVICE BULLETIN LIST


Page 7
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

SERVICE BULLETIN LIST


Page 8
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
LIST OF EFFECTIVE PAGES
Subject

Page

Date

Subject

Title Page
Blank

1
2

Nov 15/07
May 1/02

Airworthiness

Highlights

1
2
3
4

Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07

49-00-00
APU System

Blank

1
2
3
4
5
6
7
8

Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Nov 15/07
Mar 15/04

Record of Revisions
Blank

1
2

Mar 15/04
May 1/02

Record of
Temporary
Revisions

1
2

Nov 15/07
May 1/02

Service Bulletin
List

1
2
3
4
5
6
7
8

Nov 15/07
Jan 15/03
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07

Blank

1
2
3
4
5
6

Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Mar 15/04

Table of Contents
Blank

1
2

Mar 15/04
May 1/02

Introduction

1
2
3
4
5
6

Nov 15/07
Jan 15/03
May 1/02
May 1/02
Nov 15/07
May 1/02

Blank
Safety Advisory

Blank
List of Effective
Pages

Page

Date

1
2

Jan 15/03
May 1/02

Title Page
Blank

1
2

Jul 1/00
Aug 1/01

Description
and Operation

1
2

Jul 1/00
Jan 15/03

Fault Isolation

101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135

Aug 1/01
Jul 1/00
Jul 1/00
Jul 1/00
May 1/02
Jul 1/00
Jul 1/00
May 1/02
Jul 1/00
Jul 1/00
May 1/02
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
May 1/02
Jul 1/00
Jul 1/00
Mar 15/04
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jan 15/03
Jan 15/03
Aug 1/01
Aug 1/01
Jul 1/00
Jul 1/00
Jul 1/00

LIST OF EFFECTIVE PAGES


Page 1
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Subject
Fault Isolation
(Cont.)

Blank

Operational Check

Blank
Removal/Installation

Page

Date

136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152

Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02

201
202
203
204
205
206
207
208

Jul 1/00
Nov 15/07
May 1/02
Jan 15/03
May 1/02
Jul 1/00
Jul 1/00
Jul 1/00

301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322

Mar 15/04
Nov 15/07
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07

Page

Subject

Date

Removal/Installation
(Cont.)

323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344

Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07

Cleaning

601
602
603
604
605
606

Nov 15/07
Jan 15/03
Jan 15/03
Jan 15/03
Nov 15/07
Nov 15/07

801
802
803
804
805
806
806A
806B
807
808
809
810
811
812
813
814
815
816

Mar 15/04
Mar 15/04
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04

Inspection/Check

Blank

LIST OF EFFECTIVE PAGES


Page 2
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Subject

Page

Subject

Date

Inspection/Check
(Cont.)
Blank

817

Mar 15/04

818

Mar 15/04

Repair
Blank

901
902

Mar 15/04
Mar 15/04

Servicing

1101
1102
1103
1104
1105
1106

Mar 15/04
Mar 15/04
Jul 1/00
Mar 15/04
Mar 15/04
Mar 15/04

Title Page
Blank

1
2

Jul 1/00
Aug 1/01

Description and
Operation

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Jul 1/00
Aug 1/01
Jul 1/00
Jul 1/00
May 1/02
Jul 1/00
Jul 1/00
Jul 1/00
Jul 1/00
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02

501
502
503
504
505

Mar 15/04
Aug 1/01
Mar 15/04
Nov 15/07
Nov 15/07

Disassembly
(Cont.)

Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07

Assembly

1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1022
1023
1024
1025
1026
1027
1028
1029
1030
1031
1032

Nov 15/07
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07
Nov 15/07

Storage

1201
1202
1203
1204
1205
1206

Nov 15/07
Mar 15/04
Mar 15/04
Mar 15/04
Mar 15/04
Nov 15/07

49-20-00
Engine

Blank
Disassembly

Date

506
507
508
509
510
511
512

Blank

Blank

Page

LIST OF EFFECTIVE PAGES


Page 3
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Subject
Testing

Page
1301
1302
1303
1304
1305
1306
1307
1308
1309
1310
1311
1312
1313
1314
1315
1316
1317
1318
1319
1320

Nov 15/07
Jul 1/00
Jul 1/00
Jul 1/00
Jan 15/03
Jan 15/03
Jan 15/03
Jan 15/03
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
May 1/02
Nov 15/07
Jan 15/03
Jan 15/03
Jan 15/03

1501
1502
1503
1504
1505
1506

Jul 1/00
Jul 1/00
Jul 1/00
May 1/02
May 1/02
May 1/02

Title Page
Blank

1
2

Jul 1/00
Aug 1/01

Description
and Operation

1
2

Jul 1/00
Jul 1/00

Special Tools,
Fixtures, and
Equipment

Blank

Subject

Date

501
502
503
504
505
506
507
508
509
510
511

Mar 15/04
May 1/02
Jul 1/00
Jul 1/00
Jul 1/00
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Page

49-23-00
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Assembly
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Subject
Description and
Operation

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ENGINE MANUAL
PART NUMBER 4501966 SERIES

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
TABLE OF CONTENTS

Subject

Chapter
Section
Subject

Page

ENGINE MANUAL - AUXILIARY POWER UNIT (APU) SYSTEM


Title Page
Safety Advisory
Record of Revisions
Record of Temporary Revisions
Service Bulletin List
List of Effective Pages
Table of Contents
Introduction
Airworthiness Limitations
APU SYSTEM

1
1
1
1
1
1
1
1
1
49-00-00

Title Page
Description and Operation
Fault Isolation
Operational Check
Removal/Installation
Cleaning
Inspection/Check
Repair
Servicing
ENGINE

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1
101
201
301
601
801
901
1101
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Description and Operation
Disassembly
Assembly
Storage
Testing
Special Tools, Fixtures, and Equipment
TURBINE ASSEMBLY

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1
501
1001
1201
1301
1501
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Description and Operation
Disassembly
Assembly
REDUCTION DRIVE ASSEMBLY
Title Page
Description and Operation
Disassembly
Assembly

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ENGINE MANUAL
PART NUMBER 4501966 SERIES

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TABLE OF CONTENTS
Page 2
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
INTRODUCTION
1.

2.

General
A.

This document provides instructions for maintenance and repair for the Auxiliary
Power Unit (APU) System, part number 4501966 series, Model T-62T-40C11.

B.

The APU system is manufactured by Hamilton Sundstrand Power Systems, a United


Technologies Company, 4400 Ruffin Road, P.O. Box 85757, San Diego, CA
92186-5757.

C.

Maintenance, servicing or disassembly of parts which are not covered in this manual
should not be attempted. Such actions will not be supported by Hamilton Sundstrand
and will be sole responsibility of the aircraft operator.

Standard Practices
A.

3.

Standard Practices Manual (SPM) HSPS 490001 contains information on the types
and use of technical publications and provides practices and philosophies related to
maintenance.

Statement of Verification
Method

Date

Testing and Fault Isolation

Analysis

Jan 1/96

Disassembly

Analysis

Jan 1/96

Assembly

Analysis

Jan 1/96

Section

4.

Associated Manuals (Manual Effectivity)


A.

All facilities that perform maintenance and repair of the APU system will require the
following publications:
Engine Manual, Document 40C11-1
Illustrated Parts Catalog, Document 40C11-3
Cleaning, Inspection, and Repair Manual, Document APS500 C/I/R
Harness, CMM 49-10-15
Acceleration Control Assembly, CMM 49-31-05
Acceleration Control, CMM 49-31-14
Fuel Control (In Work), CMM 49-31-23
Fuel Pump, CMM 49-32-05
Ignition Exciter, CMM 49-42-08
Ignition Exciter, CMM 49-42-10
Exhaust Inlet Silencer Components, CMM 49-50-01
Anti-surge Valve, CMM 49-52-07
Bleed Valve (In Work), CMM 49-53-14
Electronic Sequence Unit, CMM 49-61-08
Silencer Components, CMM 49-80-01
INTRODUCTION
Page 1
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
5.

Application
A.

6.

Model Number

Application

T-62T-40C11

Embraer 145
Embraer 135

Materials, Equipment, Compounds, and Special Tools


A.

7.

Equipment covered in this manual applies to the following applications:

Materials, equipment, compounds, and special tools are listed in appropriate sections
as required. Consult these lists so that the materials, compounds, and special tools
may be gathered prior to starting maintenance or repair.

Repair Cycle
A.

On-Condition Maintenance
(1)

The APU system shall be maintained, subject to the maintenance intervals and
periodic inspections contained in the applicable Aircraft Maintenance Planning
Document, and the terms of the purchase agreement.

(2)

The turbine wheel and compressor impeller, will be life managed based on "OnCondition" monitoring and shop visit inspection opportunities.

INTRODUCTION
Page 2
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
8.

List of Abbreviations
A.

The following abbreviations/symbols are used in this manual.

Abbreviation

Definition

Abbreviation

Definition

APU

Auxiliary Power Unit

kg

kilograms

BITE

Built-In Test Equipment

kPa

kilopascals

Celsius

lb.

pound

cc

cubic centimeters

min

minute

cm

centimeter

mm

millimeters

CMM

Component Maintenance
Manual

Nm

Newton meters

CMC

Central Maintenance
Computer

O.D.

Outer Diameter

CPU

Central Processing Unit

PCD

Compressor Discharge
pressure

EGT

Exhaust Gas
Temperature

pph

pounds per hour

EPROM

Erasable/Programmable
Read Only Memory

psi

pounds per square inch

ESU

Electronic Sequence Unit

psia

pounds per square absolute

Fahrenheit

psid

pounds per square differential

FOD

Foreign Object Damage

psig

pounds per square gauge

ft

foot

rpm

revolutions per minute

hr

hour

RTL

Ready To Load

Hz

Hertz

SB

Service Bulletin

I.D.

inner diameter

shp

shaft horsepower

in. Hg

inches of Mercury

U.S.

United States

IPC

Illustrated Parts Catalog

Vdc

Volts direct current

l/hr

liters per hour

plus or minus

Percent

INTRODUCTION
Page 3
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
9.

Consumable Materials
A.

Consumable materials required for maintenance and repair of the auxiliary power unit
(APU) are listed in Figure 1.

Material

Description/Use

Specification

Source (Vendor Code)

Insulated wire

Fault isolation

MIL-W-22579

Commercially Available

Adhesive

Removal/Installation,
Assembly

RTV-106
(917252C1)

General Electric (01139)

Anti-seize compound

Removal/Installation

MolyKote P37

Dow Corning

Anti-seize compound
- High Temperature

Removal/Installation

Nickel Ease

Commercially Available

Anti-seize lubricant

Removal/Installation,
Assembly

169041 or 51102

Hamilton Sundstrand
(55820) or
Fel-Pro (73165)

Anti-seize compound
-C-5A

Removal/Installation

111007-1

Fel-Pro, Inc. (73165)

Assembly fluid #1

Removal/Installation,
Servicing, Assembly

4950515

Hamilton Sundstrand
(55820)

Lint free cloth

Removal/Installation,
Cleaning, Servicing

Lock wire

Removal/Installation,
Servicing

MS20995C20 or
MS20995C32

Commercially Available

Safety cable

Removal/Installation

5909034-2B and
5909034-5B

Hamilton Sundstrand
(55820)

Cartridge - ferrule

Removal/Installation

5909035-1B and
5909035-2B

Hamilton Sundstrand
(55820)

Loctite

Removal/Installation

RC640

Loctite Corp. (05972)

Lubricant - solid film,


spray

Removal/Installation,
Disassembly,
Assembly

Molykote 321R
(169015-1)

Dow Corning

Primer Grade N

Removal/Installation,
Assembly

MIL-S-22473

Commercially Available

Commercially Available

Consumable Materials List


Figure 1 (Sheet 1of 3)
INTRODUCTION
Page 4
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Material

Description/Use

Specification

Source (Vendor Code)

Sealing compound
PST 592

Removal/Installation

112015-1

Loctite Corp. (05972)

Solder

Removal/Installation

SN3WRMAP2 or
SN63WRMAP3 or
SN63BS

Commercially Available

Tape

Removal/Installation

Cat. No. 27
(950455C1)

3M Corp. (76381)

Engine oil

Removal/Installation,
Servicing

Refer to Hamilton
Sundstrand
Standard Practices
Document HSPS
490001 for oil types
and restrictions

Hamilton Sundstrand
(55820)

Lubricating oil

Cleaning, Disassembly

MIL-PRF-6081 Grade 1010

Commercially Available

TODCO 1060

Cleaning

Petroleum solvent
(Cleaning fluid)

Cleaning

Stiff -bristle brush

Cleaning

Dry cleaning solvent

Cleaning

MIL-PRF-680,
Type ll

Commercially Available

Cleaning compound
(simple green)

Cleaning

13002

Sunshine Makers, Inc.


(1Z575)

Gloves

Cleaning

Commercially Available

Goggles

Cleaning

Commercially Available

Mask

Cleaning

Commercially Available

Adhesive, type ll and


primer type l

Assembly

MIL-A-46146

Commercially Available

Adhesive, type lll

Assembly

RTV-3145 (5764433 or 22017203)

Dow Corning Corp.

Isopropyl alcohol

Assembly

Locquic primer

Assembly

Commercially Available
AMS3160F

Commercially Available
Commercially Available

Commercially Available
Grade T and Grade
N MIL-S-22473
(111009-1)

Loctite Corp.

Consumable Materials List


Figure 1 (Sheet 2 of 3)
INTRODUCTION
Page 5
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Material

Description/Use

Specification

Source (Vendor Code)

Zinc chromate primer

Assembly

Fed. Spec. TT-P-1757

Commercially Available

Barrier material

Storage

MIL-B-131

Commercially Available

Masking tape

Storage

PPP-T-42

Commercially Available

Tag

Storage

Commercially Available

Dry ice

Assembly

Commercially Available

Retaining compound

Assembly

MIL-R-46082, Type ll

Commercially Available

Pipe sealant

Assembly

Loctite 277, Type l,


Grade L

Loctite Corp (05972)

Sealing compound

Assembly

Type lll MIL-S-45180

Commercially Available

Gasket compound

Assembly

Form-a-gasket No. 3

Permatex (62377)

Sealant

Assembly

PR-1440

Products Research and


Chemical Co. (83574)

Consumable Materials List


Figure 1 (Sheet 3 of 3)

INTRODUCTION
Page 6
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
AIRWORTHINESS LIMITATIONS
1.

Life Management Plan


NOTE:

A.

The Airworthiness Limitations section is Federal Aviation Administration (FAA)


approved and specifies maintenance required under sections 43.16 and (91.403)
of the Federal Aviation Regulations unless an alternate program has been FAA
approved.

Life part inspection or replacement requirements are subject to the data collected as
part of the Life Management Plan (LMP).
(1)

The LMP is based on the calculated Low Cycle Fatigue (LCF) life,
accumulated service experience, and endurance testing of ex-service
components. Fleet wide data collection in conjunction with fracture
mechanical analyses, and simulations techniques will be used to determine
safe operating limits which allow the parts to be withdrawn from service prior
to failure.

(2)

Eddy current and Florescent Penetrant Inspection (FPI) inspections of the


turbine and compression wheel bore locations, shall be done in accordance
with the applicable Inspection and Check sections and Figure 1. The data
shall be collected for regular reviews with the FAA. The following are the
inspection requirements for the fleet:
Component

Location

Minimum Age
(Note 1) (Note 2)

Scallop

1000 Cycles

Compressor Wheel

Bore/To be Supplied

5000 Cycles

Compressor Wheel

Backface/FPI

5000 Cycles

Turbine Wheel

Note 1: Perform Eddy Current and FPI inspections on subject wheel when
returned for repair at or after the stated life cycle when the APU is
disassembled to a level that permits the inspection.
Note 2: Inspection interval minimum since last inspection to be 1000 cycles.
Inspection Requirements
Figure 1
(3)

As the average age of the inspected units moves upwards, life extensions are
justified by risk assessment and the continuing health of the inspected
engines. The occurrence of cracked hardware will be handled in the same
manner, as it would be under a fleet leader program. If an indication is
observed, the part will be removed and returned to Hamilton Sundstrand for
further evaluation. Hamilton Sundstrand will utilize the data from an in-house
test unit to substantiate the crack growth behavior.
AIRWORTHINESS
Page 1
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(4)

This approach relies on the steady occurrence of inspections at shop visits


(first opportunity) by Hamilton Sundstrand and Hamilton Sundstrands or a
Federal Aviation Regulation (FAR) 145 approved repair facilities. If, at any
time, a sufficient population (as agreed with the FAA) of the T-62T-40C11
fleet is not being inspected at a rate to support the Life Management Plan
(LMP) in risk assessment presented to the FAA during reviews, a notification
will be issued to require appropriate inspections. The LMP is a continual
process to support the T-62T-40C11 fleet.

(5)

A service information letter (SIL) will be issued periodically to share the fleet
results, which specifies the threshold target for continued disassembly for
Eddy Current inspections. If any part is found with a crack or if a failure
occurs, all operators will be informed. The notification to the operators may
also contain updates to the inspection requirement and frequency. As the T62T-40C11 fleet matures, the review will be modified as required to provide
sufficient information to the FAA.

(6)

Further details of the LMP may be found in Hamilton Sundstrand Engineering


Specification (Radial) (ESR) 0970, Hamilton Sundstrand Power Systems
Model T-62T-40C11 Auxiliary Power Unit Life Management Plan and
Engineering (Radial) Report (ERR) 2396 "Overview of Sundstrand Power
Systems Component Life Management Plan." For a copy of the specification
or reports, contact your local Hamilton Sundstrand field service
representative.

(7)

Low Cycle Fatigue (LCF) Counting

(8)

(a)

Automatic LCF counting is used on the T-62T-40C11 APU to count


the accumulated cycles (starts) on the critical components.

(b)

The APU rotating components listed in Figure 1 are subject to LCF


due to cyclic operation of the APU. As a result, these parts must be
inspected as prescribed by the LMP.

(c)

When the APU or one of the listed components in Figure 1 is


replaced, the APU logbook must be updated with the appropriate
information.

(d)

Hamilton Sundstrand recommends that the operator provide the


accumulated APU hours and cycles to Hamilton Sundstrand,
Customer Support Engineering, Department 378, 4400 Ruffin Road,
San Diego, California 92186-5757, on a monthly basis or upon
removal or replacement of the APU or any of the listed components in
Figure 1.

Service Time and Cycles Marking Method


(a)

At each removal, the service time and service cycles of the impeller
wheels and turbine wheels shall be marked in accordance with the
procedures specified in applicable Inspection and Check sections.

AIRWORTHINESS
Page 2
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

AUXILIARY POWER UNIT


SYSTEM
49-00-00

AUXILIARY POWER UNIT SYSTEM

49-00-00

Title, Page 1
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

AUXILIARY POWER UNIT SYSTEM

49-00-00

Title, Page 2
Aug 1/01

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
DESCRIPTION AND OPERATION
1.

General
NOTE: The Auxiliary Power Unit (APU) System is a source of electrical and pneumatic
power for the Embraer 145 and 135 aircraft. The APU System is a model T62T-40C11, manufactured by Hamilton Sundstrand, A United Technologies
Company.
A.

B.

The APU System consists of the following:


(1)

The engine

(2)

The electronic sequence unit (ESU)

(3)

The installation hardware kit

The engine is a gas turbine engine that supplies both shaft power and pneumatic power
in the form of compressor bleed air.
The engine has:
- A reduction drive assembly
- A turbine section
- A combustor section.

C.

The ESU is a solid state electronic unit that automatically controls the engine start
sequence, monitors critical engine parameters during steady state operation, and
automatically shuts down the engine in the event these parameters are not within
specification limits. The operation limits and parameters are listed in Figure 1.
NOTE: When the aircraft is in flight, the ESU will only shut down the engine in the event
of a CRITICAL fault, refer to FAULT ISOLATION, Figure 102.

D.

The installation hardware kit consists of an anti-surge valve, a bleed air elbow, a bleed air
venturi assembly, and installation clamps and O-rings. The anti-surge valve is always
closed on the ground. The anti-surge valve prevents compressor surges and is opened
in flight by the ESU during engine starting and when the engine is supplying shaft power
only. The remaining components of the kit are used to direct bleed air from the engine to
the aircraft pneumatic system.

DESCRIPTION AND OPERATION

49-00-00

Page 1
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Condition
Speed

Operation Mode

Limit

Normal operation

100 to 104%
(61,565 to 64,028 rpm)

Overspeed shutdown

108% (66,490 rpm)

Underspeed shutdown

Speed goes below 95% (58,487


rpm) after ready to load has been
reached

Acceleration

1,604 20F (873 11C)

Steady state (100% speed)

1,303 20F (706 11C)

High oil temperature

Start initiation or normal operation

330 5F (166 3C)

Low oil pressure

Normal operation

6 1.5 psig (41.4 10.3 kPa)

Oil sump capacity

Any

2.5 U.S. quarts (2366 cc)

Bleed duct pressure

APU bleed valve closed

0 psig (0 kPa)

APU bleed valve open

51 psia (352 kPa)

Exhaust gas temperature

Operation Limits and Parameters


Figure 1

DESCRIPTION AND OPERATION

49-00-00

Page 2
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
FAULT ISOLATION
1.

2.

Introduction
A.

This section lists faults that may occur in the Auxiliary Power Unit (APU) system and the
corrective actions to be taken. All corrective actions listed in the fault isolation charts can
be performed with the APU system in its installed position. As each corrective action is
performed, it is assumed that a restart will be attempted before proceeding to the next
action unless otherwise specified.

B.

Faults resulting in an APU system shutdown are determined by APU action and fault
messages available from the aircraft Central Maintenance Computer (CMC) or built-in
test equipment (BITE) indications in the test cell.

Equipment and Materials


A.

Equipment and materials required for fault isolation procedures are listed in Figure 101.
NOTE: Equivalent substitutes may be used for items listed.

Item

Equipment/Material

Manufacturer
(Vendor Code)

Range

(1)

Insulated wire,
MIL-W-22579

Local Supply

N/A

(2)

Digital Multimeter
8060A

Fluke Instrument
Company (8S674)

0 to 200 volts

(3)

Pressure gauge

Ashcroft (38056)

0 to 500 psig (0 to 3445 kPag)

(4)

Pressure gauge

Local Supply

0 to 60 psig (0 to 413 kPag)

(5)

Temperature guage

Local Supply

0 to 300F (0 to 149C)

Fault Isolation Equipment and Materials


Figure 101
3.

Fault Isolation
A.

Preliminary Fault Isolation Procedures


(1)

Perform fault A tasks before troubleshooting APU.

(2)

Set the APU START switch to ON. The ESU will execute a self-test and output a
BITE indication of 1000 for 100 milliseconds. The BITE output will then switch to
0000. If no fault indication is displayed this means that the ESU has reset and is
ready for a start sequence.

(3)

If the ESU does not reset, the fault may be in the external electrical system.
Perform aircraft or test cell or test cell diagnostic procedures before attempting to
troubleshoot the APU.
FAULT ISOLATION

49-00-00

Page 101
Aug 1/01

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(4)

If the APU begins to start when the APU START switch is set to START, and a fault
exists, refer to Figure 102; then proceed to the applicable fault isolation chart. The
fault categories given in Figure 102 are defined as follows:
(a)

ADVISORY - fault message or BITE code displayed only.

(b)

CRITICAL - APU shutdown in all cases.

(c)

MAJOR - APU shutdown only when not in flight.

Fault

CMC
Message

ESU failure

APU ESU FAIL

APU general
inspection

BITE
Code
1000

Fault
Category

Fault Description

CRITICAL

Action

The ESU processor


has malfunctioned

Replace
ESU

NONE

Any fault

Go to A

APU fails to
rotate

NONE

APU fails to rotate


when start power is
applied

Go to B

Bleed valve
open

APU BLEED
VALVE OPEN

1001

ADVISORY

The bleed valve is


open at start initiation

Go to C

No rotation,
external short

APU EXTERNAL
SHORT

1101

CRITICAL

A short circuit in one


of the output circuits:
- Fault Signal
- Start Command
- Anti Surge Valve

Go to D

3% RPM,
external short

APU EXTERNAL
SHORT

1101

CRITICAL

A short circuit in the


output circuit:
- Start Fuel Exciter

Go to E

14% RPM,
external short

APU EXTERNAL
SHORT

1101

CRITICAL

A short circuit in the


output circuit:
- Main Fuel Exciter

Go to F

Ready to load
(RTL), external
short

APU EXTERNAL
SHORT

1101

CRITICAL

A short circuit in one


of the output circuits:
- Ready to Load
- Maximum Fuel
- Cycle Meter

Go to G

Fault Isolation Guide


Figure 102 (Sheet 1 of 4)
FAULT ISOLATION

49-00-00

Page 102
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Fault

CMC
Message

BITE
Code

Fault
Category

Fault Description

Action

No rotation, fail
to start

APU FAIL TO
START

0110

CRITICAL

The APU speed has


not reached 3%
within 8 seconds

Go to H

APU rotates,
fail to start 0 to
< 14%

APU FAIL TO
START

0110

CRITICAL

The APU speed has


not reached 14%
within 20 seconds

Go to I

APU rotates
14% to 103%

APU FAIL TO
START

0110

CRITICAL

The APU speed has


not progressed from
14% through 103%
within 34 seconds

Go to J

APU fails to
carry load

APU
UNDERSPEED

1010

CRITICAL

APU shuts down


when load applied

Go to K

Shorted oil
pressure
switch

APU OIL PRESS


SW SHORTED

0001

MAJOR

Oil pressure has


been detected after
the start command
has been received,
but before cranking
the start motor

Go to L

High oil
temperature

APU OIL HIGH


TEMP

1110

MAJOR

High oil temperature


at start initiation or
high oil temperature
has been detected
for twelve seconds
after ready to load

Go to M

Low oil
pressure

APU OIL LOW


PRESS

0100

MAJOR

Go to N

EGT
overtemperature

APU EGT
OVERTEMP

1100

MAJOR

Low oil pressure for


twelve seconds after
ready to load
The following over
temperature limits
have been exceeded
for 0.5 second:
during start (before
RTL) 1,604 20F
(873 11C); steady
state (at RTL) 1,300
20F (704 11C)

Go to O

Fault Isolation Guide


Figure 102 (Sheet 2 of 4)
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Fault

CMC
Message

BITE
Code

Fault
Category

Fault Description

Action

Overspeed

APU
OVERSPEED

0010

CRITICAL

A speed of 108%
has been sensed or a
STOP (OVERSPEED
TEST) signal has
been received after
RTL in ground
operation

Go to P

Underspeed

APU
UNDERSPEED

1010

CRITICAL

A speed of 95%
has been sensed
after RTL has been
reached

Go to Q

Open
thermocouple

APU
THERMOCOUPLE
OPEN

0011

MAJOR

An EGT 2,100F
(1,149C) has been
detected for 0.5
second after RTL has
been reached

Go to R

Shorted
thermocouple

APU
THERMOCOUPLE
SHORTED

0101

MAJOR

An EGT 250F
(121C) has been
detected after RTL
has been reached

Go to R

Loss of speed
data

APU SPEED
DATA LOSS

1011

CRITICAL

A speed signal is no
longer sensed after
5% has been
reached

Go to S

Fault Isolation Guide


Figure 102 (Sheet 3 of 4)

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Fault

CMC
Message

BITE
Code

Fault
Category

Fault Description

Action

Fail to
accelerate

APU
UNDERSPEED

0111

CRITICAL

Acceleration rate of
1.0%/second2 is
recognized for 2
seconds before 95%
speed or speed
increases beyond
95% and then falls
below 85% before
RTL is reached

Go to K

Fail to light

APU FAIL TO
LIGHT

1111

CRITICAL

An increase in EGT
has not been
recognized within 12
seconds after start
fuel and exciter have
been energized

Go to J

Oil smell in
cabin

NONE

Oil smell in cabin

Go to T

Fuel smell in
cabin

NONE

Fuel smell in cabin

Go to U

APU will not


start in flight.
Starts on the
ground.

FAIL TO START

APU will not start in


flight

Go to V

0110

CRITICAL

Fault Isolation Guide


Figure 102 (Sheet 4 of 4)

(5)

The fault isolation diagrams are arranged in a step-by-step logic sequence. The
fault isolation diagrams should be used in conjunction with the corresponding fault
isolation tables.

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Fault A (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Metal on magnetic
plug

Bearing failure

A small amount of metal fuzz is acceptable.


Metal chunks are not acceptable. Refer to
49-20-00 "INSPECTION/CHECK".

2.

Oil level not correct

Underserviced/
Overserviced
sump

Service the oil level to the center of the sight


gauge. CAUTION: OVERSERVICE AND
UNDERSERVICE OF THE OIL SYSTEM
CAN CAUSE HIGH OIL TEMPERATURE
AND GEARBOX FAILURE.

3.

Turbine wheel
damaged

Overtemperature
or rotor rub

Check the turbine wheel for free rotation, no


rubbing allowed.
Check the turbine wheel for missing blade
tips.

4.

Inspection of APU

Various

5.

No CMC Fault
messages
displayed

Aircraft wiring,
ESU, or enable
switch

Check the combustor housing V-Band clamp


for condition and security.
Check the combustor housing for cracks.
Check all the LRUs and electrical
connectors for security.
Review date and time to determine latest
fault message.
Make sure CMC switch is in enable position
for continued troubleshooting.
Refer to Fault B.

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Step
1.

Fault
Indication
No 28 Vdc at ESU

Probable Cause

Correction

Bad relay, aircraft/test


cell wiring, or ESU

Check for 28 Vdc at pins A and E of the


ESU when power is applied. If no 28
Vdc indicated, troubleshoot aircraft/test
cell wiring and relay (K0280). If 28 Vdc,
replace ESU.

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Fault C (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Bleed valve open

Bleed valve, ESU,


or wiring

Observe bleed valve position indication on bleed


valve. If valve indicates open, then go to step 2.
If valve indicates closed, go to step 3.

2.

Bleed valve close


command

Bleed valve, ESU,


or wiring

Shut APU down. Disconnect P309 from bleed


valve. Connect 0 to 50 Vdc voltmeter across
P309 pins 1(+) to 2(-). Set APU power ON. If 28
Vdc is indicated on meter at pins 1 and 2,
replace bleed valve. If no 28Vdc indicated,
troubleshoot aircraft/test cell wiring.

CAUTION: USE A HIGH-IMPEDENCE DIGITAL MULTIMETER TO CHECK BLEED VALVE


CONTINUITY IN THE FOLLOWING STEPS. THE SWITCH CONTACTS COULD BE
DAMAGED IF A LOW-IMPEDENCE METER IS USED.
3.

Bleed valve close


commend

Bleed valve, ESU,


or wiring

Disconnect P2 from ESU. Check for ground at


P2 pin R. If ground, replace ESU. If no ground,
go to step 4.

4.

Bleed valve
closed signal

Bleed valve or
wiring

Disconnect P309. Check continuity from J309


pin 7 to J309 pin 13. If open circuit, replace
bleed valve. If continuity, troubleshoot
aircraft/test cell wiring.

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Fault D (Cont'd)
Fault
Indication

Probable Cause

1.

Start output shorted


to ground

ESU adapter harness,


aircraft wiring, or ESU

Disconnect P2 from ESU. Check P2


pins J and C for short to ground. If
shorted, troubleshoot aircraft/test cell
wiring or start contactor. If ok, replace
ESU.

2.

ESU anti-surge
valve output shorted
to ground

Anti-surge valve,
wiring, or ESU

Disconnect P1 and P308. Check P308


pin 1 for short to ground. If shorted,
troubleshoot aircraft/APU harness/test
cell wiring.

Step

Correction

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Fault E (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

ESU start fuel and


exciter output
shorted to ground

APU harness, ignition


exciter, or start fuel
valve

Disconnect P303 and P305. Check P4


pins 16 and 21 for short to ground. If
shorted, replace APU harness. If ok,
then go to step 2.

2.

ESU start fuel and


exciter output
shorted to ground

Ignition exciter or start


fuel valve

Check start fuel valve J305 pins A to B


for short. If ok (approx. 29 ohms),
replace ignition exciter. If shorted,
replace start fuel valve.

3.

ESU start fuel and


exciter output
shorted to ground

ESU adapter harness,


aircraft/test cell wiring,
APU harness, ignition
exciter, or start fuel
valve

Disconnect P4. If P1 pin T is still


shorted, troubleshoot aircraft/test cell
wiring. If short disappears, go to step 4.

4.

ESU start fuel and


exciter output
shorted to ground

ESU, ESU adapter


Disconnect P1. Check P1 pin T for short
harness, test cell
to ground. If ok, replace ESU.
wiring, APU harness,
ignition exciter, or start
fuel valve

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Fault F (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

ESU main fuel


output shorted to
ground

ESU, ESU adapter


harness, test cell
wiring, APU harness,
or main fuel valve

Disconnect P1. Check P1 pin J for short


to ground. If shorted, go to step 2. If ok,
go to step 5.

2.

ESU main fuel


output shorted to
ground

ESU adapter
harness, test cell
wiring, APU harness,
or main fuel valve

Disconnect 4. If P1 pin J is still shorted,


troubleshoot test cell wiring. If short
disappears, go to step 3.

3.

ESU main fuel


output shorted to
ground

APU harness or main


fuel valve

Disconnect P306. Check P4 pin 8 for


short to ground. If shorted, replace APU
harness. If ok, go to step 4.

4.

ESU main fuel


output shorted to
ground

APU harness or main


fuel valve

Check main fuel valve solenoid J306 pins


A and B for short (approx. 29 ohms). If
shorted, replace main fuel valve. If ok, go
to step 5.

5.

ESU faulty

ESU internal fault

Replace ESU.

6.

ESU main fuel


output shorted to
ground

Hourmeter shorted

Replace hourmeter or harness.

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Fault G (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

ESU, max fuel valve


or ready-to-load
(RTL) outputs

ESU, aircraft/test cell


wiring, APU harness,
or max fuel valve
shorted

Disconnect P1. Check P1 pin R for


short to ground. If shorted, go to step
2. If ok, go to step 4.

2.

ESU or max fuel


valve shorted

Wiring or APU max


fuel valve

Disconnect P4. If P1 pin R is still


shorted, troubleshoot aircraft/test cell
wiring. If ok, go to step 3.

3.

ESU, max fuel


valve, or wiring
shorted

APU harness or max


fuel valve

Disconnect P307. Check J307 pins A


and B for short (approx. 29 ohms). If
shorted, replace max fuel valve. If ok,
replace APU harness.

4.

Ready-to-load (RTL)
output shorted

Aircraft/test cell wiring


or ESU

Disconnect P2. Check P2 pin L for


short to ground. If shorted,
troubleshoot aircraft/test cell wiring. If
ok, replace ESU.

5.

Cycle meter shorted

Cycle meter

Replace cycle meter or harness.

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Fault H (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Fail to start (APU


rotates)

Magnetic pickup

Disconnect P302. Resistance reading of


the magnetic pickup should be 1,000 to
1,450 Ohms.

2.

Fail to start (APU


rotates)

APU/aircraft/test cell
wiring or ESU

Check wiring between ESU and P302.

3.

Fail to start (no


rotation)

starter generator

Check for 28 Vdc at starter/generator


when APU start switch set to start.

4.

Fail to start (no


rotation)

ESU

Check for 28 Vdc at ESU P2 pin J.

5.

Fail to start (no


rotation)

APU/aircraft/test cell
wiring

Check for 28 Vdc at GCU or start


contactor.

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Fault I (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Cranking speed

Undetermined

Disconnect the air line at the start purge


check valve. Perform an APU start and
check for fuel leaking from the check
valve.

2.

Speed circuit
faulty

ESU or magnetic
pickup circuit

Disconnect P1. Check resistance P1


pins M and N (through wiring across
magnetic pickup). If ok (1,190 to 1,450
ohms), replace ESU. If not ok, go to
FAULT S, loss of speed data.

3.

Slow cranking
speed, ESU timed
out

Starter/generator, APU,
driven equipment, or
battery

Disconnect starter/generator from


reduction drive. If APU is free to rotate
manually, go to step 4. If not free,
replace APU.

4.

Slow cranking

Starter/generator or
battery

Check battery voltage under load. If ok,


replace starter/generator or driven loads.
If not ok, replace battery.

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Fault J (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Hung start

Fuel restriction

Check fuel filters for restriction. Clean or


replace.

2.

Hung start

Combustor air leak

Check for air leaks at combustor. Repair


as necessary.

3.

Hung start

Main fuel solenoid

Check main fuel valve P306 pin A for 28


Vdc at 14% or greater. Repair as
necessary.

4.

Hung start

Starter/generator

Refer to FAULT H.

5.

Hung start

Acceleration control

Refer to FAULT V.

6.

Hung start

Fuel pump

Replace fuel pump.

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Fault K (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Inadequate fuel
supply

Test cell boost pump

Check test cell fuel boost pump pressure.


If ok, go to step 2. If low, repair test cell
fuel system.

2.

Starter drop-out

ESU

Check for starter voltage drop-out at


starter relay. If 28 Vdc does not drop-out
at 70% RPM, replace ESU. If ok, go to
step 3.

3.

Restricted fuel flow

Inlet fuel filter or


acceleration control

Check fuel inlet filter. If contaminated,


replace filter element. If ok, go to step 4.

4.

Restricted fuel flow

fuel pump filter or


acceleration control

Check fuel pump filter. If contaminated,


clean or replace filter element. If ok,
replace acceleration control and fuel
pump.

5.

Max fuel flow

Max fuel solenoid

Check for 28 Vdc at P307 pin A. If no 28


Vdc, repair aircraft/test cell wiring. If 28
Vdc, replace max fuel solenoid.

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Fault L (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Short circuit

ESU, APU harness,


or LOP switch

Disconnect P1. If p1 pin G is shorted to


any other pin, go to step 2. If open,
replace ESU.

2.

Short circuit

Test cell wiring, APU


harness, or LOP
switch

Disconnect P4. If P1 pin G is still


shorted, troubleshoot test cell wiring. If
open, go to step 3.

3.

Short circuit

APU harness or LOP


switch

Disconnect P304. If J304 pins B and C


are shorted, replace low oil pressure
(LOP) switch. If open, replace APU
harness.

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Fault M (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Oil level

Oil level low or high

Check oil level. If not at proper level,


service oil. If oil level ok, go to step 2.

2.

Metal on
magnetic plug

Bearing failure

A small amount of metal fuzz is acceptable,


go to step 3. Metal chunks are not
acceptable. Refer to 49-20-00
"INSPECTION/CHECK".

3.

HOT short circuit

HOT SWITCH shorted

Disconnect the HOT SWITCH (A311) at


P311. Check for continuity across A311-A
to A311-B. If shorted remove and replace
HOT SWITCH. If not shorted, go to step 4.

4.

APU HARNESS

APU HARNESS
shorted

With A311 disconnected, disconnect APU


HARNESS at firewall by disconnecting P4.
Check continuity across P4-3 to P4-4; if
shorted, remove and replace APU
HARNESS. If not shorted, go to step 5.

5.

TEST
CELL/AIRCRAFT
WIRING

TEST
CELL/AIRCRAFT
WIRING shorted, ESU
inoperative

With P4 disconnected, disconnect P1 at the


ESU interface. Check continuity across P1D to P1-E; if shorted, troubleshoot the
AIRCRAFT wiring to repair short circuit in
HOT circuit. If wiring is not shorted, remove
and replace ESU.

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Fault N (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Oil level

Oil level low or high

Check oil level. If not at proper level,


service oil. If oil level ok, go to step 2.

2.

Metal on
magnetic plug

Bearing failure

A small amount of metal fuzz is


acceptable, go to step 3. Metal chunks
are not acceptable. Refer to 49-20-00
"INSPECTION/CHECK".

3.

Short circuit, LOP


switch

Test cell wiring, LOP


switch, or APU harness

Disconnect P1 and P4. If P1 pin G is


shorted to ground, repair test cell wiring.
If open, go to step 4.

4.

Short circuit, LOP


switch

APU harness

If P4 pin 5 is shorted to ground, replace


APU harness. If ok go to step 5.

5.

Low oil pressure

ESU, LOP switch, or


internal failure

Connect ohmmeter across J304 pins A


and B (normally closed contacts of LOP
switch). Crank APU while monitoring
ohmmeter. This test can also be
performed by connecting the LOP switch
to regulated shop air.
If ohmmeter changes from continuity to
open at 6 to 8 psig (41 to 55 kPa),
replace ESU. If not, go to step 6.
Remove LOP switch. Connect pressure
gauge in place of LOP switch. Crank APU
and observe pressure gauge.

6.

Low oil pressure

LOP switch or APU

If oil pressure (step 5) reached 6 to 8 psig


(41 to 55 kPa), replace LOP switch. If oil
pressure low, replace APU.

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EGT

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Fault O (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Restricted air flow

Air intake

If air intake is restricted, clear intake as


required. If ok, go to step 2.

2.

Excessive bleed
air during start

Anti-surge valve stuck


open

If anti-surge valve is stuck open, replace


valve. If ok, go to step 3.

3.

Excessive bleed
air after ready-toload (RTL)

Anti-surge valve does


not close when bleed
valve opens

Restart APU and open bleed valve at


RTL. If anti-surge valve does not close
when bleed valve opens, go to step 4. If
ok, replace acceleration control. Retest
APU and if fault continues, replace APU.

4.

Bypass valve
does not close

Anti-surge valve, ESU,


test cell wiring, or APU
harness

Disconnect P308. Connect 0-50 Vdc


voltmeter across P308 pins 1(+) and 2(-).
Restart APU and open bleed valve at
RTL. If 28 Vdc at P308 when bleed valve
opens, replace anti-surge valve. If no 28
Vdc, go to step 5.

5.

No 28 Vdc close
bypass signal

ESU, test cell wiring, or


APU harness

Disconnect P1. If no continuity P1 pin U


to P308 pin 1 or no continuity P1V to
P308 pin 2, go to step 6. If ok, replace
ESU.

6.

Open wiring

Test cell wiring or APU


harness

Disconnect P4. Check continuity from P1


pin U to P4 pin 17 and from P1 pin V to
P4 pin 18. If open, troubleshoot test cell
wiring. If ok, replace APU harness.

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OVERSPEED

Step

Fault
Indication

Probable Cause

Correction

1.

Overspeed

Speed adjustment,
acceleration control,
fuel pump, or ESU

Attempt to adjust speed with


acceleration control speed adjustment
to 103% RPM with no load and retry. If
successful, return APU to service. If
not, go to step 2.

2.

Overspeed

Speed adjustment,
acceleration control,
fuel pump, or ESU

Replace acceleration control and fuel


pump and restart. If ok, return APU to
service. If overspeed, replace ESU.

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Fault Q (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Underspeed

Speed adjustment

Restart and observe RPM meter. If


speed is less than 103% with no load, go
to step 2. If ok, go to step 3.

2.

Underspeed

Speed adjustment

Adjust speed setting on acceleration


control to 103% with no load. If
adjustment successful, return APU to
service. If not, replace acceleration
control.

3.

Load or fuel

Premature load, max


fuel, ESU, or wiring

If generator load was applied before


ready-to-load, return APU to service. If
not, go to step 5.

4.

APU fuel pump


check

Fuel pump

Start the APU. Apply full load. Turn off


the aircraft fuel boost pump. RPM should
not drop. If RPM drops, replace fuel
pump

5.

Max fuel

Max fuel, ESU, or


wiring

Disconnect P307. If 28 Vdc at P307 pin


A(+) approximately 7 seconds after 95%
RPM, go to step 6. If no 28 Vdc, go to
step 7.

6.

Max fuel

Max fuel, ESU, or


wiring

Disconnect P307. Apply 28 Vdc


(nominal) at P307 pin A(+) and pin B(-).
If max fuel valve opens (clicks), go to step
9. If valve does not open, replace max
fuel valve.

7.

Open circuit

ESU, APU harness, or


test cell wiring

Disconnect P1. If continuity from P1 pin


R to P307 pin A and from P1 pin L to
P307 pin B, replace ESU. If either is
open, go to step 8.

8.

Open circuit

APU harness or test


cell wiring

Disconnect P4. If continuity from P4 pin


10 to P307 pin A and from P4 pin 7 to
P307 pin B, troubleshoot test cell wiring.
If open, replace APU harness.

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Fault Q (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

9.

Test cell fuel


supply

Boost pump

If aircraft boost pump supplying 5 to 40


psig (34 to 276 kPa) pressure, go to step
10. If low, repair aircraft fuel system.

10.

Fuel supply

Inlet filter, fuel pump


filter, acceleration
control, or APU

If APU inlet fuel filter is restricted, replace


filter. If ok, go to step 11.

11.

Fuel supply

Fuel pump filter,


acceleration control,
or APU

If fuel pump filter is restricted, clean or


replace filter. If ok, go to step 12.

12.

Fuel supply

Acceleration control or
APU

Install tee fitting between main manifold


and fuel line. Crank APU. Fuel pressure
should be approximately 125 psig
(862 kPa) when main fuel valve opens at
14%. If fuel pressure is ok, replace APU.
If low, go to step 13.

13.

Fuel supply

Acceleration control or
APU

Replace acceleration control and restart


APU. If ok, return APU to service. If
underspeed, replace APU.

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Fault R (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Short or Open

ESU, APU harness, or


test cell wiring

Disconnect P1. If P1 pin A is shorted to


pin B, go to step 2. If open, go to step 3.
If ok, replace ESU.

2.

Open circuit

APU harness or test


cell wiring

Disconnect P4. If ok, troubleshoot test


cell wiring. If P4 pin 1 to pin 2 is open,
disconnect thermocouple leads from P4
pins 1 and 2 and connect spare
thermocouple leads. If fault still exists,
replace thermocouple.

3.

Short circuit

APU harness or test


cell wiring

Disconnect P4. If ok, troubleshoot test


cell wiring. If P4 pin 1 to pin 2 is shorted,
disconnect thermocouple leads from P4
pins 1 and 2 and connect spare
thermocouple leads. If fault still exists,
replace thermocouple.

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Fault S (Cont'd)

Step

Fault
Indication

Probable Cause

Correction

1.

Magnetic pickup
short or open

ESU, magnetic
pickup, APU
harness, or test cell
wiring

Disconnect P1. If P1 pin M to N is open, go to


step 2. If shorted, go to step 4. If 1,000 to
1,450 ohms, replace ESU.

2.

Open circuit

Magnetic pickup,
APU harness, or
test cell wiring

Disconnect P302. If J302 pin A to B is ok


(1,000 to 1,450 ohms), go to step 6. If open,
go to step 3.

3.

Open circuit

APU harness or
test cell wiring

Connect P302. Disconnect P4. If P4 pin 11 to


12 is open, replace APU harness. If ok (1,000
to 1,450 ohms), troubleshoot test cell wiring.

4.

Short circuit

Test cell wiring or


ESU adapter
harness

Disconnect P302. If J302 pin A to B is ok


(1,000 to 1,450 ohms), go to step 6. If
shorted, go to step 5.

5.

Short circuit

Magnetic pickup,
APU harness, or
test cell wiring

Connect P302. Disconnect P4. If P4 pin 11 to


12 is shorted, replace APU harness. If ok
(1,000 to 1,450 ohms), troubleshoot test cell
wiring.

6.

Open or short
circuit

Magnetic pickup

Replace magnetic pickup.

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APU System Interconnection Diagram (Pre SB 49-180)


Figure 103
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APU System Interconnection Diagram (Post SB-49-180)


Figure 104
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PART NUMBER 4501966 SERIES
OPERATIONAL CHECK
1.

2.

Introduction
A.

This section contains the procedures necessary to perform an operational check of the
Auxiliary Power Unit (APU) system. Included in this section are prestarting procedures,
starting procedures, bleed air operation, operating limitations, protective shutdowns, and
normal shutdown procedures.

B.

The APU is cranked by a starter until self-sustaining speed is attained. Beyond this
point, the APU accelerates to rated speed.

C.

During operation, the APU will shut down automatically if the operating limits are either
exceeded or not attained within the specified periods outlined in paragraph 2.E.

Operational Check of the APU System


A.

Prestarting Procedures
(1)

Verify that the MASTER switch is positioned to OFF and the load circuit breaker is
closed.

(2)

Check for an adequate fuel supply. Make sure that the fuel supply to the APU
system has flow and pressure characteristics as follows:
(a)

The minimum fuel boost pressure should be 5 psig (34 kPa) above the true
vapor pressure of the fuel, to a maximum of 40 psig (276 kPa) at a maximum
fuel flow rate.

(b)

The minimum inlet flow rate should be 250 lb/hr (113.5 kg/hr) to the fuel inlet
filter connection.

CAUTION: NEVER ALLOW THE OIL LEVEL TO BE ABOVE THE FULL MARK ON
THE SIGHT GAUGE. AN OVERFILLED SUMP WILL RESULT IN OIL
FOAMING, LOW OIL PRESSURE AND ABNORMAL GEAR WEAR.
(3)

Check the oil level on the sight gauge with the APU in a level position. It is
essential that the oil level does not exceed FULL.

(4)

If necessary, replenish the oil level with the lubricating oil specified in Figure 1101,
SERVICING.

(5)

Check the plumbing and electrical wiring for security.

CAUTION: BE SURE THE AREA AROUND THE APU IS CLEAN AND FREE OF
FOREIGN OBJECTS. THE GREATEST HAZARDS TO A TURBINE
ENGINE ARE LEAKING FUEL CONNECTIONS AND ENTRY OF FOREIGN
MATERIAL INTO THE COMPRESSOR.
(6)

Remove any loose objects or material from around the APU, especially objects that
may be ingested into the APU during operation.
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(7)

B.

Purge the fuel system per SERVICING if:


(a)

The fuel system was opened for replacement of components and APU fails to
start after three attempts.

(b)

The fuel system was allowed to become empty and APU fails to start after
three attempts.

Starting Procedures
CAUTION: IT IS POSSIBLE FOR A START TO PRODUCE A ROAR WITH FLAME IN
THE EXHAUST. THE CAUSE IS PROBABLY AN ACCUMULATION OF
UNBURNED FUEL IN COMBUSTOR FROM PREVIOUS OPERATION. THE
APU MUST BE SHUT DOWN AND THE CAUSE INVESTIGATED. WAIT
FOR ALL FUEL TO DRAIN FROM COMBUSTOR BEFORE ATTEMPTING
ANOTHER START. DURING A START, IF IT APPEARS THAT EXHAUST
GAS TEMPERATURE EXCEEDED LIMITS IN FIGURE 201 AFTER READY
FOR SERVICE INDICATION AND APU DID NOT SHUT DOWN, THIS
INDICATES A PROBLEM WITH INSTRUMENTATION. REFER TO FAULT
ISOLATION PROCEDURES.
CAUTION: DO NOT CONTINUE APU OPERATION IF SHUTDOWN DOES NOT
OCCUR AFTER AN OVERSPEED TEST. THIS MAY INDICATE ESU IS
NOT SENSING APU SPEED CORRECTLY AND LOSS OF OVERSPEED
PROTECTION. DAMAGE TO EQUIPMENT COULD RESULT.
NOTE: During an APU fail-to-start condition on a start attempt, every effort should be
made to determine the reason for fail-to-start before another start is made. It is
recommended that a period of at least 1 minute be allowed between
consecutive start attempts to allow fuel to drain from the combustor. If after
three consecutive start attempts a fail-to-start condition still occurs, a visual
inspection of the APU compartment must be made to inspect for excessive fuel
around the tailpipe area, and a cold crank of the APU made to purge fuel from
the engine. To accomplish a cold crank, disconnect the electrical connectors
from the ignition exciter, start, and main fuel solenoid valves. Motor the APU
approximately for 15 seconds with the starter.
(1)

Start the APU and allow it to reach rated speed. Perform a simulated overspeed
shutdown test by pressing the STOP switch. The APU should shut down. If the
APU does not shut down, refer to the FAULT ISOLATION procedures and correct
the fault before proceeding.

(2)

Repeat step (1) with the exception of the overspeed test. Observe the RPM and
EGT displays during APU acceleration. During a normal start, the RPM display
indicates constantly increasing speed until approximately 103% is reached and the
EGT display shows a steady temperature rise.

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C.

Bleed Air Operation


(1)

D.

Operating Limitations
(1)

E.

Allow the APU to run for three minutes to warm up, and then move the bleed air
switch to the ON position. This will extract bleed air from the unit.

During APU operation, make sure that the operating limitations in Figure 201 are
not exceeded.

Protective Shutdowns (Ground operation)


CAUTION: DO NOT ATTEMPT TO OPERATE THE APU BY WIRING AROUND OR
DISABLING CIRCUITS TO THE SHUTDOWN OR WARNING DEVICES. A
CONDITION THAT PRODUCES AUTOMATIC SHUTDOWN OR WARNING
DESERVES ATTENTION. THESE DEVICES ARE INCORPORATED TO
PREVENT DAMAGE TO THE APU.
(1)

Protective devices in the electrical circuit monitor lubricating oil pressure, high oil
temperature, turbine exhaust temperature, APU overspeed, APU underspeed, and
sequence failure. The operation of these circuits is described as follows:

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Item
Rated Engine Speed

Limitations
61,565 rpm (100% rated speed)

NOTE: The RPM logic circuit is set to shut down the APU at 108% rated speed.
The normal no-load speed is approximately 103%.
Reduction Drive Axial Pad Speed (Rated)

12,000 rpm

Accessory Drive Pad Speeds


Starter
Fuel Pump

8,229 rpm
4,235 rpm

Overtemperature Shutdown

1303 20F (706 11C) at rated speed or


1,604 20F (873 11C) in start
sequence

NOTE: The ESU continuously monitors EGT via a thermocouple located in the
APU exhaust outlet. EGT temperatures exceeding above limits cause the
ESU to automatically shut down the APU for an overtemperature condition.
If an automatic shutdown does not occur within five seconds of an
observed overtemperature condition, the APU must be shut down
manually.
Oil Consumption

No evidence of oil consumption after


operational check of the APU

Oil Pump Pressure at Rated Speed

15 to 65 psig (103 to 448 kPa)

NOTE: An oil pressure indicator is not provided on the unit, although,


provisions for an oil pressure sensor are provided. Automatic
shutdown occurs if APU has passed 95% rated speed plus seven seconds
and oil pressure drops below 6 1 psig (41.3 6.8 kPa).
Operating Limitations
Figure 201
Low oil pressure

APU shutdown occurs whenever the oil pressure is less than


6 1 psig (41.3 6.8 kPa) after the APU has attained 70%
rated speed, plus 5 seconds.

High exhaust gas

APU shutdown occurs when the exhaust gas temperature


temperature exceeds 1303 20F (706 11C) at any
time during normal operation, or 1,604 20F (873 11C)
during start.

High oil temperature -

APU shutdown occurs whenever the oil temperature exceeds


325 to 335F (163 to 168C) for twelve consecutive seconds
after RTL.

APU overspeed

APU shutdown occurs when speed reaches 108%.

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APU underspeed

APU shutdown occurs if speed decreases below 95% after


APU has attained ready to load.

Startup failure -

APU shutdown occurs when speed fails to reach 3% speed


within 8 seconds, from 3% to 16% speed within 20 seconds,
from 16% to 70% within 34 seconds, and from 70% to 95%
within 10 seconds.

F.

(2)

The ESU incorporates built-in test equipment (BITE) features to provide visual
indications on the aircraft Central Maintenance Computer (CMC) if any of the safe
operating parameters has been exceeded, as well as indications of other
malfunctions.

(3)

If a protective (malfunction) shutdown occurs:


(a)

Note the CMC or BITE indication and go to FAULT ISOLATION to determine


the malfunction before attempting a restart.

(b)

Move start/run switch to OFF.

Normal Shutdown Procedures


NOTE: No cool down of the APU is required. The APU should be shutdown while under
load or immediately after the load is removed.
(1)

G.

Allow 30 seconds to elapse after the APU rotor has stopped before moving the offrun-start switch to the OFF position.

Acceleration Control Adjustment


CAUTION: DO NOT ADJUST THE APU SPEED UNTIL THE RPM DISPLAY
ACCURACY IS ESTABLISHED. ADJUSTING THE APU SPEED WITH THE
RPM DISPLAY INDICATING INCORRECTLY MAY RESULT IN UNNECESSARY APU AUTOMATIC SHUTDOWNS. MAKE ADJUSTMENTS WHILE
THE APU IS RUNNING.
(1)

Rated Speed adjustment


(a)

Loosen the speed adjustment jamnut (refer to Figure 202).

(b)

Turn the speed adjustment screw in the required direction to adjust APU speed
to 102.5 +/- 0.5% under a no-load condition.

(c)

Turn the speed adjustment screw clockwise to increase or counterclockwise to


decrease the speed.

(d)

Hold the speed adjustment screw in place and secure it with the jamnut.
Torque the jamnut 24 to 27 pound inches (2.7 to 3.1 Nm).

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Acceleration Control Assembly Adjustments


Figure 202

OPERATIONAL CHECK

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PART NUMBER 4501966 SERIES
(2)

Acceleration Schedule Adjustment


NOTE: The starting time will vary with environmental conditions, but should be in
the area of 8 to 15 seconds (0 to 100% speed) on a hot' (recently
operated) APU. If acceleration is not satisfactory, adjust according to the
following procedure.
(a)

Matchmark the acceleration schedule adjustment needle (refer to Figure 202)


and housing.

(b)

Loosen the acceleration control jamnut.

(c)

Turn the adjustment needle in the required direction to adjust the acceleration
schedule.

NOTE: If the turbine hesitates during acceleration, the acceleration schedule must
be increased. The acceleration schedule must be decreased if the turbine
rumbles (indication of a hot start) or the EGT is above 1,604 20F (873
11C) during acceleration. If the EGT reaches 1,604 20F (873
11C) an automatic APU shutdown will occur.
NOTE: Turn the adjustment needle clockwise to decrease or counterclockwise to
increase the acceleration schedule fuel flow. The adjustment is critical and
the initial position should be carefully noted. Make adjustments in 1/8 turn
increments. Check the acceleration rate after each adjustment.
(d)

Make a minimum of two starts between adjustments, disregarding the


characteristics of the first start after adjustment.

(e)

If after one complete turn adjustment, the desired correction is not observed,
replace the acceleration control assembly.

(f)

After final adjustment, check and readjust the rated speed if necessary.

(g)

Hold the acceleration schedule adjustment needle in place and secure it with
the jamnut. Torque the jamnut 24 to 27 pound inches (2.7 to 3.1 Nm).

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REMOVAL/INSTALLATION
1. General
A.

This section has the procedures for removal and installation of components on the
Auxiliary Power Unit (APU) system. Item numbers in the procedures and illustrations are
the same as those in the Illustrated Parts Catalog, Document 40C11-3. Refer to
Standard Practices Manual (SPM), Document HSPS 490001, for general information.
NOTE: Alpha-variant items can replace an item when permitted by the effect code for
that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

B.

Access to the APU may prevent performance of some procedures while the APU is
installed on the aircraft. Refer to the Aircraft Maintenance Manual for access.

C.

A post-maintenance operational check should be performed after doing required


maintenance tasks to verify repair. Refer to OPERATIONAL CHECK.

D.

Exercise extreme care to prevent entrance of dirt, dust, and foreign objects into the APU.
If a foreign object is dropped into the APU, stop maintenance procedure until the object is
located and removed.

E.

Cover large openings with protective covers. Cap or plug open tube assemblies, fittings,
and ports. Do not cover tube ends with tape.

F.

All parts attached with lockwire or safety cable prior to removal must be attached with
lockwire or safety cable after installation.

G.

When the fuel system has been disturbed for replacement or repair of components, the
APU must be operated and checked for fuel leakage. If the APU fails to start after three
attempts, purge fuel system of air according to APU maintenance instructions. (Refer to
SERVICING).

2. Equipment and Materials


A.

Equipment and materials required for removal and installation are listed in Figure 301.
NOTE: Equivalent substitutes may be used for items listed.
NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or
holding other small components in place for ease of assembly and prevention
of galling. If necessary, assembly fluid may be diluted with MIL-PRF-7808 or
MIL-PRF-23699.

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PART NUMBER 4501966 SERIES
Material

Source (Vendor Code)

Adhesive RTV-106 (917252C1)

General Electric (01139)

Adhesive, Thermosetting 179581

Hamilton Sundstrand (55820)

Anti-seize Compound MolyKote P37

Dow Corning

High Temperature Anti-seize Compound Nickel Ease

Commercially Available

Anti-seize Lubricant 51102 (169041)

Hamilton Sundstrand (55820)

Anti-seize Compound C-5A (111007-1)

Fel-Pro, Inc. (73165)

Assembly Fluid, 4950515

Hamilton Sundstrand (55820)

Connector Pliers, Soft-Jawed TG69

Glenair

Cotton Wipes

Commercially Available

Insulation Sleeving DR-25-1/8 or equivalent

Raychem Corporation (06090)

Isopropyl Alcohol, ASTM D770

Commercially Available

Lacing Tape 4950493-1 or equivalent

Hamilton Sundstrand (55820)

Lint-free Cloth

Commercially Available

Lockwire MS20995C20 and MS20995C32

Commercially Available

or

Hamilton Sundstrand (55820)

Safety Cable 5909034-2B and -5B and

Hamilton Sundstrand (55820)

Cartridge, Ferrule 5909035-1B and -2B


Loctite RC640

Loctite Corp. (05972)

Loctite 404 or 480 Instant Adhesive

Loctite Corp.

Lubricant, Solid film, Molykote 321R (Spray)

Dow Corning

Non-metallic Mallet

Commercially Available

Pipe Sealant (4950698)

Hamilton Sundstrand (55820)

Primer Grade N (MIL-S-22473N)

Commercially Available

Single Component Nylon Varnish Nycote 7-11 or


equivalent

Nycote Laboratories Corporation

Soft bristled brush

Commercially Available

Solder SN3WRMAP2 or SN63WRMAP3 or SN63BS

Commercially Available

Tape Cat. No. 27 (950455C1)

3M Corp.

Torque Wrench 0 to 25 lb. in.


(0 to 2.8 Nm)

Commercially Available

Torque Wrench 25 to 140 lb. in.


(2.8 to 15.8 Nm)

Commercially Available

Torque Wrench 140 to 550 lb. in.


(15.8 to 62.1 Nm)

Commercially Available

Engine Oil (MIL-PRF-7808 or MIL-PRF-23699)

Commercially Available

Removal/Installation Equipment and Materials


Figure 301
REMOVAL/INSTALLATION

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PART NUMBER 4501966 SERIES
3. Removal/Installation Procedures
A.

Removal and Installation of Air Inlet Housing Packing


(1)

Remove packing (10 or 20, IPC 49-22-00 Figure 1) from air inlet housing.

(2)

Cut new packing (10 or 20) at a 45 angle.

WARNING:

B.

LOCTITE 404 OR 480 ADHESIVE CAUSES INSTANT BONDING OF


SKIN OR OTHER HUMAN TISSUE. USE CARE WHEN HANDLING THE
ADHESIVE. USE THE ADHESIVE CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE ADHESIVE, GET THE
MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0013SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE ADHESIVE, REMOVE YOUR CONTACT
LENSES. PUT ON NITRILE OR POLYETHYLENE GLOVES AND
SAFETY GLASSES OR CHEMICAL SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ADHESIVE
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(3)

Apply Loctite 404 or 480 adhesive to the two ends.

(4)

Install packing (10 or 20) into the air inlet housing groove with the seam joint at the
top of the housing.

(5)

Hold ends together for one minute to ensure adhesive has set.

Removal and Installation of Engine Harness Assembly


WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

NOTE: The minimum clearance between tubes, and between tubes and adjacent
components must be 0.080 inch (2.032 mm).
(1)

Disconnect electrical connectors and remove engine harness assembly as follows:

(a) Disconnect electrical connector (P302) from magnetic pickup (680, IPC 49-20-00
Figure 2). If damaged, remove the connector seal (685) from magnetic pickup (680).
Discard the seal.
(b) Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC
49-20-00 Figure 3).
(c) Disconnect electrical connector (P306) from main fuel solenoid valve (530, IPC
49-20-00 Figure 2). If damaged, remove the connector seal (552) from main fuel
solenoid valve (530). Discard the seal.

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(d)

Disconnect electrical connector (P305) from start fuel solenoid valve (540). If
damaged, remove the connector seal (542) from start fuel solenoid valve
(540). Discard the seal.

(e)

Disconnect electrical connector (P307) from maximum fuel solenoid valve


(550). If damaged, remove the connector seal (552) from maximum fuel
solenoid valve (550). Discard the seal.

(f)

Disconnect electrical connector (P304) from low oil pressure switch (260). If
damaged, remove the connector seal (262) from low oil pressure switch (260).
Discard the seal.

(g)

Disconnect electrical connector (P311) from high oil temperature switch (690).
If damaged, remove the connector seal (685) from high oil temperature switch
(690). Discard the seal.

(h)

Disconnect electrical connector (P308) from anti-surge valve (40, IPC 49-0000 Figure 1).

(i)

Disconnect electrical connector (P309) from bleed air valve (100).Remove


screws (20, IPC 49-20-00 Figure 1), washers (40), nuts (30), hourmeter (100A)
and event counter (110).

NOTE: If the original hourmeter (100A or event counter (110) will not be
reinstalled, an entry must be made in the logbook for the APU
Hours/Events and the Hours/Events meter readings.
(2)

Remove bolts (70), nuts (90), and clamps (45, 50, 60, and 80).

(3)

Remove thermocouple (112) from combustor housing.

(4)

Remove engine harness assembly (10).

(5)

Wrap harness and tubes, as necessary, with tape to be sure of a tight fit in clamps
and to obtain minimum gap between fuel lines.
NOTE: Harness and tubes shall fit tightly in clamps. Verify installation for fit.

(6)

Install engine harness assembly (10) with clamps (45, 50, 60, and 80), bolts (70),
and nuts (90). Torque nuts 24 to 27 pound inches (2.7 to 3.1 Nm).

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PART NUMBER 4501966 SERIES
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(7)

Apply antiseize compound to the threads of thermocouple (112) and attach


thermocouple (112) to combustor housing. Torque thermocouple 40 to 50 pound
inches (4.5 to 5.6 Nm) and secure with lockwire.

(8)

Install hourmeter (100A) and event counter (110) with screws (20), washers (40),
and nuts (30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 Nm).

WARNING:

(9)

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

Clean all harness and component connectors using a soft-bristled brush and cotton
wipes moistened with isopropyl alcohol to remove oil, grease, and contamination
from the pins and inside of the electrical connectors. Allow connectors to air dry.

(10) If required, install the connector seals as follows:


(a)

Connector seal (685, IPC 49-20-00 Figure 2) on magnetic pickup (680).

(b)

Connector seal (552) on main fuel solenoid valve (530).


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PART NUMBER 4501966 SERIES
(c)

Connector seal (542) on start fuel solenoid valve (540).

(d)

Connector seal (552) on maximum fuel solenoid valve (550).

(e)

Connector seal (262) on low oil pressure switch (260).

(f)

Connector seal (685) on high oil temperature switch (690).

(g)

Slide all connector seals to the base of the connector pins.

(11) Connect engine harness and component connectors as follows:


NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(a)

Connect electrical connector (P302) to magnetic pickup (680, IPC 49-20-00


Figure 2).

(b)

Connect electrical connector (P303) of harness assembly (10, IPC 49-20-00


Figure 1) to ignition exciter (200, IPC 49-20-00 Figure 3)

(c)

Connect electrical connector (P306) to main fuel solenoid valve (530, IPC
49-20-00 Figure 2).

(d)

Connect electrical connector (P305) to start fuel solenoid valve (540).

(e)

Connect electrical connector (P307) to maximum fuel solenoid valve (550).

(f)

Connect electrical connector (P311) to high oil temperature switch (690).

(g)

Connect electrical connector (P304) to low oil pressure switch (260).

(h)

Connect electrical connector (P308) to anti-surge valve (40, IPC 49-00-00


Figure 1).

(i)

Connect electrical connector (P309) to bleed valve (100).

(12) Deleted.
C.

Removal and Installation of Thermocouple (Refer to Figure 302)


WARNING:

MAKE SURE ELECTRICAL POWER SUPPLY IS REMOVED FROM THE


APU. ENERGIZED CIRCUITS CAN CAUSE INJURY TO PERSONS.

NOTE: The thermocouple is a dual element type thermocouple (refer to Figure 302).
TC1 and TC2 are identical and one of the two may be used. Removal and
replacement are the same for TC1 and TC2.
(1)

If connected, disconnect electrical connector (P4) (1) from aircraft firewall receptacle
(J4)

(2)

Remove bolts (2) and lockwashers (3) and remove clamp (4) from electrical
connector (P4) (1). Loosen protective rubber (5).
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(3)

Disconnect wiring from electrical connector (P4) pins 1 and 2 and thermocouple
shield wire from P4 shell.

(4)

Remove tie wraps from engine harness assembly to gain access to thermocouple
wiring.

(5)

Remove thermocouple (112, IPC 49-20-00 Figure 1) from combustor housing


assembly.

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(6)

Coat thermocouple threads with anti-seize compound.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(7)

Install thermocouple (112, IPC 49-20-00 Figure 1) in combustor housing. Torque


thermocouple to 40 to 50 pound inches (4.5 to 5.6 Nm) and lockwire thermocouple.

(8)

Connect thermocouple wiring (K1A20-AL, K2A20-CR, and K3A20N) to electrical


connector (P4) pins 1 and 2 and P4 shell, respectively.

(9)

Install protective rubber (5, Figure 302) and attach clamp (4) to electrical connector
(P4) (1) with bolts (2) and lockwashers (3). Tighten bolts (no torque is required).

(10) Replace tie wraps on engine harness assembly.


NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(11) Connect electrical connector (P4) (1) to aircraft firewall receptacle (J4).

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PART NUMBER 4501966 SERIES

Thermocouple Removal and Installation


Figure 302

REMOVAL/INSTALLATION

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D.

Removal and Installation of Event Counter (Pre SB-49-180)


WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

NOTE: Manual soldering shall be performed in accordance with the best industry
standard practices by certified personnel. The techniques used shall not
damage wires or terminals and shall provide solder joints that are free of
contamination and provide a reliable electrical connection.
NOTE: Tinning of soldering iron tips is accomplished by heating the soldering iron until
the tip just reaches the melting point of the solder. Flow the solder, similar to
that to used to solder the connection, onto the tip until the tip is fully covered
and no base material is exposed. Leave the iron tinned until ready for use.
Just prior to soldering (or removing solder), while the iron is still heated, wipe
the tip on a wetted sponge.
(1)

Desolder harness assembly (10, IPC 49-20-00 Figure 1) wires from event counter
(110) as follows:
(a)

Remove the 45-degree protective boot from the event counter housing to
expose the solder terminals located at the back of the event counter.

(b)

Use a cleaned soldering iron and solder wick to remove solder from terminal
M1(+), located at the back of the event counter. Reheat the connection and,
while maintaining heat on the connection, apply a light steady pull on the
conductor wire until it disengages from the event counter terminal. Use care to
prevent splashing the molten solder and to avoid bending or otherwise
damaging the terminal.

(c)

Repeat step (b) above for terminal M1(-).

(2)

Remove screws (20), nuts (30), and event counter (110).

(3)

Remove any remaining adhesive from the event counter harness wires.

(4)

Use wire cutters, capable of cutting 20 AWG wire, to cut the exposed conductors off
of the wires that were removed from the event counter terminals.

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PART NUMBER 4501966 SERIES
(5)

Use a fixed die hand stripper to strip the ends of the 20 AWG wires to allow an
exposed conductor length sufficient to provide wrap around the event counter
terminals. Do not damage the stranded wires. Wires with severed strands are not
acceptable.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

(6)

Tin the exposed conductors by dipping the leads into liquid flux, followed by coating
the leads with solder. Solder shall penetrate the wire to the innermost strands but
shall not obscure the outer strands.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(7)

Use isopropyl alcohol to clean the soldered leads to remove any residual flux.
There shall be no visible evidence of flux residue.

(8)

Install new 45-degree protective boots over the event counter wires.

(9)

Build up wire bundle at egress using sleeving M23053/5-105-0 or M23053/5-104-0,


as required.

(10) Use a pair of rounded needle nose pliers to bend the soldered leads to provide a
wrap that will cover minimum of the event counter terminals.

REMOVAL/INSTALLATION

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PART NUMBER 4501966 SERIES
WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

(11) Connect the wires to the event counter terminals as follows:


NOTE: There should be enough solder to ensure that the solder covers the wire
over the extent of the wrap. The solder should wet the terminal and wire
to form a visible fillet.
(a)

Solder wire E26A20 to terminal M1(+) on the event counter.

(b)

Solder wire E27A20N to terminal M1(-) on the event counter.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(12) Use isopropyl alcohol to clean the soldered connections to remove any residual flux.
There shall be no visible evidence of flux residue.
(13) Use a digital multimeter to verify continuity (0.2 ohm maximum) between the
following points:
(a)

P0274-24 to M1(+).

(b)

P0274-25 to M1(-).

(14) Use a digital multimeter to check resistance between the event counter terminals
and P0274 connector body. The resistance should be 20 megohms minimum.
(15) Use a digital multimeter to check resistance between pins P0274-24 and P0274-25.
The resistance should be 1,000 ohms minimum.
(16) Install the 45-degree boot on the event counter body. Adjust wire sleeving as
required. Apply adhesive part number 179581 to ensure fluids resistance at wire
egress and event counter body.
(17) Install event counter (110) and attach with screws (20) and nuts (30). Torque nuts
24 to 27 pound inches (2.7 to 3.1 Nm).
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PART NUMBER 4501966 SERIES
(18) In Section 3 of the APU Log Book (Maintenance and Repair Log), record the
estimated APU cycles since new (CSN), date of repair, description of work
performed and the current reading on the event counter. Future event counter
readings should be added to the recorded estimated CSN of the APU.
E.

Removal and Installation of Hourmeter (Pre SB-49-180)


WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

NOTE: Manual soldering shall be performed in accordance with the best industry
standard practices by certified personnel. The techniques used shall not
damage wires or terminals and shall provide solder joints that are free of
contamination and provide a reliable electrical connection.
NOTE: Tinning of soldering iron tips is accomplished by heating the soldering iron until
the tip just reaches the melting point of the solder. Flow the solder, similar to
that to used to solder the connection, onto the tip until the tip is fully covered
and no base material is exposed. Leave the iron tinned until ready for use.
Just prior to soldering (or removing solder), while the iron is still heated, wipe
the tip on a wetted sponge.
(1)

Desolder harness assembly (10, IPC 49-20-00 Figure 1) wires from hourmeter
(100A) as follows:
(a)

Remove the 45-degree protective boot from the hourmeter housing to expose
the solder terminals located at the back of the hourmeter.

(b)

Use a cleaned soldering iron and solder wick to remove solder from terminal
M2(+), located at the back of the hourmeter. Reheat the connection and, while
maintaining heat on the connection, apply a light steady pull on the conductor
wire until it disengages from the hourmeter terminal. Use care to prevent
splashing the molten solder and to avoid bending or otherwise damaging the
terminal.

(c)

Repeat step (b) above for terminal M2(-).

(2)

Remove screws (20), nuts (30), and hourmeter (110).

(3)

Remove any remaining adhesive from the hourmeter harness wires.

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PART NUMBER 4501966 SERIES
(4)

Use wire cutters, capable of cutting 20 AWG wire, to cut the exposed conductors off
of the wires that were removed from the hourmeter terminals.

(5)

Use a fixed die hand stripper to strip the ends of the 20 AWG wires to allow an
exposed conductor length sufficient to provide wrap around the hourmeter
terminals. Do not damage the stranded wires. Wires with severed strands are not
acceptable.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

(6)

Tin the exposed conductors by dipping the leads into liquid flux, followed by coating
the leads with solder. Solder shall penetrate the wire to the innermost strands but
shall not obscure the outer strands.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(7)

Use isopropyl alcohol to clean the soldered leads to remove any residual flux.
There shall be no visible evidence of flux residue.

(8)

Install new 45-degree protective boots over the hourmeter wires.

(9)

Build up wire bundle at egress using sleeving M23053/5-105-0 or M23053/5-104-0,


as required.

(10) Use a pair of rounded needle nose pliers to bend the soldered leads to provide a
wrap that will cover minimum of the hourmeter terminals.

REMOVAL/INSTALLATION

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PART NUMBER 4501966 SERIES
WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

(11) Connect the wires to the hourmeter terminals as follows:


NOTE: There should be enough solder to ensure that the solder covers the wire
over the extent of the wrap. The solder should wet the terminal and wire
to form a visible fillet.
(a)

Solder wire E17A20 to terminal M2(+) on hourmeter.

(b)

Solder wire E16A20N to terminal M2(-) on hourmeter.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(12) Use isopropyl alcohol to clean the soldered connections to remove any residual flux.
There shall be no visible evidence of flux residue.
(13) Use a digital multimeter to verify continuity (0.2 ohm maximum) between the
following points:
(a)

P0274-13 to M2(+).

(b)

P0274-15 to M2(-).

(14) Use a digital multimeter to check resistance between the hourmeter terminals and
P0274 connector body. The resistance should be 20 megohms minimum.
(15) Install the 45-degree boot on the hourmeter body. Adjust wire sleeving as required.
Apply adhesive part number 179581 to ensure fluids resistance at wire egress and
hourmeter body.
(16) Install hourmeter (100A) and attach with screws (20) and nuts (30). Torque nuts 24
to 27 pound inches (2.7 to 3.1 Nm).

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PART NUMBER 4501966 SERIES
(17) In Section 3 of the APU Log Book (Maintenance and Repair Log), record the
estimated APU time since new (TSN), date of repair, description of work performed
and the current reading on the hourmeter. Future hourmeter readings should be
added to the recorded estimated TSN of the APU.
F.

Removal and Installation of Hour Meter/Event Counter (Post SB-49-180)


WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

NOTE: Manual soldering shall be performed in accordance with the best industry
standard practices by certified personnel. The techniques used shall not
damage wires or terminals and shall provide solder joints that are free of
contamination and provide a reliable electrical connection.
NOTE: Tinning of soldering iron tips is accomplished by heating the soldering iron until
the tip just reaches the melting point of the solder. Flow the solder, similar to
that to used to solder the connection, onto the tip until the tip is fully covered
and no base material is exposed. Leave the iron tinned until ready for use.
Just prior to soldering (or removing solder), while the iron is still heated, wipe
the tip on a wetted sponge.
(1)

(2)

Desolder harness assembly (10, IPC 49-20-00 Figure 1) wires from hourmeter
/event counter (111) as follows:
(a)

Remove the heat shrink boot from the hourmeter/event counter housing to
expose the solder terminals located at the back of the hourmeter/event
counter.

(b)

Use a cleaned soldering iron and solder wick to remove solder from terminal
M1(+), located at the back of the hourmeter/event counter. Reheat the
connection and, while maintaining heat on the connection, apply a light steady
pull on the conductor wire until it disengages from the hourmeter terminal. Use
care to prevent splashing the molten solder and to avoid bending or otherwise
damaging the terminal.

(c)

Repeat step (b) above for terminal M1(-).

Remove and discard screws (20, IPC 49-20-00 Figure 1), washers (40), and nuts
(30) from the hourmeter/event counter (111).

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PART NUMBER 4501966 SERIES
(3)

Pull the hourmeter/event counter (111) from the fuel filter/meters bracket assembly
(300, IPC 49-20-00, Figure 2).

(4)

Remove any remaining adhesive from the hourmeter/event counter harness wires.

(5)

Use wire cutters, capable of cutting 20 AWG wire, to cut the exposed conductors off
of the wires that were removed from the hourmeter/event counter terminals.

(6)

Use a fixed die hand stripper to strip the ends of the 20 AWG wires to allow an
exposed conductor length sufficient to provide wrap around the hourmeter/event
counter terminals. Do not damage the stranded wires. Wires with severed strands
are not acceptable.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

(7)

Tin the exposed conductors by dipping the leads into liquid flux, followed by coating
the leads with solder. Solder shall penetrate the wire to the innermost strands but
shall not obscure the outer strands.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(8)

Use isopropyl alcohol to clean the soldered leads to remove any residual flux.
There shall be no visible evidence of flux residue.

(9)

Slide heat shrink boot over the harness assembly and make sure the large end is
facing the cut end of the wires.

WARNING:

SAFETY GLASSES SHOULD ALWAYS BE WORN WHILE SOLDERING


OR DESOLDERING.

WARNING:

FUMES OF THE FLUX ARE TOXIC. USE IN WELL-VENTILATED AREA.


PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE
VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15
MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.

(10) Connect the wires to the hourmeter/event counter terminals as follows:


REMOVAL/INSTALLATION

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PART NUMBER 4501966 SERIES
NOTE: There should be enough solder to ensure that the solder covers the wire
over the extent of the wrap. The solder should wet the terminal and wire
to form a visible fillet.
(a)

Solder wire E26A20 to terminal M1(+) on hourmeter/event counter.

(b)

Solder wire E27A20N to terminal M1(-) on hourmeter/event counter.

WARNING:

USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(11) Use isopropyl alcohol to clean the soldered connections to remove any residual flux.
There shall be no visible evidence of flux residue.
(12) Use a digital multimeter to verify continuity (0.2 ohm maximum) between the
following points:
(a)

P0274-24 to M1(+).

(b)

P0274-25 to M1(-).

(13) Use a digital multimeter to check resistance between the hourmeter terminals and
P0274 connector body. The resistance should be 20 megohms minimum.
(14) Use a digital multimeter to check resistance between pins P0274-24 and P0274-25.
The resistance should be 1,000 ohms minimum.
(15) Install the heat shrink boot on the hourmeter/event counter body. Adjust wire
sleeving as required. Apply adhesive part number 179581 to ensure fluids
resistance at wire egress and hourmeter/event counter body.
(16) Install hourmeter/event counter (111) and attach with screws (20) and nuts (30).
Torque nuts 24 to 27 pound inches (2.7 to 3.1 Nm)
(17) In Section 3 of the APU Log Book (Maintenance and Repair Log), record the
estimated APU time since new (TSN) and cycles since new (CSN), date of repair,
description of work performed and the current reading on the event counter. Future
hourmeter/event counter readings should be added to the recorded estimated TSN
and CSN of the APU.

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PART NUMBER 4501966 SERIES
G. Removal and Installation of Hour Meter and Event Counter (Post SB-49-189)
WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

NOTE: Removal and installation of the fuel filter/meters bracket assembly (300, IPC
49-20-00, Figure 2) involve the removal and re-installation of the fire detection
system. Removal and re-installation of the fire detection system and/or any
work on attaching hardware or the airframe itself must be performed in
accordance with the aircraft maintenance manual (AMM). Any questions or
issues relative to the AMM must be referred directly to the aircraft
manufacturer.
(1) Refer to the AMM for the procedures necessary to remove the fire detection system
on the fuel filter/meters bracket assembly (300).
(2) Remove the screws (20, IPC 49-20-00, Figure 1), the washers (40), and the nuts
(30). Remove the hourmeter (100A).
(3) Remove the screws (20), the washers (40), and the nuts (30). Remove the event
counter (110).
(4) Remove the bolts (180, IPC 49-20-00, Figure 2) and the fuel filter assembly (170)
from the fuel filter/meters bracket assembly (300).
(5) Remove the bolts (310), the washers (320), and the fuel filter/meters bracket
assembly (300).
(6) Install the fuel filter/meters bracket assembly (300) with the bolts (310) and the
washers (320).
(7) Install the fuel filter assembly (170) onto the fuel filter/meters bracket assembly (300)
with the bolts (180).
(8) Install the event counter (110, IPC 49-20-00, Figure 1) with the screws (20), the
washers (40), and the nuts (30).
(9) Install the hourmeter (100A) with the screws (20), the washers (40), and the nuts
(30).
(10) Refer to the AMM for the procedures necessary to install the fire detection system on
the fuel filter/meters bracket assembly (300, IPC 49-20-00, Figure 2).

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PART NUMBER 4501966 SERIES

H. Removal and Installation of Anti-Surge Valve and Bleed Air Elbow


WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

(1)

Disconnect electrical connector (P308) from anti-surge valve (40, IPC 49-00-00
Figure 1).

(2)

Disconnect the aircraft ducts connected to the anti-surge valve (40) and bleed air
elbow (10).

(3)

Remove V-band clamp (50) and packing (60). Discard the packing. Remove
anti-surge valve (40) from bleed air elbow (10).

(4)

Remove V-band clamp (20), packing (30) and bleed air elbow (10). Discard the
packing.

(5)

Install bleed air elbow (10) with V-band clamp (20) and packing (30). Torque clamp
locknut 33 to 37 pound inches (3.7 to 4.1 Nm).

(6)

Install anti-surge valve (40) with V-band clamp (50) and packing (60). Torque clamp
locknut 23 to 27 pound inches (2.5 to 3.0 Nm).

(7)

Connect aircraft ducts to bleed air elbow (10) and anti-surge valve (40).

(8)

Connect electrical connector (P308) to anti-surge valve (40).

NOTE: When possible, connectors should be tightened with a pair of soft-jawed


connector pliers. Tighten until the soft-jawed pliers slip on the connector.
I.

Removal and Installation of Bleed Air Valve and Filter


(1)

Disconnect electrical connector (P309) from bleed air valve (100, IPC 49-00-00
Figure 1).

(2)

Disconnect aircraft ducts from bleed air valve (100) and remove bleed air valve.

(3)

Remove plug (10, IPC 49-00-00 Figure 2), packing (20), filter (30), spring (40), and
filter retainer (50). Discard packing (20) and filter (30).

(4)

Install packing (20) on plug (10). Install filter retainer (50), spring (40), filter (30),
and plug into actuator housing of bleed air valve (100, IPC 49-00-00 Figure 1).

(5)

Connect aircraft ducts to bleed air valve (100).

(6)

Connect electrical connector (P309) to bleed air valve (100).

NOTE: When possible, connectors should be tightened with a pair of soft-jawed


connector pliers. Tighten until the soft-jawed pliers slip on the connector.

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PART NUMBER 4501966 SERIES
J. Removal and Installation of Ignition Cable(s)
WARNING:

(1)

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

Pre-SB-49-150 configuration:

(a) Disconnect ignition cable (130, IPC 49-20-00 Figure 3) from igniter plug (170).
(b) Remove bolt (150), nut (160), and clamp (140).
(c) Disconnect ignition cable from exciter (200) and remove cable.
(d) Remove and replace washers (137), if damaged.
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS
SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE
LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN
CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE
SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE
PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE
YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY
GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE
LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE
OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE
SURE THAT A TRAINED MEDICAL PERSON REMOVES THE
LOCKWIRE.
(e) Connect ignition cable (130) to igniter plug (170). Torque B-nut 40 to 60 pound
inches (4.5 to 6.8 Nm) and secure with lockwire.
(f) Put clamp (140) around cable and attach to bracket (180) with bolt (150) and nut
(160). Torque nut 24 to 27 pound inches (2.7 to 3.1 Nm).
(g) Connect ignition cable (130) to exciter (200). Torque B-nut 40 to 60 pound inches
(4.5 to 6.8 Nm).
(2)

Post-SB-49-150 configuration:

(a) Disconnect ignition cables (130 and 135, IPC 49-20-00 Figure 3) from igniter plugs
(170A).
(b) Remove bolts (155 and 157), nuts (160A), and clamps (145 and 147).
(c) Disconnect ignition cables from exciter (200A) and remove cables.
(d) Remove and replace washers (137), if damaged.

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PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS
SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE
LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN
CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE
SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE
PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE
YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY
GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE
LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE
OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE
SURE THAT A TRAINED MEDICAL PERSON REMOVES THE
LOCKWIRE.
(e) Connect ignition cable (130 and 135) to igniter plugs (170A). Torque B-nuts 40 to 60
pound inches (4.5 to 6.8 Nm) and secure with lockwire.
(f) Put clamps (145) around cables and clamp (147) around main fuel valve to manifold
tube assembly (90, IPC 49-20-00 Figure 2). Attach clamps with bolts (155 and 157,
IPC 49-20-00 Figure 3) and nuts (160A). Torque nuts 24 to 27 pound inches (2.7 to
3.1 Nm).
(g) Connect ignition cables (130 and 135) to exciter (200A). Torque B-nut 40 to 60
pound inches (4.5 to 6.8 Nm).
K. Removal and Installation of Igniter Plug(s)
WARNING:

(1)

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

Pre-SB-49-150 configuration:

(a) Disconnect ignition cable (130, IPC 49-20-00 Figure 3) from igniter plug (170) and
remove plug.
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO THE


TIP OF THE IGNITER OR DAMAGE TO THE PLUG WILL OCCUR.

(b) Apply anti-seize (169041) to the threads of igniter plug (170).


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PART NUMBER 4501966 SERIES
(c) Install igniter plug (170) in combustor housing. Torque plug 108 to 132 pound
inches (12 to 15 Nm). Connect ignition cable (130) to igniter plug. Torque B-nut 40
to 60 pound inches (4.5 to 6.8 Nm).
(2)

Post-SB-49-150 configuration:

(a) Disconnect ignition cables (130 and 135, IPC 49-20-00, Figure 3) from igniter plugs
(170A) and remove plugs.
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO THE


TIP OF THE IGNITER OR DAMAGE TO THE PLUG WILL OCCUR.

(b) Apply anti-seize (169041) to the threads of igniter plug (170A).


(c) Install igniter plugs (170A) in combustor housing. Torque plugs 108 to 132 pound
inches (12 to 15 Nm).
(d) Connect ignition cables (130 and 135) to igniter plugs. Torque B-nuts 40 to 60
pound inches (4.5 to 6.8 Nm).
L. Removal and Installation of Ignition Exciter
WARNING:

(1)

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL
COMPONENTS CAPABLE OF RETAINING A CHARGE HAVE BEEN
GROUNDED.

Pre-SB-49-150 configuration:

(a) Disconnect electrical connector (P303) from ignition exciter (200, IPC 49-20-00,
Figure 3).
(b) Disconnect ignition cable (130) from ignition exciter (200).
(c) Remove bolts (210 and 215), lockwashers (220), brackets (230 and 240), and
ignition exciter (200).
(d) Install ignition exciter (200) and brackets (230 and 240) with bolts (210 and 215) and
lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1 Nm).

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PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS
SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE
LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN
CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE
SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE
PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE
YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY
GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE
LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE
OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE
SURE THAT A TRAINED MEDICAL PERSON REMOVES THE
LOCKWIRE.
(e) Connect ignition cable (130) to ignition exciter (200). Torque B-nut 40 to 60 pound
inches (4.5 to 6.8 Nm) and secure with lockwire.
(f) Connect electrical connector (P303) to ignition exciter (200).
NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(2)

Post-SB-49-150 configuration:

(a) Disconnect electrical connector (P303) from ignition exciter (200A, IPC
49-20-00 Figure 3).
(b) Disconnect ignition cables (130 and 135) from ignition exciter (200A).
(c) Remove bolts (210A), lockwashers (220), brackets (240B), and ignition exciter
(200A).
NOTE:

Bolts (150A), clamps (148), and nuts (160A) do not have to be removed
from brackets (240B).

(d) If required, remove bolts (210A), lockwashers (220), and exciter bracket (193).
(e) If removed, install exciter bracket (193) with bolts (210A) and lockwashers (220).
Torque bolts 24 to 27 pound inches (2.7 to 3.1 Nm).
(f) Install ignition exciter (200A) and brackets (240B) with bolts (210A) and lockwashers
(220). Torque bolts 24 to 27 pound inches (2.7 to 3.1 Nm).

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PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS
SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE
LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN
CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE
SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE
PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE
YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY
GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE
LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE
OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE
SURE THAT A TRAINED MEDICAL PERSON REMOVES THE
LOCKWIRE.
(g) Connect ignition cables (130 and 135) to ignition exciter (200A). Torque B-nuts 40 to
60 pound inches (4.5 to 6.8 Nm) and secure with lockwire.
(h) Connect electrical connector (P303) to ignition exciter (200A).
NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(3)

Post-SB-49-185 configuration:

(a) Disconnect electrical connector (P303) from ignition exciter (200A, IPC
49-20-00 Figure 3).
(b) Disconnect ignition cables (130 and 135) from ignition exciter (200A).
(c) Remove bolts (195).
(d) Remove washers (197).
(e) Remove the exciter mounting bracket assembly (193, 49-20-00, Figure 3).
(f) Install isolators (199) on exciter mounting bracket assembly (-193A).
(g) Install exciter mounting bracket assembly (-193A).
(h) Install washers (-198).
(i) Install bolts (-196).
(j) Torque bolts (-196) to 55 to 70 pound inches (6.2 to 7.9 N.m).
(k) Install ignition exciter (200A) with bolts (210A) and lockwashers (220). Torque bolts
24 to 27 pound inches (2.7 to 3.1 Nm).

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PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS
SAFETY WIRE) IS TWISTED OR CUT CAN CAUSE THE
LOCKWIRE TO BECOME A PROJECTILE. THE FORCE CAN
CAUSE THE LOCKWIRE TO DAMAGE OR GO THROUGH THE
SURFACE OF YOUR EYES. THIS DAMAGE COULD CAUSE
PERMANENT BLINDNESS IN THE EFFECTED EYE. BEFORE
YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON SAFETY
GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF THE
LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE
OF THE EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE
SURE THAT A TRAINED MEDICAL PERSON REMOVES THE
LOCKWIRE.
(l) Connect ignition cables (130 and 135) to ignition exciter (200A). Torque B-nuts 40 to
60 pound inches (4.5 to 6.8 Nm) and secure with lockwire.
(m) Connect electrical connector (P303) to ignition exciter (200A).
NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
M. Removal and Installation of Start Fuel Nozzle(s)
(1)

Pre and Post SB-49-124 configuration:


NOTE: On pre-SB-49-124 configuration APU, one start nozzle tube assembly
(145, IPC 49-20-00 Figure 2) and one of the start fuel nozzle holder
assemblies (380, IPC 49-20-00 Figure 3) will not be present.

(a) Loosen start nozzle tube assemblies (140 and 145, IPC 49-20-00, Figure 2) at tee
(350, IPC 49-20-00, Figure 3).
(b) Disconnect tube assemblies (140 and 145, IPC 49-20-00, Figure 2) from start fuel
nozzle holder assemblies (380, IPC 49-20-00, Figure 3) and remove the start fuel
nozzle holder assemblies (380).
(c) Remove fitting (390) and nozzle (400) from each start fuel nozzle holder (380).
(2)

Pre SB-49-152 configuration:

(a) Assembly of start fuel nozzle assembly (380):

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PART NUMBER 4501966 SERIES
WARNING: USE LOCQUIC PRIMER GRADE T, CORRECTLY. THE
PRIMER IS FLAMMABLE AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY.
BEFORE YOU USE THE PRIMER, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY.
READ THE DETAILED WARNING, W0135SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE
PRIMER, PUT ON CHEMICAL-SPLASH GOGGLES AND
SOLVENT-RESISTANT GLOVES (BUTYL RUBBER). MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE PRIMER FUMES BELOW THE MATERIAL SAFETY
DATA SHEET LIMIT
1

Apply primer Grade T to three threads closest to nozzle (410) hex. Allow 3 to 4
minutes for primer to dry.
WARNING: USE LOCTITE RC640, CORRECTLY. THE COMPOUND IS
FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE
COMPOUND, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0067SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE COMPOUND,
PUT ON SAFETY GLASSES OR GOGGLES AND RUBBER
GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE COMPOUND FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT

(3)

Apply Loctite RC640 to the same area on the fuel nozzle.

Install fuel nozzle into fitting (390). Torque nozzle 55 to 60 pound inches (6.2 to
6.7 Nm).

Post SB-49-152 configuration:

(a) Loosen start nozzle tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2) at
tee (350, 350A, 350B, or 350C, IPC 49-20-00, Figure 3) and fitting (352).
(b) Disconnect tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2) from start
fuel nozzle holder assemblies (380, IPC 49-20-00, Figure 3) and remove the start
fuel nozzle holder assemblies (380).
(c) Remove fitting (390) and nozzle (400) from each start fuel nozzle holder (380).
(d) Assembly of start fuel nozzle assembly (380A, 380B or 380C):
1

Install nozzle (400A) into fitting (390 or 390A) or nozzle (400B) into fitting (390B).
Torque nozzle 55 to 60 pound inches (6.2 to 6.7 Nm).
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PART NUMBER 4501966 SERIES
2

Stake nozzle (400A or 400B) and fitting (390, 390A or 390B) three places as
shown in Figure 306.
NOTE:

Staking is limited to a maximum of six places.

Staking Of Start Fuel Nozzle Assembly


Figure 306
CAUTION:

DO NOT INTERCHANGE START FUEL NOZZLE HOLDERS. ONLY USE


A START FUEL NOZZLE HOLDER WITH A NOTCHED HEX HEAD IN A
THREE-START FUEL NOZZLE CONFIGURATION. IN A ONE OR TWOSTART FUEL NOZZLE CONFIGURATION ONLY USE A START FUEL
NOZZLE HOLDER WITH NO NOTCH ON THE HEX HEAD.
INSTALLATION OF AN INCORRECT START FUEL NOZZLE HOLDER
MAY RESULT IN AN OVER TEMPERATURE OR HUNG START
CONDITION.

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(4)

Pre and Post SB-49-124 configuration:

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

NOTE:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER


THAN THE THREADS OF THE START NOZZLE HOLDER AND
COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL
CONTAMINATE THE START NOZZLE HOLDER.

On pre-SB-49-124 configuration APU, one start nozzle tube assembly


(145, IPC 49-20-00, Figure 2) and one of the start fuel nozzle holder
assemblies (380, IPC 49-20-00, Figure 3) is not used.

(e) Apply a light coat of anti-seize lubricant (part number 169041) to the threads of the
nozzle holder assemblies (380) and the mating threads of the combustor housing.
(f) Install fitting (390) and nozzle (400) to each start fuel nozzle holder (380).
(g) Install start fuel nozzle holder assemblies (380) in combustor housing. Torque fittings
50 to 55 pound inches (5.6 to 6.2 Nm).
(h) Connect start nozzle tube assemblies (140 and 145, IPC 49-20-00, Figure 2) to tee
(350, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85 pound inches (8.5 to 9.6
Nm).
(i) Connect start nozzle tube assemblies (140 and 145, IPC 49-20-00, Figure 2) to start
fuel nozzle holder assemblies (380, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85
pound inches (8.5 to 9.6 Nm).

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PART NUMBER 4501966 SERIES
(4)

Post SB-49-152 configuration:

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER


THAN THE THREADS OF THE START NOZZLE HOLDER AND
COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL
CONTAMINATE THE START NOZZLE HOLDER.

(a) Apply a light coat of anti-seize lubricant (part number 169041) to the threads of the
nozzle holder assemblies (380C) and the mating threads of the combustor housing.
(b) Install start fuel nozzle holder assemblies (380C) in combustor housing. Torque
fittings 50 to 55 pound inches (5.6 to 6.2 Nm).
(c) Connect start nozzle tube assemblies (140, 145 and 147, IPC 49-20-00
Figure 2) to tee (350, IPC 49-20-00 Figure 3) and fitting (352). Torque B-nuts 75 to
85 pound inches (8.5 to 9.6 Nm).
(d) Connect start nozzle tube assemblies (140, 145 and 147, IPC 49-20-00,
Figure 2) to start fuel nozzle holder assemblies (380C, IPC 49-20-00, Figure 3).
Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 Nm).
(5)

Post SB-49-190 configuration:

(a) Disconnect tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2) from start
fuel nozzle holder assemblies (380, IPC 49-20-00, Figure 3).
(b) Remove Start Fuel Nozzle Holder Assembly (-380D, IPC 49-20-00, Figure 3) or Start
Fuel Nozzle Holder Assembly (-380E)
(c) Remove nozzle (400).
(d) Remove tabbed washer (-382, IPC 49-20-00, Figure 3) and discard.
(e) Install new tabbed washer (-382) and Start Fuel Nozzle Holder Assembly (-380D), or
Start Fuel Nozzle Holder Assembly (-380E)
(f) Install nozzle (400).
(g) Install Start Fuel Nozzle Holder Assembly (-380D, IPC 49-20-00, Figure 3) or Start
Fuel Nozzle Holder Assembly (-380E)

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(h) Install tube assemblies (140, 145 and 147, IPC 49-20-00, Figure 2).
(6)

Post SB-49-181 configuration:

WARNING:

USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTI-SEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

CAUTION:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN


THE THREADS OF THE START FUEL NOZZLE HOLDER AND
COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL
CONTAMINATE THE START FUEL NOZZLE HOLDER.

(a) Loosen tube assemblies (140B and 147) at 90-elbow (350D, IPC 49-20-00, Figure
3).
(b) Disconnect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) from the two
start fuel nozzle holder assemblies (380F, IPC 49-20-00, Figure 3) and remove the
start fuel nozzle holder assemblies.
(c) If necessary, remove plug (385).
(d) Remove fitting (390D) and injector (400C) from each start fuel nozzle holder
assembly (380F).
(e) Apply a light coat of anti-seize lubricant (51102) to the threads of the two start fuel
nozzle holder assemblies (380F) and the mating threads of the combustor housing.
(f) Install fitting (390D) and injector (400C) to each start fuel nozzle holder assembly
(380F).
(g) Install the two start fuel nozzle holder assemblies (380F) in combustor housing.
Torque fittings to 50 to 55 pound inches (5.6 to 6.2 Nm).
(h) If removed, install plug (385).
(i) Connect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) to 90-elbow
(350D, IPC 49-20-00, Figure 3). Torque B-nuts to 75 to 85 pound inches (8.5 to 9.6
Nm).
(j) Connect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) to the two start
fuel nozzle holder assemblies (380F, IPC 49-20-00, Figure 3). Torque B-nuts to 75
to 85 pound inches (8.5 to 9.6 Nm).

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(7)

Post SB-49-191 configuration:

WARNING:

USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTI-SEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

CAUTION:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN


THE THREADS OF THE START FUEL NOZZLE HOLDER AND
COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL
CONTAMINATE THE START FUEL NOZZLE HOLDER.

(a) Loosen tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) at tee
(350B, IPC 49-20-00, Figure 3).
(b) Disconnect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) from the
three start fuel nozzle holder assemblies (380E, IPC 49-20-00, Figure 3) and remove
the start fuel nozzle holder assemblies.
(c) Remove fitting (390C) and injector (400B) from each start fuel nozzle holder
assembly (380E).
(d) Apply a light coat of anti-seize lubricant (51102) to the threads of the three start fuel
nozzle holder assemblies (380E) and the mating threads of the combustor housing.
(e) Install fitting (390C) and injector (400B) to each start fuel nozzle holder assembly
(380E).
(f) Install the three start fuel nozzle holder assemblies (380E) in combustor housing.
Torque fittings to 50 to 55 pound inches (5.6 to 6.2 Nm).
(g) Connect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) to tee
(350B, IPC 49-20-00, Figure 3). Torque B-nuts to 75 to 85 pound inches (8.5 to 9.6
Nm).
(h) Connect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) to the
three start fuel nozzle holder assemblies (380E, IPC 49-20-00, Figure 3). Torque Bnuts to 75 to 85 pound inches (8.5 to 9.6 Nm).

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N.

O.

Removal and Installation of Purge Check Valve


(1)

Disconnect tube assembly (150, IPC 49-20-00, Figure 2) from union (330, IPC 4920-00, Figure 3).

(2)

Remove bolt (300), nut (310), and clamp (290) from check valve (280).

(3)

Remove check valve (280) from reducer (360).

(4)

Remove union (330) and packing (340) from check valve (280). Discard packing.

(5)

Install packing (340) and union (330) on check valve (280). Torque union 75 to 85
pound inches (8.5 to 9.6 Nm).

(6)

Install check valve (280) on reducer (360). Torque reducer 75 to 85 pound inches
(8.5 to 9.6 Nm).

(7)

Install clamp (290) on check valve (280) with bolt (300) and nut (310). Torque nut
25 to 30 pound inches (2.8 to 3.4 Nm).

(8)

Connect tube assembly (150, IPC 49-20-00 Figure 2) to union (330, IPC 49-20-00,
Figure 3). Torque B-nut 135 to 150 pound inches (15 to 17 Nm).

Removal and Installation of Fuel Manifold Assembly


(1)

Disconnect tube assembly (90, IPC 49-20-00, Figure 2) from union (560, IPC 49-2000, Figure 3).

(2)

Remove bolts (480), nuts (490), and washers (500).

(3)

Unscrew B-nuts of fuel manifold assembly (470) from combustor housing assembly
and remove fuel manifold.

(4)

Remove union (560) and packing (570) from fuel manifold assembly (470). Discard
packing.

(5)

Remove bolts (520), nuts (530), washers (540), clamps (510), and cushions (550)
from fuel manifold assembly (470).

(6)

Install cushions (550) and clamps (510) on fuel manifold assembly (470) with bolts
(520), nuts (530), and washers (540). Torque bolts 24 to 27 pound inches (2.7 to
3.1 Nm).

(7)

Install union (560) and packing (570) on fuel manifold assembly (470). Torque
union 75 to 85 pound inches (8.5 to 9.6 Nm).

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WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION: ANTI-SEIZE COMPOUNDS CONTAINING LEAD ARE HARMFUL TO THE
COMBUSTOR LINER AND HOUSING ASSEMBLIES. DO NOT APPLY
ANTI-SEIZE COMPOUNDS CONTAINING LEAD TO THESE
COMPONENTS.

P.

Q.

(8)

Apply a light coat of anti-seize compound to fuel manifold assembly B-nuts and to
manifold collars.

(9)

Install fuel manifold assembly (470) on combustor assembly. Tighten B-nuts evenly
in the following sequence: 3 and 9 oclock positions, 2 and 7 oclock, and 5 and 11
oclock. Torque B-nuts 55 to 65 pound inches (6.2 to 7.3 Nm).

Removal and Installation of Combustor Drain Check Valve Assembly


(1)

Disconnect aircraft fuel drain tube from check valve assembly (250, IPC 49-20-00,
Figure 3).

(2)

Remove check valve assembly (250) and packing (260) from reducer (270).
Discard packing.

(3)

Install check valve assembly (250), with the flow arrow pointing forward, and
packing (260) on reducer (270). Torque check valve assembly 75 to 100 pound
inches (8.5 to 11.3 Nm).

(4)

Connect aircraft fuel drain tube to check valve assembly (250).

Removal and Installation of Fuel Inlet Filter Element


WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.
USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
(1)

Position a container or drip pan under APU to catch spilled fuel.

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(2)

Remove filter bowl (190, IPC 49-20-00, Figure 2), filter element (200), packing
(205), and backing ring (208) from fuel filter assembly (170). Discard filter element
and packing.

(3)

Install packing (205) and backing ring (208) on filter element (200) and install filter
element in filter bowl (190).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(4)
R.

Install filter bowl (190) on fuel filter assembly (170). Torque filter bowl 20 to 60
pound inches (2.3 to 6.8 Nm) and install lockwire.

Removal and Installation of Fuel Pump Filter Element


(1)

Remove screws (20, IPC 49-20-00, Figure 4), cover (10), and packing (30). Discard
packing.

(2)

Remove filter element (40) and packing (50). Discard packing.


NOTE: Do not discard reusable filter element unless damaged.

S.

(3)

Put packing (50) on filter element (40) and install filter element.

(4)

Put packing (30) on cover (10) and install cover. Attach cover with screws (20).
Torque screws 24 to 27 pound inches (2.7 to 3.1 Nm).

Removal and Installation of Fuel Solenoid Valves


WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

(1)

Position a container or drip pan under APU to catch spilled fuel.

(2)

Disconnect tube assemblies, as required, from the following components:


NOTE: Be sure caps and plugs are installed on all open lines, fittings, and ports.
(a)

Disconnect tube assembly (130, IPC 49-20-00, Figure 1) from start valve bolt
fitting (420, IPC 49-20-00, Figure 2) and from fuel control assembly (250, IPC
49-20-00, Figure 1).

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(b) Disconnect tube assembly (240, IPC 49-20-00, Figure 1) from reducer (490, IPC 4920-00, Figure 2) and from fuel control assembly (250, IPC 49-20-00, Figure 1).
(c) Disconnect tube assembly (140, IPC 49-20-00, Figure 1) from union (510,
IPC 49-20-00, Figure 2) and from fuel control assembly (250, IPC 49-20-00, Figure
1).
(d) Disconnect tube assemblies (90 and 130, IPC 49-20-00, Figure 2) from reducers
(490).
(3)

Disconnect electrical connectors, as required, from the following:

(a) Connector (P306) from main fuel solenoid valve (530). If damaged, remove
connector seal (552) from main fuel solenoid valve (530).
(b) Connector (P305) from start fuel solenoid valve (540). If damaged, remove
connector seal (542) from start fuel solenoid valve (540).
(c) Connector (P307) from maximum fuel solenoid valve (550). If damaged, remove
connector seal (552) from maximum fuel solenoid valve (550).
(4)

Remove bolts (560), nuts (570), and fuel solenoid valves (530, 540, and 550), as
required.

(5)

Disassemble fuel solenoid valves as follows:

(a) Remove fittings (420, 450, and 480) and packings (430, 440, 460, and 470). Discard
packings.
(b) Remove reducers (490) and packings (500). Discard packings.
(c) Remove union (510) and packing (520). Discard packing.
(6)

Install fuel solenoid valves (530, 540, and 550) as follows:


NOTE:

During installation, be sure main fuel and start fuel solenoid valves (530
and 540) are installed with flow arrows pointed away from fitting (480).
Be sure maximum fuel solenoid valve (550) is installed with flow arrow
pointed towards fitting (480).

(a) Put packing (430) on fitting (420) and packing (460) on fitting (450). Put packings
(440 and 470) on fitting (480). Install fitting (480) on start fuel and maximum fuel
solenoid valves (540 and 550) and attach with fitting (420) in start fuel solenoid valve
(540) and fitting (450) in maximum fuel solenoid valve (550). Torque fittings (420
and 450) 135 to 150 pound inches (15 to 17 Nm).
(b) Put packings (500) on reducers (490) and install reducers into main and start
solenoid valves (530 and 540). Torque reducers 135 to 150 pound inches (15 to 17
Nm).
(c) Put packing (520) on union (510) and install union into maximum fuel solenoid valve
(550). Torque union 135 to 150 pound inches (15 to 17 Nm).
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(d) Install fuel solenoid valves (530, 540, and 550) with bolts (560) and nuts (570).
Torque bolts 24 to 27 pound inches (2.7 to 3.1 Nm).
(7)

Connect tube assemblies to the following components:

(a) Connect tube assembly (130, IPC 49-20-00, Figure 1) to start valve bolt fitting (420,
IPC 49-20-00, Figure 2) and to fuel control assembly (250, IPC 49-20-00, Figure 1).
Torque B-nuts 95 to 105 pound inches (10.7 to 11.9 Nm).
(b) Connect tube assembly (240, IPC 49-20-00, Figure 1) to reducer (490, IPC 49-2000, Figure 2) and to fuel control assembly (250, IPC 49-20-00, Figure 1). Torque Bnuts 75 to 85 pound inches (8.5 to 9.6 Nm).
(c) Connect tube assembly (140, IPC 49-20-00, Figure 1) to union (510, IPC 49-20-00,
Figure 2) and to fuel control assembly (250, IPC 49-20-00, Figure 1). Torque B-nuts
95 to 105 pound inches (10.7 to 11.9 Nm).
(d) Connect tube assemblies (90 and 130, IPC 49-20-00, Figure 2) to reducers (490).
Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 Nm).
(8)

Connect electrical connectors, as required, as follows:

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(a) Clean engine control harness assembly electrical connectors P306, P305 and P307
and the electrical connector on the main fuel solenoid valve (530), start fuel solenoid
valve (540) and maximum fuel solenoid valve (550) using a soft-bristled brush and
cotton wipes moistened with isopropyl alcohol to remove oil, grease, and
contamination from the pins and inside of the electrical connectors. Allow
connectors to air dry.
(b) If required, install the connector seals (552) in the main fuel solenoid valve (530)
connector, (542) in the start fuel solenoid valve (540) connector, and (552) in the
maximum fuel solenoid valve (550) connector. Press the seals over the connector
pins to the base of the pins.
NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(c) Connector (P306) to main fuel solenoid valve (530).
(d) Connector (P305) to start fuel solenoid valve (540).

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(e) Connector (P307) to maximum fuel solenoid valve (550).
T. Removal and Installation of Fuel Control Assembly, Acceleration Control, and Fuel Pump.
WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.
USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
(1)

Position a container or drip pan under APU to catch spilled fuel.

(2)

Disconnect tube assemblies from the following components:


NOTE: Be sure caps and plugs are installed on all open lines, fittings, and ports.

(a) Disconnect tube assembly (130, IPC 49-20-00, Figure 1) from union (420) and from
start valve bolt fitting (420, IPC 49-20-00, Figure 2).
(b) Disconnect tube assembly (240, IPC 49-20-00, Figure 1) from reducer (440) and
from reducer (490, IPC 49-20-00, Figure 2).
(c) Disconnect tube assembly (140, IPC 49-20-00, Figure 1) from reducer (380) and
from union (510, IPC 49-20-00, Figure 2).
(d) Disconnect tube assembly (120, IPC 49-20-00, Figure 1) from union (490) and from
elbow (230, IPC 49-20-00, Figure 2).
(e) Disconnect tube assembly (180, IPC 49-20-00 Figure 1) from union (360) and from
elbow (20, IPC 49-20-00, Figure 3).
(f) Disconnect aircraft drain tube from elbow (460, IPC 49-20-00, Figure 1).
(3)

Remove bolts (260, IPC 49-20-00, Figure 1), washers (270), and assembled fuel
control assembly (250). Remove gasket (280) and discard.

(4)

Remove bolts (300), washers (310), and fuel pump (320). Remove packings (330,
340, and 350) and discard.

(5)

Remove elbow (460), nut (480), and packing (470). Discard packing.

(6)

Remove unions (360, 380, 420, 440, and 490) and packings (370, 390, 430, 450,
and 500). Discard packings.

(7)

Remove plug (400) and packing (410). Discard packing.

(8)

Mate fuel pump (320) to acceleration control (290) without packings. The faces
should mate with no clearance and without force. If force is necessary, separate
and inspect splines. Remove all foreign material and burrs.

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(9)

Put packings (330, 340, and 350) on acceleration control (290) and mate to fuel
pump (320). Attach with bolts (300) and washers (310). Torque bolts 24 to 27
pound inches (2.7 to 3.1 Nm).

(10) Install elbow (460), packing (470) and nut (480). Torque nut 180 to 200 pound
inches (20.3 to 22.6 Nm).
(11) Install unions (360, 380, 420, and 440) and packings (370, 390, 430, and 450).
Torque unions 90 to 100 pound inches (10.2 to 11.3 Nm).
(12) Install union (490) and packing (500). Torque union 135 to 150 pound inches (15 to
17 Nm).
(13) Install plug (400) and packing (410). Torque plug 135 to 150 pound inches (15 to
17 Nm).
(14) Install assembled fuel control assembly (250) and gasket (280) and attach with bolts
(260) and washers (270). Torque bolts 55 to 70 pound inches (6.2 to 7.9 Nm).
(15) Connect tube assemblies to the following components:
(a) Connect tube assembly (130) to union (420) and to start valve bolt fitting (420, IPC
49-20-00, Figure 2). Torque B-nuts 135 to 150 pound inches (15.2 to 16.9 Nm).
(b) Connect tube assembly (240, IPC 49-20-00, Figure 1) to reducer (440) and to
reducer (490, IPC 49-20-00, Figure 2). Torque B-nuts 50 to 60 pound inches (5.6 to
6.8 Nm).
(c) Connect tube assembly (140, IPC 49-20-00 Figure 1) to reducer (380) and to union
(510, IPC 49-20-00, Figure 2). Torque B-nuts 135 to 150 pound inches (15.2 to 16.9
Nm).
(d) Connect tube assembly (120, IPC 49-20-00, Figure 1) to union (490) and to elbow
(230, IPC 49-20-00, Figure 2). Torque B-nuts 270 to 300 pound inches (30.5 to 33.9
Nm).
(e) Connect tube assembly (180, IPC 49-20-00, Figure 1) to union (360) and to elbow
(20, IPC 49-20-00, Figure 3). Torque B-nuts 135 to 150 pound inches (15.2 to 16.9
Nm).
(f) Connect aircraft drain tube to elbow (460, IPC 49-20-00, Figure 1).
U. Removal and Installation of High Oil Temperature Switch
WARNING:

(1)

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

Disconnect electrical connector (P311) from high oil temperature switch (690, IPC
49-20-00 Figure 2). If damaged, remove the connector seal (685) from high oil
temperature switch (690). Discard the seal.

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WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(2)

Place a container under the reduction drive to catch oil and remove high oil
temperature switch (690) and packing (700). Discard packing. Put packing (700) on
high oil temperature switch (690) and install switch. Torque switch 55 to 75 pound
inches (6.2 to 8.5 Nm) and secure with lockwire.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(3)

Clean engine control harness assembly electrical connector P311 and the electrical
connector on the high oil temperature switch (690) using a soft-bristled brush and
cotton wipes moistened with isopropyl alcohol to remove oil, grease, and
contamination from the pins and inside of the electrical connectors. Allow
connectors to air dry.

(4)

If required, install the connector seal (685) in the high oil temperature switch (690)
connector. Press the seal over the connector pins to the base of the pins.

NOTE: When possible, connectors should be tightened with a pair of soft-jawed


connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(5)

Connect electrical connector (P311) to high oil temperature switch (690).

(6)

Service APU with oil (refer to SERVICING).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
V. Removal and Installation of Magnetic Pickup
WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

(1)

Disconnect electrical connector (P302) from magnetic pickup (680, IPC 49-20-00
Figure 2). If damaged, remove the connector seal (685) from magnetic pickup
(680). Discard the seal.

(2)

Loosen nut and remove magnetic pickup (680).


NOTE:

(3)

To aid removal of pickup, it may be necessary to apply heat around boss


to soften thread sealant.

Insert a 7/16 Allen wrench in the starter gear of the accessory drive assembly. Use
the wrench to manually turn the gear until one tooth of the starter gear is in line with
the center of the speed pickup mounting hole.

WARNING:

USE LOCQUIC PRIMER GRADE N, MIL-S-22473N, CORRECTLY. THE


PRIMER IS FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
PRIMER, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0135SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE PRIMER, PUT
ON CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT
GLOVES (BUTYL RUBBER). MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE PRIMER FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

WARNING:

USE TEFLON SEALANT, PST 592, CORRECTLY. THE COMPOUND IS


FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE COMPOUND, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0067SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE COMPOUND, PUT ON SAFETY GLASSES OR
GOGGLES AND RUBBER GLOVES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT

(4)

Apply MIL-S-22473N Primer Grade "N" to threads of magnetic pickup (680) and
allow to dry for 5 minutes. Apply Pipe Sealant with Teflon (PST 592) to threads of
magnetic pickup.

(5)

Rotate Accessory Drive Gear until top of one of the Gear Teeth is in line with center
of Magnetic Pick-up mounting hole.

(6)

Install Magnetic Pick-up (680) by hand into Accessory Drive until contact with Gear
is made.
REMOVAL/INSTALLATION

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
(7)

Using key in electrical connector as a reference, back off magnetic pickup (680) one
quarter (1/4) turn (0.14 inch or 0.356 mm) and tighten Jam Nut into housing.
Torque Jam Nut to 75-100 pound inches (8.5 to 11.3 N.m).
NOTE: Gap between pole of speed pickup and gear tooth is 0.012 to 0.016 inch
(0.305 to 0.406 mm).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(8)

Use the Allen wrench to manually turn the starter gear through a complete
revolution. Make sure speed pickup does not touch the gear. Secure jam nut with
lockwire or safety cable and ferrule.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(9)

Clean engine control harness assembly electrical connector P302 and the electrical
connector on the magnetic pickup (680) using a soft-bristled brush and cotton wipes
moistened with isopropyl alcohol to remove oil, grease, and contamination from the
pins and inside of the electrical connectors. Allow connectors to air dry.

(10) If required, install the connector seal (685) in the magnetic pickup (680) connector.
Press the seal over the connector pins to the base of the pins.
(11) Connect the engine control harness assembly electrical connector P302 to the
magnetic pickup (680).
NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
W. Removal and Installation of Low Oil Pressure Switch
WARNING:

BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.

(1)

Disconnect electrical connector (P304) from low oil pressure switch (260, IPC 4920-00, Figure 2). If damaged, remove the connector seal (262) from low oil
pressure switch (260). Discard the seal.

(2)

Remove low oil pressure switch (260) and packing (270). Discard packing.

(3)

Put packing (270) on low oil pressure switch (260) and install switch. Torque switch
40 to 60 pound inches (4.5 to 6.7 Nm).

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(4)

Clean engine control harness assembly electrical connector P304 and the electrical
connector on the low oil pressure switch (260) using a soft-bristled brush and cotton
wipes moistened with isopropyl alcohol to remove oil, grease, and contamination
from the pins and inside of the electrical connectors. Allow connectors to air dry.

(5)

If required, install the connector seal (262) in the low oil pressure switch (260)
connector. Press the seal over the connector pins to the base of the pins.

(6)

Connect electrical connector (P304) to low oil pressure switch (260).

NOTE: When possible, connectors should be tightened with a pair of soft-jawed


connector pliers. Tighten until the soft-jawed pliers slip on the connector.

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
X. Removal and Installation of Oil Sight Plug
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.
(1)

Drain oil below level of sight plug (580, IPC 49-20-00, Figure 2) according to
SERVICING.

(2)

Remove oil sight plug (580) and packing (590) from nut (610). Discard packing.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(3)

Put packing (590) on oil sight plug (580) and install plug into nut (610). Torque plug
65 to 85 pound inches (7.3 to 9.6 Nm) and secure to nut (610) with lockwire or
safety cable and ferrule.

(4)

Service APU with oil (refer to SERVICING).

Y. Removal and Installation of Oil Filter Element


WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.
(1)

Position a container under oil filter bowl (332, IPC 49-20-00, Figure 2) to catch
spilled oil.

(2)

Remove oil filter bowl (332), backup ring (334), packing (335), filter element (340),
and packing (350). Discard filter element and packings.

(3)

Put packing (350) in filter element (340).

(4)

Put backup ring (334) and packing (336) on oil filter bowl (332).

(5)

Put filter element (340) into oil filter bowl (332) and install bowl.

(6)

Service APU with oil (refer to SERVICING).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Z. Removal and Installation of Magnetic Plug / Magnetic Drain Plug
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.
(1)

Position a container under the APU to catch spilled oil.

(2)

Remove magnetic drain plug (10, IPC 49-23-00, Figure 1), and packing (20). Allow
oil to drain into container. Discard packing.

(3)

Remove magnetic plug (30) and packing (40). Discard packing.

(4)

Put packing (20) on magnetic drain plug (10) and install plug. Torque plug 40 to 50
pound inches (4.5 to 5.7 Nm).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(5)

Put packing (40) on magnetic plug (30) and install plug. Torque plug 15 to 20 pound
inches (1.6 to 2.2 Nm). Secure plugs (10 and 30) with lockwire.

(6)

Service APU with oil (refer to SERVICING).

REMOVAL/INSTALLATION

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
CLEANING
1.

Introduction
A.

This section has the procedures for cleaning the Auxiliary Power Unit (APU) system
components. Item numbers in the procedures and illustrations are the same as those in
the Illustrated Parts Catalog (IPC), Document 40C11-3. Refer to Standard Practices
Manual (SPM), Document HSPS 490001, for general information.
NOTE: Alpha-variant items can replace an item when permitted by the effect code for
that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Cleaning Materials
A.

Cleaning materials are listed in Figure 601.


NOTE: Equivalent substitutes may be used for items listed.
Material

Source (Vendor Code)

Lint-free cloth

Commercially Available

Lubricating oil MIL-PRF-6081, Grade 1010

Commercially Available

TODCO 1060

Commercially Available

Cleaning Solution MIL-PRF-85704 Type II or


Type II RTU

Commercially Available

Isopropyl Alcohol, ASTM D770

Commercially Available

Cotton Wipes, A-A-51025

Commercially Available

Soft-bristle Brush

Commercially Available

Stiff-bristle brush

Commercially Available

Dry cleaning Solvent (Federal Specification


MIL-PRF-680, Type II)

Commercially Available

Cleaning Compound (Simple Green, 13002)


or equivalent alkaline cleaner with a pH of 8-9.

Sunshine Makers, Inc. (1Z575)

Ultrasonic Cleaner, B-2200-R-1

Branson Ultrasonics Corp. (10042)

Gloves

Commercially Available

Goggles

Commercially Available

Mask

Commercially Available

Spray Gun

Commercially Available

Q-Tip or rounded toothpick

Commercially Available

Razor Knife

Commercially Available

Oil (Federal Specification VV-L-800)

Commercially Available
Cleaning Materials
Figure 601
CLEANING

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
3.

Cleaning Procedures
A.

General
(1)

B.

When considerable time may elapse between cleaning and inspection or


reassemble, apply a light coat of lubricating oil to components and mating surfaces.
Place cleaned parts in clean plastic bags to prevent contamination.

Cleaning
(1)

Cleaning requirements are listed in Figure 602.


Component

Cleaning Method

Fuel pump filter (40, IPC 49-20-00 Figure 4)


Fuel pump (320, IPC 49-20-00 Figure 1)

Wash and flush. Clean by ultrasonic


method.
Wipe with clean, lint-free cloth soaked in
dry- cleaning solvent.

Acceleration control (290, IPC 49-20-00 Figure 1)

Wipe with clean, lint-free cloth soaked in


dry- cleaning solvent.

Low oil pressure switch (260, IPC 49-20-00 Figure 2)

Wipe with clean lint-free, dry cloth.

Thermocouple (112, IPC 49-20-00 Figure 1)

Wipe with clean lint-free, dry cloth.

Ignition exciter (200 or 200A, IPC 49-20-00 Figure 3)

Wipe clean with lint-free, dry cloth.


NOTE: Cap electrical receptacles or
connections as required before cleaning.

Hourmeter (100A, IPC 49-20-00 Figure 1)

Wipe clean with lint-free, dry cloth.

Event counter (110, IPC 49-20-00 Figure 1)

Wipe clean with lint-free, dry cloth.

Anti-surge valve (40, IPC 49-00-00 Figure 1)

Wipe clean with lint-free, dry cloth.

High oil temperature switch (690, IPC 49-20-00


Figure 2)

Wipe clean with lint-free, dry cloth.

Solenoid valves (530, 540, and 550, IPC 49-20-00


Figure 2)

Wipe clean with lint-free, dry cloth.


CAUTION: TO PREVENT DAMAGE, DO
NOT USE CONVENTIONAL ABRASIVE
OR IGNITER PLUG CLEANER.

Igniter plug (170 or 170A, IPC 49-20-00 Figure 3)

Use a dry, stiff-bristle brush and wipe with


clean, lint-free, dry cloth.

Magnetic pickup (690, IPC 49-20-00 Figure 2)

Wipe clean with lint-free, dry cloth.

Start Fuel Nozzle (380C and 380E, IPC 49-20-00


Figure 3)

Refer to steps 6.A. thru 6.I.


NOTE: Refer to APS 500C/I/R Cleaning
number 5 as an alternate cleaning
method.

Cleaning Requirements
Figure 602
CLEANING

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(2)

Cleaning/Checking of Combustor Drain Check Valve Assembly


WARNING: USE CLEANING SOLVENT (ALSO KNOWN AS DRY CLEANING
SOLVENT, STODDARD SOLVENT, MINERAL SPIRITS, NAPHTHA,
PETROLEUM SPIRITS, MIL-PRF-680 TYPE II, ASTM D235 TYPE II,
OR AMS3160) CORRECTLY. THE SOLVENT IS FLAMMABLE. IT
CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY.
BEFORE YOU USE THE SOLVENT, GET THE MATERIAL SAFETY
DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0158SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE SOLVENT, PUT ON CHEMICALSPLASH
GOGGLES, AND SOLVENT-RESISTANT GLOVES (BUTYL
RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE SOLVENT FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.
(a)

Wash and flush check valve assembly (250, IPC 49-20-00 Figure 3) thoroughly
with dry-cleaning solvent.

(b)

Connect a source of regulated air pressure to bulkhead end of check valve


assembly.
NOTE: The line length must be 4 to 5 feet (1.2 to 1.5m) with pressure gage
placed right next to check valve assembly.

4.

(c)

Slowly apply air. Valve must close when 25 psig (172.5 kPa) air pressure is
applied to the inlet. Valve leakage not to exceed 0.01 psig (0.07 kPa) per
minute. Replace check valve assembly if ball valve does not seat properly.

(d)

Return air pressure to 0 psig (0 kPa).

(e)

Remove check valve from air source.

(f)

Pour dry-cleaning solvent into bulkhead end of check valve assembly. Solvent
must flow freely from valve. Replace check valve assembly if solvent flow is
restricted.

Turbine Assembly Water Wash


CAUTION: THE COMPRESSOR WHEEL IS OF TITANIUM CONSTRUCTION. DO NOT USE
WATER SOLUBLE CLEANERS CONTAINING CHLORINATED
HYDROCARBONS. CHLORINATED HYDROCARBONS ARE DETRIMENTAL
TO TITANIUM.
A.

Prepare to Clean
NOTE: Cap or plug all open lines and ports.
(1)

Remove components as necessary to gain access to air inlet screen (770, IPC
49-20-00 Figure 3). Do not remove screen.
CLEANING

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(2)

Disconnect electrical connectors (P305, P306, and P307) from solenoid valves
(530, 540, and 550, IPC 49-20-00 Figure 2).

(3)

Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC
49-20-00 Figure 3).

(4)

Disconnect tube assembly (180, IPC 49-20-00 Figure 1) from elbow (20, IPC 49-2000 Figure 3).
NOTE: This will prevent cleaning solution reaching acceleration control.

(5)

Mix 1 part cleaning solution MIL-PRF-85704 Type II to 4 parts distilled water.


NOTE: Cleaning solution MIL-PRF-85704 Type II requires no dilution.

(6)
B.

Fill a suitable spray gun with cleaning solution mixture.

Clean the Turbine Rotor Assembly


(1)

Set master switch to START for approximately 5 seconds and release. Allow
engine RPM to build up. Set master switch to OFF.

(2)

Spray cleaning solution into air inlet while engine is rotating.


NOTE: Cleaning solution that is ingested during slow rotation of the turbine will be
most effective for cleaning operation.

C.

(3)

Repeat steps (1 and 2) until cleaning solution has been ingested.

(4)

Allow engine to stand for approximately 15 minutes to allow deposits to be


dissolved.

(5)

Fill a suitable spray gun with one quart (1 liter) of distilled or demineralized water.

(6)

Repeat steps (1 and 2) and spray water into air inlet while engine is rotating. Repeat
steps (1 and 2) until all water has been ingested.

Reassembly
(1)

Allow engine to stand until all water has drained from the check valve assembly
(250, IPC 49-20-00 Figure 3). Inspect check valve assembly (250) and clean as
necessary.

(2)

Connect tube assembly (180, IPC 49-20-00 Figure 1) to elbow (20, IPC 49-20-00
Figure 3). Torque B-nut 135 to 150 pound inches (15 to 17 Nm).

(3)

Connect electrical connector (P303) to ignition exciter (200 or 200A, IPC 49-20-00
Figure 3) and secure with lockwire.

(4)

Connect electrical connector (P305) to solenoid valve (530, IPC 49-20-00 Figure 2),
(P306) to solenoid valve (540), and (P307) to solenoid valve (550) and secure with
lockwire.

(5)

Install components removed to gain access to the inlet screen.


CLEANING

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
5.

6.

Cleaning the Fuel Pump Filter Element


A.

Clean filter element (40, IPC 49-20-00 Figure 4) using the ultrasonic cleaning method.

B.

The filter element should remain in ultrasonic tank for about 5 minutes.

C.

Wipe surfaces with clean, lint-free cloth.

Cleaning the Fuel Nozzle and Components


WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR SPLASH
GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN
CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION.
A.

Place the cleaning compound in the cleaning tank at 40 to 50% of tank capacity and heat
the solution to 120 to 140 F (49 to 60 C).

CAUTION: DO NOT ALLOW PARTS TO REMAIN IN CLEANING SOLUTION FOR


EXTENDED PERIODS OF TIME OR RUST SPOTS CAN FORM. IF PARTS ARE
NOT INSPECTED IMMEDIATELY AFTER CLEANING, DIP THEM IN CLEAN
LUBRICATING OIL TO PREVENT FORMATION OF RUST.
B.

Place the part to be cleaned in the cleaning tank for 15 to 20 minutes.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT
PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD
TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO
PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE
INJURY, GET MEDICAL ATTENTION.
C.

Pressure rinse the part with the hand gun for three to five minutes.

D.

Using a stainless steel brush or Scotch Brite, and hot water, brush areas which might
exhibit oxidation.
NOTE: A Q-tip and a round tooth pick may be used to remove any remaining
contaminants from the fuel nozzle body. If necessary, use a razor knife to
remove contaminants from the slots in the face of the distributor.

CLEANING

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR SPLASH
GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN
CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION.
E.

Place the cleaning compound in the cleaning tank to 40 or 50% of tank capacity and heat
the solution to 120 to 140 F (49 to 60 C) until all traces of varnish or carbon have
been removed.

CAUTION: DO NOT ALLOW PARTS TO REMAIN IN CLEANING SOLUTION FOR


EXTENDED PERIODS OF TIME OR RUST SPOTS CAN FORM. IF PARTS ARE
NOT INSPECTED IMMEDIATELY AFTER CLEANING, DIP THEM IN CLEAN
LUBRICATING OIL TO PREVENT FORMATION OF RUST.
F.

Place the part to be cleaned in the cleaning tank for five to ten minutes.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT
PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD
TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO
PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE
INJURY, GET MEDICAL ATTENTION.
G.

Pressure rinse the part with the hand gun for three to five minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR SPLASH
GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN
CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION.
H.

Rinse the part in the hot rinse tank for three to five minutes.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT
PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD
TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO
PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE
INJURY, GET MEDICAL ATTENTION.
I.

Use compressed air at 29 psi (200 kPa) or lower to dry part.

CLEANING

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
INSPECTION/CHECK
1.

General
A.

This section provides procedures to determine serviceability of the Auxiliary Power Unit
(APU) system. Item numbers in the procedures are the same as those in the Illustrated
Parts Catalog (IPC), Document 40C11-3. Refer to Standard Practices Manual (SPM),
Document HSPS 490001, for general information.
NOTE: Alpha-variant items can replace an item when permitted by the effect code for
that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

B.

Overtemperature Inspection
(1)

The measured continuous exhaust gas temperature (EGT) shall not exceed 1303
20F (706 11C). In the event the temperature exceeds these limits, an
overtemperature shutdown should occur. If the APU does not shutdown
automatically, it must be manually shutdown immediately. A notation of the
temperature reached and the duration of operating time in an overtemperature
condition should be entered in the log book. The following checks shall be
performed if the corrective actions suggested by FAULT ISOLATION procedures do
not correct the condition:
(a)

Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC
49-20-00 Figure 3).

(b)

Crank APU to maximum cranking speed and allow to coastdown. Carefully


listen for unusual noises or vibration during runup and coastdown.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO
BECOME A PROJECTILE. THE FORCE CAN CAUSE THE
LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF
YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT
BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR
INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDESHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO
YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE
HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY
TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED
MEDICAL PERSON REMOVES THE LOCKWIRE.
NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(c)

Connect electrical connector (P303) to ignition exciter (200 or 200A, IPC


49-20-00 Figure 3) and secure with lockwire.

INSPECTION/CHECK

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

C.

(d)

Start APU and accelerate to 50% rated speed and shutdown APU. Carefully
listen for unusual noises or vibration during runup and coastdown.

(e)

If all conditions appear normal, start APU and accelerate to rated speed. If
APU operation is normal, apply partial load. At each change of load, allow
EGT to stabilize to determine if APU operation is normal before applying
additional load.

(f)

If all conditions appear normal at rated speed and load, the APU can be
returned to service. However, if over-temperature continues, remove APU for
repair.

APU Inspection
(1)

Refer to Figure 801 for the APU inspection limits.


(a)

Operationally check APU for proper starting (refer to OPERATIONAL CHECK).

INSPECTION/CHECK

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Nomenclature

Inspection Limits

Corrective Action

Loop Clamps

Check for condition and security.


No deterioration permitted.

Replace damaged clamps.

Brackets (730, IPC


49-20-00 Figure 2)

Check for condition, security,


and cracks.

Replace bracket.

Check for corrosion.

Remove corrosion.

Check for chafing, cracks, or


leakage. Nicks or gouges in
excess of 10% of wall thickness.
Kinks not allowed.

Reposition support clamps to


prevent chaffing. Replace
cracked or leaking tubes with
nicked/gouged in excess of 10%.

Visually check B-nuts for cracks


and/or damaged.

Replace tube assembly.

Check for corrosion.

Remove corrosion.

Check for minimum clearance of


0.080 inch (2.032 mm) between
external rigid tubing.

Reposition tubing.

Check for cracked, broken, or


blockage of screen mesh.

Remove blockage. Remove


screen to check for possible
foreign object damage (FOD). If
FOD is suspected, remove turbine
assembly for further investigation.

Check screen for condition of


lacing hooks.

Replace screen if damaged.

Check for crazing, fracture, delamination, erosion, chips and


resin starvation (dryness) in
composite areas of top and
bottom halves.

Refer to INSPECTION 104 (4922-01) of Document APS500C/I/R.

Check for wear, crazing, fracture


and erosion through the
laminate of top and bottom
halves [less than or equal to 1
inch (25.4 mm) in diameter].

Refer to INSPECTION 104 (4922-01) of Document APS500C/I/R.

Check for damaged or missing


piece(s) in composite radial
closure and/or flanges.

Refer to INSPECTION 104 (4922-01) of Document APS500C/I/R.

Tube Assemblies

Air Inlet Screen (770,


IPC 49-20-00 Figure 3)

Air Inlet Duct Assembly


(10, IPC 49-20-00 Figure
3)

APU Inspection Limits


Figure 801 (Sheet 1 of 5)
INSPECTION/CHECK

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Page 803
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Nomenclature

Inspection Limits

Corrective Action

Check for crazing, fracture or


erosion of multiple layers of plies
[less than or equal to 3 square
inches (19.35 square
centimeters)]

Refer to INSPECTION 104 (4922-01) of Document APS500C/I/R.

Check for damage or evidence


of cracks in housing.

Replace APU.

Check for corrosion.

Remove corrosion.

Turbine wheel should rotate


easily. No rubbing or unusual
noise is permitted.

Replace APU.

Preformed Packing
(10 and 20, IPC Figure 1,
49-22-00)

Inspect preformed packing for


damage (worn), nicks and cuts.

Refer to REPAIR 26 (49-22-01) of


Document APS500C/I/R.

Harness Assembly (10,


IPC 49-20-00 Figure 1)

Check for condition and security.

Replace harness.

Check heat shrink tubing for


deterioration.

Replace damaged tubing.

Check for harness chafing.

Reposition harness and clamps as


necessary.

Check terminal lugs for damage.

Replace damaged terminal lugs.

Ignition Cables (130 and


135, IPC, 49-20-00
Figure 3)

Check for frayed braiding.

Replace ignition cable.

Exciter (200 or 200A,


IPC 49-20-00 Figure 3)

Check housing and mounting


bracket for nicks, burrs, or
scratches.

Blend out minor nicks, burrs, or


scratches.

Check housing for dents,


distortion, or cracks.

Replace exciter.

Check mounting bracket for


distortion.

Straighten mounting bracket to


original contour.

Check mounting bracket for


cracks.

Replace exciter.

Check connectors for corrosion.

Remove corrosion.

Turbine Assembly (780,


IPC 49-20-00 Figure 3)

APU Inspection Limits


Figure 801 (Sheet 2 of 5)
INSPECTION/CHECK

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Page 804
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Nomenclature

Inspection Limits

Corrective Action

Check mounting bracket for


cracks.

Replace exciter.

Check connectors for corrosion.

Remove corrosion.

Thermocouple (112, IPC


49-20-00 Figure 1)

Check sheath and shielding for


damage.

Replace thermocouple.

Magnetic Pickup (680,


IPC 49-20-00 Figure 2)

Check for security and damage.

Replace magnetic speed pickup.

Test Magnetic Pickup according


to paragraph 1.I.

Replace magnetic pickup if test


failed.

Check for mechanical damage.

Replace igniter plug if it shows


impact damaged, if connector well
or firing end insulator is cracked or
loose, or if connector pin is badly
bent or broken.

Check firing end shell for chafing


or fretting wear.

Replace igniter plug if wear


exceeds 0.015 inch (0.38 mm) or
if wear is more than one-half the
circumference of the shell.

Check for swollen or distorted


shell body.

Replace igniter plug.

Check for electrical erosion.

Replace igniter plug if erosion


exceeds limit shown in figure 802.

High Oil Temperature


Switch (690, IPC
49-20-00 Figure 2)

Check for security and damage.

Replace high oil temperature


switch.

Low Oil Pressure Switch


(260, IPC 49-20-00
Figure 2)

Check for corrosion.

Remove corrosion.

Main, Start, and


Maximum Fuel Solenoid
Valves (530, 540, and
550, IPC 49-20-00
Figure 2)

Check connector and valve body


for corrosion.

Remove corrosion.

Igniter Plugs (170 or


170A, IPC 49-20-00
Figure 3)

APU Inspection Limits


Figure 801 (Sheet 3 of 5)

INSPECTION/CHECK

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Page 805
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Nomenclature

Inspection Limits

Corrective Action

Check for movement between


valve body and housing.

If the valve body is cast, torque


screws 6 to 8 pound inches (0.68
to 0.90 Nm). If the valve body is
solid, torque screws 4.7 to 5.3
pound inches (0.53 to 0.59 Nm).

Check mounting flange gasket


for damage. A minimum of
0.150 inch (3.81 mm) gasket
around the connector is
acceptable.

Replace solenoid valve.

Fuel Manifold (470, IPC


49-20-00 Figure 3)

Check for condition, security,


and evidence of fuel leakage.

Torque B-nuts. Replace manifold


if fuel leakage continues.

Fuel Control Assembly


(250, IPC 49- 20-00
Figure 1)

Check for condition, security,


and evidence of fuel leakage.

Disassemble and replace


packings.

Acceleration Control
(280, IPC 49-20-00
Figure 1)

Check for evidence of fuel


leakage. A maximum of 6 drops
per minute is allowed.

Replace acceleration control.

Fuel Pump (320, IPC


49-20-00 Figure 1)

Check for evidence of fuel


leakage. A maximum of 6 drops
per minute is allowed.

Replace fuel pump.

Anti-Surge Valve (40,


IPC 49-00-00 Figure 1)

Check for condition and security.

Replace anti-surge valve.

Check mounting flange for


evidence of gas leakage.

Replace packing.

Check for oil leakage.

Tighten connections as needed.


Replace APU.

Check for cracks in housing.

Replace APU.

Check for corrosion.

Remove corrosion.

Check for chipped or worn paint.

Repair according to REPAIR-59


(49-26-01) of Document
APS500C/I/R

Reduction Drive
Assembly (820, IPC 4920-00 Figure 3)

Accessory Drive Cover


Assembly (70, IPC
49-23-00 Figure 2)

APU Inspection Limits


Figure 801 (Sheet 4 of 5)
INSPECTION/CHECK

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Page 806
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Nomenclature

Fuel Nozzle (400, IPC


49-20-00 Figure 3)

Inspection Limits

Corrective Action

Check for loose or missing paint.

For aesthetic purposes,


intumescent coating may be
touched up or repainted.

Check for security and damage.

Replace nozzle assembly.

Test according to paragraph 1.J.

Replace nozzle assembly if test is


failed.

APU Inspection Limits


Figure 801 (Sheet 5 of 5)

Igniter Plug
Figure 802

INSPECTION/CHECK

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Page 806A
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

INSPECTION/CHECK

49-00-00

Page 806B
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
D.

Magnetic Plug (Chip Detector) Inspection


WARNING: DO NOT TOUCH THE COMPONENTS OF THE OIL SYSTEM IF THE APU
IS HOT. THESE COMPONENTS STAY HOTTER THAN OTHER
COMPONENTS. HOT COMPONENTS CAN BURN YOU.
WARNING: HOT OIL MAY CAUSE BURNS TO EYES AND SKIN. PUT ON SPLASH
GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN
CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION.
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
CAUTION:

(1)

DO NOT OIL GET ON THE ENGINE OR OTHER COMPONENTS.


IMMEDIATELY CLEAN THE OIL WHEN IT FALLS ON THEM. OIL CAN
CAUSE DAMAGE TO PAINT AND RUBBER.

Remove the magnetic plug (30, IPC 49-23-00, Figure 1) from the magnetic drain
plug (10).

NOTE: It is not necessary to drain the oil when you examine the magnetic drain plug.
The magnetic drain plug has a valve that closes when the magnetic element is
removed.
(2)

Remove the preformed packing (40) from the magnetic plug (30). Discard the
preformed packing.

(3)

Examine the magnetic plug (30) for contamination.


(a)

If the plug is free of contamination, wipe with a clean, lint-free cloth, install new
packing (40), and reinstall it into the APU.

NOTE: Occasionally, new or overhauled APU's may produce a small amount of


fuzz, flakes, or splinters during initial operation.
(b)

If contamination is found, refer to Figure 803 for contamination criteria.

INSPECTION/CHECK

49-00-00

Page 807
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
E.

Oil Contamination Inspection


(1)

If particles are found in the reduction drive oil, refer to Figure 803 for contamination
criteria.

Contamination
Type
Magnetic

Particle Form/Quantity
(Note 1)
Fuzz (Finewear)

Magnetic or
Nonmagnetic

Small Flakes or Granules


Flakes smaller than 0.060 square
inch (0.387 square cm), or
approximately 0.25 x 0.25 inches
(0.64 x 0.64 cm)
Quantity of flakes does not cover
an area larger than 0.060 square
inch (0.387 square cm), or
approximately 0.25 x 0.25 inches
(0.64 x 0.64 cm)
Splinters (1 to 3 pieces)

Disposition
Change oil and filter. Clean magnetic
plug and return APU to service.
Change oil and filter (Refer to
SERVICING).
Clean the oil sump, visually inspect the
gearbox, and perform Step 1 below.
Step 1.
Operate the APU normally for
approximately 1 hour and recheck the
magnetic drain plug and filter.
If no particles are found during the
recheck, return the APU to service and
normally scheduled maintenance.
If fewer particles are found than were
originally seen before the 1 hour period,
change the oil and filter again and
perform Step 2 below. (Notes 2, 3, and 4).
If more or larger particles are found than
were originally seen before the 1 hour
period, remove the APU.
Step 2.
Operate the APU normally for
approximately 25 hours and recheck the
magnetic drain plug and filter.
If no particles are found during the
recheck, return the APU to service.
If fewer particles are found than were
originally seen before the twenty-five hour
period, change the oil and filter again and
perform Step 1 above. (Notes 2, 3, and
4).
If more or larger particles are found than
were originally seen before the 25 hour
period, remove the APU.

Contamination Criteria (Small Sized Particles)


Figure 803 (Sheet 1 of 3)

INSPECTION/CHECK

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Page 808
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Contamination
Type
Magnetic or
Nonmagnetic

Particle Form/Quantity
(Note 1)
Large Flakes or Granules

Disposition

Flakes larger than 0.060 square


inch (0.387 square cm), or
approximately 0.25 x 0.25 inches
(0.64 x 0.64 cm)
Quantity of smaller flakes covers
an area larger than 0.060 square
inch (0.387 square cm), or
approximately 0.25 x 0.25 inches
(0.64 x 0.64 cm)
Splinters (3 or more pieces)

Change oil and filter (Refer to


SERVICING).
Clean the oil sump or perform flush and
drain (refer to SERVICING), visually
inspect the gearbox, and perform Step 1
below.
CAUTION: IF A PARTICLE IS FOUND
WHICH IS RECOGNIZABLY
A PIECE OF AN INTERNAL
GEARBOX COMPONENT,
SUCH AS A GEAR TOOTH,
REMOVE THE APU.
Step 1.
Resume normal APU operation to
accumulate between thirty (30) minutes
and no more than one (1) APU operating
hour and recheck the magnetic plug and
filter.
If no particles are found during the
recheck, return the APU to service and
perform Step 2 below. (Notes 2, 3, and 4)
If particles are found, remove the APU.
Step 2.
Resume normal APU operation to
accumulate no more than fifteen (15)
APU operating hours and recheck the
magnetic plug and filter.
If no particles are found during the
recheck, return the APU to service.
If particles are found, remove the APU.

Contamination Criteria (Large Sized Particles)


Figure 803 (Sheet 2 of 3)

INSPECTION/CHECK

49-00-00

Page 809
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Notes
Note 1: Definition of particle forms:
Flake:
thin flat piece or layer
Fuzz (Finewear): light particles or fibers
Granular:
consisting of or appearing to consist of grains
Splinter:
thin pieces or sliver split off lengthwise
Note 2: Contamination evidence should be removed from the magnetic drain plug and/or oil
sump and preserved by encapsulating the evidence in a piece of clear plastic tape
placed in a clean, new plastic bag.
The oil filter should be removed and placed in a clean, new plastic bag.
An oil sample should be taken and stored in an oil sample kit.
Record the date, APU serial number, and APU hours and cycles since new or since last
oil check. Include this information with the items sent for analysis.
It is recommended that this information be recorded in the APU logbook.
Return evidence, the oil filter, and oil sample with the removed APU for analysis.
Note 3: Perform a Spectrographic Oil Analysis Program (SOAP) analysis of the oil and material
removed (refer to Figure 804). The presence of M50 material in the results of the
analysis is cause for removal. (M50 material contains approximately 90% iron, 4%
chromium, 4% molybdenum, 1% vanadium, 0.8% carbon, and 0.2% silicon.)
Note 4: Confirmation of the findings should be communicated to either Hamilton Sundstrand
Customer Service, Field Service, or an authorized Hamilton Sundstrand Service Center
before APU removal.

Contamination Criteria
Figure 803 (Sheet 3 of 3)

INSPECTION/CHECK

49-00-00

Page 810
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Magnetic Chip Detector Inspection


Figure 804

INSPECTION/CHECK

49-00-00

Page 811
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Spectrographic Oil Analysis Program (SOAP)
NOTE: Samples for SOAP analysis may be submitted to any qualified laboratory. Hamilton
Sundstrand does not recommend nor require any specific facility be used.
NOTE: It is necessary to establish a baseline for SOAP analysis for each APU and watch for
changes from that baseline as an indicator of a possible problem.
NOTE: These guideline levels are not considered as ultimate limits for oil analysis; they are strictly
target watch levels used to develop a trend.
Element

Watch Limits in parts per million


(ppm)

Iron (Fe)

Copper (Cu)

Chromium (Cr)

Aluminum (Al)

Nickel (Ni)

Silicon (Si)

10

Boron (B)

10

Sodium (Na)

10

Phosphorous (Ph)

10

Zinc (Zn)

60

Magnesium (Mg)

Molybdenum (Mo)

Silver (Ag)

1.

If an element value is exceeded on first analysis, check magnetic plug and resample.

2.

If an element value is exceeded on the second check, change the oil, oil filter, and change the
inspection interval to one half normal period.

3.

If an element value is exceeded on the third check, contact Hamilton Sundstrand Customer
Service, Field Service, or an authorized Hamilton Sundstrand Service Center.
Spectrographic Oil Analysis Program
Figure 805

INSPECTION/CHECK

49-00-00

Page 812
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
F.

Borescope Inspection
(1)

G.

Remove the necessary components and insert the probe of a borescope through
the following openings in the APU to gain access to the internal components of the
turbine assembly. Refer to Figure 801 for inspection limits.
(a)

Start fuel nozzle (380, IPC 49-20-00 Figure 3) opening. Provides access to
the combustor liner.

(b)

Igniter plug (170 or 170A, IPC 49-20-00 Figure 3) opening. Provides access to
the combustor liner.

(c)

Air inlet screen (770, IPC 49-20-00 Figure 3). Provides access to the
compressor wheel and diffuser.

(d)

Anti-surge valve (40, IPC 49-00-00 Figure 1) opening. Provides access to the
diffuser.

(e)

Exhaust end of the combustor housing (640, IPC 49-20-00 Figure 3). Provides
access to the turbine wheel and turbine nozzle.

APU Shutdown Check


NOTE: The thermocouple (112, IPC 49-20-00 Figure 1) is a dual element component
with two sets of alumel and chromel wires (T/C 1 and T/C 2). T/C 1 wires go to
pins A, and B, T/C 2 wires got to pins D, and E. The electronic sequence unit
(ESU) reads only signals from pins A, and B. To eliminate an intermittent
thermocouple shutdown problem, use T/C 2 connector.
NOTE: Before you change the thermocouple wires, determine if the wire change will
correct the APU shutdowns. Use adapter harness (part number 4504950 or
equivalent) to do check procedure.
(1)

Disconnect the APU harness connector J4 from the aircraft bulkhead connector P4.

(2)

Connect the APU harness connector J4 to adapter harness connector P4.

(3)

Connect opposite end of adapter harness J4 to the aircraft bulkhead connector P4.

(4)

Do several APU cycles in an attempt to duplicate the APU shutdown (refer to


Aircraft Operation Manual).

(5)

If the shutdowns continue, the cause(s) of the auto shutdowns are most likely not
related to the thermocouple. Proceed to paragraph (6). If the shutdowns stop, do
procedures in paragraph G.

(6)

Disconnect the adapter harness from the aircraft bulkhead connector P4 and from
the APU harness connector J4.

(7)

Connect the APU harness connector J4 to the aircraft bulkhead connector P4.

INSPECTION/CHECK

49-00-00

Page 813
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
H.

Thermocouple Wire Change


(1)

Disconnect the APU harness connector J4 from the aircraft bulkhead connector P4.

(2)

Remove the backshell.

CAUTION: MAKE SURE TO MARK WIRES CORRECTLY AND DOCUMENT


PROCEDURES SO THAT THE HARNESS CAN BE RETURNED TO THE
ORIGINAL CONFIGURATION.

I.

(3)

Remove the harness pins A, and B and mark them. Move pins out of the way and
secure.

(4)

Remove harness pins D, and E and mark them.

(5)

Insert pins D, and E into slots A and B respectively.

(6)

Attach the backshell.

(7)

Connect the APU harness connector J4 to the aircraft bulkhead connector P4.

Magnetic Pickup Test


(1)

Remove the magnetic pickup (680, IPC 49-20-00 Figure 2) (refer to 49-00-00,
Removal/Installation).

(2)

Use an ohmmeter to measure the resistance between pins A and B of the magnetic
pickup (680) connector (this is the coil resistance). The coil resistance shall be
between 1,000 and 1,300 ohms at ambient temperature.

(3)

Install the magnetic pickup (680) (refer to 49-00-00, Removal/Installation).

INSPECTION/CHECK

49-00-00

Page 814
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
J.

Fuel Nozzle Inspection


NOTE: Use a microscope (10X) and a bright light to check the parts.
Nomenclature

Inspection Limits

Corrective Action

Nozzle Assemblies

Check orifice erosion. Flow


test, refer to Figure 807.

Replace nozzle.

Spring Retainer (-440, IPC 4920-00 Figure 3)

Check for obstructed fuel


passage and damage

Reclean or replace retainer.

Nozzle Body (-400B, IPC 4920-00 Figure 3)

Check for nicks, burrs on


threads.
Check for wear or erosion on
surface of tapered cone.
Check for nicks or scratches on
exterior especially at fuel outlet.
Check for nicks or scratches on
seal surface.
Check for nicks or scratches in
retaining ring grove.

Replace nozzle assembly.

Distributor

Check for wear, erosion, or


scratches on front face or slots.
Check for contaminants on
front face or slots.

Replace nozzle assembly.

Retaining Ring (-420, IPC 4920-00 Figure 3)

Check for nicks or burrs on


edges.
Check for correct shape.

Replace retaining ring.

Screen (-430, IPC 49-20-00


Figure 3)

Check screen for


contamination.
Check for correct shape.

Clean or replace screen.

Spring (-410, IPC 49-20-00


Figure 3)

Check for free height o 0.265


0.015 inch (6.73 0.38 mm).

Replace spring.

Reclean distributor.

Fuel Nozzle Inspections Limits


Figure 806
(1)

Install holder assembly in fuel nozzle flow fixture TM90190 or ST92300B.


NOTE: If staking is required per the applicable APU repair manual, stake after
successful flow check.

INSPECTION/CHECK

49-00-00

Page 815
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Fuel Nozzle
Figure 807
WARNING: USE CLEANING SOLVENT (ALSO KNOWN AS DRY CLEANING
SOLVENT, STODDARD SOLVENT, MINERAL SPIRITS, NAPHTHA,
PETROLEUM SPIRITS, MIL-PRF-680 TYPE II, ASTM D235 TYPE II, OR
AMS3160) CORRECTLY. THE SOLVENT IS FLAMMABLE. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE SOLVENT, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0158SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE SOLVENT, PUT
ON CHEMICALSPLASH GOGGLES, AND SOLVENT-RESISTANT
GLOVES (BUTYL RUBBER), APRON, AND SHOES. MAKE SURE THAT
YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SOLVENT FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(2)

Use solvent at the specific pressure and verify that flow is between the maximum
and minimum values with a nominal specific gravity at 80F (26.7C) as shown in
Figure 808.

INSPECTION/CHECK

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ENGINE MANUAL
PART NUMBER 4501966 SERIES

Part Number
169046-1
169111-2, 4951965

Pressure
psig (kPa)

Flow-pph
Minimum

Maximum

100-400
(689-2,756)

8.4

17.1

198-202
(1,365-1,393)

10.5

12.0

340-360
8.6
10.0
(2,344-2,482)
Fuel Nozzle Flow Rate
Figure 808
Measure the spray angle approximately 0.5 inch (12.7 mm) downstream of the
nozzle and make sure the values are within the limits specified in Figure 809.
4951277

(3)

Part Number

Spray Angle

Pressure
psig (kPa)

Minimum

Maximum

169046-1

100-400
(689-2,756)

70

N/A

169111-2

198-202
(1,365-1,393)

70

100

4951277

340-360
(2,344-2,482)

70

100

198-202
98
112
(1,365-1,393)
Fuel Nozzle Spray Angle
Figure 809
There should be no streaks, spitting dribbling, or variations in the spray pattern.
4951965

(4)

Streaks
Spitting
Dribbling
(5)

Variations in spray density


Large irregular drops occurring intermittently
Sluggish dripping and large drops of unatomized fluid forming
on nozzle tip

If inspection limits are not met, replace the fuel nozzle (400 and 400A, IPC
49-20-00, Figure 3). Nozzle holder assemblies (-380E and -380F) and fuel nozzle
(-400B and -400C) are repairable (refer to 49-00-00 REPAIR).

INSPECTION/CHECK

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
REPAIR
1.

General
A.

This section provides procedures for repair of the Auxiliary Power Unit (APU) system.
Item numbers in the procedures are the same as those in the Illustrated Parts Catalog
(IPC), Document 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS
490001, for general information.
NOTE: Alpha-variant items can replace an item when permitted by the effect code for
that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Repair
Do a repair of the components as follows:
A.

Return the nozzle holder assembly (-380E or -380F, IPC 49-20-00 Figure 3) to Hamilton
Sundstrand for repair (according to HSPS Proprietary Repair Number XXX).

B.

Return the fuel nozzle (-400B or -400C) to Hamilton Sundstrand for repair (according to
HSPS Proprietary Repair Number XXX).

REPAIR

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PART NUMBER 4501966 SERIES

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REPAIR

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
SERVICING
1.

General
A.

This section has the procedures for flushing of the Auxiliary Power Unit (APU) system
lubricating oil system, purging the fuel system of air, and reading the data from the
hourmeter and event counter. Item numbers in the procedures are the same as those in
the Illustrated Parts Catalog (IPC), Bulletin 40C11-3. Refer to Standard Practices
Manual (SPM), Document HSPS 490001, for general information.
NOTE: Alpha-variant items can replace an item when permitted by the effect code for
that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

B.

Access to the APU may prevent performance of some procedures while the APU is
installed on the aircraft. Refer to the Aircraft Maintenance Manual for access.

C.

Exercise extreme care to prevent entrance of dirt, dust, and foreign objects into the
APU. If a foreign object is dropped into the APU, stop maintenance procedure until the
object is located and removed.

D.

Cover large openings with protective covers. Cap or plug open tube assemblies, fittings,
and ports. Do not cover tube ends with tape.
NOTE: Refer to Standard Practices Manual (SPM), Document HSPS 490001 for a
listing of all protective covers used on the APU for shipment and/or storage.

E.
2.

All parts attached with lockwire prior to removal must be re-attached with lockwire after
installation.

Equipment and Materials


A.

Equipment and materials required for servicing are listed in Figure 1101.
NOTE: Equivalent substitutes may be used for items listed.
NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or
holding other small components in place for ease of assembly and prevention of
galling. If necessary, assembly fluid may be diluted with MIL-PRF-7808 or
MIL-PRF-23699.
Material

Source (Vendor Code)

Assembly Fluid, 4950515

Hamilton Sundstrand (99167)

Container 1 Gallon (3.8 liters)

Commercially Available

Drain Line

Commercially Available
Servicing Equipment and Materials
Figure 1101 (Sheet 1 of 2)
SERVICING

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
Material

Source (Vendor Code)

Lint-free Cloth

Commercially Available

Lockwire MS20995C20 and MS20995C32

Commercially Available

Lubricating Oil, Refer to Hamilton Sundstrand


Standard Practices Document HSPS 490001
for oil types and restrictions

Hamilton Sundstrand
(55820)

Torque Wrench 25 to 140 lb. in. (2.8 to 15.8 Commercially Available


Nm)
Data Reader Model 1170 (P/N M7793-12-1) or

Curtis Instruments, Inc. (18583)

Meter Reader (P/N 4951807)

Oxley (K0066)

Connector Pliers, Soft-Jawed TG69

Glenair

Servicing Equipment and Materials


Figure 1101 (Sheet 2 of 2)
3.

Flushing the APU Oil System


The flushing procedure is used whenever the oil becomes contaminated or is being changed
to a different brand.
WARNING: DO NOT TOUCH THE COMPONENTS OF THE OIL SYSTEM IF THE APU IS
HOT. THESE COMPONENTS STAY HOTTER THAN OTHER COMPONENTS.
HOT COMPONENTS CAN BURN YOU.
WARNING: HOT OIL MAY CAUSE BURNS TO EYES AND SKIN. PUT ON SPLASH
GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN
CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL ATTENTION.
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES.
PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
CAUTION: DO NOT LET OIL GET ON THE ENGINE OR OTHER COMPONENTS.
IMMEDIATELY CLEAN THE OIL WHEN IT FALLS ON THEM. OIL CAN CAUSE
DAMAGE TO PAINT AND RUBBER.
A.

B.

Drain APU Lubrication Oil


(1)

Place a container of approximately 1 gallon (3.8 liters) capacity beneath the


magnetic drain plug (10, IPC 49-23-00 Figure 1).

(2)

Remove magnetic drain plug (10) from reduction drive assembly (820, IPC 49-20-00
Figure 3). Drain the oil from the reduction drive assembly oil sump.

Replenish APU Lubrication Oil


(1)

Install magnetic drain plug (10, IPC 49-23-00 Figure 1) into reduction drive
assembly (820, IPC 49-20-00 Figure 3). Torque magnetic drain plug 40 to 50
pound inches (4.5 to 5.7 Nm).

SERVICING

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
(2)

Remove plug (870).

CAUTION: DO NOT ALLOW THE OIL LEVEL TO BE ABOVE THE "FULL" MARK ON
THE SIGHT GLASS. AN OVERFILLED SUMP WILL RESULT IN OIL
FOAMING AND LOW OIL PRESSURE AND/OR OVERTEMPERATURE.
(3)

Fill the reduction drive assembly oil sump with 2.5 quarts (2366 cc) of approved oil.
Check the sump oil level on oil level sight plug (580, IPC 49-20-00 Figure 2). Do not
exceed the FULL mark.

(4)

Install the plug (870, IPC 49-20-00 Figure 3) in oil fill cap assembly (860).

C.

Start APU and allow it to stabilize at 100% for 10 minutes.

D.

Shut down APU and allow it to coast to a stop.

E.

Drain reduction drive assembly sump (step A above).

F.

Install new preformed packings as follows:

G.

(1)

Remove packing (20, IPC 49-23-00 Figure 1) from magnetic drain plug (10).
Discard packing.

(2)

Apply assembly fluid to a new packing (20) and install packing on magnetic drain
plug (10).

(3)

Remove plug (870, IPC 49-20-00 Figure 3) and packing (910). Discard packing.

(4)

Apply assembly fluid to a new packing (910) and install packing on plug (870).

Replenish APU Lubrication Oil


(1)

Install magnetic drain plug (10, IPC 49-23-00 Figure 1) into reduction drive
assembly (820, IPC 49-20-00 Figure 3). Torque magnetic drain plug 40 to 50
pound inches (4.5 to 5.7 Nm) and secure with lockwire.

CAUTION: DO NOT ALLOW THE OIL LEVEL TO BE ABOVE THE "FULL" MARK ON
THE SIGHT GLASS. AN OVERFILLED SUMP WILL RESULT IN OIL
FOAMING AND LOW OIL PRESSURE AND/OR OVERTEMPERATURE.

4.

(2)

Fill the reduction drive assembly oil sump with 2.5 quarts (2366 cc) of approved oil.
Check the sump oil level on oil level sight plug (580, IPC 49-20-00 Figure 2). Do not
exceed the FULL mark.

(3)

Install the plug (870, IPC 49-20-00 Figure 3) in oil fill cap assembly (860).

Purge Fuel System of Air


A.

The APU fuel system must be purged of air after the following conditions:
(1)

After initial installation of the APU.


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ENGINE MANUAL
PART NUMBER 4501966 SERIES

B.

(2)

When the system has been disturbed for replacement of components and the APU
fails to start after three attempts.

(3)

When the fuel system has become empty and the APU fails to start after three
attempts.

Purge APU fuel system of air as follows:


WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR
AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.
(1)

Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC
49-20-00 Figure 3).

(2)

Disconnect start nozzle tube assemblies (140 and 145, IPC 49-20-00 Figure 2) from
start nozzle holder assemblies (380, IPC 49-20-00 Figure 3). Connect drain lines to
the open tubes.

(3)

Disconnect main fuel tube assembly (90, IPC 49-20-00 Figure 2) from fuel manifold
(470, IPC 49-20-00 Figure 3). Connect a drain line to the open tube.

(4)

Place open end of drain lines into a container.

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.


USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
(5)

Be sure there is an adequate fuel supply in the storage tanks. Turn on the fuel
supply and check for leaks and correct as necessary.

(6)

Set MASTER switch to ON, set START-STOP-RUN switch momentarily to START,


and release to RUN. Check fuel flow from drain lines. Be sure an air- free flow of
fuel is obtained. After 15 seconds, set START-STOP-RUN switch to STOP.
NOTE: It may be necessary to repeat this step to obtain an air-free flow of fuel.

(7)

Set MASTER switch to OFF.

(8)

Remove drain lines and connect start fuel tube assemblies (140 and 145, IPC 4920-00 Figure 2) to start nozzle holder assemblies (380, IPC 49-20-00 Figure 3).
Torque B-nuts 75 to 85 pound inches (8.5 to 9.6 Nm).

(9)

Remove drain line and connect main fuel tube assembly (90, IPC 49-20-00 Figure
2) to fuel manifold (470, IPC 49-20-00 Figure 3). Torque B-nut 75 to 85 pound
inches (8.5 to 9.6 Nm).
SERVICING

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(10) Connect electrical connector (P303) to ignition exciter (200 or 200A, IPC 49-20-00
Figure 3) and secure with lockwire.
(11) Start and operate APU and check all fuel line connections for leakage. Shut down
APU.
5.

Hourmeter and Event Counter Data Readout


A.

Prepare for Data Readout

NOTE: Refer to Figure 1102 for reader and meter compatibility.

B.

C.

(1)

Remove the protective covers from the hourmeter (100A, IPC Figure 1) and event
counter (110) or hourmeter/event counter (111).

(2)

Connect the reader to the connector on either the hourmeter (100A) or event
counter (110) or hourmeter/event counter (111).

Data Readout (Curtis Reader)


(1)

Depress the reader center button. The reader will self test for approximately 5
seconds. A vertical marker will appear to indicate which reading is being given,
either events (left side of display) or hours (right side of display).

(2)

Record the number shown in the reader display window.

(3)

Repeat this procedure for the other solid state device.

Restore APU to Normal


(1)

Disconnect the reader from the last solid state device read.

(2)

Install the protective covers on the hourmeter (100A) and event counter (110).

SERVICING

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
D.

Data Readout (Oxley Reader)


NOTE: Oxley Reader must be plugged into the solid state meter before the Reader is
switched ON or inaccurate reading may occur.

E.

(1)

Press and hold the left-mouse button on the button panel of the Reader for a
moment to switch the Reader to ON. The Reader will display "INTERROGATING
ETT" in the LCD display panel. The STATUS lamp will flash red. The Reader will
display the type indicator, e.g., "INTERROGATING _________". The STATUS
lamp stays green. Hours and Events are displayed on the LCD display panel.

(2)

Record the number shown in the reader display window.

(3)

Hours and Events may be stored in the Reader by pressing the right-mouse button
on the Reader button panel. The LCD display panel will state "STORE READING?"
Press the right-mouse button again to store.

Restore APU to Normal


(1)

Press the left-mouse button on the Reader button panel to turn the Reader OFF.

(2)

Disconnect the Reader from the last solid state device read.

(3)

Install the protective cover on the hourmeter/event counter (111).

Reader
M7793-2-1
(Curtis)
1170-001
1170-003
1170-004
4951807
(Oxley)

4950077(A-E)
X
X
X
X
X

4950077(F)
X
X
X
X

Meter (Revision Letter)


4950135(A-E) 4950135(F)
X
X
X
X
X
X

4951559

X
X
X
X

Reader and Meter Compatibility


Figure 1102

SERVICING

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

ENGINE
49-20-00

ENGINE

49-20-00

Title, Page 1
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ENGINE MANUAL
PART NUMBER 4501966 SERIES

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ENGINE

49-20-00

Title, Page 2
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ENGINE MANUAL
PART NUMBER 4501966 SERIES
DESCRIPTION AND OPERATION
1. General (Refer to Figure 1)
A.

The engine is a gas turbine engine that supplies both shaft power and pneumatic power
in the form of compressor bleed air.

B.

The engine has:


- The reduction drive assembly
- The turbine section
- The combustor section.
The engine also has:
- A fuel system
- An ignition/starting system
- An air system
- APU controls
- An oil system.

C.

The engine gets ambient air, which is compressed in the compressor of the turbine
section. The compressed air flows into the combustor section where it mixes with fuel
which then burns. The burned fuel and air mixture moves through the turbine section to
give power to turn the turbine rotor and to drive the reduction drive assembly.

2. Component Description (Refer to Figure 2)


A.

Combustor section
(1) The combustor section is the part of the engine where the fuel mixes with air and
burns.
(2) The combustor section is attached to the turbine section.
(3) The combustor is an annular type that has:
- A combustor housing with an integral bleed air scroll
- A combustor liner
- The igniter plugs (one, pre-SB-49-150; two, post SB-49-150)
- A combustor drain valve
- A fuel manifold
- The start fuel nozzle assemblies, (one, pre SB-49-124; two, post SB 49-124 and
three, post SB-49-152).

B.

Turbine section
(1) The turbine section gives the power to drive the reduction drive assembly.
(2) The turbine section provides compressed air to the combustor section for bleed air
supply.
DESCRIPTION AND OPERATION

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ENGINE MANUAL
PART NUMBER 4501966 SERIES

Engine Modular Sections


Figure 1
(3) The turbine section is installed between the reduction drive assembly and the
combustor section.
(4) The turbine section has:
- An air inlet housing
- A rotor assembly
- A diffuser
- A turbine nozzle assembly
- An input pinion.

DESCRIPTION AND OPERATION

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ENGINE MANUAL
PART NUMBER 4501966 SERIES

A-68079
Engine Cross Section
Figure 2

DESCRIPTION AND OPERATION

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
C.

Reduction drive assembly


(1) The reduction drive assembly transmits shaft power from the turbine section to the
accessories during APU operation. It also transmits start power to the compressor
during starting.
(2) The reduction drive assembly is attached to the turbine section.
(3) The reduction drive assembly has:
- An accessory drive assembly
- An oil filler cap
- A low oil pressure switch
- A high oil temperature switch
- An integral oil sump.

3. Engine Operation
A.

Initially, the starter/generator turns the engine. When the engine turns, the compressor
pulls in the air through the air intake ducting. This air is then compressed and sent to the
diffuser. From the diffuser, the air goes to the combustor section.

B.

In the combustor the air is mixed with atomized fuel from the start fuel nozzles and fuel
manifold venturies. The igniter starts the ignition of the start fuel. The combustor then
burns main and max fuel continuously. When the fuel is burned, the gases from the
combustor are sent through the turbine nozzle onto the blades of the turbine wheel.
From the turbine wheel, the gases go through the center of the combustor housing to the
exhaust.

C.

The turbine wheel provides power to the compressor and the reduction drive assembly.

4. Fuel System
A.

The fuel system consists of components that function automatically to provide proper
APU acceleration and maintain a near constant operating speed under varying load
conditions. These components are the acceleration control/fuel pump, start, main, and
maximum fuel solenoid valves, fuel filter assembly, fuel manifold, start fuel nozzles,
check valve, and interconnecting tubing assemblies. Fuel must be supplied to the APU
from the aircraft fuel supply which provides fuel to a 10 micron nominal (25 micron
absolute) fuel filter at a pressure at least 5 psi (34 kPa) over the true vapor pressure.

B.

Acceleration Control/Fuel Pump


(1) The acceleration control/fuel pump is mounted on the accessory pad of the
reduction drive assembly. The fuel pump is a positive-displacement, gear- type unit.
(2) The acceleration control consists of three major components secured together.
These are the governor housing, the governor housing cover, and the bellows cover
assembly.

DESCRIPTION AND OPERATION

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PART NUMBER 4501966 SERIES
(3) A cleanable fuel pump outlet filter (25-micron filtration, nominal) is installed in the
pump housing. The fuel pump splined shaft fits into a drive in the reduction drive
assembly. The other end of the fuel pump drive shaft is spline-coupled to the
drivehead assembly of the acceleration control.
(4) Adjustment to APU governed speed is made by turning the speed adjustment screw
in or out. This changes the position of the governor tension lever, which increases
or decreases the force of the governor control spring against the rotating drivehead
assembly.
(5) The governor characteristics are designed to provide 3% droop. When adjustments
are required, the no-load speed is set at 103%. This setting will provide 100% rated
speed at full load.
C.

Start Purge Valve


(1) The purge system consists of a check valve downstream of the start fuel solenoid
that is connected to the compressor discharge. When the solenoid is turned off, this
compressor discharge pressure purges the start fuel nozzles and fuel lines.

D.

Fuel Inlet Filter Assembly


(1) The low pressure fuel inlet filter protects the fuel system from contamination. The
filter is a full flow type with a disposable 10 micron nominal (25 micron absolute) fuel
filter element. The fuel filter assembly has provision for an impending filter bypass
differential pressure sensor and bypass relief valve. The bypass relief valve has a
cracking pressure not less than 3 psid (21 kPa) with full bypass at a differential
pressure of 7 psid (48 kPa) maximum. The bypass relief valve is designed to
prevent the discharge of fuel filter contaminants when bypassing fuel around a
clogged filter.

E.

Fuel Manifold
(1) The fuel manifold provides fuel to the six equally spaced main fuel nozzles around
the circumference of the combustor. Fuel is supplied to the fuel manifold through
the main and maximum fuel solenoid valves.
(2) Fuel flow to the fuel manifold assembly is controlled by the flyweight assembly in the
acceleration control to limit the speed of the APU. Increasing rotor speed above the
set speed causes the free ends of the fly weights to pivot away from the axis of the
rotating drivehead assembly. The pivoting action of the flyweights against the
bearing plate of the piston/valve assembly, compresses the governor control spring,
and moves the fuel metering valve in a direction to reduce fuel flow to the APU.
This action results in near constant speed over the APU operating range.

F.

Start Fuel Nozzles


(1) The start fuel nozzles project radially into the combustor. Fuel atomized by the
nozzles is ignited by the igniter plug located on the combustor directly in line with
the start fuel nozzles. The nozzles incorporate integral screens with hole diameters
of 0.005 - 0.009 inch (0.127 - 0.228 mm) to provide additional filtration.
DESCRIPTION AND OPERATION

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
NOTE: The pre-SB-49-124 configuration has one start fuel nozzle, the post-SB49-124 configuration has two start fuel nozzles and the post-SB-49-152
has three start fuel nozzles.
G.

Start, Main, and Maximum Fuel Solenoid Valves


(1) The fuel solenoid valves are operated by a nominal electrical input of 28 Vdc from
the ESU. The three fuel solenoid valves are bolted to a bracket on the reduction
drive assembly adjacent to the acceleration control/fuel pump. The fuel system
components are interconnected with stainless steel tubing.
(2) The start fuel solenoid valve is energized to the open position by the ESU at start
initiation (if air borne) or at 3% rated speed (if on the ground) to supply fuel to the
start fuel nozzle(s). At 70% rated speed, the valve is de-energized. In the deenergized condition, the valve shuts off the fuel flow to the start fuel nozzle(s) and
the check valve opens to allow compressor discharge pressure (Pcd) to flow
through the nozzle(s). This clears the nozzle(s) and lines of fuel to prevent coking
of the start fuel nozzle(s).
(3) Fuel is supplied to the fuel manifold assembly through the main and maximum fuel
solenoid valves. The main fuel solenoid valve is energized to the open position by
the ESU at 14% rated speed. De-energizing this valve produces a normal
shutdown of the APU.
(4) The maximum fuel solenoid valve is energized at 95% rated speed, plus 7 seconds,
bypassing the acceleration orifice and allowing maximum fuel flow for governing at
rated APU speeds and loads.

DESCRIPTION AND OPERATION

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
5. Fuel System Operation (Refer to Figure 3)
A.

The fuel system consists of components that function automatically to provide proper
APU acceleration and maintain a near constant operating speed under varying load
conditions. At initiation of start and in proper sequence, the ESU actuates the start fuel
solenoid valve to the open position, and energizes the ignition circuit. Fuel is then
directed through the start fuel solenoid valve to the start fuel nozzles. After combustion
ignition, at 14% rated APU speed, the main fuel solenoid valve is activated by the ESU
and fuel is directed through the fuel manifold, in addition to the start fuel nozzles. Main
and maximum fuel is supplied to the combustor fuel nozzles by the fuel manifold and is
atomized by venturies for normal operation. Combustion ignition takes place in the
combustor when atomized fuel from the start fuel nozzles is ignited by the igniter plug.
All fuel flow to the combustor during the acceleration phase is controlled by APU
compressor discharge pressure acting on the diaphragm in the delta-P (P) regulator
chamber of the acceleration control assembly. One side of the diaphragm is ported
through the compressor pressure line to compressor outlet pressure; the other side is
ported to ambient air pressure. Compressor discharge pressure, acting on the
diaphragm, controls the setting of the P regulator. The P regulator, in turn, controls
the differential pressure across the orifice and governor.

B.

As compressor discharge pressure increases, the P regulator lowers the governor outlet
pressure, thus increasing the pressure drop across the governor. This increase in
pressure drop results in an increase in fuel flow to the APU. Fuel flow to the main fuel
nozzles is increased in proportion to increasing compressor discharge pressure.
Between 14% and 70% rated APU speed, the ESU also pulses the main fuel solenoid
valve on and off. This is done to prevent an overtemperature shutdown of the APU. At
approximately 70% rated APU speed, the fuel flow to the start fuel nozzles is cut off, and
the main fuel nozzles continue to supply fuel for combustion. At 95% rated APU speed,
plus 7 seconds, the maximum fuel solenoid valve is opened (energized) allowing
maximum fuel flow for speed governing at rated speed and varying load conditions.

C.

Ambient air pressure varies inversely with altitude. The diaphragm in the P regulator
chamber, in conjunction with an aneroid bellows and a lever, reacts to changes in
ambient air pressures, causing a reduction in fuel flow as altitude is increased.

D.

A minimum fuel flow orifice, installed in the acceleration control housing bypassing the
governor, allows a small amount of fuel under pump pressure to flow to the fuel nozzles
even if fuel flow through the governor has been greatly reduced. In the event the load is
removed suddenly, the setting of the minimum fuel flow orifice maintains adequate fuel
flow to sustain combustion.

E.

Drain provisions for the fuel system are as follows:


(1) An acceleration control/fuel pump drain and vent provides overboard drain of
leakage within the acceleration control/fuel pump.
(2) A combustor drain located on the bottom of the combustor provides drain for the
combustion chamber. It consists of a spring-loaded ball valve (check valve
assembly) which is held open until approximately 45 percent engine speed is
attained when compressor discharge pressure overcomes the spring pressure.

DESCRIPTION AND OPERATION

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PART NUMBER 4501966 SERIES

APU Fuel System Schematic


Figure 3

DESCRIPTION AND OPERATION

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6. Ignition/Starting System (Refer to Figure 4)
A.

The ignition/starting system initially turns the engine, provides acceleration assistance
and starts the ignition of the fuel-air mixture in the combustor.

B.

The ignition/starting system has:


- An ignition exciter
- One or two ignition cables
- One or two igniter plugs
- A starter/generator (not supplied with the APU).
NOTE: The pre-SB-49-150 configuration has one ignition cable and one igniter plug.
The post SB-49-150 configuration has two ignition cables and two igniter plugs.

C.

The ignition/starting system also uses:


- The electronic sequencing unit (ESU).

D.

When the APU is operated, the ignition/starting system is fully automatic in operation.
The starter portion of the starter/generator turns the engine through the reduction drive
assembly to get sufficient air flow for combustion. Then the ignition exciter supplies a
high energy current to the igniter plug for ignition. When the engine gets to a set speed
the ignition/starting system is automatically deenergized.

E.

The ESU controls the ignition/starting system. The electrical supply for the starter motor
is 28 Vdc from the aircraft electrical system.

7. Ignition/Starting System Operation


A.

When the ESU gets a start signal from the APU Panel, it automatically controls the
ignition/starting cycle.
(1) The ESU energizes the start contactor and gives a start signal to the
starter/generator.
(2) The starter/generator rotation turns the gear train in the reduction drive assembly,
allowing the APU to get sufficient air flow for combustion.
(3) When the engine speed is 0% during airborne operation or 3% for ground operation,
the ESU energizes the ignition exciter and start fuel solenoid valve. The ignition
exciter then supplies an intermittent high energy current to the igniter plug(s). Then
the igniter plug(s) make(s) sparks to start and sustain the ignition of the fuel-air
mixture in the combustion housing.
(4) At 14% engine speed, the main fuel solenoid valve is energized. Between 14% and
70% engine speed, the ESU pulses the main fuel solenoid valve on and off to
prevent an overtemperature shutdown. If ignition is not detected by the ESU, the
starter is disengaged until 8% engine speed then re-engaged (swing start). Swing
start is limited to one time per start attempt.

DESCRIPTION AND OPERATION

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PART NUMBER 4501966 SERIES

APU Wiring Diagram (Pre SB-49-180)


Figure 4
DESCRIPTION AND OPERATION

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PART NUMBER 4501966 SERIES

APU Wiring Diagram (Post SB-49-180)


Figure 5

DESCRIPTION AND OPERATION

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(5) The starter portion of the starter/generator continues to help the engine
acceleration. When the engine speed is about 70%, the starter contactor, start fuel
solenoid valve, and ignition exciter are de-energized. The sparks from the igniter
plug(s) then stop(s) and self-sustained combustion continues.
(6) When the engine speed is 95%, the ESU starts a 7-second timer. At the end of the
7 seconds, the maximum fuel solenoid valve, the ready-to-load signal, and event
counter are energized.
8. Air System
A.

The APU air system supplies bleed air to the aircraft main engine start (MES) system and
bypass air to prevent compressor surge during in-flight APU starting and operation.

B.

The main components of the APU air system are:


- the bleed valve
- the anti-surge valve
- the flow-limiting venturi.

9. Air System Operation


A.

Air enters the APU through the APU air inlet duct. From the duct, the air passes through
the compressor and into the combustor housing. Bleed air for the aircraft ECS and APU
surge protection is tapped off the compressor via the combustor housing bleed scroll.

B.

The anti-surge valve provides additional discharge capability to keep the compressor out
of surge during periods when the APU is started in flight or is operating in flight with
exclusively shaft loads. When not in flight the valve is always energized closed.

C.

The bleed valve drive control is provided directly by the aircraft through the ESU. Bleed
air can be selected after the RTL signal has been provided by the ESU. The ESU
monitors the status of the bleed valve via a position switch ("closed"), which is used to
generate an "advisory" fault BITE out put during the APU start sequence and is used to
control anti-surge valve usage. A second position switch in the bleed valve is used for
aircraft pneumatic systems control.

10. APU Controls


A.

The APU controls system is required for control, monitoring, and protection of the APU
during stating, operation, and shutdown.

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B.

The APU controls system consists of:


- an electronic sequence unit (ESU)
- a low oil pressure switch
- a high oil temperature switch
- a magnetic speed pickup
- an EGT thermocouple.

C.

Electrical power for the APU controls system is obtained from the battery +28Vdc.

D.

During operation, the ESU receives signals from the magnetic speed sensor probe, low
oil pressure switch, EGT thermocouple, and the high oil temperature switch; all of which
monitor critical engine parameters. These signals provide data which enable the ESU to
operate APU primary protective circuits of:
- Overspeed (engine rpm at or above 108.3% rated speed)
- Underspeed (engine rpm 95% or less rated speed)
- Low oil pressure (6 1.5 psig, 41.4 10.3 kPa)
- Overtemperature (1303 20F, 706 11C)
- High oil temperature (330 5F, 165.6 2.8 C).

E.

Electronic Sequence Unit (ESU) (Refer to Figure 6)


(1) The ESU is located in the bay just forward of the APU compartment.
(2) The ESU is a solid-state electronic control unit that controls the APU. The ESU
controls the start up and shut down sequences of the APU, monitors the APU for
proper operational parameters, powers down the APU in case of malfunction, and
isolates failures of the APU through four built-in test equipment (BITE) discrete
outputs to the aircraft central maintenance computer.

F.

Low Oil Pressure Switch


(1) The low oil pressure switch is remotely mounted and is located on the left side of
the reduction drive assembly (lubrication oil sump).
(2) The switch has two positions: normal and low oil pressure. When the oil pressure
increases above 6 1.5 psig (41.4 10.3 kPa), the switch is set to the normal
position, which causes the hourmeter to run. If the oil pressure falls below 6 1.5
psig (41.4 10.3 kPa), the switch sends a low oil pressure signal (ground) to the
ESU. The ESU begins checking for low oil pressure once the APU speed has
reached 95% plus 7 seconds.

G.

High Oil Temperature Switch


(1) The high oil temperature switch is located on the lower, aft face of the reduction
drive assembly (lubrication oil sump).
(2) The normally open switch closes when the oil temperature exceeds 330 5F
(165.6 2.8C).

DESCRIPTION AND OPERATION

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PART NUMBER 4501966 SERIES

A-69858
Electronic Sequence Unit
Figure 6

H.

Thermocouple
(1) The dual-element chromel/alumel thermocouple is mounted to the combustor
assembly and extends into the exhaust stream. One element of the thermocouple
is used to sense APU exhaust gas temperature and the other element is a spare.
(2) The millivolt output of the thermocouple is transmitted to the ESU, which analyzes
the signal for an overtemperature condition.

I.

Magnetic Speed Pickup


(1) The magnetic speed pickup is installed into the accessory drive housing of the
reduction drive assembly.
(2) The magnetic speed pickup is threaded into the housing and aligns with the teeth
on the accessory drive gear.
(3) The magnetic speed pickup generates a sinusoidal signal which is transmitted to the
ESU, where it is used for start sequencing, speed sensing (overspeed and
underspeed conditions), and output to the aircraft EICAS.
DESCRIPTION AND OPERATION

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PART NUMBER 4501966 SERIES
11. APU Controls Operation (Refer to Figures 7 and 8)
A.

APU start sequencing is based upon information received from the magnetic speed
pickup. The ESU uses this information to sequence and control, through preprogrammed logic, the energizing of the fuel solenoid valves and the ignition exciter.

B.

Information from the magnetic speed pickup is also used by the ESU for monitoring the
APU for an overspeed or underspeed condition. The ESU shuts down the APU for an
overspeed condition anytime the rotor speed exceeds 108%. An underspeed shutdown
occurs only after the rotor speed reaches 95% and then drops below this speed, when a
normal shutdown command has not been received.

C.

The ESU uses signals received from the thermocouple to monitor the APU for an
overtemperature condition. The ESU will shutdown the APU when the exhaust gas
temperature exceeds 1604F 20F (873C 11 C) during acceleration or 1303F
20F (706C 11C) after ready-to-load.

12. APU Oil System


A.

The oil system lubricates and cools all the bearings, gears, and shaft components in the
APU.

B.

The oil system includes (Refer to Figure 9):


- An oil filler cap
- An oil pump
- An oil sump
- A pressure relief valve
- An oil filter
- A magnetic drain plug
- An oil level sight glass.

C.

A high oil temperature switch and a low oil pressure switch are installed in the oil system.
The system also uses:
- The drain system
- The reduction drive assembly
- The electronic sequencing unit (ESU).

DESCRIPTION AND OPERATION

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PART NUMBER 4501966 SERIES

A-69859
APU Control Sequence
Figure 7

DESCRIPTION AND OPERATION

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PART NUMBER 4501966 SERIES

APU Control Schematic


Figure 8

DESCRIPTION AND OPERATION

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APU Lubrication System Components


Figure 9
D.

The oil system is contained in or installed on the reduction drive assembly. The pressure
pump supplies the pressurized oil from the reduction drive sump. The internal passages
through the engine supply the oil to lubricate the movable components. The oil then
returns to the reduction drive sump.

DESCRIPTION AND OPERATION

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(1) Oil Filler Cap
(a) The oil filler cap is used to fill the reduction drive sump.
(b) The cap is installed on the right side of the reduction drive assembly.
(2) Oil Pump
(a) The oil pump is a gear-type pump assembly that is internal to the reduction
drive assembly. It is driven by the reduction gear train.
(3) Oil Sump
(a) The oil sump is integral with the lower portion of the reduction drive assembly
housing. It has a capacity of 2.5 US quarts (2366 cc).
(4) Pressure Relief Valve
(a) The pressure relief valve is a spring-loaded, ball-type relief valve, internally
mounted in the reduction drive assembly. The valve regulates the system oil
pressure at 15 to 40 psig (103 to 276 kPa). When the valve opens, excess oil
is directed against the inside surface of the air inlet housing to cool the oil.
The oil then drains to the sump.
(5) Oil Filter
(a) The oil filter assembly is remotely installed on a bracket near the left side of
the reduction drive assembly.
(b) The oil filter assembly has a disposable 10 micron filter element installed in a
removable bowl.
(c) The oil flows through the pressure filter element to the lubrication system. A
differential pressure indicator is installed on the filter housing and extends to
show when the filter element is becoming clogged and requires replacement.
(6) Magnetic Drain Plug
(a) The magnetic drain plug catches the metal particles, which may cause internal
damage to the APU.
(b) The magnetic drain plug is installed in the reduction drive sump.
(c) It has two parts:
- A drain plug at the base of the reduction drive sump
- A magnetic insert installed in the plug.
(d) Removal of the magnetic insert will not cause loss of oil.
DESCRIPTION AND OPERATION

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(7) Oil Level Sight Glass
(a) An oil level sight glass is used to check the oil level.
(b) The oil level sight glass is installed on the left side of the reduction drive
assembly.
(c) Oil should be added when the oil level is at the base of the sight glass. The
dot on the sight glass indicates that the sump is full.
13. APU Oil System Operation (Refer to Figure 10)
A.

The pump draws oil out of the sump and through internal drilled passages and external
lubrication lines to the oil filter. Oil enters the oil filter housing, passes through the filter
element from outside to inside, and is returned to the internal passages of the reduction
drive housing by the external lubrication lines.

A-69861
APU Lubrication System Schematic
Figure 10

DESCRIPTION AND OPERATION

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B.

If the oil filter becomes clogged, oil will bypass the filter element. The differential
pressure indicator extends and locks in position if the pressure differential across the
filter reaches 85 to 95 psig (586 to 655 kPa). The filter bypass valve opens when the
differential pressure across the filter reaches 110 to 120 psid (758 to 827 kPa), permitting
the oil to bypass a restricted filter.

C.

High-pressure oil from the oil filter is returned to the reduction drive into a passage
leading to four oil jets and the system relief valve. Three of the oil jets direct oil spray to
the points where the high-speed reduction drive input pinion meshes with the three
planetary gears. The other jet directs an oil spray between the end of the output shaft
and the input pinion to create a mist for lubrication of the rotor shaft bearings. The
remainder of the gears and gear shaft bearings are lubricated by oil spray created when
oil strikes the planetary gears and the input pinion.

D.

The air-oil mist for rotor shaft bearing lubrication is supplied through another oil jet
adjacent to the oil jet ring. This jet directs oil spray to the aft end of the output shaft. It is
then directed through a hole in the center of the input pinion and flows aft through the
hollow rotor shaft. Near the end of the rotor shaft, mist passes through a hole in the rotor
shaft wall and reverses direction to flow forward through the roller bearing, around the
outside of the rotor shaft, through the ball bearing, and out of the oil slinger nut into the
reduction drive assembly housing.

E.

The system relief valve regulates system oil pressure at 15-40 psid (103-172 kPa) by
bypassing a portion of the pump output directly into the reduction drive assembly
housing. The bypassed oil is directed against the inside surface of the air inlet housing
to cool the oil. The oil then flows to the sump by gravity flow through an opening in the
bottom of the planetary gear carrier assembly.

DESCRIPTION AND OPERATION

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DESCRIPTION AND OPERATION

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DISASSEMBLY
1.

General
A.

This section has the procedures for disassembly of the engine. Item numbers in the
procedures are the same as those in the Illustrated Parts Catalog (IPC), Document
40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001,
DISASSEMBLY, for general disassembly information.
NOTE: Alpha-variant items can replace an item when permitted by the effect code for
that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Equipment and Materials


A.

Equipment and materials required for disassembly are listed in Figure 501.
NOTE: Equivalent substitutes may be used for items listed.
Equipment and Material

Source (Vendor Code)

Lubricating Oil MIL-PRF-6081, Grade 1010

Commercially Available

Molycote 321R (169015-1)

Commercially Available

ST91125, Combustor Assembly Puller

Hamilton Sundstrand (99167)

ST70396, Assembly Fixture

Hamilton Sundstrand

ST70137, Rotor Fixture

Hamilton Sundstrand
Equipment and Materials
Figure 501

3.

Preparation
A.

General Procedure
(1)

Place each disassembled part on a clean workbench in the order of disassembly in


preparation for cleaning and inspection. Keep hardware and small parts together in
trays.

(2)

Provide proper coverings or supports to protect shafts, gears, studs, and projecting
parts from damage.

(3)

Do not use steel or lead hammers directly on assemblies or their parts. Use
cellulose-tipped hammers and fiber or rawhide mallets as specified. Do not clamp
parts directly in the steel jaws of a bench vise. Use a vise having micarta jaws or
equivalent.

(4)

After disassembly, spray steel parts with lubricating oil. Cover all parts with clean
paper or suitable coverings unless cleaning and inspection is to be accomplished
immediately.
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PART NUMBER 4501966 SERIES
(5)

Do not disassemble tube assemblies, hose assemblies, wiring harness assemblies,


riveted assemblies, staked, or press-fit parts. Do not remove nameplates,
modification plates, lubrication plates, decals, studs, stud lockrings, or thread
inserts, unless specifically required in the text or necessary for replacement of a
part. If disassembly or removal is necessary, proceed in accordance with current
procedures.

(6)

Always keep ports, bores, and passages of assemblies or components sealed with
suitable closure between repair procedures. Cover large openings with covers
retained in place.
NOTE: Do not use tape to cover openings or connections on fuel or lubrication
system components.

B.

(7)

During disassembly, examine all parts and assemblies for signs of scoring, burning,
or other damage. Note physical conditions which will not be apparent after
cleaning. Tag involved parts before they are cleaned and laid out for detail
inspection. Check for evidence of damage caused by improper repair procedures.
Report such damage in accordance with current practice.

(8)

Record manner of lockwiring for duplication at reassembly.

(9)

All seals, gaskets, preformed packings, tabwashers, lockpins, and lockwire are to be
discarded when removed and replaced with new items.

Preparation for Disassembly


(1)

If the engine is mounted in a shipping container, crate, or other support unit, transfer
it to assembly fixture ST70396.

(2)

If necessary, drain lubrication oil from the reduction drive assembly. (Refer to 4900-00, SERVICING).
NOTE: Retain lubrication oil for inspection for evidence of metal particles or other
foreign matter.

4.

Removal of Engine Components


NOTE: Determine fault isolation indication, recorded malfunction, and total operating time to
establish the condition of the engine or most probable cause of its malfunction. This
is to determine the extent of disassembly required to accomplish repairs.
A.

Engine Harness Assembly

WARNING: MAKE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. MAKE SURE ALL COMPONENTS
CAPABLE OF RETAINING AN ELECTRICAL CHARGE HAVE BEEN
GROUNDED.
(1)

Disconnect electrical connectors and remove engine harness assembly as follows:


DISASSEMBLY

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(2)

(a)

Disconnect electrical connector (P302) from magnetic pickup (680, IPC


49-20-00 Figure 2).

(b)

Disconnect electrical connector (P303) from ignition exciter (200 or 200A, IPC
49-20-00 Figure 3).

(c)

Disconnect electrical connector (P306) from main fuel solenoid valve (530, IPC
49-20-00 Figure 2).

(d)

Disconnect electrical connector (P305) from start fuel solenoid valve (540).

(e)

Disconnect electrical connector (P307) from maximum fuel solenoid valve


(550).

(f)

Disconnect electrical connector (P304) from low oil pressure switch (260).

(g)

Disconnect electrical connector (P311) from high oil temperature switch (690).

(h)

Disconnect electrical connector (P308) from anti-surge valve (40, IPC 49-0000 Figure 1).

(i)

Disconnect electrical connector (P309) from bleed air valve (100).

Remove screws (20, IPC 49-20-00 Figure 1), washers (40), nuts (30), hourmeter
(100A) and event counter (110).
NOTE: If the original hourmeter (100A) or event counter (110) will not be
reinstalled, an entry must be made in the logbook for the APU
Hours/Events and the Hours/Events meter readings.

B.

(3)

Remove bolts (70), nuts (90), and clamps (45, 50, 60, and 80).

(4)

Remove thermocouple (112) from combustor housing.

(5)

Remove engine harness assembly (10).

Sensors
(1)

Loosen nut and remove magnetic pickup (680, IPC 49-20-00 Figure 2).
NOTE: To aid removal of pickup, it may be necessary to apply heat around boss to
soften thread sealant.

(2)

If damaged, remove the connector seal (685) from magnetic pickup (680). Discard
the seal.

(3)

Remove low oil pressure switch (260) and packing (270). Discard packing.

(4)

If damaged, remove the connector seal (262) from low oil pressure switch (260).
Discard the seal.

(5)

Remove high oil temperature switch (690) and packing (700). Discard packing.

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(6) If damaged, remove the connector seal (685) from high oil temperature switch
(690). Discard the seal.
C.

Tube Assemblies
(1)

Remove bolt (70, IPC 49-20-00 Figure 1), nut (90), and loop clamps (50 and 220)
from tube assemblies (120 and 130).

(2)

Remove bolts (160 and 200), nuts (170 and 210), and loop clamps (150, 190, and
220) from tube assemblies (140 and 180).

(3)

Remove bolts (40, 520, and 525, IPC 49-20-00 Figure 2), nuts (50 and 530), and
loop clamps (30, 70 and 510) from tube assemblies (10, 20, and 80).

(4)

Remove bolts (110), nuts (120), and loop clamps (30, 100, and 160) from tube
assemblies (90, 130, 145, and 150).

(5)

Post SB-49-152: Remove bolt (157A, IPC 49-20-00 Figure 3), nut (160A), and loop
clamp (147A) from tube assembly (147, IPC 49-20-00 Figure 2).

(6)

Post SB-49-181: Remove bolt (110B), washer (115), and loop clamp (100C) from
tube assembly (147).

(7)

Post SB-49-191:
(a)

Remove bolt (110B), washer (115), and loop clamp (100C) from tube
assembly (147).

(b)

Remove bolt (163), nut (164), and loop clamps (161 and 162) from tube
assemblies (145A and 140B).

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.


USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.
(8)

Position a container or drip pan under engine to catch spilled fuel and oil.

(9)

Disconnect tube assemblies from the following components and remove tube
assemblies:
(a)

Disconnect tube assembly (130, IPC 49-20-00 Figure 1) from union (420) and
from start valve bolt fitting (420, IPC 49-20-00 Figure 2).

(b)

Disconnect tube assembly (240, IPC 49-20-00 Figure 1) from reducer (440)
and from reducer (490, IPC 49-20-00 Figure 2).
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(c)

Disconnect tube assembly (140, IPC 49-20-00 Figure 1) from reducer (380)
and from union (510, IPC 49-20-00 Figure 2).

(d)

Disconnect tube assembly (120, IPC 49-20-00 Figure 1) from union (490) and
from elbow (230, IPC -49-20-00 Figure 2).

(e)

Disconnect tube assembly (180, IPC 49-20-00 Figure 1) from union (360) and
from elbow (20, IPC 49-20-00 Figure 3).

(f)

Disconnect tube assembly (10, IPC 49-20-00 Figure 2) from union (60) and tee
(360).

(g)

Disconnect tube assembly (20) from elbow (400) and reducer (50, IPC 49-2300 Figure 1).

(h)

Disconnect tube assembly (80, IPC 49-20-00 Figure 2) from union (60) and
reducer (50, IPC 49-23-00 Figure 1).

(i)

Disconnect tube assembly (90, IPC 49-20-00 Figure 2) from reducer (490) and
union (560, IPC 49-20-00 Figure 3).

(j)

Disconnect tube assembly (130, IPC 49-20-00 Figure 2) from reducer (490)
and tee (350, IPC 49-20-00 Figure 3).

(k)

Disconnect start fuel nozzle tube assemblies:


1

Pre and Post SB-49-124 configuration:


a

Post SB-49-152 configuration:


a

Disconnect tube assemblies (140, 145 and 147, IPC 49-20-00


Figure 2) from tee (350, IPC 49-20-00 Figure 3), fitting (352) and
start fuel nozzle holder assemblies (380C).

Post SB-49-181 configuration:


a

Disconnect tube assemblies (140 and 145, IPC 49-20-00 Figure 2)


from tee (350, IPC 49-20-00 Figure 3) and start fuel nozzle holder
assemblies (380).

Disconnect tube assemblies (140B and 147, IPC 49-20-00, Figure 2)


from 90-elbow (350D, IPC 49-20-00, Figure 3) and from the two
start fuel nozzle holder assemblies (380F).

Post SB-49-191 configuration:


a

Disconnect tube assemblies (140B, 145A, and 147, IPC 49-20-00,


Figure 2) from tee (350B, IPC 49-20-00, Figure 3) and from the
three start fuel nozzle holder assemblies (380E).

DISASSEMBLY

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(l)
D.

E.

F.

G.

Disconnect tube assembly (150B, IPC 49-20-00 Figure 2) from union (330, IPC
49-20-00 Figure 3).

Fuel Control Assembly, Acceleration Control, and Fuel Pump


(1)

Remove bolts (260, IPC 49-20-00 Figure 1), washers (270), and assembled fuel
Remove bolts (300), washers (310), and fuel pump (320). Remove packings (330,
340, and 350) and discard.

(2)

Remove elbow (460), nut (480), and packing (470). Discard packing.

(3)

Remove unions (360, 380, 420, 440, and 490) and packings (370, 390, 430, 450,
and 500). Discard packings.

(4)

Remove plug (400) and packing (410). Discard packing.

Fuel Solenoid Valves


(1)

Remove bolts (560, IPC 49-20-00 Figure 2), nuts (570), and fuel solenoid valves
(530, 540, and 550).

(2)

Remove fittings (420 and 450), packings (430, 440, 460, and 470) and fitting (470).
Discard packings.

(3)

Remove reducers (490), union (510), and packings (500 and 520). Discard
packings.

(4)

If damaged, remove connector seals (542 and 552) from fuel solenoid valves (530,
540, and 550). Discard seals.

Fuel Filter Assembly


(1)

Remove bolts (180) and fuel filter assembly (170).

(2)

Remove bowl (190) and element (200), packing (205), and backing ring (208).
Discard packing and backing ring.

(3)

Remove union (210) and packing (220). Discard packing.

(4)

Remove elbow (230), packing (240), and nut (250). Discard packing.

Oil Filter Assembly


(1)

Remove reducer (280) and packing (290). Discard packing.

(2)

Remove bolts (310), washers (320), bracket (300), and oil filter/pressure indicator
(330).

(3)

Remove filter bowl (332), backup ring (334), packing (336), filter element (340) and
packing (350). Discard packings and backup ring.
DISASSEMBLY

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

H.

I.

J.

5.

(4)

Remove tee (360), retainer (370), packing (380), and nut (390). Discard packing.

(5)

Remove elbow (400) and packing (410). Discard packing.

Accessory Bracket and Components


(1)

Remove oil level sight plug (580) and packing (590). Discard packing.

(2)

Remove nut (610), screws (620 and 660), washers (630 and 670), spacer (640),
and accessory bracket (600).

(3)

Remove oil level sight spacer (710) and packing (590). Discard packing.

(4)

Remove support bracket (650) by removing bolt (210, IPC 49-23-00 Figure 1) and
washer (240).

(5)

Reinstall bolt (210) and washer (240) in reduction drive assembly. Torque bolt 24 to
27 pound inches (2.7 to 3.1 Nm).

Lifting Brackets
(1)

Remove bolt (790, IPC 49-20-00 Figure 2), nut (800), washer (810), clamp (770),
and sensor bushing (780).

(2)

Remove bolts (740), washers (750), and brackets (730 and 760).

Fire Control Loop Brackets and Clamps


(1)

Remove bolts (520), nuts (530), clamps (510), and sensor bushings (540).

(2)

Remove one bolt (210, IPC 49-23-00 Figure 1) and washer (605, IPC 49-20-00
Figure 1) from the reduction drive assembly and remove bracket (600).

(3)

Reinstall bolt (210, IPC 49-23-00 Figure 1) with washer (240) in reduction drive
assembly. Torque bolt 24 to 27 pound inches (2.7 to 3.1 Nm).

(4)

Remove bolt (590, IPC 49-20-00 Figure 1) and bracket (580).

(5)

Remove bolt (560), nut (570), and bracket (550).

Engine Module Disassembly


A.

Air Inlet Duct and Engine Mount


(1)

Loosen captive fasteners and remove air inlet duct (10, IPC 49-20-00 Figure 3).

(2)

Remove elbow (20), union (30), and packing (40). Discard packing.

(3)

Remove bolt (120) and engine mount (110).

DISASSEMBLY

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
B.

Ignition Cable(s)
WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR
AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.
(1)

(2)

C.

Pre-SB-49-150 configuration:
(a)

Disconnect ignition cable (130) from igniter plug (170).

(b)

Remove bolt (150), nut (160), and clamp (140). Disconnect ignition cable from
exciter (200) and remove cable.

(c)

Remove and discard washers (137), if damaged.

Post-SB-49-150 configuration:
(a)

Disconnect ignition cables (130 and 135) from igniter plugs (170A).

(b)

Remove bolts (155 and 157), nuts (160A), and clamps (145 and 147).

(c)

Disconnect ignition cables from exciter (200A) and remove cables.

(d)

Remove and discard washers (137), if damaged.

Ignition Exciter
WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR
AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.
(1)

Pre-SB-49-150 configuration:
(a)

(2)

(3)

Remove bolts (210 and 215), lockwashers (220), brackets (230 and 240), and
ignition exciter (200).

Post-SB-49-150 configuration:
(a)

Remove bolts (210A), lockwashers (220), brackets (240B), and ignition exciter
(200A).

(b)

Remove bolts (150A), clamps (148), sensor bushings (149), and nuts (160A)
from brackets (240B).

(c)

Remove bolts (210A), lockwashers (220), and exciter bracket (193).

Post-SB-49-185 configuration:
(a)

Disconnect electrical connector (P303) from ignition exciter (200A, IPC


49-20-00 Figure 3).
DISASSEMBLY

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

D.

F.

Disconnect ignition cables (130 and 135) from ignition exciter (200A).

(c)

Remove safety wire, part number MS20995C32, and bolts (196)

(d)

Remove washers (-198)

(e)

Remove the exciter mounting bracket assembly (193, 49-20-00 Figure 3)

(f)

Remove isolators (193A) from the exciter mounting bracket assembly (193).

Igniter Plugs
(1)

E.

(b)

Remove igniter plug(s) (170 or 170A) from combustor housing.

Purge Check Valve


(1)

Remove bolt (300), nut (310), check valve (280), and brackets (320). Remove loop
clamp (290).

(2)

Remove union (330), tee(s) (350), reducer (360), and packings (340 and 370).
Discard packings.

Start Fuel Nozzles


(1)

Pre and Post SB-49-124 configuration:


NOTE: On pre-SB-49-124 configuration APU, one start nozzle tube assembly
(145, IPC 49-20-00 Figure 2) and one of the start fuel nozzle holder
assemblies (380, IPC 49-20-00 Figure 3) will not be present.

(2)

(a)

Loosen start nozzle tube assemblies (140 and 145, IPC 49-20-00, Figure 2) at
tee (350, IPC 49-20-00, Figure 3).

(b)

Disconnect tube assemblies (140 and 145, IPC 49-20-00, Figure 2) from start
fuel nozzle holder assemblies (380, IPC 49-20-00, Figure 3) and remove the
start fuel nozzle holder assemblies (380).

(c)

Remove fitting (390) and nozzle (400) from each start fuel nozzle holder (380).

Post SB-49-190 configuration:


(a)

Remove Start Fuel Nozzle Holder Assembly (-380D, IPC Figure 3, 49-20-00)
or Start Fuel Nozzle Holder Assembly (-380E).

(b)

Remove tabbed washer (-382, IPC Figure 3, 49-20-00) and discard.

DISASSEMBLY

49-20-00

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(3)

(4)

G.

H.

Post SB-49-181 configuration:


(a)

Loosen tube assemblies (140B and 147, IPC 49-20-00, Figure 2) at 90-elbow
(350D, IPC 49-20-00, Figure 3).

(b)

Disconnect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) from the
two start fuel nozzle holder assemblies (380F, IPC 49-20-00, Figure 3) and
remove the start fuel nozzle assemblies.

(c)

If necessary, remove plug (385).

(d)

Remove fitting (390D) and injector (400C) from each start fuel nozzle holder
assembly (380F).

Post SB-49-191 configuration:


(a)

Loosen tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2) at tee
(350B, IPC 49-20-00, Figure 3).

(b)

Disconnect tube assemblies (140B, 145A, and 147, IPC 49-20-00, Figure 2)
from the three start fuel nozzle holder assemblies (380E, IPC 49-20-00, Figure
3) and remove the start fuel nozzle holder assemblies.

(c)

Remove fitting (390C) and injector (400B) from each start fuel nozzle holder
assembly (380E).

Fuel Manifold
(1)

Unscrew B-nuts of fuel manifold (470) from combustor housing assembly (640).

(2)

Remove bolts (480), nuts (490), washers (500), and assembled fuel manifold (470).

(3)

Remove bolts (520), nuts (530), washers (540), loop clamps (510) and cushions
(550) from fuel manifold (470).

(4)

Remove union (560) and packing (570). Discard packing.

(5)

Remove filter assembly (590) and packing (580) from fuel manifold (470).

(6)

Remove retaining ring (600) and filter (610) from filter housing (620).

Combustor Housing and Liner


WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING
EXHAUST DEPOSITS INTO OPEN WOUNDS.
(1)

Remove spacers (630) and slide containment ring (670) towards the reduction drive
assembly (820).

DISASSEMBLY

49-20-00

Page 510
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

I.

(2)

Remove V-band clamp (650), use combustor puller and remove combustor housing
(640), preformed packing (660), and containment ring (670). Discard packing.

(3)

Remove radial pins (680) or liner holder plug (680A), brackets (690) (if installed),
sensor bushings (700) (if installed), and combustor liner assembly (710).

(4)

Remove packings (720) and discard.

Turbine Assembly
(1)

Remove bolts (740), washers (750), cover (730), and gasket (760). Discard gasket.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.

J.

(2)

Cut lockwire and remove inlet screen (770).

(3)

Remove bolts (790) and washers (800). Separate turbine assembly (780) from
reduction drive assembly (820) and remove gasket (810). Discard gasket.

Modification and Identification Plates


(1)

Do not remove modification plate (830) unless damaged. If necessary, remove


plate.

(2)

Do not remove identification plate (850) unless damaged. If necessary, remove


plate.

DISASSEMBLY

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ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

DISASSEMBLY

49-20-00

Page 512
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
ASSEMBLY
1.

General
A.

This section has the procedures for assembly of the engine. Item numbers in the
procedures are the same as those in the Illustrated Parts Catalog (IPC), Document
40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS 490001,
ASSEMBLY, for general assembly information.
NOTE: Alpha-variant items can replace an item when permitted by the effect code for
that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Equipment and Materials


WARNING: OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN USING
CONSUMABLES. TO AVOID INJURY, WEAR NECESSARY PROTECTIVE
GEAR DURING HANDLING AND USE. MAKE CERTAIN CONSUMABLES AND
THEIR VAPORS ARE KEPT AWAY FROM HEAT, SPARK, AND FLAME.
A.

Equipment and materials required for assembly are listed in Figure 1001.
NOTE: Equivalent substitutes may be used for items listed.
Equipment and Material

Source (Vendor Code)

Adhesive, Type II and Primer, Type I MIL-A46146

Commercially Available

Adhesive , Type III RTV3145


(576443-3 or 22017203)

Dow Corning Corp.

Adhesive, Thermosetting 179581

Hamilton Sundstrand (55820)

Anti-seize compound 169041-1 or 51102

Hamilton Sundstrand (55820) or


Fel-Pro, Inc (73165)

Assembly fixture, ST78601

Hamilton Sundstrand (55820)

Assembly fluid, 4950515

Hamilton Sundstrand (55820)

Connector Pliers, Soft-Jawed TG69

Glenair

Combustor assembly puller, ST91125

Hamilton Sundstrand (55820)

Cover, 162400-200

Hamilton Sundstrand (55820)

Insulating Compound #4

Dow Corning Corp.

Isopropyl Alcohol, ASTM D770

Commercially available

Lint-free cloth

Commercially available

Equipment and Materials


Figure 1001 (Sheet 1 of 2)
ASSEMBLY

49-20-00

Page 1001
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Equipment and Material

Source (Vendor Code)

Lockwire MS20995C20 and MS20995C32


Or
Safety Cable 5909034-2B and -5B and
Cartridge, Ferrule 5909035-1B and -2B
Locquic primer, Grade T and Grade N MIL-S22473 (111009-1)

Commercially available

Loctite retaining compound, RC640

Loctite Corp. (05972)

Lubricating oil MIL-PRF-6081, Grade 1010

Commercially Available

Non-metallic mallet

Commercially available

Pipe Sealant (4950698)

Hamilton Sundstrand (55820)

Soft-bristled Brush

Commercially available

Tape Cat No. 27 (950455C1)

3M Corp. (76381)

Tape Silicone - Self-Bonding (MIL-I-46852C,


Type 1)

Commercially available

Zinc chromate primer Fed. Spec. TT-P-1757

Commercially available

Engine oil MIL-PRF-7808 or MIL-PRF-23699

Commercially available

Hamilton Sundstrand (55820)


Loctite Corp. (05972)

Equipment and Materials


Figure 1001 (Sheet 2 of 2)
3.

Engine Module Assembly


NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or holding
other small components in place for ease of assembly and prevention of galling. If
necessary, assembly fluid may be diluted with MIL-PRF-7808 or MIL-PRF-23699.
A.

Modification and Identification Plates


(1)

Install new modification plate as follows:


(a)

Mark new plate (830, IPC 49-20-00 Figure 3) with the information found on the
old plate.

ASSEMBLY

49-20-00

Page 1002
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE SILICONE ADHESIVE/SEALANT, DOW CORNING 3145,
CORRECTLY. KEEP THE SEALANT AWAY FROM WATER OR
MOIST AIR. THE SEALANT CAN REACT WITH WATER OR MOIST
AIR TO MAKE METHYL ALCOHOL GAS. METHYL ALCOHOL GAS
IS VERY FLAMMABLE AND CAN BE EXPLOSIVE. DO NOT
SWALLOW THE SEALANT, IT CAN MAKE METHYL ALCOHOL
THAT CAN CAUSE DEATH OR BLINDNESS. BEFORE YOU USE
THE SEALANT, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0202SE,
IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
SEALANT, PUT ON SAFETY GLASSES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(2)

(b)

Apply RTV 3145 adhesive to back of plate.

(c)

Attach plate to reduction drive assembly (820).

Install new identification plates as follows:


(a)

Mark new plate (850) with the information found on the old plates.

WARNING: USE SILICONE ADHESIVE/SEALANT, DOW CORNING 3145,


CORRECTLY. KEEP THE SEALANT AWAY FROM WATER OR
MOIST AIR. THE SEALANT CAN REACT WITH WATER OR MOIST
AIR TO MAKE METHYL ALCOHOL GAS. METHYL ALCOHOL GAS
IS VERY FLAMMABLE AND CAN BE EXPLOSIVE. DO NOT
SWALLOW THE SEALANT, IT CAN MAKE METHYL ALCOHOL
THAT CAN CAUSE DEATH OR BLINDNESS. BEFORE YOU USE
THE SEALANT, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0202SE,
IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
SEALANT, PUT ON SAFETY GLASSES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(b)

Apply RTV 3145 adhesive to back of plates.

(c)

Attach plate (850) to reduction drive assembly (820) and containment ring
(670).

ASSEMBLY

49-20-00

Page 1003
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
B.

Turbine Assembly
(1)

Place reduction drive assembly (820) with turbine mounting surface facing up.

(2)

Put gasket (810) on reduction drive assembly mating surface with rubber side
facing reduction drive.
NOTE: Do not use any form of lubricant when installing the gasket.

(3)

Install turbine assembly (780) and attach with bolts (790) and washers (800).
Tighten bolts evenly in a criss-cross pattern. Torque bolts in a criss- cross pattern
65 to 75 pound inches (7.34 to 8.47 Nm). Make sure turbine input pinion shaft
meshes with reduction drive star gear.

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.

C.

(4)

Install inlet screen (770) and attach with lockwire. Install cover 162400-200.

(5)

Put gasket (760) on turbine assembly. Install cover (730) with bolts (740) and
washers (750). Torque bolts 24 to 27 pound inches (2.7 to 3.1 Nm).

Combustor Housing Assembly Components


WARNING: PRODUCTS OF COMBUSTION MAY BE TOXIC. AVOID GETTING
EXHAUST DEPOSITS INTO OPEN WOUNDS.
(1)

Apply a light coat of assembly fluid on packings (720) and install packings into
atomizer fittings of liner (710).

CAUTION: DO NOT USE A SHARP TOOL WHEN INSERTING PACKINGS. A SMALL


STRAIGHT PUNCH OR EQUIVALENT MAY BE USED.
(2)

Insert a 0.125 inch (3.18 mm) diameter rod with a rounded, tapered end into each
atomizer fitting to make sure that packings (720) are seated in their grooves.

ASSEMBLY

49-20-00

Page 1004
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION: ANTI-SEIZE COMPOUNDS CONTAINING LEAD ARE HARMFUL TO THE
COMBUSTOR LINER AND HOUSING ASSEMBLIES. DO NOT APPLY
ANTISEIZE COMPOUNDS CONTAINING LEAD TO THESE
COMPONENTS.

D.

(3)

Apply a light coating of antiseize compound to mating surfaces of combustor


housing assembly (640) and combustor liner assembly (710).

(4)

Place combustor housing assembly vertical, exhaust flange down. Position


combustor liner in housing. Make sure of correct alignment of start fuel nozzle and
ignitor plug bosses in combustor housing and liner assemblies.

(5)

Apply a light coating of antiseize compound to threads of radial pins (680) or liner
holder plug (680A). Install radial pins (680) or liner holder plug (680A), as
appropriate for the engine configuration. If brackets (690) are required for the
configuration, install them, making sure of free entry into liner. Do not tighten radial
pins or liner holder plug at this time.

(6)

If necessary, install sensor bushings (700) into brackets (690).

Fuel Manifold Assembly


(1)

If necessary, install filter (610) into housing (620) and secure with retaining ring
(600).

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(2)

Apply a light coat of antiseize compound to fuel manifold (470) B-nuts and manifold
collars.
ASSEMBLY

49-20-00

Page 1005
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

E.

(3)

Install fuel manifold (470). Tighten B-nuts evenly in the following sequence: 3 and
9 o'clock positions, 2 and 7 o'clock positions, and 5 and 11 o'clock positions.
Torque B-nuts 55 to 65 pound inches (6.2 to 7.3 Nm).

(4)

Apply a light coat of assembly fluid to packings (570 and 580).

(5)

Put packing (580) and filter housing (590) on fuel manifold (470) and attach
manifold with bolts (480), washers (500), and nuts (490). Torque bolts 24 to 27
pound inches (2.7 to 3.1 Nm).

(6)

Put packing (570) on union (560) and install union. Torque union 25 to 35 pound
inches (2.8 to 3.9 Nm).

(7)

Put cushions (550) in loop clamps (510) and install clamps. Attach loop clamps
with bolts (520), washers (540), and nuts (530). Torque bolts 24 to 27 pound
inches (2.7 to 3.1 Nm).

Combustor Assembly
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION: ANTI-SEIZE COMPOUNDS CONTAINING LEAD ARE HARMFUL TO THE
COMBUSTOR LINER AND HOUSING ASSEMBLIES. DO NOT APPLY
ANTISEIZE COMPOUNDS CONTAINING LEAD TO THESE
COMPONENTS.
(1)

Position turbine assembly (780) vertical. Apply a light coating of antiseize


compound to mating surfaces of combustor housing assembly (640) and turbine
nozzle.

(2)

Put containment ring (670) over turbine assembly. Install packing (660) on
combustor housing assembly (640).

(3)

Apply a small amount of lubricant to inside of V-band clamp (650) and install
loosely over combustor housing assembly (640).

(4)

Install combustor puller on combustor housing assembly (640) and install turbine
assembly with combustor drain at 6 oclock position. Be sure that matchmarks on
combustor housing assembly (640) and turbine assembly are aligned.

(5)

Position V-band clamp (650) on combustor housing. Align clamp nut at 8 o'clock
position and torque clamp nut 45 to 55 pound inches (5.1 to 6.2 Nm).
ASSEMBLY

49-20-00

Page 1006
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(6)

Remove combustor assembly puller.

(7)

Slide containment ring (670) up onto turbine assembly and attach with spacers
(630). Torque spacers 97 to 107 pound inches (11 to 12 Nm).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(8)

Tighten radial pins (680) or liner holder plug (680A). Torque pins or plug 140 to
150 pound inches (16 to 20 Nm) and secure with lockwire or safety cable and
ferrule.

WARNING:

(9)

USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

Apply a light coating of antiseize compound to threads of elbow (450).

(10) Install nut (460) and elbow (450). Torque nut 90 to 100 pound inches (10.2 to
11.3 Nm).
F.

Start Fuel Nozzles


(1)

Pre SB-49-150 configuration:


(a)

For start fuel nozzle holder assembly (380), assemble fitting (390) and nozzle
(400) as follows:

ASSEMBLY

49-20-00

Page 1007
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE LOCQUIC PRIMER GRADE T, CORRECTLY. THE
PRIMER IS FLAMMABLE AND A MILD POISON. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE
YOU USE THE PRIMER, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0135SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE PRIMER, PUT ON CHEMICALSPLASH GOGGLES AND SOLVENT-RESISTANT GLOVES
(BUTYL RUBBER). MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE PRIMER FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT
1

Apply Grade T primer to three threads closest to nozzle (410) hex. Allow
3 to 4 minutes for primer to set.

WARNING: USE GRADE T PRIMER AND LOCTITE RC640 SEALANT,


CORRECTLY. THE COMPOUND IS FLAMMMABLE. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY.
BEFORE YOU USE THE COMPOUND, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY.
READ THE DETAILED WARNING, W0067SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE
COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND
RUBBER GLOVES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT
2

(2)

Apply Loctite RC640 to the same area on nozzle. Install nozzle into fitting
(390). Torque nozzle 55 to 60 pound inches
(6.2 to 6.7 Nm).

Post SB-49-150 configuration:


(a)

For start fuel nozzle holder assembly (380A, 380B, 380C), assemble fitting
(390 or 390A) and nozzle (400A) or fitting (390B) and nozzle (400B) as
follows:
1

Install nozzle (400A) into fitting (390 or 390A) or (400B) into fitting (390B)
Torque nozzle 55 to 60 pound inches (6.2 to 6.7 Nm).

Stake nozzle (400A or 400B) and fitting (390, 390A or 390B) three places
as shown in Figure 1002.
NOTE:

Staking is limited to a maximum of six places.

ASSEMBLY

49-20-00

Page 1008
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
CAUTION: DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER THAN THE
THREADS OF THE START NOZZLE HOLDER AND COMBUSTOR
HOUSING. ANTI-SEIZE LUBRICANT WILL CONTAMINATE THE START
NOZZLE HOLDER.
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(3)

Apply a light coat of antiseize lubricant to the threads of the start nozzle holder
assembly fitting (380) and the mating threads of the combustor housing.

CAUTION: DO NOT INTERCHANGE START FUEL NOZZLE HOLDERS. ONLY USE A


START FUEL NOZZLE HOLDER WITH A NOTCHED HEX HEAD IN A
THREE-START FUEL NOZZLE CONFIGURATION. IN A ONE OR TWOSTART FUEL NOZZLE CONFIGURATION ONLY USE A START FUEL
NOZZLE HOLDER WITH NO NOTCH IN THE HEX HEAD. INSTALLATION
OF AN INCORRECT START FUEL NOZZLE HOLDER MAY RESULT IN AN
OVER TEMPERATURE OR HUNG START CONDITION.
(4)

For pre-SB-49-124 configuration, install assembled holder assembly (380 or 380A)


in combustor housing assembly (640). Torque holder 50 to 55 pound inches (5.6 to
6.2 Nm).

(5)

For post-SB-49-124 configuration, install two assembled holder assemblies (380B)


in combustor housing assembly (640). Torque holder 50 to 55 pound inches (5.6 to
6.2 Nm).

(6)

For post-SB-49-152 configuration, install three assembled holder assemblies


(380C) in combustor housing assembly (640). Torque holder 50 to 55 pound
inches (5.6 to 6.2 Nm).

ASSEMBLY

49-20-00

Page 1009
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Staking Of Start Fuel Nozzle Assembly


Figure 1002
(7)

Post SB-49-190 configuration:


(a)

Install tabbed washer (-382, IPC Figure 3, 49-20-00).

(b)

Install Start Fuel Nozzle Holder Assembly (-380D, IPC Figure 3, 49-20-00) or
Start Fuel Nozzle Holder Assembly (-380E).

ASSEMBLY

49-20-00

Page 1010
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(8)

Post SB-49-181 configuration:


WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE
YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ
THE DETAILED WARNING, W0200SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE ANTI-SEIZE
COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OILRESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER


THAN THE THREADS OF THE START FUEL NOZZLE HOLDER
AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL
CONTAMINATE THE START FUEL NOZZLE HOLDER.

(a)

Apply a light coat of anti-seize lubricant (51102) to the threads of the two start
fuel nozzle holder assemblies (380F) and the mating threads of the combustor
housing.

(b)

Install fitting (390D) and injector (400C) to each start fuel nozzle holder
assembly (380F).

(c)

Install the two start fuel nozzle holder assemblies (380F) in combustor
housing. Torque fittings to 50 to 55 pound inches (5.6 to 6.2 Nm).

(d)

If removed, install plug (385).

ASSEMBLY

49-20-00

Page 1011
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(9)

Post SB-49-191 configuration:


WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE
YOU USE THE ANTI-SEIZE COMPOUND, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ
THE DETAILED WARNING, W0200SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE ANTI-SEIZE
COMPOUND, PUT ON CHEMICAL-SPLASH GOGGLES AND OILRESISTANT GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

G.

DO NOT APPLY ANTI-SEIZE LUBRICANT TO AREAS OTHER


THAN THE THREADS OF THE START FUEL NOZZLE HOLDER
AND COMBUSTOR HOUSING. ANTI-SEIZE LUBRICANT WILL
CONTAMINATE THE START FUEL NOZZLE HOLDER.

(a)

Apply a light coat of anti-seize lubricant (51102) to the threads of the three
start fuel nozzle holder assemblies (380E) and the mating threads of the
combustor housing.

(b)

Install fitting (390C) and injector (400B) to each start fuel nozzle holder
assembly (380E).

(c)

Install the three start fuel nozzle holder assemblies (380E) in combustor
housing. Torque fittings to 50 to 55 pound inches (5.6 to 6.2 Nm).

Purge Check Valve


(1)

Apply light coat of assembly fluid on packings (370 and 340).

(2)

Put packing (370) on reducer (360) and install reducer into check valve (280).
Torque reducer 40 to 55 pound inches (4.5 to 6.2 Nm).

(3)

Put packing (340) on union (330) and install union into check valve (280). Torque
union 135 to 150 pound inches (15.2 to 17 Nm).

(4)

Install tee (350) into reducer (360). Torque tee 40 to 55 pound inches (4.5 to 6.2
Nm).

(5)

For post SB-49-124 configuration, install tee (350B or 350C) onto tee (350).
Torque tee 40 to 55 pound inches (4.5 to 6.2 Nm).

(6)

Put loop clamp (290) on check valve (280). Install clamp, check valve, and
brackets (320) with bolt (300) and nut (310). Torque bolt 24 to 27 pound inches
(2.7 to 3.1 Nm).

ASSEMBLY

49-20-00

Page 1012
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
H.

I.

Combustor Drain Check Valve


(1)

Install reducer (270) in combustor housing assembly (640). Torque reducer 75 to


100 pound inches (8.5 to 11.3 Nm).

(2)

Apply light coat of assembly fluid on packing (260).

(3)

Put packing (260) on check valve (250) and install valve. Torque valve 75 to 100
pound inches (8.5 to 11.3 Nm).

Ignition Exciter
(1)

Pre-SB-49-150 configuration:
(a)

(2)

(3)

Install ignition exciter (200) and brackets (230 and 240) with bolts (210 and
215) and lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1
Nm).

Post-SB-49-150 configuration:
(a)

Install exciter bracket (193) with bolts (210A) and lockwashers (220). Torque
bolts 24 to 27 pound inches (2.7 to 3.1Nm).

(b)

Install ignition exciter (200A) and brackets (240B) with bolts (210A) and
lockwashers (220). Torque bolts 24 to 27 pound inches (2.7 to 3.1Nm).

(c)

Install clamps (148) and sensor bushings (149) with bolts (150A) and nuts
(160A). Torque bolts 24 to 27 pound inches (2.7 to 3.1Nm).

Post-SB-49-185 configuration:
(a)

Install isolators (199, IPC 49-20-00, Figure 3) on exciter mounting bracket


assembly (-193A).

(b)

Install exciter mounting bracket assembly (-193A).

(c)

Install washers (-198).

(d)

Install bolts (-196).

(e)

Torque bolts (-196) to 55 to 70 pound inches (6.2 to 7.9 N.m).

ASSEMBLY

49-20-00

Page 1013
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO
BECOME A PROJECTILE. THE FORCE CAN CAUSE THE
LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF
YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT
BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR
INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDESHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO
YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE
HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY
TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED
MEDICAL PERSON REMOVES THE LOCKWIRE.
(4)
J.

Secure bolts (-196) with safety cable and ferrule cartridge or safety wire.

Igniter Plugs
(1)

Pre-SB-49-150 configuration:

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO TIP


OF IGNITER PLUG OR DAMAGE TO THE PLUG WILL OCCUR.

(a)

Apply a light coat of antiseize compound to both threaded ends of ignitor plug
(170).

(b)

Install igniter plug (170) in combustor housing. Torque plug 108 to 132 pound
inches (12 to 15 Nm).

ASSEMBLY

49-20-00

Page 1014
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(2)

Post-SB-49-150 configuration:

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

K.

ENSURE ANTI-SEIZE COMPOUND DOES NOT MIGRATE TO TIP


OF IGNITER PLUG OR DAMAGE TO THE PLUG WILL OCCUR.

(a)

Apply a light coat of antiseize compound to both threaded ends of ignitor plugs
(170A).

(b)

Install igniter plugs (170A) in combustor housing. Torque plugs 108 to 132
pound inches (12 to 15 Nm).

Ignition Cables
(1)

(2)

Pre-SB-49-150 configuration:
(a)

If removed, install washers (137).

(b)

Install bracket (180) with bolt (190). Torque bolt 55 to 70 pound inches (6.2 to
7.9 Nm).

(c)

Connect ignition cable (130) to igniter plug (170). Torque B-nut 40 to 60


pound inches (4.5 to 6.8 Nm) and secure with lockwire or safety cable and
ferrule.

(d)

Put clamp (140) around cable and attach to bracket (180) with bolt (150) and
nut (160). Torque nut 24 to 27 pound inches (2.7 to 3.1 Nm).

(e)

Connect ignition cable (130) to exciter (200). Torque B-nut 40 to 60 pound


inches (4.5 to 6.8 Nm)

Post-SB-49-150 configuration:
(a)

If removed, install washers (137).

ASSEMBLY

49-20-00

Page 1015
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO
BECOME A PROJECTILE. THE FORCE CAN CAUSE THE
LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF
YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT
BLINDNESS IN THE EFFECTED EYE. BEFORE YOU REMOVE OR
INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDESHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO
YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE
HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY
TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED
MEDICAL PERSON REMOVES THE LOCKWIRE.
(b)

Connect ignition cables (130 and 135) to igniter plugs (170A). Torque B-nuts
40 to 60 pound inches (4.5 to 6.8 Nm) and secure with lockwire or safety
cable and ferrule.

(c)

Put clamps (145) around cables at two locations. Attach clamps with bolts
(155) and nuts (160A). Torque nuts 24 to 27 pound inches (2.7 to 3.1 Nm).
NOTE: The center two clamps (145) and clamp (147) are not installed at this
time.

(d)
L.

4.

Connect ignition cables (130 and 135) to exciter (200A). Torque B-nut 40 to
60 pound inches (4.5 to 6.8 Nm).

Engine Mount and Air Inlet Duct


(1)

Install engine mount (110) with bolt (120). Torque bolt 100 to 130 pound inches
(11.3 to 14.6 Nm).

(2)

Install elbow (20) and torque 135 to 150 pound inches (15.2 to 17 Nm).

(3)

Put packing (40) on union (30) and install in elbow (20). Torque union 135 to 150
pound inches (15.2 to 17 Nm).

(4)

Remove cover 162400-200 and install air inlet duct (10) with captive fasteners.

Engine Assembly
A.

Lifting Brackets
(1)

Install brackets (730 and 760, IPC 49-20-00 Figure 2) with bolts (740) and washers
(750). Torque bolts 55 to 70 pound inches (6.2 to 7.9 Nm).

(2)

Install sensor bushing (780) and clamp (770) with bolt (790), nut (800), and washer
(810). Torque bolt 24 to 27 pound inches (2.7 to 3.1 Nm).

ASSEMBLY

49-20-00

Page 1016
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
B.

High Oil Temperature Switch


WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(1)

C.

Apply a light coat of assembly fluid on packing (700) and install packing on high oil
temperature switch (690) and install switch. Torque switch 55 to 75 pound inches
(6.2 to 8.5 Nm) and secure with lockwire or safety cable and ferrule.

Speed Pickup
(1)

Insert a 7/16 Allen wrench in the starter gear of the accessory drive assembly. Use
the wrench to manually turn the gear until one tooth of the starter gear is in line with
the center of the speed pickup mounting hole.

WARNING: USE ANAEROBIC RETAINING COMPOUND, MIL-R-46082, CORRECTLY.


THE COMPOUND IS FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET
THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER
OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ
THE DETAILED WARNING, W0067SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY
GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT
YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(2)

Apply MIL-S-22473N Primer Grade "N" to threads of magnetic pickup (680) and
allow to dry for 5 minutes. Apply Pipe Sealant with Teflon (PST 592) to threads of
magnetic pickup.

(3)

Rotate Accessory Drive Gear until top of one of the Gear Teeth is in line with center
of Magnetic Pick-up mounting hole.

(4)

Install Magnetic Pick-up (680) by hand into Accessory Drive until contact with Gear
is made.

(5)

Using key in electrical connector as a reference, back off magnetic pickup (680)
one quarter (1/4) turn (0.14 inch or 0.356 mm) and tighten Jam Nut into housing.
Torque Jam Nut to 75-100 pound inches (8.5 to 11.3 N.m).
NOTE: Gap between pole of speed pickup and gear tooth is 0.012 to 0.016 inch
(0.305 to 0.406 mm).
ASSEMBLY

49-20-00

Page 1017
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(6)

D.

Use the Allen wrench to manually turn the starter gear through a complete
revolution. Make sure speed pickup does not touch the gear. Secure jam nut with
lockwire or safety cable and ferrule.

Oil Level Sight Plug and Accessory Bracket


(1)

Install bracket (650) with screw (210, IPC 49-23-00 Figure 1) and washer (240).
Torque screw 20 to 22 pound inches (2.2 to 2.5 Nm).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(2)

Apply a light coat of assembly fluid on packing (590, IPC 49-20-00 Figure 2) and
install packing on spacer (710). Install spacer and torque 150 to 200 pound inches
(16.9 to 22.6 Nm). Secure spacer to oil cap (74, IPC 49-23-00 Figure 1) with
lockwire or safety cable and ferrule.

(3)

Install accessory bracket (600, IPC 49-20-00 Figure 2) with screws (620 and 660),
washers (630 and 670), and spacer (640). Torque screws 20 to 22 pound inches
(2.2 to 2.5 Nm).

ASSEMBLY

49-20-00

Page 1018
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.

E.

F.

(4)

Install nut (610) and torque 95 to 115 pound inches (10.7 to 13.0 Nm). Secure nut
to bracket (600) with lockwire or safety cable and ferrule.

(5)

Apply a light coat of assembly fluid on packing (590) and install packing on oil
level sight plug (580) and install plug. Torque plug 65 to 85 pound inches (7.3 to
9.6 Nm) and secure to nut (610) with lockwire or safety cable and ferrule.

Solenoid Valves
(1)

Put solenoid valve (550) on bolts (560) so that flow arrow will face forward when
installed on the engine.

(2)

Put solenoid valve (540) on bolts (560) so that flow arrow will face aft when
installed on the engine.

(3)

Put solenoid valve (530) on bolts (560) so that flow arrow will face aft when
installed on the engine.

(4)

Install assembled valves in bracket (600) and attach with nuts (570). Torque bolts
25 to 30 pound inches (2.8 to 3.3 Nm).

(5)

Apply a light coat of assembly fluid on packing (520) and install packing on union
(510) and install union. Torque union 135 to 150 pound inches (15.1 to 16.9 Nm).

(6)

Apply a light coat of assembly fluid on packings (500) and install packings on
reducers (490) and install reducers. Torque reducers 135 to 150 pound inches
(15.1 to 16.9 Nm).

(7)

Apply a light coat of assembly fluid on packings (430 and 460) and install packings
on fittings (420 and 450). Put fittings (420 and 450) into fitting (480) and install
packings (440 and 470). Install assembled fitting (480) into solenoid valves (540
and 550). Torque fittings 135 to 150 pound inches (15 to 17 Nm).

Oil Filter/Pressure Indicator


(1)

Apply a light coat of assembly fluid on packing (410) and install packing on elbow
(400) and install elbow in oil filter/pressure indicator (330). Torque elbow 60 to 80
pound inches (6.7 to 9.0 Nm).

(2)

Install retainer (370), nut (390), and packing (380) on tee (360). Install tee and
torque 75 to 100 pound inches (8.5 to 11.3 Nm).
ASSEMBLY

49-20-00

Page 1019
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

G.

(3)

Install oil filter/indicator (330) and bracket (300) and attach with bolts (310) and
washers (320). Torque bolts 108 to 120 pound inches (12.2 to 13.5 Nm).

(4)

Apply a light coat of assembly fluid on packing (336) and install packing (336) and
backup ring (334) in filter bowl (332).

(5)

Apply a light coat of assembly fluid on packing (350) and install packing in filter
element (340) and install element in filter bowl (332). Install filter bowl to oil
filter/pressure indicator (330).

Low Oil Pressure Switch


(1)

Apply a light coat of assembly fluid on packings (290 and 270) and install packing
(290) into reducer (280) and packing (270) on low oil pressure switch (260).

WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY


WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(2)
H.

I.

Install reducer and switch on tee (360). Torque reducer and switch 135 to 150
pound inches (15.2 to 17 Nm) and secure with lockwire or safety cable and ferrule.

Fuel Filter Assembly


(1)

Apply a light coat of assembly fluid on packing (240) and install nut (250) and
packing on elbow (230) and install elbow in fuel filter assembly (170). Torque
elbow 95 to 105 pound inches (10.7 to 11.8 Nm).

(2)

Apply a light coat of assembly fluid on packing (220) and install packing on union
(210) and install union in fuel filter assembly (170). Torque union 95 to 105 pound
inches (10.7 to 11.8 Nm).

(3)

Put backing ring (208), packing (205), and element (200) in bowl (190) and install
bowl. Torque bowl 40 to 60 pound inches (4.5 to 6.7 Nm).

(4)

Install assembled fuel filter (170) with bolts (180). Torque bolts 24 to 27 pound
inches (2.7 to 3.1 Nm).

Fire Control Loop Brackets and Clamps


(1)

Remove one bolt (210, IPC 49-23-00 Figure 1) and washer (240) from the
reduction drive assembly. Discard washer.

(2)

Install bracket (600, IPC 49-20-00 Figure 1) and washer (605) with the bolt
previously removed in step (1). Torque bolt 24 to 27 pound inches (2.7 to 3.1 Nm).

ASSEMBLY

49-20-00

Page 1020
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

J.

(3)

Install bracket (580) with bolt (590). Torque bolt 190 to 230 pound inches (21.5 to
25 Nm).

(4)

Install bracket (550) with bolt (560) and nut (570). Torque bolt 24 to 27 pound
inches (2.7 to 3.1 Nm).

(5)

Install clamps (510) and sensor bushings (540) and with bolts (520) and nuts (530).
Torque bolts 24 to 27 pound inches (2.7 to 3.1 Nm).

Fuel Control Assembly


(1)

Apply a light coat of assembly fluid on packing (500). Install packing on union
(490) and install union. Torque union 180 to 200 pound inches (20.3 to 22.6 Nm).
Apply a light coat of assembly fluid on packing (470). Put nut (480) and packing
(470) on elbow (460) and install elbow. Torque elbow 95 to 105 pound inches
(10.7 to 11.8 Nm).

(2)

Apply a light coat of assembly fluid on packing (450). Install packing on reducer
(440) and install reducer. Torque reducer 40 to 55 pound inches (4.5 to 6.2 Nm).

(3)

Apply a light coat of assembly fluid on packing (430). Install packing on union
(420) and install union. Torque union 40 to 55 pound inches (4.5 to 6.2 Nm)

(4)

Apply a light coat of assembly fluid on packing (410). Install packing on plug (400)
and install plug. Torque plug 40 to 55 pound inches (4.5 to 6.2 Nm).

(5)

Apply a light coat of assembly fluid on packing (390). Put packing on reducer (380)
and install reducer. Torque reducer 25 to 35 pound inches (2.8 to 3.9 Nm).

(6)

Apply a light coat of assembly fluid on packing (370). Install packing on union
(360) and install union. Torque union 40 to 55 pound inches (4.5 to 6.2 Nm).

(7)

Mate fuel pump (320) to acceleration control (290) without installing packings. The
faces should mate with no clearance and with no force required. If force is
necessary, separate and inspect splines. Remove all foreign material and burrs.

(8)

Separate fuel pump from acceleration control.

(9)

Apply a light coat of assembly fluid on packings (330, 340, and 350). Install
packings on acceleration control (290).

(10) Install fuel pump (320) on acceleration control (290) with bolts (300) and washers
(310). Torque bolts 24 to 27 pound inches (2.7 to 3.1 Nm).
(11) Install gasket (280) and fuel control assembly (250) with bolts (260) and washers
(270). Torque bolts 55 to 70 pound inches (6.2 to 7.9 Nm).
K.

Tube Assemblies
NOTE: The minimum clearance between tubes and between tubes and adjacent
components must be 0.080 inch (2.03 mm).
(1)

Connect tube assemblies to the following components:

ASSEMBLY

49-20-00

Page 1021
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(a)

Connect tube assembly (130) to union (420) and to start valve bolt fitting (420,
IPC 49-20-00 Figure 2). Torque B-nuts 135 to 150 pound inches (15.1 to 16.9
Nm).

(b)

Connect tube assembly (240, IPC 49-20-00 Figure 1) to reducer (440) and to
reducer (490, IPC 49-20-00 Figure 2). Torque B-nuts 50 to 60 pound inches
(5.6 to 6.8 Nm).

(c)

Connect tube assembly (140, IPC 49-20-00 Figure 1) to reducer (380) and to
union (510, IPC 49-20-00 Figure 2). Torque B-nuts 135 to 150 pound inches
(15.1 to 16.9 Nm).

(d)

Connect tube assembly (120, IPC 49-20-00 Figure 1) to union (490) and to
elbow (230, IPC 49-20-00 Figure 2). Torque B-nuts 135 to 150 pound inches
(15.1 to 16.9 Nm).

(e)

Connect tube assembly (180, IPC 49-20-00 Figure 1) to union (360) and to
elbow (20, IPC 49-20-00 Figure 3). Torque B-nuts 135 to 150 pound inches
(15.1 to 16.9 Nm).

(f)

Connect tube assembly (10, IPC 49-20-00 Figure 2) to union (60) and to tee
(360). Torque B-nuts 270 to 300 pound inches (30.5 to 33.9 Nm).

(g)

Connect tube assembly (20) to elbow (400) and to reducer (50, IPC 49-23-00
Figure 1). Torque B-nuts 95 to 105 pound inches (10.7 to 11.8 Nm).

(h)

Connect tube assembly (80, IPC 49-20-00 Figure 2) to union (60) and to
reducer (50, IPC 49-23-00 Figure 1). Torque B-nuts 95 to 105 pound inches
(10.7 to 11.8 Nm).

(i)

Connect tube assembly (90, IPC 49-20-00 Figure 2) to reducer (490) and to
union (560, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85 pound inches (8.5
to 9.6 Nm).

(j)

Connect tube assembly (130, IPC 49-20-00 Figure 2) to reducer (490) and to
tee (350, IPC 49-20-00 Figure 3). Torque B-nuts 75 to 85 pound inches (8.5 to
9.6 Nm).

(k)

Connect start fuel nozzle tube assemblies:


1

Pre and Post SB-49-124 configuration:


a

Connect tube assemblies (140 and 145, IPC 49-20-00 Figure 2)


to tee (350, IPC 49-20-00 Figure 3) and to start fuel nozzle holder
assemblies (380). Torque B-nuts 40 to 50 pound inches (4.5 to
5.6 Nm).

Post SB-49-152 configuration:


a

Connect tube assemblies (140, 145 and 147, IPC 49-20-00


Figure 2) to tee (350, IPC 49-20-00 Figure 3), fitting (352) and to
start fuel nozzle holder assemblies (380C). Torque B-nuts 40 to 50
pound inches (4.5 to 5.6 Nm).

ASSEMBLY

49-20-00

Page 1022
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
3

Post SB-49-181 configuration:


a

Post SB-49-191 configuration:


a

(l)

Connect tube assemblies (140B and 147, IPC 49-20-00, Figure 2) to


90-elbow (350D, IPC 49-20-00, Figure 3) and to the two start fuel
nozzle holder assemblies (380F). Torque B-nuts to 40 to 50 pound
inches (4.5 to 5.6 Nm).

Connect tube assemblies (140B, 145A, and 147, IPC 49-20-00,


Figure 2) to tee (350B, IPC 49-20-00, Figure 3) and to the three start
fuel nozzle holder assemblies (380E). Torque B-nuts to 40 to 50
pound inches (4.5 to 5.6 Nm).

Connect tube assembly (150, IPC 49-20-00 Figure 2) to union (330, IPC 4920-00 Figure 3). Torque B-nut 135 to 150 pound inches (15.1 to 16.9 Nm).

(2)

Install loop clamps (30, 100, and 160, IPC 49-20-00 Figure 2) on tube assemblies
(90, 130, 145, and 150) with bolts (110) and nuts (120). Torque bolts 24 to 27
pound inches (2.7 to 3.1 Nm).

(3)

Install loop clamp (147A, IPC 49-20-00 Figure 3) on tube assembly (147, IPC 4920-00 Figure 2) with bolt (157A, IPC 49-20-00 Figure 3) and nut (160). Torque
bolts 24 to 27 pound inches (2.7 to 3.1 Nm).

(4)

Install loop clamps (30, 70 and 510) on tube assemblies (10, 20, and 80) with bolts
(40, 520, and 525, ) and nuts (50 and 530). Torque bolts 24 to 27 pound inches
(2.7 to 3.1 Nm).

(5)

Install loop clamps (150, 190, and 220, IPC 49-20-00 Figure 1) on tube assemblies
(140 and 180) with bolts (160 and 200) and nuts (170 and 210). Torque bolts 24 to
27 pound inches (2.7 to 3.1 Nm). Install loop clamps (50 and 220) on tube
assemblies (120 and 130) with bolt (70) and nut (90). Torque bolt 24 to 27 pound
inches (2.7 to 3.1 Nm).

(6)

For post SB-49-150 configuration, install loop clamps (145, IPC 49-20-00 Figure 3)
(middle set of clamps) on ignition cables (130 and 135). Install loop clamp (147) on
tube assembly (90, IPC 49-20-00 Figure 1). Attach all three loop clamps with bolt
(157, IPC 49-20-00 Figure 3) and nut (160A). Torque bolt 24 to 27 pound inches
(2.7 to 3.1 Nm).

(7)

For Post SB-49-181 configuration, install loop clamp (100C, IPC 49-20-00, Figure
2) with bolt (110B) and washer (115) to tube assembly (147).

(8)

Post SB-49-191 configuration:


(a)

Install loop clamp (100C) with bolt (110B) and washer (115) to tube assembly
(147).

(b)

Install loop clamps (161 and 162) with bolt (163) and nut (164) to tube
assemblies (145A and 140B).

ASSEMBLY

49-20-00

Page 1023
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
L.

Engine Harness Assembly (Pre SB 49-180)


(1)

Wrap harness and tubes, as necessary, with tape to be sure of a tight fit in clamps
and to obtain minimum gap between fuel lines.
NOTE: Harness and tubes shall fit tightly in clamps. Verify installation for fit.
NOTE: The minimum clearance between tubes, and between tubes and adjacent
components must be 0.080 inch (2.03 mm).

(2)

Install engine harness assembly (10) with clamps (45, 50, 60, and 80), bolts (70),
and nuts (90). Torque nuts 24 to 27 pound inches (2.7 to 3.1 Nm).

WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO BECOME
A PROJECTILE. THE FORCE CAN CAUSE THE LOCKWIRE TO
DAMAGE OR GO THROUGH THE SURFACE OF YOUR EYES. THIS
DAMAGE COULD CAUSE PERMANENT BLINDNESS IN THE EFFECTED
EYE. BEFORE YOU REMOVE OR INSTALL THE LOCKWIRE, PUT ON
SAFETY GLASSES WITH SIDE-SHIELDS OR SAFETY GOGGLES. IF
THE LOCKWIRE GETS INTO YOUR EYE, GET IMMEDIATE MEDICAL
AID. IF THE LOCKWIRE HAS GONE THROUGH THE SURFACE OF THE
EYE, DO NOT TRY TO REMOVE THE LOCKWIRE. MAKE SURE THAT A
TRAINED MEDICAL PERSON REMOVES THE LOCKWIRE.
(3)

Apply antiseize compound to the threads of thermocouple (112) and attach


thermocouple to combustor housing. Torque thermocouple 40 to 60 pound inches
(4.5 to 6.8 Nm) and secure with lockwire or safety cable and ferrule.

(4)

Install hourmeter (100A) and event counter (110) with screws (20), washers (40),
and nuts (30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 Nm).

ASSEMBLY

49-20-00

Page 1024
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL
ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN
THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(5)

Clean all harness and component connectors using a soft-bristled brush and cotton
wipes moistened with isopropyl alcohol to remove oil, grease, and contamination
from the pins and inside of the electrical connectors. Allow connectors to air dry.

(6)

If required, install connector seals (262, 542, 552, and 685, IPC 49-20-00 Figure 2)
in the connectors of low oil pressure switch (260), fuel solenoid valves (530, 540
and 550), and magnetic pickup (680). Press the seals over the connector pins to
the base of the pins.

(7)

Connect harness assembly electrical connectors to the following components:


NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(a) Connect electrical connector (P302) to magnetic pickup (680, IPC 49-20-00
Figure 2).
(b)

Connect electrical connector (P303) of harness assembly (10, IPC 49-20-00


Figure 1) to ignition exciter (200, IPC 49-20-00 Figure 3) as follows:
Apply self-bonding tape onto the harness, connector, and connector
backshell. (Refer to Figure 1003).

NOTE:

When installing self-bonding tape, the overlapping and stretching


instructions must be followed to correctly install tape.

Apply tape onto harness, connector, and connector backshell by


wrapping the tape, with the blue stripe on the outside, in a clockwise
rotation onto ZONE A.

Start at the connector end near the strain relief screws.

Stretch the tape as it is being applied so that the width of the tape
decreases by approximately 25-percent.

Begin by wrapping two layers of 100-percent coverage for a tight seal.

Continue wrapping the tape with a 50-percent overlap through ZONE A


and onto ZONE B.

Finish wrapping onto ZONE B with two layers of 100-percent coverage.


ASSEMBLY

49-20-00

Page 1025
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
g

Allow tape to cure according to manufacturers instructions.


NOTE:

The tape cures to an airworthy condition in approximately one


hour. It fully cures in 48 hours at an ambient temperature of 70
to 80 F (21 to 27 C).

Wrapping Harness and Connectors with Self-Bonding Tape


Figure 1003
(c)

Connect electrical connector (P306) to main fuel solenoid valve (530, IPC
49-20-00 Figure 2).

(d)

Connect electrical connector (P305) to start fuel solenoid valve (540).

(e)

Connect electrical connector (P307) to maximum fuel solenoid valve (550).

(f)

Connect electrical connector (P311) to high oil temperature switch (690).

(g)

Connect electrical connector (P304) to low oil pressure switch (260).

(h)

Connect electrical connector (P308) to the anti-surge valve (40, IPC 49-00-00
Figure 1).

NOTE: Electrical connector (P308) is connected to the anti-surge valve and (P309)
is connected to the bleed air valve during finally assembly of the APU.

ASSEMBLY

49-20-00

Page 1026
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(i)

Connect electrical connector (P309) of harness assembly (10, IPC 49-20-00


Figure 1) to bleed air valve (100, IPC 49-00-00 Figure 1) as follows:
WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.
ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A
MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL,
GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING,
W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH
GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT

M.

Clean the harness, connector, and connector backshell with isopropyl


alcohol and a lint free cloth.

Apply self-bonding tape onto the harness, connector, and connector


backshell following the procedures oulined in step 4.L.(5)(c)2. (Refer to
Figure 1003).

Installation of Engine Harness Assembly (Post SB 49-180)


(1)

Wrap harness and tubes, as necessary, with tape to be sure of a tight fit in clamps
and to obtain minimum gap between fuel lines.
NOTE: Harness and tubes shall fit tightly in clamps. Verify installation for fit.
NOTE: The minimum clearance between tubes, and between tubes and adjacent
components must be 0.080 inch (2.03 mm).

(2)

Install engine harness assembly (10) with clamps (45, 50, 60, and 80), bolts (70),
and nuts (90). Torque nuts 24 to 27 pound inches (2.7 to 3.1 Nm).

(3)

Route the engine harness assembly as shown in Figures 1004 and 1005.

(4)

Install the clamps (quantity 2) (190), bolt (200) removed in step 3 (b) above with
new nut (210), at the location and positions shown. Torque bolt 20 to 22 pound
inches (2.2 to 2.4 N.m).

(5)

The clamp holding the engine harness assembly wires was positioned downward
and is now positioned upward.

(6)

Reinstall the sensor bushing (230), clamp (220), clamp (190) and bolt removed in
step 3 (b) above as originally located, along with a new nut (210) and the clamp
(65), removed in step 2 (a) above. Torque bolt to 20 to 22 pound inches (2.2 to 2.4
N.m).

ASSEMBLY

49-20-00

Page 1027
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT
HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(7)

Apply antiseize compound to the threads of thermocouple (112) and attach


thermocouple (112) to combustor housing. Torque thermocouple 40 to 50 pound
inches (4.5 to 5.6 Nm) and secure with lockwire.

(8)

Install hourmeter/event counter (111) with screws (20), washers (40), and nuts
(30). Torque nuts 24 to 27 pound inches (2.7 to 3.1 Nm).

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL


ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(9)

Clean all harness and component connectors using a soft-bristled brush and cotton
wipes moistened with isopropyl alcohol to remove oil, grease, and contamination
from the pins and inside of the electrical connectors. Allow connectors to air dry.

(10) If required, install connector seals (262, 542, 552, and 685, IPC 49-20-00 Figure 2)
in the connectors of low oil pressure switch (260), fuel solenoid valves (530, 540
and 550), and magnetic pickup (680). Press the seals over the connector pins to
the base of the pins.
(11) Connect engine harness and component connectors as follows:
NOTE: When possible, connectors should be tightened with a pair of soft-jawed
connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(a)

Connect electrical connector (P302) to magnetic pickup (680, IPC 49-20-00


Figure 2).

(b)

Connect electrical connector (P303) of harness assembly (10, IPC 49-20-00


Figure 1) to ignition exciter (200, IPC 49-20-00 Figure 3).

ASSEMBLY

49-20-00

Page 1028
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(c)

Connect electrical connector (P306) to main fuel solenoid valve (530, IPC
49-20-00 Figure 2).

(d)

Connect electrical connector (P305) to start fuel solenoid valve (540).

(e)

Connect electrical connector (P307) to maximum fuel solenoid valve (550).

(f)

Connect electrical connector (P311) to high oil temperature switch (690).

(g)

Connect electrical connector (P304) to low oil pressure switch (260).

(h)

Connect electrical connector (P308) to anti-surge valve (40, IPC 49-00-00


Figure 1).

(i)

Connect electrical connector (P309) to bleed valve (100).

(12) Use a lint free cloth and remove any visible insulating compound.

ASSEMBLY

49-20-00

Page 1029
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Top View - Engine Control Harness Installation (Post SB 49-180)


Figure 1004
ASSEMBLY

49-20-00

Page 1030
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Side View - Engine Control Harness Installation (Post SB 49-180)


Figure 1005

49-20-00

ASSEMBLY
Page 1031
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

ASSEMBLY

49-20-00

Page 1032
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
STORAGE
1.

General
A.

This section details the requirements necessary to prepare the engine for on-wing and
off-wing storage. It also provides depreservation procedures for the engine from storage.
Refer to ASTM D-3951-82 for general requirements of industrial packaging. Item
numbers in the procedures are the same as those in the Illustrated Parts Catalog (IPC),
Document 40C11-3. Refer to Standard Practices Manual, Document HSPS 490001, for
general information.
NOTE: Alpha-variant items can replace an item when permitted by the effect code for
that item. For example, procedures that apply to item (10) also apply to alphavariant items (-10A, -10B, and -10C).

2.

Equipment and Materials


NOTE: Refer to Standard Practices Manual, Document HSPS 490001, ASSEMBLY for a list
of protective covers used on the engine for shipment or storage.
A.

Preservation, storage and depreservation equipment and materials are listed in Figure
1201.
(1)

Equivalent substitutes may be used for items listed.


Material

Source (Vendor Code)

VCI - 121

Cortec Corporation (44695)

MIL-I-2210C (1 pak per each cubic foot of bag


volume)

Cortec Corporation (44695)

Barrier bag (optional), 165151-1 or 165151-2

Hamilton Sundstrand (55820)

Barrier material MIL-B-131

Commercially Available

Bracket assembly, 164174-100 and 165166-102 Hamilton Sundstrand (55820)


Cleaning Compound (Simple Green, 13002) or
equivalent alkaline cleaner with a pH of 8 - 9

Sunshine Makers (1Z575)

Connector Pliers, Soft-Jawed TG6

Glenair

Container 1 gallon (3.8 liter)

Commercially Available

Desiccant (88 units), MIL-D-3464

Commercially Available

Desiccant Cor - Pak 1-MUL

Commercially Available

Heat seal machine

Commercially Available

Humidity indicator card

Commercially Available

Label

Commercially Available

Lint-free cloth

Commercially Available

Lubricating oil MIL-PRF-6081, Grade 1010

Commercially Available

Masking tape PPP-T-42

Commercially Available

Preservation and Storage Equipment and Materials


Figure 1201 (Sheet 1 of 2)
STORAGE

49-20-00

Page 1201
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Material

Source (Vendor Code)

Protective caps and plugs, MIL-C-5501

Commercially Available

Shipping container
Tag

Hamilton Sundstrand (55820)


Commercially Available

Tube assembly

Commercially Available

Vacuum machine (air)

Commercially Available

Vacuum tube

Commercially Available

Water vapor proof barrier material, MIL-B-131

Commercially Available

Solvent resistant gloves

Commercially Available

Engine exhaust cover, 4951923-1

Hamilton Sundstrand (55820)

Air inlet duct cover, 4951924

Hamilton Sundstrand (55820)

Preservation and Storage Equipment and Materials


Figure 1201 (Sheet 2 of 2)
3.

Preservation and Storage - OFF WING


A.

Fuel System Preservation


(1)

Connect a tube assembly to fuel inlet at union (210, IPC 49-20-00 Figure 2).

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.
(2)

Connect a gravity-feed oil supply to tube assembly.

WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.
(3)

Disconnect electrical connectors (P305 and P306) from solenoid valves (530
and 540).

(4)

Apply 28 Vdc to solenoid valve electrical connectors (J305 and J306).

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.


USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
(5)

Place container under combustor drain check valve (250, IPC 49-20-00 Figure 3) to
catch spilled fuel.
STORAGE

49-20-00

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(6)

Turn turbine rotor clockwise looking at turbine wheel from exhaust of APU. Rotor
will turn freely if starter-generator is not on gearbox.
NOTE: If there is a starter-generator on APU, turn turbine rotor counter clockwise
from gearbox accessory pad using a wrench.

(7)

Disconnect 28 Vdc from solenoid valves and install connectors (P305 and P306).

NOTE: When possible, connectors should be tightened with a pair of soft-jawed


connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(8)

Disconnect gravity-feed oil supply from tube assembly and remove tube assembly
from fuel inlet at union (210, IPC 49-20-00 Figure 2).

(9)

Install protective caps and plugs in all open ports and fittings.

(10) Attach a tag warning that fuel system has been preserved.
B.

General Preservation
NOTE: The following procedure will allow the engine to be stored for a maximum of 90
days.
(1)

Install air inlet cover on air inlet duct (10, IPC 49-20-00 Figure 3).

(2)

Clean external surfaces of APU with a lint-free cloth dampened with Simple Green.

(3)

Wipe off residual Simple Green with a dry, lint-free cloth.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. WEAR RUBBER GLOVES AND SAFETY GOGGLES.

C.

(4)

Remove magnetic drain plug (10, IPC 49-23-00 Figure 1) as an assembly and allow
lubricating oil to drain from reduction drive assembly into container.

(5)

Install magnetic drain plug (10) in reduction drive assembly and torque 180 to 200
pound inches (20.3 to 22.6 Nm).

(6)

Attach a tag to engine warning that oil system has been drained.

(7)

Cover all open connections, ports, and openings including anti-surge valve, bleed
air valve, and exhaust outlet with barrier material and masking tape.

Preparation for Storage or Shipment


NOTE: The following procedure will allow the engine to be stored for a maximum of 12
months.
(1)

Cover all open connections, ports, and openings, including start bypass valve, bleed
air valve, and exhaust outlet with barrier material and masking tape.

(2)

Hoist APU from assembly stand.


STORAGE

49-20-00

Page 1203
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(3)

Attach bracket assemblies to APU.


NOTE: When possible; bracket assemblies, support assembly, attaching
hardware, and other items supplied with APU shipping container, shall be
reused to ship or store identical APU model.

(4)

Position barrier material around APU and shipping frames to form a barrier bag.

(5)

Hoist APU onto shipping container skid.

(6)

Cut small holes in barrier bag to allow bolts to protrude.

(7)

Lift barrier bag and place gaskets on each protruding bolt. Apply adhesive around
bolts and gaskets.

(8)

Place gaskets on bolts from inside of barrier bag.

(9)

Secure bracket assemblies to shipping container skid with nuts and washers.

(10) Install humidity indicator card on inside of barrier bag so as to coincide with shipping
container window.
(11) Using masking tape, secure cellular cushioning material around APU to prevent
protruding corners and edges from cutting barrier bag.
(12) Place fresh desiccants in barrier bags as required.
(13) Position top of barrier bag over APU and align seam edges. Apply staples around
edge of barrier bag to keep seams even.
(14) Seal barrier bag seam around APU, except for one opening small enough to permit
installation of vacuum tube, using heat seal machine.
NOTE: When using heat seal machine, use care to prevent wrinkles in barrier bag
seams and fabric pulling which will cause leaks.
(15) Place vacuum tube in small opening of barrier bag and attach air vacuum machine
to tube.
(16) Operate air vacuum machine to remove air from barrier bag until bag clings snugly
to APU.
(17) Remove air vacuum machine and tube from barrier bag and immediately seal the
small opening.
(18) Apply masking tape around barrier bag.
(19) Attach APU records and applicable documents to barrier bag.
(20) Position shipping container cover so that window in cover coincides with humidity
indicator card attached to barrier bag. Secure cover to skid with bolts.
STORAGE

49-20-00

Page 1204
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(21) Attach applicable records, documents, and markings to exterior of shipping
container.
4.

Preservation and Storage - ON WING


A.

Fuel System Preservation


(1)

Disconnect the fuel inlet tube from the fuel inlet on the fuel control assembly.

(2)

Connect a tube assembly to fuel inlet.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES
(3)

Connect a gravity-feed supply of lubricating oil, MIL-PFR-6081, Grade 1010 to the


tube assembly.

WARNING: BE SURE ELECTRICAL POWER IS OFF BEFORE WORKING ON OR


AROUND ELECTRICAL COMPONENTS. BE SURE ALL COMPONENTS
CAPABLE OF RETAINING A CHARGE HAVE BEEN GROUNDED.
(4)

Disconnect electrical connectors from solenoid valve.

(5)

Apply 28 Vdc to solenoid valve electrical connectors.

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.


USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER.
(6)

Place container under combustor fuel tube assembly drain hose to catch spilled
fuel.

(7)

Turn turbine rotor counterclockwise until fuel-free oil flows from drain hose.

(8)

Disconnect 28 Vdc from solenoid valve and install connectors.

NOTE: When possible, connectors should be tightened with a pair of soft-jawed


connector pliers. Tighten until the soft-jawed pliers slip on the connector.
(9)

Disconnect the gravity-feed oil supply from the tube assembly and remove the tube
assembly from the fuel inlet on the fuel control assembly.

(10) Install protective caps and plugs in all open ports and fittings.
B.

Drain all oil from the gearbox assembly

C.

Continue preserving the APU engine assembly for on wing storage as follows

STORAGE

49-20-00

Page 1205
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(1)

Attach a tag to the oil filler cap with the information that follows:
(a)

(2)

WARNING - No Oil in Gearbox.

Attach a tag to the fuel supply hose with the information that follows:
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN
AND EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES
(a)

The fuel system of this engine has been preserved with lubricating oil MILPRF-6081, Grade 1010.

(b)

This preservation is valid until MM/DD/YY


NOTE: Date should be 90 days from beginning of preservation of the APU
engine assembly.

(3)
5.

Install protective covers on the APU engine assembly exhaust, air inlet duct and
bleed control valve duct.

Depreservation of the APU Engine Assembly from Storage


A.

Remove the APU engine assembly from storage.

B.

Prepare the APU engine assembly for test.

C.

Remove the protective covers from the APU engine assembly exhaust, air inlet duct,
bleed air valve, and anti-surge valve.

D.

Remove any tags from the fuel supply hose.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES.
PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
E.

Drain all oil from the fuel system.

F.

Connect the fuel supply to the inlet on the fuel control assembly and open the fuel supply
valve.

G.

Remove any tags from the gearbox assembly oil filler cap.

H.

Fill the gearbox assembly with oil.

I.

Operate the APU engine assembly for a minimum of 3 minutes.

J.

Shut down the APU engine assembly.

K.

Do a visual inspection of the APU engine assembly for fuel leaks or for oil leaks at the
output pads, seals, fittings and connections.

STORAGE

49-20-00

Page 1206
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
TESTING
1.

Introduction
A.

2.

This section details the test procedures required to evaluate the engine operational
efficiency after repair. Refer to 49-00-00, FAULT ISOLATION for corrective actions if the
engine fails during test.

Test Cell Requirements


A.

Equipment and Instrumentation


(1)

Test cell equipment and instrumentation are listed in Figure 1301.


NOTE: Equivalent substitutes may be used for listed items.

B.

Fuel and Lubrication Oil Criteria


(1)

Fuel used during test shall conform to MIL-T-5624 (Grade JP-4 or JP-5 or JP-8) or
ASTM D-1655 (Type A or A-1).

(2)

Lubrication oil used shall conform to MIL-PRF-23699 specification or the


commercial equivalent.

(3)

Fuel boost pressure shall be 5 to 40 psig (34.47 to 275.79 kPa).

(4)

The fuel flowrate (pph) shall be measured with a calibrated flowmeter.

(5)

The following procedures are required when using a turbine meter flowmeter:
NOTE: Direct flow measurement maybe accomplished using a Micromotion massflowmeter, therefore, specific gravity and temperature measurements are
not required.

(6)

(a)

The actual fuel specific gravity (S.G. ACT) at the time of the acceptance tests,
for use in determining the actual fuel flowrate, will be determined indirectly by
measuring the actual fuel temperature (TFUEL ACT.) at the time of test, along
with the type-fuel specific gravity curve.

(b)

The S.G. ACT. and TFUEL ACT. shall be recorded on the test data sheet.

Oil level change shall be measured and recorded during the initial and final
acceptance tests, using the following procedures:
NOTE:

Evidence of oil consumption after test shall be cause for rejection.

(a)

The reduction drive assembly oil sump shall be filled with room-temperature
oil, to the full mark on the oil level sight glass, prior to starting tests.

(b)

Mark oil level on sight glass with a grease pencil before starting tests.
TESTING

49-20-00

Page 1301
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Name

Number

Manufacturer
(Vendor Code)

Use

Clock

Commercially
Available

Test timing

Stop watch

Commercially
Available

Recording starting
cycle time

Starting motor

Model MT50

Delco-Remy (16764)

Test setup

Water dynamometer

101-080

Kahn (33980)

Test setup

Dynamometer Load
0-100 pounds (0-45 Kg)

3397

Lebow (60012)

Measure shaft load

Digital frequency counter


(0 to 5 kHz)

TACTROL-3

Airpax (82227)

Magnetic speed
pickup

Torque arm length

Kahn

Test setup

Drain line (2)

Commercially
Available

Test setup

Filler cap thermometer

Modified
117851-1

Hamilton Sundstrand
(99167)

Test setup

Accelerometer

2221F

Endevco (97896)

Vibration
measurement

Vibration meter

6634M10

Endevco

Vibration
measurement

Vibration filter (@ rotor


frequency)

AB193-1046

TTE (07766)

Band pass filter

Pressure gauge
0 to 100 psig
(0 to 690 kPa) (quantity 4)

118

Viatran (27385)

Measure oil
pressure

Thermometer
32 to 450F (0 to 232C)
.125 x 6, Type K,
ungrounded, single element

M1212CSU6

C-Temp (6X013)

Measure oil
temperature

Exhaust gas temperature


test probe 0 to 2,000F
(0 to 1,093C)

M2512CSE6

C-Temp

Measure exhaust
temperature

Test Cell Equipment and Instrumentation


Figure 1301 (Sheet 1 of 2)
TESTING

49-20-00

Page 1302
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Name

Number

Manufacturer
(Vendor Code)

Use

Hamilton Sundstrand
(99167)

Measure compressor
inlet temperature

Orifice plate 2.5924 in.


(65.85 mm) diameter

Commercially Available

Measure bleed air flow

Variable/Controllable Air
Load Valve

Commercially Available

Regulates (Controls)
bleed air flow

Air inlet temperature


probe 0 to 150F (0 to
113C)

MT574

Electronic sequence unit

4501974

Hamilton Sundstrand

Test setup

Bleed air shutoff valve,


slave

4950699

Hamilton Sundstrand

Test setup

Barometer pressure
gauge 28 to 32 in. Hg (95
to 108 kPa)

125-K094

Robinson/Halpern

Measure barometric
pressure

Flowmeter 0 to 200 pph

D12

Micro Motion (63985)

Mass flowmeter

Bleed air static pressure 0


to 100 psig (0 to 689 kPa)

118

Viatran (27385)

Measure pressure

Compressor discharge
pressure 0 to 100 psig (0
to 689 kPa)

118

Viatran

Measure compressor
discharge pressure

Test probe 0 to 500F (0


to 360C)

M2512CSE6

C-Temp (6X013)

Measure bleed air


temperature

Pressure gauge 0 to 200


inch H2O

123

Viatran

Measure bleed air


delta pressure

Exhaust duct pressure


123
Viatran
Measure exhaust duct
0 to -10 inch H2O
pressure
NOTE: All instrumentation and equipment used in APU testing shall be calibrated to provide a
static accuracy within 3 percent of the values obtained when the APU is operating at
maximum output
Test Cell Equipment and Instrumentation
Figure 1301 (Sheet 2 of 2)

TESTING

49-20-00

Page 1303
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

C.

(c)

The change in oil level, as indicated on the oil level sight glass, is to be
measured with a scale (inches) immediately after shutdown of the last run.

(d)

Record oil temperature at the time of measurement.

Facilities
(1)

A fuel supply system incorporating a 10 micron filter and boost pump capable of
delivering 250 pph (237 l/hr) at 5 to 40 psig (34.5 to 276 kPa).

(2)

Fuel source capable of maintaining test procedure for a minimum of three hours
(675 US gallons, 565 UK gallons, 2,700 liters approximately).

(3)

Exhaust ducting system shall not recirculate APU exhaust gases into the
compressor inlet.

(4)

Orifice plate 2.5924 inch (65.85 mm) diameter installed in bleed duct to measure air
bleed from bleed valve.

(5)

Refer to Figure 1302 for additional control panel facilities required.


NOTE: A position switch may be used to simulate open/closed position of a load
valve.

TESTING

49-20-00

Page 1304
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Test Interconnection Diagram (Pre SB-49-180)


Figure 1302

TESTING

49-20-00

Page 1305/1306
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Test Interconnection Diagram (Post SB-49-180)


Figure 1303
TESTING

49-20-00

Page 1307/1308
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
D.

Glossary
(1)

The following terms and abbreviations are used in the test procedures:

P1

Measured engine inlet total pressure (psia[kPa]). The


test cell barometric pressure (P0) may be used for this
measurement

(P1, psia[kPa])/14.7

T1

Measured engine inlet temperature

EGTmeas

Measured exhaust gas temperature using a 6 point rake.


The EGT shall be measured in the engine exhaust duct.
NOTE: The Pexh and EGT measurements shall not be
taken in the same locations.

SHPmeas

Shaft power measured at the reduction drive output shaft


(dyno horsepower)

SHPmeas/

Shaft power measured at the reduction drive output shaft


corrected for barometric pressure

RPMmeas

Rotor speed measured at the set-point

Pexh =
(Pexh,meas)/

Measured exhaust gas static pressure, inches


(millimetres) of water (gage pressure relative to P0),
corrected to standard ambient pressure. This pressure
shall be measured at the engine exhaust using static
pressure taps. This pressure will be recorded as a
negative number if the static pressure is less than P1 or
recorded as a positive number if the static pressure is
greater than P1

WBmeas

Measured bleed flow (pounds [kilograms] per minute)

WBmeas/

Measured bleed flow corrected for barometric pressure

Pcdmeas

Measured compressor discharge pressure (psia [kPa])

Pcdmeas/

Measured compressor discharge pressure corrected for


barometric pressure

SHPset

Dyno load set-point as defined in acceptance test

EGTset

T1 biased EGT set-point as defined in acceptance test

RPMset

Rotor speed set-point as defined in acceptance test

P0

Test cell barometric pressure

TESTING

49-20-00

Page 1309
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
3.

Preparation for Test


A.

Installation of Engine in Test Cell


(1)

Install engine in test cell mounting attachment points.

(2)

Connect fuel supply line to fuel inlet filter.

(3)

Install fuel pump seal and turbine drain lines.

(4)

Connect exhaust ducting to combustor housing.

(5)

Connect the bleed air line to the engine bleed air port.

(6)

Connect start by-pass air duct to anti-surge valve.

(7)

Connect the electrical test harness to connector (P4).

(8)

Remove oil filler cap. Fill reduction drive assembly with oil to full mark on sight
glass. Note oil level before starting test. Install filler cap modified 117851-1
complete with oil temperature thermometer and oil pressure gauge line.

(9)

Make sure exhaust gas temperature thermocouple test probes ST91172 are
connected.

(10) Install compressor air inlet temperature probe MT574.


(11) Remove lifting eye from air inlet housing and install vibration pickup adapter bolt,
vibration pickup, and cable. Check all equipment for security. Remove all loose
articles from the test area. Ensure that the air inlet screen and exhaust outlet are
free from obstructions.
(12) Make sure that the test cell downstream bleed valve is fully closed.
B.

Slave Devices
(1)

The engine shall be operated with ESU (4501974 Series) or electronically


equivalent unit.

(2)

A slave bleed air valve, 4950699, must be electrically wired into the ESU control
system to run the engine.
NOTE: A position switch may be used to simulate the valve position.

(3)

The bleed air valve indication must be in the fully closed position to start the engine.
It must be in the full open position to close the start-bypass valve during engine
operation.

(4)

The hourmeter and event counter should be installed and operating for both the
initial and final tests.
TESTING

49-20-00

Page 1310
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(5)
4.

The bleed flow limiting venturi, 4502368, shall not be used during the tests.

Test Operation
A.

B.

Starting Power
(1)

The engine shall be started using a Delco-Remy electric starting motor, model
MT50 (or equivalent), driving through the water dynamometer.

(2)

A 24 to 28 Vdc power source shall be used to supply electrical power to the starter
motor.

Conditions Requiring Shutdown of Engine


CAUTION: SHOULD ANY OF THE FOLLOWING CONDITIONS OCCUR DURING
TESTING, THE ENGINE SHALL BE SHUT DOWN. THE TEST SHALL NOT
CONTINUE UNTIL THE CONDITION IS CORRECTED.
(1)

Evidence of oil, fuel, or air leaks, including evidence of fuel control drain leakage in
excess of 4 drops per minute.

(2)

Abnormal noise, smoking, or exhaust flaming.

(3)

Vibration in excess of 0.2 mil (peak-to-peak) at rotor frequency.

(4)

Oil pressure below 18 psig (124.1 kPa) or greater than 100 psig (689.5 kPa) for
more than 30 seconds at 100 percent speed.

(5)

Oil sump temperature exceeding 275F (135C).

(6)

Surge during operation or acceleration.

(7)

Exhaust gas temperature exceeding 1,624F (885C) during a start.

(8)

Exhaust gas temperature exceeding 1,323F (718C) during steady state operation.

(9)

Governor droop greater than 4 percent from no load to full bleed load or from no
load to 60 shaft horsepower.

(10) Speed oscillation in excess of +0.5 percent at steady state conditions.


C.

Engine Shut Down Procedure


(1)

Set the control panel OFF-RUN-START switch to OFF.

(2)

Set test cell fuel boost pump off.

(3)

Allow the engine to run down and stop.

(4)

Close the main fuel supply valve to the engine.


TESTING

49-20-00

Page 1311
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
D.
5.

Record test data in accordance with Figure 1304.

Preliminary Check and Safety Test


A.

B.

Preliminary Check
(1)

Verify for fully closed bleed valves.

(2)

Inspect installation of engine in test cell and security of all connections to the
engine.

Safety Test
(1)

Electrically disable connectors P305 start and P306 main fuel solenoid valves and
P303 ignition exciter.

(2)

Open the engine main fuel supply valve.

(3)

Crank the engine for approximately 30 seconds. Record maximum engine oil
pressure down-stream of the oil filter.

(4)

Set OFF-RUN-START switch OFF.

(5)

Set fuel boost pump to ON.

(6)

Purge the fuel system of air (refer to 49-00-00, SERVICING).

TESTING

49-20-00

Page 1312
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Test Step

Test Data
5.B

7.C

7.D

7.E

7.F

7.G

Operating time (hours) via


hourmeter
Start cycles via event counter
Barometric pressure (in. Hg)
Start time (initiation of cranking to
rated speed) (seconds)
Maximum exhaust gas
temperature during start (F) (C)
Magnetic pickup (Hz)
Engine speed and/or accessory
drive pad speed (rpm)
Torque arm length (Ft) (m)
Dynamometer load (lbs) (kg)
Calculated output horsepower
(hp) (corrected for barometric
pressure)
Fuel flow (pph)
Fuel boost pressure (psig) (kPa)
Fuel temperature at flowmeter
(F) (C)*
Fuel specific gravity (S.G. ACT.)*
Ambient temperature (F) (C)
Exhaust duct pressure (in. H2O)
Compressor inlet temperature
(F) (C)
*Required when using turbine flow meter.
Test Data Sheet
Figure 1304 (Sheet 1 of 2)

TESTING

49-20-00

Page 1313
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Test Step

Test Data
5.B

7.C

7.D

7.E

7F

7G

Exhaust gas temperature,


performance average
Exhaust gas temperature, EGT
probe (F) (C)
Bleed air temperature (F) (C)
Bleed air static pressure (psia)
(kPa)
Bleed air delta P (in. H2O)
Bleed air flow (ppm)
Compressor discharge pressure
(psig) (kPa)
Oil sump temperature (F) (C)
Oil pump discharge pressure (psig)
(kPa)
Oil level change (in.) (mm)
Engine vibration (mils) (Pk to Pk)
Gearbox pressure (measured at
the filler cap with a 1/8 in. orifice at
the vent) (in. H2O)
Engine rundown time (seconds)
Fuel type

Test Data Sheet


Figure 1304 (Sheet 2 of 2)

(7)

Connect electrical connectors (P305 and P306) to start and main fuel solenoid
valves.

(8)

Connect electrical connector (P303) to ignition exciter.

TESTING

49-20-00

Page 1314
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
CAUTION: IF A FALSE START OCCURS, ALLOW AT LEAST ONE MINUTE FOR
RESIDUAL FUEL TO DRAIN THROUGH COMBUSTOR FUEL DRAIN
CHECK VALVE BEFORE ATTEMPTING TO RESTART.
(9)

Set OFF-RUN-START switch momentarily to START and release to RUN.

(10) Allow the engine to accelerate to 50 percent rpm, (2,400 Hz), then set OFF-RUNSTART switch to OFF. Note operation of all instruments. Check engine for oil
and/or fuel leaks.
(11) Start the engine. Record the time for acceleration from initiation of cranking to
stabilized, ready to load engine running.
CAUTION: ACCELERATION ADJUSTMENT IS CRITICAL. THE INITIAL NEEDLE
POSITION MUST BE CAREFULLY NOTED BEFORE ANY ADJUSTMENT
IS MADE. MAKE ADJUSTMENTS IN INCREMENTS OF 1/8-TURN.
CHECK ACCELERATION RATE AFTER EACH ADJUSTMENT.
(12) Adjust acceleration needle of the acceleration control unit to increase fuel flow if a
smooth acceleration is not achieved, or to decrease fuel flow if a hot start occurs
during acceleration. Torque paint acceleration needle on completion.
(13) Operate the APU at governed speed.
(14) Adjust acceleration control unit governor rpm adjuster to control engine speed at
101.5% - 102.5%N (4872 - 4920 Hz) with no shaft load and bleed valve closed.
(15) Run the engine at governed speed, no load, for 5 minutes. Check for proper
operation of hourmeter and event counter. Inspect for oil, air, or fuel leaks. Record
data.
(16) Ensure that the combustor drain check valve is fully closed.
6.

System Malfunction Checks


A.

System Check
NOTE: System malfunction check must be made with the strut switch in the ground
position.
(1)

System malfunction check shall be conducted in accordance with the following


procedures:
(a)

Operate engine with no load at governed speed. Adjust, if necessary, to 101.5


- 102.5 +1/-0 percent rpm (4,872 to 4,920 Hz).

(b)

Check the engine low oil pressure (high oil temperature) circuit by removing
the connector (P304) from the oil pressure switch. This shall cause the unit to
shut down. Check BITE indications on ESU to be sure of correct operation.

TESTING

49-20-00

Page 1315
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
7.

Performance Tests
A.

Test Data
(1)

B.

Record test data in accordance with Figure 1303.

Test Steps
CAUTION: DURING TEST STEPS, A RUMBLING NOISE MAY BE HEARD. RUMBLE
IS AN ACCEPTABLE ENGINE CONDITION. RUMBLE MUST NOT BE
CONFUSED WITH SURGE. SURGE IS VERY APPARENT AS A LOUD,
SHARP REPORT OR BANG EITHER SINGLY OR IN RAPID
SUCCESSION. SURGE IS HARMFUL AND WILL CAUSE APU DAMAGE IF
ALLOWED TO CONTINUE.
NOTE: During test, the engine shall be loaded by a water dynamometer. The air bleed
shall be measured from the bleed port by an orifice or nozzle conforming to
current ASME standards.
NOTE: No degradation is allowed for Run No. 2, EGT. All other performance runs are
allowed 1.5% degradation.

C.

Test Step 1 - BLEED FLOW ONLY


(1)

Operate for a minimum of 5 minutes on-point at:


Speed = 60,023 to 62,181 rpm (97.5 - 101.0%N) (Speed drop as result of loading)
EGTset = 1,300 10F (704 6C)
SHPset/ = <4 hp (no load dyno drag power)

(2)

Use the measured bleed flow WBmeas/ and correct back to set-point for EGT
variation, shaft power variation, speed variation and exhaust pressure loss by the
following equation:
(WBmeas/)corr = (WBmeas/) - (0.0571 x [EGTmeas - 1,300F{704C}]) + (0.189 x
SHPmeas/) - 89.0 x [RPMmeas/61,565-1.]) + (0.15 x Pexh/)

(3)

Use the measured Pcdmeas/ and correct back to set-point for EGT variation, shaft
power variation, speed variation and exhaust pressure loss by the following
equation:
(Pcdmeas/)corr = (Pcdmeas/) + (0.0064 x [EGTmeas - 1,300F{ 704C}]) - (0.075 x
SHPmeas/) -(98.0 x [RPMmeas/61,565-1.]) - (0.050 x Pexh/)
NOTE: The governed speed shall not droop more than 4 percent from no load to
full bleed load.

TESTING

49-20-00

Page 1316
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
NOTE: The EGT engine probe may be overridden to prevent an unwarranted
ESU shutdown while operating at 1,300F (704C) EGT facility probes
performance rake average. While operating in this mode, a safety backup
must be active to shut down the engine if the EGT facility probes rake
average exceeds 1,323 F (717C).
(4)

The acceptance criteria are:


Allowable degradation on bleed flow: 1.5%, incorporated as a .985 factor in
equation:
(WBmeas/)corr [105.6 - 0.4067 x T1 + 0.0004997 x (T12)] x .985
(Pcdmeas/)corr [58.55 - 0.0857 xT1 + 0.0001118 x (T12)] x .985

D.

Test Step 2 - SHP ONLY:


(1)

Operate for a minimum of 5 minutes on-point at:


RPMset = 60,949 to 63,104 rpm
SHPset/ = 60.0 2.0 hp
Anti-surge valve and bleed valve fully closed.

(2)

The adjustment for EGTmeas may be made with the following equation:
EGTcorr = EGTmeas - (2.75 x [SHPmeas/ - 60]) + (232.0 x [RPMmeas/61565-1]) - (2.3 x
Pexh) - (0.187 x [T1 - 59])

(3)

The acceptance criteria is:


Allowable degradation on EGT Rate average: No degradation is allowed.
EGTcorr =[675.7 + 1.93 x T1 + 0.004674 x (T12)]

E.

Test Step 3 - BLEED FLOW WITH LOAD:


(1)

Operate for a minimum of 7 minutes on-point at:


RPMset = 60,949 to 62,181 rpm
SHPset/ = 13.0 2.0 HP
EGTset = 0.0035 x T1 2 + 2.0274 x T1 + 932.0 10 F (500 C)

(2)

Measure and obtain valves for EGTmeas, SHPmeas, Pexh,meas, and RPMmeas at the set
point.
NOTE: Adjustments for deviation from the set point must be made before
comparison to the acceptance criteria for test step 3. WBmeas, Pcdmeas must
be adjusted as follows:

TESTING

49-20-00

Page 1317
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(3)

Adjust EGTmeas if different from EGTset as follows:


EGT = EGTset - EGTmeas
WBEGT = EGT x (-0.0003 x T1 + 1.034)
PcdEGT = EGT x (0.0001 x T1 - 0.021)

(4)

Adjust SHP meas if different from SHP set as follows:


SHP = (SHPset - SHPmeas) /
WBshp = SHP x (0.0002 x T1 - 0.2923)
Pcdshp = SHP x (-0.0002 x T1 + 0.091)

(5)

Adjust exhaust static pressure if different from zero as follows:


Pexh = Pexh, meas/
WBPexh = Pexh x 0.21
PcdPexh = Pexh x -0.05

(6)

Adjust for rotor speed as follows:


RPM = 100.0 x ([61565.0 - RPMmeas] / 61565.0)
WBRPM = RPM x 0.50
PcdRPM = RPM x (7.0E-5 x T1 2 - 0.0163 x T1 + 2.024)

(7)

Adjust the measured values of WB and Pcd by the amounts found in steps E.1
through E.6 as follows:
WBtest = WBmeas/ + WBEGT + WBshp + WBPexh + WBRPM
Pcdtest = Pcdmeas/ + Pcdegt + PcdSHP + PcdPexh +PcdRPM

(8)

Compare the values found in step (7) to the acceptance values found in the
following:
WBATP = 0.0004 x T12 - 0.2108 x T1 + 76.70
PcdATP = 0.0002 x T12 - 0.1401 x T1 + 66.58

(9)

The engine performance is acceptable if:


Allowable degradation on bleed flow and PCD: 1.5%, incorporated as a .985 factor
in equation:
WBtest [WBATP] x .985
and
Pcdtest [PcdATP] x .985

TESTING

49-20-00

Page 1318
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
F.

G.

Test Step 4 - ANTI-SURGE AND BLEED VALVE ELECTRICAL CIRCUIT FUNCTION:


(1)

Operate APU at:


Speed = 62,488 to 63,104 rpm
SHP < 4 HP (no-load)
Anti-surge valve and bleed valve fully closed

(2)

Open the anti-surge valve and allow engine to stabilize. Make sure that the antisurge valve exit temperature increased by more than 300F (149C).

(3)

Open APU bleed valve. Verify APU bleed valve is open.

Test Step 5 - RUN DOWN TIME.


(1)

H.

Shut down engine and allow it to come to a complete stop. Record run down time.

Test Step 6 LEAN BLOW OUT CHECK (Fast Acting Bleed Valve Closure):
(1)

Install flow limiting venturi, (ref Document 40C11-3, 49-00-00, Figure 1, Item 70),
between the APU bleed elbow, (10) and the APU bleed valve (90).

(2)

Start engine and operate at governed speed. Verify engine speed is 102.0 +/0.5%. Adjust governor as needed to achieve this speed range.

(3)

Let engine stabilize at this condition.

(4)

Open facility and engine bleed valves and allow engine to achieve full bleed load as
limited by the venturi.
Bleed Flow: Above 62 PPM
EGT Rake Average: Above 1000F (538C)

(5)

Let engine stabilize at full bleed load. Print or record datalog to record stabilized
condition.

(6)

Close the fast-acting valve. Record APU condition (running, popping, flame out,
etc.). Flame out or continuous popping is caused for rejection. A single popping
noise after each valve closure is acceptable, as long as the APU does not flame out.
NOTE: Prior to re-opening fast-acting valve, close other bleed valves. This will
prevent sudden loading (and possible overtemperature shutdown) of APU.

(7)

Repeat this valve closure sequence three times.

(8)

After completion of three sequences, shutdown APU. Let engine cool. Remove the
flow limiting venturi.

TESTING

49-20-00

Page 1319
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
8.

Preservation Run
Not Required.

9.

Inspections Following Performance Tests


A.

Turbine Assembly
(1)

B.

Visually inspect for oil or gas leaks, loose hardware, etc. The turbine engine shall
be disassembled only in the event of unit failing test parameters or if unusual
characteristics are noticed during test.

Reduction Drive Assembly


(1)

Inspect the reduction drive assembly as follows:


(a)

Visually inspect the reduction drive assembly for oil leaks at the output pad
seals and at all fittings and connections.

(b)

The reduction drive assembly shall be disassembled for detail inspection if


metal chips are found on the magnetic drain plug, if abnormal contaminants
are found in the oil filter element, or if unusual noise, vibration, or other
conditions are observed during or after the Test Runs (refer to 49-23-00,
DISASSEMBLY).

10. Final Inspections


A.

Turbine Assembly
(1)

B.

Accessory Drive Assembly


(1)

C.

Visually inspect the turbine assembly for fuel, oil, or gas leaks, and loose hardware.

Visually inspect the accessory drive assembly for oil leaks at the output pad seals.

Engine
(1)

If engine is not required for service, perform preservation, packaging, and storage
procedures in accordance with STORAGE.

TESTING

49-20-00

Page 1320
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
1.

Introduction
A.

2.

This section lists the special tools, fixtures, and equipment required to perform the
maintenance procedures listed throughout this manual.

Special Tools, Fixtures, and Equipment


A.

Special tools, fixtures, and equipment required for user level maintenance are listed in
Figure 901.
NOTE: Equivalent substitutes may be used for items listed.

3.

Test Tools, Fixtures, and Equipment


A.

Tools, fixtures, and equipment required for testing the APU are listed in Figure 902.
NOTE: Equivalent substitutes may be used for items listed.

4.

Life-Limited Tools, Fixtures, and Equipment


A.

Stretch tool ST78693 is a life-limited tool. Maintain a record of each load (torque) cycle
when using ST78693 stretch tooling. Remove and replace ST78693-02 stretch rod on or
before 400 load cycles.

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

49-20-00

Page 1501
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Tool
Number

Description

Manufacturer (Vendor Code)

AID-00359

Retaining ring checking tool

Hamilton Sundstrand (99167)

AID-00494

Compressor tool

Hamilton Sundstrand

AID-00592

Alignment tool

Hamilton Sundstrand

AID-00653

Depth gauge guide tool

Hamilton Sundstrand

FXT04840

Holding fixture

Hamilton Sundstrand

FXT04966

Holding fixture

Hamilton Sundstrand

ST60714

Inspection fixture

Hamilton Sundstrand

ST60880

Wire gauge set

Hamilton Sundstrand

ST61189

Bridge gauge

Hamilton Sundstrand

ST61189-06

Plug

Hamilton Sundstrand

ST61195

Bridge gauge

Hamilton Sundstrand

ST70107

Bearing puller

Hamilton Sundstrand

ST70109

Bearing puller

Hamilton Sundstrand

ST70110

Driver

Hamilton Sundstrand

ST70137

Rotor fixture

Hamilton Sundstrand

ST70170

Carrier puller

Hamilton Sundstrand

ST70230

Spanner wrench

Hamilton Sundstrand

ST70282

Driver

Hamilton Sundstrand

ST70284

Retaining ring removal/Installation tool

Hamilton Sundstrand

ST70394

Assembly fixture

Hamilton Sundstrand

ST70414

Driver

Hamilton Sundstrand

ST70414-05

Driver

Hamilton Sundstrand

ST70414-08

Driver

Hamilton Sundstrand

ST70416

Socket wrench

Hamilton Sundstrand

ST70461

Ring spacer

Hamilton Sundstrand

ST70468

Bearing seal aligning tool

Hamilton Sundstrand

ST70942

Pinion puller

Hamilton Sundstrand

ST71232

Dry ice containment ring

Hamilton Sundstrand

ST71240

Driver

Hamilton Sundstrand
Special Tools, Fixtures, and Equipment
Figure 1501 (Sheet 1 of 3)
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

49-20-00

Page 1502
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Tool
Number

Description

Manufacturer (Vendor Code)

ST71241

Installation tool

Hamilton Sundstrand (99167)

ST71248

Aligning pin

Hamilton Sundstrand

ST78693

Stretch tooling

Hamilton Sundstrand

ST78693-01

Socket

Hamilton Sundstrand

ST78693-02

Stretch rod

Hamilton Sundstrand

ST78693-03

Main body

Hamilton Sundstrand

ST78693-06

Containment cage

Hamilton Sundstrand

ST78693-07

Torque adapter

Hamilton Sundstrand

ST78704

Dummy bearing

Hamilton Sundstrand

ST78716

Assembly aid

Hamilton Sundstrand

ST80043

Balancing cradle

Hamilton Sundstrand

ST80211

Filter cap removal tool

Hamilton Sundstrand

ST80472

Balancing machine

Hamilton Sundstrand

ST81131

Ball bearing inner race

Hamilton Sundstrand

ST81132

Shaft nut

Hamilton Sundstrand

ST90133

Driver

Hamilton Sundstrand

ST90134

Bearing puller

Hamilton Sundstrand

ST90139

Driver

Hamilton Sundstrand

ST90141

Bearing puller

Hamilton Sundstrand

ST90154

Bearing puller

Hamilton Sundstrand

ST90288

Puller

Hamilton Sundstrand

ST90361

Driver

Hamilton Sundstrand

ST90427

Seal plate support

Hamilton Sundstrand

ST90455

Motor pulley

Hamilton Sundstrand

ST90675

Driver

Hamilton Sundstrand

ST90889

Driver and guide assembly

Hamilton Sundstrand

ST91699

Oil pump puller

Hamilton Sundstrand

ST92619

Puller fixture

Hamilton Sundstrand

ST93013

Support fixture

Hamilton Sundstrand

ST93057

Seal puller

Hamilton Sundstrand

Special Tools, Fixtures, and Equipment


Figure 1501 (Sheet 2 of 3)
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

49-20-00

Page 1503
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Tool
Number

Description

Manufacturer (Vendor Code)

ST93058

Gear puller

Hamilton Sundstrand (99167)

ST93228

Driver

Hamilton Sundstrand

ST93946

Bearing guide

Hamilton Sundstrand

ST93974

Installation tool

Hamilton Sundstrand

ST95153

Holding fixture

Hamilton Sundstrand

ST95253

Check fixture

Hamilton Sundstrand

SV65172

Curvic master

Hamilton Sundstrand

702-00244

Glass master

Hamilton Sundstrand

Special Tools, Fixtures, and Equipment


Figure 1501 (Sheet 3 of 3)
Tool
Number

Description

Manufacturer (Vendor Code)

AB193-1046

Vibration filter

TTE (07766)

D12

Flowmeter

Micro Motion (63985)

MT50

Starting motor

Delco-Remy (16764)

MT574

Air inlet temperature probe

Hamilton Sundstrand (99617)

M1212CSU6

Thermometer

C-Temp (6X013)

M2512CSE6

EGT probe

C-Temp

Steinel HL1802E
with Reflector
074616 or
equivalent

Heat Gun

Raychem Corporation
(06090)

TACTROL-3

Digital frequency counter

Airpax (82227)

Testing Tools, Fixtures, and Equipment


Figure 1502 (Sheet 1 of 2)

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

49-20-00

Page 1504
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Tool
Number

Description

Manufacturer (Vendor Code)

101-080

Water dynamometer

Kahn (33980)

117851-1

Filter cap thermometer

Hamilton Sundstrand

118

Pressure gauge

Viatran (27385)

123

Pressure gauge

Viatran

125-K094

Barometer pressure gauge

Robinson/Halpern

2221F

Accelerometer

Endevco (97896)

3397

Dynamometer

Lebow (600012)

4501974

Electronic sequence unit

Hamilton Sundstrand

4950699

Bleed shutoff valve, slave

Hamilton Sundstrand

4951807

Oxley Meter Reader

Hamilton Sundstrand (55820)

6634M10

Vibration meter

Endevco

Testing Tools, Fixtures, and Equipment


Figure 1502 (Sheet 2 of 2)

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

49-20-00

Page 1505
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

49-20-00

Page 1506
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

TURBINE ASSEMBLY
49-22-00

TURBINE ASSEMBLY

49-22-00

Title, Page 1
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

TURBINE ASSEMBLY

49-22-00

Title, Page 2
Aug 1/01

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
DESCRIPTION AND OPERATION
1.

Description (Refer to Figure 1)


A.

The turbine assembly has an air inlet housing, rotor assembly, diffuser, turbine nozzle
assembly and an input pinion.

Turbine Assembly
Figure 1
B.

The air inlet housing is a contoured, cylindrical casting with forward and rear openings.
The flanged forward end of the air inlet housing is bolted to the rear end of the reduction
drive assembly. The rear end of the air inlet housing is externally flanged to permit
attachment of the combustor assembly.

DESCRIPTION AND OPERATION

49-22-00

Page 1
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

2.

C.

The rotor assembly has a rotor shaft, single-stage centrifugal compressor impeller,
radial-inflow turbine wheel, forward seal plate, bearing retainer nut, spacer, thrust
bearing, turbine roller bearing, packing and a rotor shaft plug. The rotor shaft is mounted
on bearings within a sleeve in the bore of the air inlet housing; the single thrust bearing
supports thrust and radial loads; the turbine roller bearing supports radial loads only.
The thrust bearing is held in position in the inlet housing by a bearing retainer plate and a
bearing retainer nut on the shaft. A spiral snap ring and two split rings retain the input
pinion in the forward end of the rotor shaft.

D.

The compressor impeller is press-fit onto the rotor shaft. It shoulders against a flange on
the rear end of the shaft. The turbine wheel is pressed into the rear end of the rotor
shaft. The turbine wheel tie bolt fastens the turbine wheel through an internally threaded
plug to a slotted nut inserted through the front of the rotor shaft.

E.

A circular forward seal plate separates the compressor section from the turbine section.
A pilot diameter in the diffuser housing radially positions the seal. Compressor pressure
maintains axial position of the seal on the rotor shaft, which forces the seal against the
turbine nozzle.

F.

The cantilevered arrangement of the rotor assembly in the air inlet housing places both
the thrust and turbine roller bearings in areas of reduced temperature. A flow of air-oil
mist from the reduction drive housing cools and lubricates the rotor shaft bearings. The
mist goes through the input pinion (within the rotor shaft) turbine roller and thrust ball
bearings, and back into the reduction drive unit. A labyrinth seal and O-ring on the end
of the air inlet sleeve are used to seal the lubrication system.

G.

The radial diffuser is a circular casting made of vanes on the outer periphery and on the
forward face. It is press fit into the housing assembly. The turbine nozzle is a one piece
machined casting. The turbine nozzle assembly seats against a mating surface of the
forward seal plate (forward and rear only).

Operation
A.

During operation, air is drawn through the air intake screen to the center of the
compressor. Rotary action of the compressor and a change of cross section of the
housing directs the air through the diffuser increasing pressure and reducing velocity.
The air passes through the combustor assembly where it is heated. The hot gases flow
through the turbine nozzle to strike the blades of the turbine wheel. The resulting rotation
of the turbine wheel gives the power to drive the compressor and the input pinion of the
gas turbine engine. The gases pass to atmosphere through the inner liner of the
combustor assembly.

DESCRIPTION AND OPERATION

49-22-00

Page 2
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
DISASSEMBLY
1.

General
A.

This section has the turbine assembly disassembly procedures. When necessary,
disassembly illustrations are also given. References to item numbers in the text and
accompanying illustrations are identical to those in the Illustrated Parts Catalog (IPC),
Document 40C11-3. Refer to Standard Practices Manual, Document HSPS 490001,
DISASSEMBLY, for general disassembly procedures.
NOTE: References to item numbers in text implies that alpha-variant items shown in the
IPL can be used as shown with the effect code for that item. For example,
reference to item (1) also applies to alpha-variant items (-1A, -1B, and -1C).
(1)

A turbine assembly that requires maintenance shall be disassembled to the extent


required to correct faults.

(2)

Special tools used for disassembly are shown in Figure 501.


NOTE: Equivalent substitutes may be used for items listed.

(3)

Parts recommended for discard are shown in Figure 502.


NOTE: Equivalent substitutes may be used for items listed.

DISASSEMBLY

49-22-00

Page 501
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Part Number

Description

Source (Vendor Code)

FXT04966

Holding Fixture

Hamilton Sundstrand (55820)

ST70107

Bearing Puller

Hamilton Sundstrand (55820)

ST70109

Bearing Puller

Hamilton Sundstrand (55820)

ST70137

Rotor Fixture

Hamilton Sundstrand (55820)

ST70230

Spanner Wrench

Hamilton Sundstrand (55820)

ST70942

Pinion Puller

Hamilton Sundstrand (55820)

ST71232

Dry Ice Containment Ring

Hamilton Sundstrand (55820)

ST78693

Stretch Tooling

Hamilton Sundstrand (55820)

ST92619

Puller Fixture

Hamilton Sundstrand (55820)

ST92619-05

Rod

Hamilton Sundstrand (55820)

ST93946-01

Bearing Guide

Hamilton Sundstrand (55820)

Special Tools and Equipment


Figure 501

IPC 49-22-00 Figure

Nomenclature and Item Number

Preformed Packings (10, 20, 170 and 190)

Seal (160) and Bolts (70)

Bearings (110 and 130)

Spacer (120)

Preformed Packing (20)

All Parts Except Air Inlet Housing (90)

NOTE: Items shown are to be discarded when removed or disturbed.


Parts Recommended for Discard
Figure 502

DISASSEMBLY

49-22-00

Page 502
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
2.

Disassembly of the Turbine Assembly


A.

Remove preformed packings (10 and 20, IPC 49-22-00 Figure 1). Discard packings.

B.

Remove retaining ring (30) from input pinion (40).

C.

Use pinion puller ST70942 to remove input pinion (40) (refer to Figure 503). Remove
split rings (50, IPC 49-22-00 Figure 1).

D.

Remove bolts (70), or pins (71) and washers (72 and 73) and nozzle assembly (60).
Discard bolts.

Remove Input Pinion


Figure 503

DISASSEMBLY

49-22-00

Page 503
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
E.

Install turbine assembly in rotor fixture ST70137 with turbine wheel facing down (refer to
Figure 504).

F.

Remove the staked material of the bearing retainer nut (80, IPC 49-22-00 Figure 1) from
the slots in the rotor shaft. Use spanner wrench ST70230 and remove bearing retainer
nut (80) (refer to Figure 505). Discard the nut if more than six stake marks are present.

G.

Install bearing guide ST93946-01 in air inlet housing (refer to Figure 506).

CAUTION: THE COMPRESSOR IMPELLER IS OF TITANIUM CONSTRUCTION. RIGIDLY


ADHERE TO HANDLING AND CLEANING PROCEDURES TO PREVENT
DAMAGE TO THE COMPRESSOR IMPELLER.
H.

Push down on rotor shaft. Lift air inlet housing assembly (210, IPC 49-22-00 Figure 1)
from rotor assembly (140).

I.

Remove screws (100) and bearing retainer plate (90).

Turbine Assembly in Rotor Fixture


Figure 504
DISASSEMBLY

49-22-00

Page 504
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Bearing Retainer Nut Removal


Figure 505
CAUTION: THE THRUST AND TURBINE ROLLER BEARINGS ARE EASILY
CONTAMINATED. DO NOT HANDLE BEARINGS UNNECESSARILY WITH
BARE HANDS. DO NOT ALLOW CLEANING SOLVENTS OR LUBRICATING
OILS TO CONTACT BEARINGS.
J.

Use bearing puller ST70107 and remove thrust bearing (110) (refer to Figure 507).
Discard bearing.

K.

Remove spacer (120, IPC 49-22-00 Figure 1). Discard spacer.

L.

Install dry ice containment ring ST71232 in diffuser (200) (refer to Figure 508).

DISASSEMBLY

49-22-00

Page 505
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Bearing Guide Installation


Figure 506
WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE) CORRECTLY.
THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE DRY ICE, GET THE
MATERIAL SAFETY DATA SHEETMATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0088SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE DRY ICE, PUT ON INSULATED
GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE DRY ICE FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
M.

Place dry ice between containment ring and diffuser. Cool inner surface of diffuser for 15
minutes minimum.

N.

Remove diffuser (200, IPC 49-22-00 Figure 1) from air inlet housing (210).

O.

Remove retaining ring (150), labyrinth seal (160) and packing (170). Discard labyrinth
seal and packing.
DISASSEMBLY

49-22-00

Page 506
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Thrust Bearing Removal


Figure 507
CAUTION: THE THRUST AND TURBINE ROLLER BEARINGS ARE EASILY
CONTAMINATED. DO NOT HANDLE BEARINGS UNNECESSARILY WITH
BARE HANDS. DO NOT ALLOW CLEANING SOLVENTS OR LUBRICATING
OILS TO CONTACT BEARINGS.
P.

Use bearing puller ST70109 to remove roller bearing (130) (refer to Figure 509). Discard
bearing.

Q.

Remove plug (180, IPC 49-22-00 Figure 1) and packing (190). Discard packing.

R.

Remove setscrews (230) and containment ring (220).

DISASSEMBLY

49-22-00

Page 507
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Diffuser Removal
Figure 508
3.

Disassembly of Rotor Assembly


CAUTION: THE COMPRESSOR IMPELLER IS OF TITANIUM CONSTRUCTION. RIGIDLY
ADHERE TO HANDLING AND CLEANING PROCEDURES TO PREVENT
DAMAGE TO THE COMPRESSOR IMPELLER.
A.

Verify the MM matchmark on the back faces of the compressor impeller and turbine
wheel.

DISASSEMBLY

49-22-00

Page 508
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Removal of Turbine Roller Bearing


Figure 509
B.

Install turbine wheel (80, IPC 49-22-00 Figure 2) on holding fixture FXT04966 and install
stretch tooling ST78693 for turbine wheel tie bolt de-stretch (refer to Figure 510).
(1)

Install tool main body ST78693-03 over inseparable impeller assembly (25, IPC
49-22-00 Figure 2).

(2)

Install tool socket ST78693-01 into slotted nut (10).

(3)

Install Enerpac Ram head RCH-120.

(4)

Install stretch rod ST78693-02.

(5)

Install containment cage ST78693-06.

DISASSEMBLY

49-22-00

Page 509
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Tie Bolt De-Stretch Setup (ST78693 Tool Kit)


Figure 510

DISASSEMBLY

49-22-00

Page 510
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: TO AVOID INJURY, STAY CLEAR OF ENERPAC RAM DURING STRETCHING
PROCEDURE. DO NOT USE STRETCH ROD (ST78643-02) IF THE 400
CYCLE LIMIT IS ACHIEVED.
CAUTION: DO NOT EXCEED A PRESSURE OF 7500 POUNDS FORCE (3405 KG) WHILE
STRETCHING THE TURBINE WHEEL TIE BOLT. DAMAGE TO THE TIE BOLT
CAN OCCUR.
NOTE: Record load cycles of ST78693 stretch tool in accordance with 49-20-00, Special
Tools, Fixtures, and Equipment.

4.

C.

Use the Enerpac Ram to apply 7300 to 7500 pounds force (3314 to 3405 Kg) to destretch turbine wheel (80) tie bolt.

D.

Remove slotted nut (10) and carefully separate the inseparable impeller assembly (25)
from the turbine wheel (80). Remove stretch tooling ST78693.

E.

Install rotor assembly (140, IPC 49-22-00 Figure 1) in puller fixture ST92619.

F.

Use rod ST92619-05 and remove turbine wheel (80, IPC 49-22-00 Figure 2) and packing
(20) from shaft (50).

G.

Remove seal plate (60) and segmented plate assemblies (70).

H.

Mark accumulated service life hours and number of start cycles on backface of the
turbine wheel (80) and compressor impeller (40) using electro-chemical marking.

Disassembly of Air Inlet Housing Assembly


A.

If damaged, remove lockrings (10, 20 and 50, IPC 49-22-00 Figure 3), pin (55) and
inserts (30, 40 and 70). Refer to Standard Practices Manual, Document HSPS 490001
for removal and installation of inserts and lockrings.

DISASSEMBLY

49-22-00

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

DISASSEMBLY

49-22-00

Page 512
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
ASSEMBLY
1.

General
A.

This section has the assembly procedures for the turbine assembly. When necessary,
assembly illustrations are also given. References to item numbers in the text and
accompanying illustrations are identical to those in the Illustrated Parts Catalog (IPC),
Document 40C11-3. Refer to Standard Practices Manual (SPM), Document HSPS
490001, ASSEMBLY, for general assembly procedures. Storage instructions are also
contained in this section.
NOTE: References to item numbers in text implies that alpha-variant items shown in the
IPL can be used as shown with the effect code for that item. For example,
reference to item (1) also applies to alpha-variant items (-1A, -1B and -1C).

B.

Materials needed for assembly is shown in Figure 1001.


NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or
holding other small components in place for ease of assembly and prevention of
galling. If necessary, assembly fluid may be diluted with MIL-PRF-7808 or
MIL-PRF-23699.

C.

Special tools used for assembly are shown in Figure 1002.

NOTE: Equivalent substitutes may be used for items listed.


Equipment and Material

Source (Vendor Code)

Antiseize Compound 51102 or 169041-1

Fel-Pro, Inc. (73165) or


Hamilton Sundstrand (55820)

Assembly Fluid (4950515)


Dry Ice
Joint Sealant (4951776-1)
Lockwire MS20995C20 and MS20995C32
or
Safety Cable 5909034-2B and -5B and
Cartridge, Ferrule 5909035-1B and -2B
Lubricant MIL-PRF-7808
Lubricant MIL-PRF-23699
Primer MIL-S-22473, Grade T
Retaining Compound MIL-R-46082, Type II

Hamilton Sundstrand (55820)


Commercially Available
Hamilton Sundstrand (55820)
Commercially Available
or
Hamilton Sundstrand (55820)
Commercially Available
Commercially Available
Commercially Available
Commercially Available

Assembly Materials
Figure 1001

ASSEMBLY

49-22-00

Page 1001
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
Number

Description

Source (Vendor Code)

------AID-00359
AID-00592
AID-00653
FXT04840
FXT04966
ST60714
ST60880
ST61189
ST61189-06
ST61195
ST70110
ST70137
ST70230
ST70461
ST70468
ST78693
ST78704
ST78716
ST80043
ST80472
ST81131
ST81132
ST90427
ST90455
ST93946-02
ST95253
SV65172
702-00244

Oven
Enerpac Hydraulic Jack
Digital Pressure Gauge
Retaining Ring Checking Tool
Alignment Tool
Depth Gauge Guide Tool
Holding Fixture
Holding Fixture
Inspection Fixture
Wire Gauge Set
Bridge Gauge
Plug
Bridge Gauge
Driver
Rotor Fixture
Spanner Wrench
Ring Spacer
Bearing Seal Aligning Tool
Stretch Tooling
Dummy Bearing
Assembly Aid
Balancing Cradle
Balancing Machine
Ball Bearing Inner Race
Shaft Nut
Seal Plate Support
Motor Pulley
Bearing Guide
Check Fixture
Curvic Master
Glass Master

Commercially Available
Commercially Available
Commercially Available
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)

Special Tools and Equipment


Figure 1002

ASSEMBLY

49-22-00

Page 1002
May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
2.

Assembly of Air Inlet Housing Assembly


CAUTION: BE SURE ALL INSERT TANGS ARE ACCOUNTED FOR AFTER BREAKING
OFF. DAMAGE TO INTERNAL COMPONENTS CAN OCCUR IF A TANG
ENTERS THE OIL PASSAGES.
A.

3.

If removed, install inserts (30, 40 and 70, and lockrings (10, 20 and 50). Use procedures
in Standard Practices Manual, 49-00-01, ASSEMBLY.

Assembly of Rotor Assembly


A.

Position rotor shaft (50, IPC 49-22-00 Figure 2) in holding fixture FXT04840. Apply
primer (P/N MIL-S-22473) and retaining compound (P/N MIL-R-46082) to plug (30)
threads. Wipe off excess primer and compound. Use assembly aid ST78716 and install
plug (30) in rotor shaft (50). Torque plug 396 to 444 pound -inches (44 to 50 N.m).

B.

Assemble compressor impeller and rotor shaft as follows:


WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
CAUTION: THE COMPRESSOR IMPELLER IS OF TITANIUM CONSTRUCTION.
RIGIDLY ADHERE TO HANDLING AND CLEANING PROCEDURES TO
PREVENT DAMAGE TO THE COMPRESSOR IMPELLER.
(1)

Put compressor impeller (40) in an oven and heat to 630 to 670F (332 to 354C)
for one hour minimum.

WARNING: LIQUID NITROGEN WILL FREEZE SKIN INSTANTLY. USE IN WELLVENTILATED AREA. PREVENT EYE AND SKIN CONTACT. PUT ON
SPLASH GOGGLES AND INSULATED GLOVES. IN CASE OF SKIN
CONTACT SEEK MEDICAL ATTENTION. IN CASE OF EYE CONTACT,
SEEK MEDICAL ATTENTION.
(2)

Freeze rotor shaft (50) in liquid nitrogen during heating cycle for compressor
impeller.

(3)

Put the heated compressor impeller (40) into holding fixture FXT04962 on hydraulic
press. Use hand pressure only and install rotor shaft (50) into compressor impeller
(40) until it bottoms out.
NOTE: Keep pressure on the shaft to make sure it does not back out of the
impeller.

(4)

Install shaft press tool ST78717 completely on rotor shaft (50). Use the hydraulic
press to apply 7.5 to 8 tons (66,700 to 71,100 N) of pressure until the temperature
normalizes.
NOTE: Fan cooling is permissible during temperature normalization.

(5)

Use curvic master SV65172 and measure compressor impeller assembly (25).
Refer to Figure 1003.

ASSEMBLY

49-22-00

Page 1003
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Runout of Compressor Impeller Assembly Bearing Journals


Figure 1003

C.

Balance compressor impeller assembly (25, IPC 49-22-00 Figure 2) as follows:


NOTE: All balancing procedures should be performed at a speed of 1400 150 rpm.
Once a speed has been selected, all balancing should be done at the same
speed.
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
(1)

Apply lubricant MIL-PRF-7808 to threads and face of bearing retainer nut ST81132.

(2)

Install bearing race ST81131 and bearing retainer nut ST81132 onto rotor shaft
(50). Torque nut 110 to 170 pound inches (12.4 to 19.2 Nm).
ASSEMBLY

49-22-00

Page 1004
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
(3)

Lubricate cradle with a small amount of lubricating oil MIL-PRF-6081.

(4)

Wrap rotor shaft (50) with black electrical tape (P/N PPP-T-76). Position a small
strip of silver electrical tape (P/N PPP-T-97) on the rotor shaft to act as a zero
reference for the balancing machine.

CAUTION: BALANCING MACHINE CALIBRATION MUST BE WITHIN 10% (INCHOUNCE) OF TRAIL WEIGHT VALUE AND 15.0 DEG OF CALCULATED
PHASE ANGLE.
(5)

Setup compressor impeller assembly (25) in balancing cradle ST80043, cradle


adapter ST81129, and balancing machine ST80472 in measurement planes A and
B (refer to Figure 1004 and 1005).

Compressor Impeller Assembly Balancing Setup


Figure 1004

ASSEMBLY

49-22-00

Page 1005
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Balancing Details for Compressor Impeller Assembly


Figure 1005

ASSEMBLY

49-22-00

Page 1006
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
CAUTION: USE CAUTION WHEN YOU REMOVE MATERIAL FROM THE
COMPRESSOR IMPELLER TO PREVENT DAMAGE TO THE ROTOR
SHAFT OR COMPRESSOR IMPELLER.
(6)

Dynamically balance compressor impeller assembly (25, IPC 49-22-00 Figure 2) in


balance planes C1 and C2 to 0.003 inch-ounce (0.00002 Nm). (Refer to Figure
1005). Remove material from balance planes C1 and C2 as shown in Figure 1005.
Use material removal guard FXT04967 to protect the rotor shaft during material
removal.
NOTE: If material is removed from blades, a frequency analysis of the compressor
wheel is required in accordance with Bulletin 500C/I/R.
NOTE: Make sure all measurements are within limits shown in Figure 1005.

D.

(7)

Remove compressor impeller assembly (25, IPC 49-22-00 Figure 2) from balancing
machine. Remove bearing retainer nut ST81132 and bearing race ST81131.

(8)

If necessary, flush assembly to remove chips from oil holes in rotor shaft (50).

Assemble turbine wheel to compressor impeller assembly (25) for balancing as follows:
(1)

Position turbine wheel (80) on holding fixture FXT04966.

(2)

Install compressor impeller assembly (25) on turbine wheel (80).

(3)

Install tool main body ST78693-03 over compressor impeller (40).


NOTE:

Make sure the curvic is clean.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
(4)

Apply a light coat of oil MIL-PRF-7808 to the threads and face of nut (10).

(5)

Use tool socket ST78693-01 to install and hand tighten nut (10) on turbine wheel
(80) tie bolt, then back nut off one-half to one full turn.

(6)

Install stretch tooling ST78693 for turbine wheel tie bolt stretch as follows:

(7)

Install tool socket ST78693-01 onto nut (10).

(8)

Install Enerpac Ram head RCH-120.

(9)

Install stretch rod ST78693-02.

(10) Install containment cage ST78693-06.

ASSEMBLY

49-22-00

Page 1007
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: TO AVOID INJURY, STAY CLEAR OF ENERPAC RAM DURING
STRETCHING PROCEDURE. DO NOT USE STRETCH ROD
(ST78693-02) IF THE 400 CYCLE LIMIT IS ACHIEVED.
CAUTION: DO NOT EXCEED A PRESSURE OF 7500 POUNDS FORCE (3400 KG)
WHILE STRETCHING THE TURBINE WHEEL TIE BOLT. DAMAGE TO
THE TIE BOLT CAN OCCUR.
NOTE: Record load cycles of ST78693 stretch tool in accordance with 49-20-00,
Special Tools, Fixtures, and Equipment.
(11) Use the Enerpac ram to apply 5900 to 6100 pounds force (2681 to 2772 Kg).
(12) Use socket ST78693-01 and a torque wrench to torque nut (10) 50 to 60 pound
inches (5.6 to 6.8 Nm). Carefully release Enerpac pressure.
(13) Remove containment cage ST78693-06, stretch rod ST78693-02, and socket
ST78693-01.
CAUTION: MAKE SURE THERE IS NO CONTAMINATION OF THE CURVIC
COUPLING AND BEARING JOURNALS IF MATERIAL IS REMOVED.
CLEAN AREA THOROUGHLY OR DAMAGE TO THE ROTOR ASSEMBLY
WILL OCCUR.
(14) Install bearing race ST81131 and bearing retainer nut ST81132. Torque nut to 110
to 170 pound inches (12.4 to 19.2 Nm).
(15) Setup compressor impeller assembly (25) and turbine wheel (80) in balancing
cradle ST80043, cradle adapter ST81129, and balancing machine ST80472 on
measurement planes A and B (refer to Figure 1004 and 1006).
NOTE: The turbine wheel may be clocked if required to meet the requirements of
step (15).
(16) Measure unbalance at planes T1 and T2 (refer to Figure 1006). Unbalance shall not
exceed 0.006 inch-ounce (0.00004 Nm). Material may be removed from planes T1
and T2 according to figure 1007.
CAUTION: MAKE SURE MARKINGS ARE LIGHTLY ETCHED AND NO CLOSER THAN
0.12 INCHES (3.04 MM) FROM ANY EDGE. FAILURE TO DO SO WILL
CAUSE DAMAGE TO THE TURBINE WHEEL OR COMPRESSOR IMPELLER.
(17) Match mark the mating surface of the turbine wheel (80, IPC 49-22-00 Figure 2) and
compressor impeller (40) curvic coupling by Vibro-etch or Laser Marking method
(refer to Figure 1006).
(18) Repeat steps 6 through 9.
(19) Use socket ST78693-01 and remove nut (10, IPC 49-22-00 Figure 2), and turbine
wheel (80).
(20) Remove containment cage ST78693-06, stretch rod ST78693-02, socket
ST78693-01, bearing race ST81131, and bearing retainer nut ST81132.

ASSEMBLY

49-22-00

Page 1008
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Balancing Details for Turbine Wheel and Compressor Impeller Assembly


Figure 1006

ASSEMBLY

49-22-00

Page 1009
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
E.

Assemble turbine wheel and forward seal plate to compressor impeller assembly for final
balancing as follows:
(1)

Position turbine wheel (80) on holding fixture FXT04966.

(2)

Install packing (20) on turbine wheel (80) shaft with assembly fluid.

(3)

Install forward seal plate (60) on turbine wheel (80).


NOTE: Make sure the curvic is clean.

(4)

Install compressor impeller assembly (25) on turbine wheel (80). Align match
marks. Install tool main body ST78693-03 over compressor impeller (40). Make sure
the curvic is clean.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
(5)

Apply a light coat of oil MIL-PRF-7808 to the threads and face of nut (10).

(6)

Use tool socket ST78693-01 to install and hand tighten nut (10) on turbine wheel
(80) tie bolt, then back nut off one-half to one full turn.
NOTE: Do not remove or pickup rotor assembly from holding fixture.

(7)

Install stretch tooling ST78693 for turbine wheel tie bolt stretch as follows:
(a)

Install tool socket ST78693-01 onto nut (10).

(b)

Install Enerpac Ram head RCH-120.

(c)

Install stretch rod ST78693-02.

(d)

Install containment cage ST78693-06.

WARNING: TO AVOID INJURY, STAY CLEAR OF ENERPAC RAM DURING


STRETCHING PROCEDURE. DO NOT USE STRETCH ROD
(ST78693-02) IF THE 400 CYCLE LIMIT IS ACHIEVED.
CAUTION: DO NOT EXCEED A PRESSURE OF 7500 POUNDS FORCE (3400 KG)
WHILE STRETCHING THE TURBINE WHEEL TIE BOLT. DAMAGE TO
THE TIE BOLT CAN OCCUR.
NOTE: Record load cycles of ST78693 stretch tool in accordance with 49-20-00,
Special Tools, Fixtures, and Equipment.
(8)

Use the Enerpac ram to apply 6400 to 6600 pounds force (2903 to 2994 Kg).

(9)

Carefully release Enerpac pressure.


NOTE: Do not remove or pickup rotor assembly from holding fixture.

(10) Remove containment cage ST78693-06, stretch rod ST78693-02, and socket
ST78693-01.

ASSEMBLY

49-22-00

Page 1010
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(11) Use a depth gauge and depth gauge guide tool and measure depth of turbine wheel
tie bolt (80) inside rotor shaft (50). (Refer to Figure 1007). Record measurement.

Tie Bolt Stretch Measurement


Figure 1007
ASSEMBLY

49-22-00

Page 1011
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(12) Repeat step (7).
WARNING: TO AVOID INJURY, STAY CLEAR OF ENERPAC RAM DURING
STRETCHING PROCEDURE. DO NOT USE STRETCH ROD
(ST78693-02) IF THE 400 CYCLE LIMIT IS ACHIEVED.
CAUTION: DO NOT EXCEED A PRESSURE OF 7600 POUNDS FORCE (3447 KG)
WHILE STRETCHING THE TURBINE WHEEL TIE BOLT. DAMAGE TO
THE TIE BOLT CAN OCCUR.
NOTE: Record load cycles of ST78693 stretch tool in accordance with 49-20-00,
Special Tools, Fixtures, and Equipment.
(13) Stretch turbine wheel tie bolt for rotor assemblies (1, 1A, 1B, 1C, 1D, IPC
49-22-00 Figure 2 and 1A, IPC 49-22-00 Figure 2A) as follows:
(a)

Use the Enerpac ram to apply 7300 to 7500 pounds force (3311 to 3401 Kg).

(b)

Use socket ST78693-01 and a torque wrench to torque nut (10) 35 to 45


pound inches (3.9 to 5.0 Nm). Carefully release Enerpac pressure.

(14) Stretch turbine wheel tie bolt for rotor assemblies (1E and subsequent, IPC
49-22-00 Figure 2 and 1B, IPC 49-22-00 Figure 2A) as follows:
(a)

Use the Enerpac ram to apply 7400 to 7600 pounds force (3356 to 3447 Kg).

(b)

Use socket ST78693-01 and a torque wrench to torque nut (10) 55 to 65


pound inches (6.2 to 7.3 Nm). Carefully release Enerpac pressure.

(15) Remove containment cage ST78693-06, stretch rod ST78693-02, and socket
ST78693-01.
(16) Use a depth gauge and depth gauge guide tool and measure depth of turbine wheel
tie bolt (80, IPC 49-22-00 Figure 2). (Refer to Figure 1007). Record measurement.
(17) For rotor assemblies (1, 1A, 1B, 1C, 1D, IPC 49-22-00 Figure 2 and 1A, IPC
49-22-00 Figure 2A): The difference between the measurement obtained in step
(16) and the measurement obtained in step (11) must be 0.0088 to 0.0095 inch
(0.223 to 0.241 mm).
(18) For rotor assemblies (1E and subsequent, IPC 49-22-00 Figure 2 and 1B, IPC
49-22-00 Figure 2A): The difference between the measurement obtained in step
(16) and the measurement obtained in step (11) must be 0.0098 to 0.0105 inch
(0.248 to 0.266 mm).
(19) If the value is out of tolerance repeat step (7).

ASSEMBLY

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: TO AVOID INJURY, STAY CLEAR OF ENERPAC RAM DURING
STRETCHING PROCEDURE. DO NOT USE STRETCH ROD
(ST78693-02) IF THE 400 CYCLE LIMIT IS ACHIEVED.
CAUTION: DO NOT EXCEED A PRESSURE OF 7600 POUNDS FORCE (3447 KG)
WHILE STRETCHING THE TURBINE WHEEL TIE BOLT. DAMAGE TO
THE TIE BOLT CAN OCCUR.
NOTE: Record load cycles of ST78693 stretch tool in accordance with 49-20-00,
Special Tools, Fixtures, and Equipment.
(20) Stretch the turbine wheel tie bolt for rotor assemblies (1, 1A, 1B, 1C, 1D, IPC
49-22-00 Figure 2 and 1A, IPC 49-22-00 Figure 2A) as follows:
(a)

Use the Enerpac ram to apply 7300 to 7500 pounds force (3311 to 3401 Kg).

(b)

Use socket ST78693-01 and loosen nut (10). Repeat steps (13) (b), (15), (16)
and (17). Increase or decrease the torque value in step (13) (b) until there is a
difference of 0.0088 to 0.0095 inch (0.223 to 0.241mm) from the first
measurement to the last.

(21) Stretch the turbine wheel tie bolt for rotor assemblies (1E and subsequent, IPC
49-22-00 Figure 2 and 1B, IPC 49-22-00 Figure 2A):
(a)

Use the Enerpac ram to apply 7400 to 7600 pounds force (3356 to 3447 Kg).

(b)

Use socket ST78693-01 and loosen nut (10). Repeat steps (14) (b), (15), (16)
and (18). Increase or decrease the torque value in step (14) (b) until there is a
difference of 0.0098 to 0.0105 inch (0.223 to 0.241mm) from the first
measurement to the last.

(22) Install bearing race ST81131 and bearing retainer nut ST81132. Torque nut to 110
to 170 pound inches (12.4 to 19.2 Nm).
F.

Balance rotor assembly as follows:


CAUTION: BALANCING MACHINE CALIBRATION MUST BE WITHIN 10% (INCHOUNCE) OF TRAIL WEIGHT VALUE AND 15.0 DEG OF CALCULATED
PHASE ANGLE.
(1)

Install rotor assembly (140) and balancing cradle ST80043 in balancing machine
ST80472. Use seal plate support adapter ST90838 and seal plate support
ST90427 to support the forward seal plate. (Refer to Figure 1008).

ASSEMBLY

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May 1/02

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Balance Rotor Assembly Installation


Figure 1008
(2)

Position a small strip of tape (P/N PPP-T-76) on rotor shaft (50, IPC 49-22-00
Figure 2) to act as zero-reference for the balancing machine pickup.

(3)

Dynamically balance the rotor assembly (140, IPC 49-22-00 Figure 1). Maximum
unbalance is 0.008 inch-ounce (0.00005 Nm) in plane T1 and T2 (refer to Figure
1009).
NOTE: Make sure all measurements are within limits set in Figure 1009.

ASSEMBLY

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Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Final Balance Rotor Assembly


Figure 1009

ASSEMBLY

49-22-00

Page 1015
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(4)

If rotor assembly (140, IPC 49-22-00 Figure 1) exceeds the maximum unbalance of
0.008 inch-ounce (0.00005 Nm), remove material from the turbine wheel (80, IPC
49-22-00 Figure 2) as follows:
NOTE: Balancing in plane T2 shall begin with material removal from the turbine
wheel nubbin. Any additional material removal shall be limited to a
maximum of five blades for plane T1.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
(a)

Apply lubricant MIL-PRF-7808 to threads and face of bearing retainer nut


ST81132.

(b)

Install bearing race ST81131 and bearing retainer nut ST81132 onto the rotor
shaft (50). Torque the nut 110 to 170 pound inches (12.4 to 19.2 Nm).

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.

(5)

(c)

Lubricate cradle with a small amount of lubricating oil MIL-PRF-6081.

(d)

Wrap rotor shaft (50) with black electrical tape (P/N PPP-T-76). Position a
small strip of silver electrical tape (P/N PPP-T-97) on the rotor shaft to act as a
zero reference for the balancing machine.

(e)

Set up rotor assembly (140) in balancing cradle ST80043, cradle adapter


ST81129, and balancing machine ST80472 (refer to Figure 1004).

(f)

Remove material from turbine wheel (80, IPC 49-22-00 Figure 2) in areas
shown (refer to Figure 1010) to balance the rotor assembly (140, IPC 49-22-00
Figure 1).

(g)

Remove rotor assembly from balancing machine and tooling from assembly.
Remove tape from rotor shaft.

(h)

After material removal from the turbine wheel blade tips, measurement of the
material must be verified by use of an optical comparator and glass master
702-00244 (refer to Figure 1010) or fixture ST65409 (refer to Figure 1011).

Map each blade, record an X on balance mapping form to indicate blade from which
material was removed. (Refer to Figure 1012).
NOTE: The balance mapping form shall be kept as a permanent record with the
turbine wheel.

ASSEMBLY

49-22-00

Page 1016
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Optical Comparator
Figure 1010

ASSEMBLY

49-22-00

Page 1017
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Material Removal Verification Using Fixture ST95253


Figure 1011

ASSEMBLY

49-22-00

Page 1018
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Balance Mapping Form


Figure 1012
4.

Assembly of Turbine Assembly


CAUTION: THE THRUST AND TURBINE ROLLER BEARINGS ARE EASILY
CONTAMINATED. DO NOT HANDLE BEARINGS UNNECESSARILY WITH
BARE HANDS. DO NOT ALLOW CLEANING SOLVENTS OR LUBRICATING
OILS TO CONTACT BEARINGS.
NOTE: Make sure retaining ring groove is clean before installation of bearing.
NOTE: For air inlet housing (210 or 210A, IPC 49-22-00 Figure 1) proceed with step
4.A. For air inlet housing (210B) go to step 4.A.1.
ASSEMBLY

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ENGINE MANUAL
PART NUMBER 4501966 SERIES
A.

Assembly of labyrinth seal (160, IPC 49-22-00 Figure 1) and roller bearing (130) in air
inlet housing (210 and 210A).
(1)

Install the dummy bearing ST78704 into forward end of the air inlet housing (210)
and secure with three 0.19 - 32 UNFX.32LG screws. Torque screws to 16 to 18
pound inches (1.8 to 2.0 N.m).

(2)

If required, use the bearing driver ST70110 and hand press and install the roller
bearing (130), with the part number and serial number side up, into the air inlet
housing (210). (Refer to Figure 1013). Make sure the bearing is fully seated in the
housing.
NOTE: The air inlet housing sleeve may be heated to 200F (82 to 93C)
maximum for easier installation of the roller bearing.
NOTE: Clearance between the turbine roller bearing (130, IPC 49-22-00 Figure 1)
and rotor shaft (50, IPC 49-22-00 Figure 2) is 0.0004 to 0.001 inch (0.0101
to 0.0254 mm). Any change in either of these components requires a
measurement of the clearance.

(3)

Install the packing (170, IPC 49-22-00 Figure 1) on top of the roller bearing (130).

(4)

Install the labyrinth seal (160) into the air inlet housing (210).
NOTE: Make sure the labyrinth seal is not dirty or damaged before or after
installation.

Installation of Turbine Roller Bearing


Figure 1013

ASSEMBLY

49-22-00

Page 1020
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
CAUTION: INSTALLTHE BEARING GUIDE BEFORE INSTALLATION AND REMOVAL
OF THE INSTALLATION TOOL OR DAMAGE TO THE LABYRINTH SEAL
MAY OCCUR.
(5)

Install the bearing guide ST93946-02 on the aligning tool, ST70468 or AID-00592,
and carefully insert through bearing (130), labyrinth seal (160), and air inlet housing
(210).

(6)

Remove the bearing guide and install the threaded knob on the aligning tool.
Tighten the aligning tool threaded knob until the retaining ring groove in the air inlet
housing (210) is clear.

CAUTION: DO NOT USE A SHARP, METALLIC TOOL TO INSTALL THE RETAINING


RING OR DAMAGE TO THE LABYRINTH SEAL MAY OCCUR.
(7)

Use alignment tool AID-00592 and carefully install the retaining ring (150) into the
air inlet housing (210).

CAUTION: INSTALLTHE BEARING GUIDE BEFORE INSTALLATION AND REMOVAL


OF THE INSTALLATION TOOL OR DAMAGE TO THE LABYRINTH SEAL
MAY OCCUR.
(8)

Install the bearing guide ST93946-02 on the aligning tool ST70468 or AID-00592,
and carefully remove the aligning tool.

(9)

Use retaining ring checking tool AID-00359 to check for proper seating of the
retaining ring (150) by installing the tool between the labyrinth seal O.D. and
retaining ring I.D. The tool button must extend above the surface of the tool
housing to indicate correct seating of the retaining ring (150).

WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE)


CORRECTLY. THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A
BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
DRY ICE, GET THE MATERIAL SAFETY DATA SHEETMATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0088SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE DRY ICE, PUT ON INSULATED GLOVES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION: KEEP MOISTURE FROM THE BEARING AND BEARING AREA OR
FAILURE OF THE BEARING COULD OCCUR.
(10) Make sure the labyrinth seal (160) is pressed against the retaining ring (150). If
required, chill the labyrinth seal (160) area with dry ice for approximately five
minutes. Recheck to make sure the labyrinth seal (160) is pressed against the
retaining ring (150).
(11) Remove the dummy bearing ST78704 and three 0.19 - 32 UNFX.32LG screws from
forward end of the air inlet housing (210).

ASSEMBLY

49-22-00

Page 1021
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
A.1 Installation of labyrinth seal (160) and roller bearing (130) in air inlet housing (210B).
(1)

Make sure the roller bearing anti-rotation pin in the air inlet housing (210) is not
damaged or missing. Replace or repair as required, refer to APS500C/I/R.

(2)

Install dummy bearing ST78704 into forward end of the air inlet housing (210) and
secure with three 0.19 - 32 UNFX.32LG screws. Torque screws to 16 to 18 pound
inches (1.8 to 2.0 N.m).

(3)

If required, use the bearing driver ST70110 and hand press and install the roller
bearing (130), with the part number and serial number side up, into the air inlet
housing (210) while aligning the slot in the bearing outer race with the housing antirotation pin. Make sure the bearing is fully seated in the housing.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE


PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
NOTE: he air inlet housing sleeve may be heated to 200F (82 to 93C) maximum
for easier installation of the roller bearing.
(4)

Look from the front of the air inlet housing (210) to make sure the anti-rotation pin is
engaged in the outer race slot of the roller bearing (130).
NOTE: Clearance between the turbine roller bearing (130) and rotor shaft (50) is
0.0004 to 0.001 inch (0.0101 to 0.0254 mm). Any change in either of these
components requires a measurement of the clearance.

(5)

Install the packing (170) on top of the roller bearing (130).

(6)

Install the labyrinth seal (160) into the air inlet housing (210) by hand while aligning
the groove in the labyrinth seal (160) with the groove in the air inlet housing (210).
NOTE: Make sure the labyrinth seal (160) is not dirty or damaged before or after
installation.

(7)

Remove the dummy bearing ST78704 and three screws from the forward end of the
air inlet housing (210).

ASSEMBLY

49-22-00

Page 1022
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE ANAEROBIC SEALANT AND LOCKING COMPOUND, MIL-S-22473,
CORRECTLY. THE COMPOUND IS FLAMMABLE. IT CAN HAVE A BAD
EFFECT ONYOUR HEALTH OR SAFETY. BEFORE YOU USE THE
COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING W0068SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND
PUT ON SAFETY GLASSES OR GOGGLES AND RUBBER GLOVES.
MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE
COMPOUND FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.
WARNING: USE ANAEROBIC RETAINING COMPOUND, MIL-R-46082, CORRECTLY.
THE COMPOUND IS FLAMMMABLE. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COMPOUND, GET
THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER
OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ
THE DETAILED WARNING, W0067SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE COMPOUND, PUT ON SAFETY
GLASSES OR GOGGLES AND RUBBER GLOVES. MAKE SURE THAT
YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COMPOUND FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
(8)

Apply primer (MIL-S-22473) and retaining compound (MIL-R-46082) to anti-rotation


pin (165). Wipe off excess primer and compound. Install the labyrinth seal antirotation pin in the groove between the labyrinth seal (160) and the air inlet housing
(210).

CAUTION: INSTALLTHE BEARING GUIDE BEFORE INSTALLATION AND REMOVAL


OF THE INSTALLATION TOOL OR DAMAGE TO THE LABYRINTH SEAL
MAY OCCUR.
(9)

Install the bearing guide ST93946-02 on the aligning tool, ST70468 or AID-00592,
and carefully insert through bearing (130), labyrinth seal (160), and air inlet housing
(210).

(10) Install spacer ST70461 (for aligning tool ST70468 only) in aft side of the air inlet
housing (210).
(11) Remove the bearing guide and install the threaded knob on the aligning tool.
Tighten the aligning tool threaded knob until the retaining ring groove in the air inlet
housing (210) is clear.
CAUTION: DO NOT USE A SHARP METALLIC TOOL TO INSTALL THE RETAINING
RING OR DAMAGE TO THE LABYRINTH SEAL MAY OCCUR.
NOTE: Make sure the labyrinth seal anti-rotation pin (165) is correctly installed in
the groove between the labyrinth seal (160) and the air inlet housing (210)
before installing the retaining ring (150).
(12) Use alignment tool AID-00592 and carefully install the retaining ring (150) into the
air inlet housing (210).
ASSEMBLY

49-22-00

Page 1023
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
CAUTION: INSTALLTHE BEARING GUIDE BEFORE INSTALLATION AND REMOVAL
OF THE INSTALLATION TOOL OR DAMAGE TO THE LABYRINTH SEAL
MAY OCCUR.
(13) Install the bearing guide ST93946-02 on the aligning tool, ST70468 or AID-00592,
and carefully remove the aligning tool and spacer ST70461.
(14) Use retaining ring checking tool AID-00359 to check for proper seating of the
retaining ring (150) by installing the tool between the labyrinth seal O.D. and
retaining ring I.D.. The tool button must extend above the surface of the tool
housing to indicate correct seating of the retaining ring (150).
WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE)
CORRECTLY. THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A
BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
DRY ICE, GET THE MATERIAL SAFETY DATA SHEETMATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0088SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE DRY ICE, PUT ON INSULATED GLOVES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
CAUTION:

KEEP MOISTURE FROM THE BEARING AND BEARING AREA OR


FAILURE OF THE BEARING COULD OCCUR.

(15) Make sure the labyrinth seal (160) is pressed against the retaining ring (150). If
required, chill the labyrinth seal (160) area with dry ice for approximately five
minutes. Recheck to make sure the labyrinth seal (160) is pressed against the
retaining ring (150).
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
B.

Heat air inlet housing assembly (210) 180 to 200F (82 to 93C) for 30 minutes.

WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE) CORRECTLY.
THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE DRY ICE, GET THE
MATERIAL SAFETY DATA SHEETMATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0088SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE DRY ICE, PUT ON INSULATED
GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.
C.

Cool diffuser (200) in dry ice for 30 minutes.

D.

Install diffuser (200) in air inlet housing assembly (210). Make sure bolt holes in diffuser
line up with bolt holes in air inlet housing assembly.
ASSEMBLY

49-22-00

Page 1024
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
CAUTION: THE COMPRESSOR IMPELLER IS OF TITANIUM CONSTRUCTION. RIGIDLY
ADHERE TO HANDLING AND CLEANING PROCEDURES TO PREVENT
DAMAGE TO THE COMPRESSOR IMPELLER.
E.

Place rotor assembly (140) with turbine wheel down in rotor fixture ST70137 (refer to
Figure 1014).

Installation of Bearing Guide


Figure 1014
F.

Install bearing guide ST93946-02 on rotor shaft (50, IPC 49-22-00 Figure 2) to prevent
damage to labyrinth seal (160, IPC 49-22-00 Figure 1).

G.

Install air inlet housing assembly (210) on rotor assembly (140). Press down on air inlet
housing assembly to fully seat rotor assembly. Remove bearing guide.
NOTE: Do not reuse spacer. Only one spacer per assembly.

H.

Install spacer (120) with chamfered internal diameter towards rotor assembly (140),
facing down.

ASSEMBLY

49-22-00

Page 1025
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
CAUTION: THE THRUST AND TURBINE ROLLER BEARINGS ARE EASILY
CONTAMINATED. DO NOT HANDLE BEARINGS UNNECESSARILY WITH
BARE HANDS. DO NOT ALLOW CLEANING SOLVENTS OR LUBRICATING
OILS TO CONTACT BEARINGS.
I.

If the ball bearing has a split inner race, make sure the V scribed into bearing I.D. is
aligned. Install thrust bearing (110) in air inlet housing assembly (210) with serial number
visible. Do not seat thrust bearing.

J.

Apply joint sealant (P/N 4951776-1) to bearing retainer plate (90B) as follows:
(1)

Apply a tensile load of approximately 1 lb. (5 N) to a length of joint sealant to fully


expand stock.

(2)

Cut a length of approximately 7.35 in. (186.69 mm) from the expanded stock.

(3)

Apply assembly fluid to seal groove in bearing retainer plate (90).

(4)

Position the joint sealant centered in the seal groove of bearing retainer plate (90)
so that the ends overlap 0.40 to 0.60 in. (10.2 to 15.2 mm) without compressing the
joint sealant (refer to Figure 1015).

Joint Sealant Installation


Figure 1015

ASSEMBLY

49-22-00

Page 1026
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
K.

Loosely install plate (90), chamfer side toward bearing, and screws (100), align plate (90)
with pin (85, IPC 49-22-00 Figure 3) if present. Do not tighten screws.

L.

Place ST61189-06 plug in rotor shaft (50, IPC 49-22-00 Figure 2).

M.

Install bridge gauge ST61189. Match-mark bridge gauge and air inlet housing assembly
(210, IPC 49-22-00 Figure 1) (refer to Figure 1016).

N.

Press down on air inlet housing assembly (210, IPC 49-22-00 Figure 1) and set dial
indicator of bridge gauge to zero. Remove bridge gauge. Do not change dial indicator
setting. Tighten screws (100) evenly to seat thrust bearing (110). Torque screws
35 to 45 pound inches (3.95 to 5.08 N.m).

Compressor Rotor Clearance Check


Figure 1016

ASSEMBLY

49-22-00

Page 1027
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
O.

Determine rotor assembly (140) clearance as follows (refer to Figure 1017):


NOTE: Refer to Figure 1017 for all clearance limits.
(1)

Install bridge gauge ST61189 aligning match-marks established in step M. and read
dial indicator.

(2)

If compressor impeller (40, IPC 49-22-00 Figure 2) clearance (A3) is more than
maximum, select a thinner spacer (120, IPC 49-22-00 Figure 1) to obtain required
clearance. If compressor rotor clearance is less than minimum use a larger spacer
(120).

(3)

If required, repeat steps K. through N.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
(4)

Apply lubricant MIL-PRF-7808 or MIL-PRF-23699 to threads and face of bearing


retainer nut (80). Use spanner wrench ST70230 and install bearing retainer nut
(80).

(5)

Torque bearing retainer nut (80) 35 to 40 foot-pounds (47 to 54 N.m).

(6)

Check the clearance between bearing retainer nut (80) and plate (90) (A4), refer to
Figure 1017. If clearance is not obtained, disassemble and measure bearings and
spacers.

(7)

Use wire gauge set ST60880 and examine compressor impeller vane to air inlet
housing assembly throat clearance (R1) (refer to Figure 1018). Measure clearance
at four positions around circumference. Refer to Figure 1017 for clearance limits.

ASSEMBLY

49-22-00

Page 1028
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Turbine Assembly Clearances


Figure 1017

ASSEMBLY

49-22-00

Page 1029
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Clearance Check Between Rotor Vanes and Air Inlet Housing


Figure 1018
P.

Determine turbine clearances as follows:


(1)

Position turbine assembly with turbine wheel (80, IPC 49-22-00 Figure 2) up, on
rotor fixture ST70137.

(2)

Measure the seal plate to turbine wheel clearance (A2), refer to Figure 1017.

(3)

Position nozzle assembly (60, IPC 49-22-00 Figure 1) in air inlet housing assembly
(210).

(4)

Install bridge gauge ST61195 (refer to Figure 1019). Match-mark bridge gauge and
nozzle assembly (60, IPC 49-22-00 Figure 1). Set bridge gauge dial indicator to
zero while pressing down on nozzle assembly.

ASSEMBLY

49-22-00

Page 1030
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING:

USE ANTI-SEIZE COMPOUND CORRECTLY. IT IS FLAMMABLE AT


HIGH TEMPERATURES AND A POISONOUS MATERIAL. IT CAN HAVE
A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE
THE ANTI-SEIZE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0200SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ANTISEIZE COMPOUND, PUT ON CHEMICAL-SPLASH
GOGGLES AND OIL-RESISTANT GLOVES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ANTI-SEIZE COMPOUND
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.

(5)

Apply anti-seize lubricant to retainer bolts (70) or pins (71). Install nozzle assembly
(60) with bolts (70) or pins (71) and washers (72 and 73). Torque bolts 25 to 30
pound inches (2.83 to 3.39 N.m) and secure with lockwire or safety cable.

(6)

Install bridge gauge ST61195, aligning match-marks established in step (4).

(7)

Dial indicator reading is the turbine clearance (A1), refer to Figure 1017.

Turbine Wheel Clearance Check


Figure 1019
(8)

Lift rotor assembly (140, IPC 49-22-00 Figure 1) and read dial indicator to establish
rotor assembly end play clearance (A5), refer to Figure 1017. Remove bridge
gauge.
ASSEMBLY

49-22-00

Page 1031
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(9)

Examine turbine wheel (80, IPC 49-22-00 Figure 2) to nozzle assembly (60, IPC
49-22-00 Figure 1) clearance (R2), using wire gauge set ST60880 (refer to Figure
1020). Measure clearance between blade edge and nozzle assembly along four
different blades of turbine wheel for a distance of 0.31 inch (7.874 mm), refer to
Figure 1017.

(10) Secure bolts (70, IPC 49-22-00 Figure 1) with lockwire.


(11) Apply assembly fluid (P/N 4950515 to packing (150). Install packing and plug (140).
Secure with lockwire.

Turbine Wheel to Nozzle Assembly Clearance Check


Figure 1020
(12) Put turbine assembly in horizontal position and spin rotor assembly with your hand.
Make sure rotor assembly (140) turns smoothly and there is no abnormal noise.
(13) Stake bearing retainer nut (80) in three places into slots on rotor shaft (50, IPC
49-22-00 Figure 2).
(14) Install split rings (50, IPC 49-22-00 Figure 1) onto input pinion (40). Install input
pinion (40) into turbine assembly and secure with retaining ring (30).
ASSEMBLY

49-22-00

Page 1032
Jan 15/03

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING:

5.

PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE


PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

Q.

Heat containment ring (220) to 225 to 275 F (107 to 135 C).

R.

Slide containment ring (220) onto air inlet housing assembly (210) until it bottoms out.
Apply primer (P/N MIL-S-22473) and retaining compound (P/N MIL-R-46082) to set
screws (230).

S.

Install set screws (230) and wipe off excess primer and retaining compound.

T.

Apply assembly fluid (P/N 4950515) to packings (10 and 20) and install packings.

Storage After Assembly


A.

This paragraph gives the procedures for preservation, packaging, and storing the turbine
assembly. Equipment and materials necessary for packaging the turbine assembly are
shown in Figure 1021.
NOTE: Equivalent substitutes may be used for items listed.

Part Number
MIL-B-131
PPP-C-843/PPP-C-795
MIL-D-3464
- -- -PPP-T-76/PPP-T-97
MIL-PRF-6081, Grade 1010

Description
Barrier material
Cushioning material
Desiccant
Fiberboard container
Label
Tape
Lubricating oil

Source
Commercially Available
Commercially Available
Commercially Available
Commercially Available
Commercially Available
Commercially Available
Commercially Available

Preservation and Storage Equipment and Materials


Figure 1021
B.

Refer to Standard Practices Manual, Document HSPS 490001, ASSEMBLY, for a list of
protective covers used on the APU for shipment and storage.

C.

Storage Instructions
(1)

Store the turbine assembly as follows:


CAUTION: THE COMPRESSOR IMPELLER IS OF TITANIUM CONSTRUCTION.
RIGIDLY ADHERE TO HANDLING AND CLEANING PROCEDURES
TO PREVENT DAMAGE TO THE COMPRESSOR IMPELLER.
(a)

Wipe external areas of turbine assembly to remove finger prints and assembly
stains.

(b)

Make sure that all openings are correctly covered to prevent foreign object
damage.

(c)

Put air inlet cover around air inlet screen.

ASSEMBLY

49-22-00

Page 1033
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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
D.

E.

Packing
(1)

Insert a layer of cushioning material (P/N PPP-C-843/PPP-C-795) in bottom of


fiberboard container.

(2)

Wrap turbine assembly with barrier material (P/N MIL-B-131).

(3)

Put the turbine assembly in a fiberboard container and fill remainder of space with
cushioning material (P/N PPP-C-843/PPP-C-795).

(4)

Install eight units of desiccant (P/N MIL-D-3464) around turbine assembly.

(5)

Close and seal the container with tape (P/N PPP-T-76/PPP-T-97) to keep moisture
out.

(6)

Attach a label, that identifies component nomenclature, part number, serial number
and date of repair, to the outside of the container.

(7)

Store turbine assembly in an indoor storage environment.

The rotor assembly (140, IPC 49-22-00 Figure 1) can be stored separately as follows.
CAUTION: THE COMPRESSOR IMPELLER IS OF TITANIUM CONSTRUCTION. DO
NOT ALLOW COMPRESSOR IMPELLER, OTHER PARTS, OR TOOLS
THAT CONTACT COMPRESSOR IMPELLER TO BE CONTAMINATED
WITH CHLORINATED HYDROCARBONS, CHLORINE SALTS, METHYL
ALCOHOL SILVER COMPOUNDS OR CADMIUM.
(1)

Clean the rotor assembly (refer to Standard Practices Manual, Document HSPS
490001, CLEANING).

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND
EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
(2)

Apply a light layer of lubricating oil MIL-PRF-6081 on the rotor assembly.

(3)

Insert a layer of cushioning material in bottom of a fiberboard container.

(4)

Wrap rotor assembly with barrier material.

(5)

Put the rotor assembly in the container and fill remainder of space with cushioning
material.

(6)

Install four units of desiccant (P/N MIL-D-3464) around rotor assembly.

(7)

Close and seal the container with tape to keep moisture out.

(8)

Attach a label, that identifies component nomenclature, part number, serial number
and date of repair, to the outside of the container.

(9)

Store rotor assembly in a dry area where temperatures remain between 55 and
95F (13 and 35C).
ASSEMBLY

49-22-00

Page 1034
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

REDUCTION DRIVE ASSEMBLY


49-23-00

REDUCTION DRIVE ASSEMBLY

49-23-00

Title, Page 1
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

REDUCTION DRIVE ASSEMBLY

49-23-00

Title, Page 2
Aug 1/01

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
DESCRIPTION AND OPERATION
1.

Description (Refer to Figure 1)


A.

The reduction drive assembly consists of two gearboxes attached together that utilize a
common input speed.

Reduction Drive Assembly


Figure 1
B.

Reduction Drive Assembly


(1)

The reduction drive assembly reduces the output rotational speed of the turbine
assembly rotor to the speeds necessary to drive the auxiliary power unit (APU)
accessories and driven equipment.

DESCRIPTION AND OPERATION

49-23-00

Page 1
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(2)

C.

D.

The reduction drive housing is machined from a magnesium casting. The APU
lubricating system, consisting of an oil pump, oil filter, pressure relief valve, filter
bypass relief valve, oil jets, oil sump, oil sight gauge, and connecting passages is
contained in the housing.

Accessory Drive Assembly


(1)

The accessory drive assembly is a two-piece, two-pad magnesium housing


containing an accessory (fuel pump/acceleration control) drive gear, ball bearings,
seals, an oil separator closure, a magnetic pickup, and a vent port. The housing is
attached to the top of the reduction drive assembly.

(2)

Only the front pad is utilized for the fuel pump/acceleration control mounting and
drive. A cover is installed on the rear pad.

Lubrication System (Refer to Figure 2)


(1)

The lubrication system provides lubrication to the high-speed input pinion, reduction
and accessory gears, and bearings. The lubrication system consists of the oil
pump, oil filter, pressure relief valve, filter bypass relief valve, low oil pressure
switch, high oil temperature switch, oil jet ring, oil passages, and oil sump.

(2)

The oil pump consists of two gears pinned on shafts mounted inside a two- piece
housing, which is secured in the reduction drive housing. One oil pump gear (driver
gear) is pinned to the oil pump drive shaft. The other gear (driven gear) is pinned to
the oil pump driven shaft. A third gear, the oil pump drive gear, is pinned and
secured with a nut to the end of the pump drive shaft outside the oil pump housing,
and is driven by the reduction gear train.

(3)

The oil filter is installed external to the reduction drive assembly. It consists of a
filter housing, a nominal 10-micron, disposable filter element, and a bypass relief
valve housing that serves as a cap for the filter element. The cap (relief valve
housing) incorporates a spring-loaded, ball-type, bypass relief valve.

(4)

The low oil pressure switch is mounted external to the reduction drive assembly.
The normally-open contacts of the switch open or close when the oil pressure
passes through 6 1 psig (41.3 6.8 kPa) (increasing or decreasing oil pressure).

(5)

The high oil temperature switch is installed in the lower portion of the oil sump,
attached to the reduction drive unit housing. The normally closed contacts of the
switch open upon a rising temperature of 270 to 280F (132 to 138C).

(6)

The pressure relief valve is a spring-loaded, ball-type relief valve, internally


mounted in the main oil gallery. The valve regulates the system oil pressure at 15
to 40 psig (103 to 276 kPa) by passing excess oil flow. The excess oil flow is
directed against the inside surface of the air inlet housing to cool the oil. The cooled
oil then flows to the sump.

(7)

The oil jet ring is located in the bearing carrier assembly for the planetary gear
system. The jet ring encircles the high-speed input pinion and provides three jets of
oil that are directed at the mesh points of the input pinion and planetary gears.
DESCRIPTION AND OPERATION

49-23-00

Page 2
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

A-69861

Lubrication System Schematic


Figure 2

DESCRIPTION AND OPERATION

49-23-00

Page 3
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(8)

2.

The integral sump is located on the lower portion of the reduction drive housing. A
shield installed in the reduction drive housing between the sump and the lowest
gear in the gear train prevents direct contact between rotating parts and bulk oil,
thus preventing foaming of the oil. An oil level sight gauge provides oil level
indication.

Operation
A.

B.

Accessory Drive Assembly


(1)

The intermediate accessory drive gear of the reduction drive assembly transmits
power to the accessory (fuel pump/acceleration control) drive. With an APU rotor
speed of 61,565 rpm, the accessory drive gear rotates at 4,251 rpm.

(2)

The gears are mounted on shafts supported by ball bearings within the accessory
drive housing. The gears and bearings are lubricated by splash oil from the
reduction drive assembly. Shaft seals, mounted in both housing halves, prevent oil
leakage from the accessory drive.

Reduction Drive Assembly


(1)

The turbine assembly input pinion drives three planetary gears. These gears drive
an internally splined ring gear within the reduction drive. The ring gear is centrally
splined to a short output shaft. An external gear, which is integral to the output
shaft, drives the oil pump drive gear. Also integral to the output shaft is an internal
spline, to which the driven equipment is coupled. The output shaft is supported at
both ends by ball bearings. Axial positioning of the shaft is provided by the front
bearing in addition to carrying most of the applied loads.

(2)

The forward and rear ends of the three planetary gear shafts are also supported by
ball bearings in a bearing carrier housing. This circular housing, which provides the
bearing bores for the planetary gears is piloted and secured to the reduction drive
housing. This housing establishes the running center for the turbine assembly input
pinion and the rear running center for the output shaft. The rear center also
becomes the running center for the ring gear. The intermediate accessory drive
gear is mounted on a gear support shaft supported by a double-row ball bearing.

(3)

A deflector shield is installed between the sump and gear portions of the reduction
drive assembly to prevent foaming and to minimize direct contact of the lubricating
oil in the oil sump and the rotating gears. Lubrication of the gears and bearings is
by oil jet stream and splash oil.

(4)

The oil fill cap is located on the side of the drive housing. The cap incorporates a
short chain to prevent its loss. The oil fill port also includes a wire mesh screen to
prevent foreign objects from entering the sump. The APU mounting pads are
located on each side of the housing. An electrical grounding stud is located on the
right side of the housing.

DESCRIPTION AND OPERATION

49-23-00

Page 4
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
C.

Lubrication System
(1)

The pump draws oil from the sump and into the pump housing. Oil is forced from
the pump through drilled passages to the external oil filter. Oil enters the filter
housing, passes through the element (from outside to inside), and flows out from
the housing through a passage in the filter element cap.

(2)

In the filter element cap, a bypass relief valve unseats at a preset pressure
differential across the filter and allows oil to flow from outside the element, through a
passage in the element cap to the filter outlet passage. If the filter element
becomes clogged, oil will bypass the element. This will occur when a pressure
differential of 15 to 25 psig (103 to 172 kPa) is present.

(3)

High-pressure oil from the oil filter moves into a passage leading to four oil jets and
the system relief valve. Three jets in the oil jet ring that encircle the high-speed
reduction drive input pinion direct oil spray to the points where the high-speed
reduction drive input pinion meshes with the three planetary gears. One spray is
directed between the end of the output shaft and input pinion to create a mist for
lubrication of the rotor shaft bearings. The remainder of the gears and gear shaft
bearings are lubricated by oil spray created when oil strikes the planetary gears and
the input pinion.

(4)

The air-oil mist for rotor shaft bearing lubrication is supplied through an oil jet
adjacent to the oil jet ring. This jet directs oil spray to the rear end of the output
shaft, then through the hole in the center of the input pinion from where it flows to
the rear through the hollow rotor shaft. A dam collects a portion of this oil mist and
centrifugal force causes it to flow through the rotor shaft. Near the end of the rotor
shaft, mist passes through a hole in the rotor shaft wall, then reverses direction to
flow forward through the rear roller bearing. It then flows around the outside of the
rotor shaft, through the forward ball bearing, and out from the oil slinger nut into the
reduction drive housing.

(5)

The system relief valve regulates system oil pressure between 40 to 60 psig (276 to
414 kPa) by bypassing a portion of the pump output directly into the reduction drive
housing. The bypassed oil impinges on the inside surface of the air inlet housing,
contributing to oil cooling. Bypassed oil then returns to the sump by gravity flow
through an opening in the bottom of the planetary gear carrier assembly.

(6)

The normally open contacts of the low oil pressure switch close on increasing oil
pressure at 6 1 psig (41.3 6.8 kPa). At rated engine operating speed,
decreasing oil pressure below 6 1 psig (41.3 6.8 kPa) opens the low oil pressure
switch contacts, which is sensed by the ESU as a malfunction. The ESU then
commands the main and maximum fuel solenoid valves to close and shuts down the
APU (except when in flight).

DESCRIPTION AND OPERATION

49-23-00

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

THIS PAGE INTENTIONALLY LEFT BLANK

DESCRIPTION AND OPERATION

49-23-00

Page 6
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
DISASSEMBLY
1.

General
A.

This section has the reduction drive assembly disassembly procedures. When
necessary, disassembly illustrations are also provided. References to item numbers
in the text and accompanying illustrations are identical to those in the Illustrated
Parts Catalog, Document 40C11-3. See Standard Practices Manual, Document
HSPS 490001, DISASSEMBLY, for general disassembly procedures.
NOTE:

References to item numbers in text imply that alpha-variant items listed in


the IPL may be used as determined by the effect code for that item. For
example, reference to item (1) means that procedures also apply to alphavariant items (-1A, -1B, and -1C).

(1)

A reduction drive assembly that requires maintenance shall be disassembled


to the extent required to correct faults.

(2)

Parts to be maintained as matched sets are listed in Figure 501. Special


tools used for disassembly are listed in Figure 502. Parts recommended for
discard are listed in Figure 503.

IPC 49-23-00 Figure

Nomenclature and Item Number

Star Gear (400)

Lube Pump Housing (20) and Lube Pump Cover (30)


Parts to Be Maintained as Matched Sets
Figure 501
Tool Number

Description

Source (Vendor Code)

ST70170

Carrier puller

Hamilton Sundstrand (55820)

ST70284

Retainer ring removal/installation tool

Hamilton Sundstrand (55820)

ST80211

Filter cap removal tool

Hamilton Sundstrand (55820)

ST90134

Bearing puller

Hamilton Sundstrand (55820)

ST90139

Driver

Hamilton Sundstrand (55820)

ST90141

Bearing puller

Hamilton Sundstrand (55820)

ST90154

Bearing puller

Hamilton Sundstrand (55820)

ST90288

Puller

Hamilton Sundstrand (55820)

ST91699

Oil pump puller

Hamilton Sundstrand (55820)

ST93013

Support fixture

Hamilton Sundstrand (55820)

ST93057

Seal puller

Hamilton Sundstrand (55820)

ST93058

Gear puller

Hamilton Sundstrand (55820)

Special Tools and Equipment


Figure 502

DISASSEMBLY

49-23-00

Page 501
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
IPC 49-23-00 Figure

Nomenclature and Item Number

Preformed Packings (20, 40, 60, 90, 110, 140,


250, 613, and 615), Gasket (370), Bearings
(410, 430, 480, and 550), Seal (555)

Gasket (60), Bearings (190), Preformed


Packings (20 and 130), Seal (210)

Inserts (10, 20, and 50A)

NOTE: Discard listed items only if disturbed.


Parts Recommended for Discard
Figure 503
2.

Disassembly of the Reduction Drive Assembly


A.

Remove magnetic drain plug (10, IPC 49-23-00 Figure 1) and packing (20). Remove
magnetic plug (30) and packing (40). Discard packings.

B.

Remove reducers (50) and packings (60). Remove plug and bleeder (55) and
packing (60). Discard packing.

C.

Remove oil fill cap assembly (70) and packing (90). Discard packing.

D.

Remove plug and bleeder (100) and packing (110). Discard packing.

E.

Remove retaining ring (120).

F.

Using removal tool ST80211, remove bypass valve housing (130) (refer to Figure
504).

G.

Remove and discard packing (140, IPC 49-23-00 Figure 1).

H.

Remove screws (210) and washers (240). Remove accessory drive assembly (200)
from reduction drive assembly.

I.

Remove and discard packing (250).

J.

Remove screws (270), washers (280), and relief valve housing (260).

K.

Remove spring (290) and ball (300).

L.

Remove screws (320) and washers (330).

M.

Install puller ST70170 on assembled carrier (360) and remove carrier from reduction
drive assembly (refer to Figure 505). Remove puller from carrier.

DISASSEMBLY

49-23-00

Page 502
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

A-61504
Removal Tool ST80211 In Use
Figure 504

A-61497
Carrier Puller ST70170 In Use
Figure 505
DISASSEMBLY

49-23-00

Page 503
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
N.

Remove and discard gasket (370, IPC 49-23-00 Figure 1).

O.

Remove bypass elbow (380).

P.

Disassemble carrier assembly as follows:


(1)

Install carrier onto fixture ST93013 (refer to Figure 506).

CAUTION: DO NOT USE L-PINS OF SUPPORT FIXTURE AS A DRIFT TO


PRESS OUT STAR GEAR PIN.
(2)

Use an arbor press and a 0.312 inch (7.925 mm) diameter drift to remove
pins (390, IPC 49-23-00 Figure 1).

(3)

Remove star gears (400).


NOTE: Star gears are a matched set and must be kept together.

(4)

Remove retaining rings (420), washers (427), wavy washers (422) and
tabbed washers (425). Press bearings (410) inward and remove from carrier
(360). Discard bearings.

(5)

Remove carrier from support fixture.

A-68564
Support Fixture ST93013 In Use
Figure 506

DISASSEMBLY

49-23-00

Page 504
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(6)

Do not remove inserts (340 and 350) unless damaged. If necessary, refer to
Standard Practices Manual, Document HSPS 490001, REPAIR.

Q.

Use puller ST93058 to remove ball bearing (430) and ring gear (440) from output
shaft (530) (refer to Figure 507). Discard ball bearing.

R.

Remove retaining ring (450, IPC 40-23-00 Figure 1).

S.

Install puller ST90141 and remove assembled idler gear (460) from shaft (590) (refer
to Figure 508).

T.

Remove retaining ring (470, IPC 49-23-00 Figure 1). Use driver ST90139 and an
arbor press to remove ball bearing (480) (refer to Figure 509). Discard ball bearing.

U.

Remove locknut (500, IPC 49-23-00 Figure 1), washer (510), and gear (490).

V.

Use a non-metallic drift in the internally splined end of output shaft to remove output
shaft (530).

W.

Use puller ST90134 to remove ball bearing (550) from output shaft (refer to Figure
510). Remove spacer (540, IPC 49-23-00 Figure 1). Discard ball bearing.

X.

Remove screws (570), pump assembly (560), and ring (575), using puller ST91699.

A-61499
Puller ST93058 In Use
Figure 507
DISASSEMBLY

49-23-00

Page 505
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

A-61500
Puller ST90141 In Use
Figure 508

A-61501
Driver ST9019 In Use
Figure 509

DISASSEMBLY

49-23-00

Page 506
Jul 1/00

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

A-61502
Puller ST90134 In Use
Figure 510
Y.

Remove shield (580).

Z.

If damaged, remove gear support shaft (590) as follows:


(1)

Match-mark gear support shaft (590) and housing assembly (640).

(2)

Remove screws (600) and washer (620).

DISASSEMBLY

49-23-00

Page 507
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

AA.

WARNING:

PUT ON THERMALLY INSULATED GLOVES AND OTHER


SUITABLE PROTECTION TO PREVENT BURNS WHEN LOADING
PARTS INTO A PREHEATED OVEN OR HANDLING HEATED OR
CHILLED PARTS.

WARNING:

USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE)


CORRECTLY. THE DRY ICE FUMES ARE POISONOUS. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE
YOU USE THE DRY ICE, GET THE MATERIAL SAFETY DATA
SHEETMATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0088SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE DRY ICE,
PUT ON INSULATED GLOVES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE DRY ICE FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.

(3)

Using a heat gun, heat housing in gear support shaft area 140 to 150F (60
to 65.5C) for 30 minutes. At the same time, cool gear support shaft with dry
ice.

(4)

Using a 0.156 inch (3.962 mm) diameter drift, drive the gear support shaft
(590) from housing assembly (640).

If damaged, remove oil seal (555) as follows:


CAUTION: TO PREVENT DAMAGE, DO NOT ALLOW SHAVINGS TO FALL INTO
THE GEARBOX HOUSING.
(1)

Drill three equally spaced 0.125-inch (3.175 mm) diameter holes or punch
through existing pilot holes in seal (555) to match mounting holes of puller
ST93057.

(2)

Install puller, using number 10 sheet metal screws (refer to Figure 511), and
remove seal. Discard seal.

DISASSEMBLY

49-23-00

Page 508
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

A-61503
Puller ST93057 In Use
Figure 511
3.

4.

Disassembly of the Accessory Drive Assembly (ACCESS)


A.

Remove union (10, IPC 49-23-00 Figure 2) and packing (20). Discard packing.

B.

Remove screws (40), washers (50), lifting plate (30), and gasket (60).

C.

Remove screws (80), washers (90), accessory drive cover (120), and packing (130).
Discard packing.

D.

Remove seals (210) from accessory drive cover (120) and accessory drive housing
(170).

E.

Remove accessory gear (180) and associated parts from accessory drive housing
(170).

F.

Remove bearings (190) and oil separator plates (200).

G.

Do not remove inserts (115) unless damaged. If necessary, refer to Standard


Practices Manual, Document HSPS 490001, REPAIR.

Disassembly of the Oil Pump


A.

Remove pin retaining ring (100, IPC 49-23-00 Figure 3).

B.

Remove one dowel pin (90) in pump driver shaft (60).

C.

Separate lube pump cover (30) from lube pump housing (20) and remove gears (80).

D.

Remove dowel pins (90) and shafts (60 and 70).


DISASSEMBLY

49-23-00

Page 509
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
E.
5.

Remove pins (40 and 50).

Disassembly of the Reduction Drive Housing Assembly


A.

Do not remove stud (60, IPC 49-23-00 Figure 4) unless damaged.

B.

Do not remove inserts (10, 20, and 50A) unless damaged. If necessary, remove
according to Standard Practices Manual , Document HSPS 490001, REPAIR.

C.

Do not remove lockrings (30) and studs (40) unless damaged. If necessary, remove
according to Standard Practices Manual, Document HSPS 490001, REPAIR.

DISASSEMBLY

49-23-00

Page 510
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
ASSEMBLY
1.

General
A.

This section has the assembly procedures for the reduction drive assembly. When
necessary, assembly illustrations are also provided. References to item numbers in the
text and accompanying illustrations are identical to those in the Illustrated Parts Catalog,
Bulletin 40C11-3. Refer to Standard Practices Manual, Document HSPS 490001,
ASSEMBLY, for general assembly procedures. Storage instructions are also contained in
this section.
NOTE: References to item numbers in text imply that alpha-variant items listed in the IPL
may be used as determined by the effect code for that item. For example,
reference to item (1) means that procedures also apply to alpha-variant items
(-1A, -1B, and -1C).
(1)

Materials required for assembly are listed in Figure 1001.


NOTE: Equivalent substitutes may be used for items listed.
NOTE: Assembly fluid may be used for aiding in installation of packings, gaskets, or
holding other small components in place for ease of assembly and
prevention of galling. If necessary, assembly fluid may be diluted with MIL-L7808 or MIL-L-23699.

(2)

Parts to be maintained as matched sets are listed in Figure 1002.

(3)

Special tools used for assembly are listed in Figure 1003.


NOTE: Equivalent substitutes may be used for items listed.

Part Number
ASTM D770
169015-1
4950515
--Loctite 277
RTV-106
Grade T or N MIL-S-22473
RTV-3145
Type III MIL-S-45180
Form-a-gasket No. 3
PR1440 B2

Description
Isopropyl Alcohol
Solid Film Lubricant
Assembly Fluid
Dry Ice
Pipe Sealant, Type I,
Grade L
Adhesive
Primer
Adhesive
Sealing Compound
Gasket Compound
Sealant

Source (Vendor Code)


Commercially Available
Hamilton Sundstrand (99167)
Hamilton Sundstrand
Commercially Available
Loctite Corp. (05972)
General Electric (01139)
Commercially Available
General Electric
Commercially Available
Permatex (62377)
Products Research and Chemical
Corp. (83574)

Assembly Material
Figure 1001
ASSEMBLY

49-23-00

Page 1001
Nov 15/07

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
IPC 49-23-00 Figure

Nomenclature and Item Number

Star Gear (400)

Lube Pump Housing (20) and Lube Pump


Cover (30)
Parts to Be Maintained as Matched Sets
Figure 1002
Number

AID-00494
ST70282
ST70284
ST70394
ST70414
ST70414-05
ST70414-08
ST70416
ST71240
ST71241
ST71248
ST90133
ST90361
ST90675
ST90889-03
ST90889-06
ST93013
ST93228
ST93974
ST95153

Description
Compressor Tool
Driver
Installation tool
Assembly fixture
Driver
Driver
Driver
Socket Wrench
Driver
Installation Tool
Aligning pin
Driver
Driver
Driver
Driver and guide assembly
Driver and guide assembly
Support fixture
Driver
Installation tool
Holding Fixture

Source (Vendor Code)


Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)
Hamilton Sundstrand (55820)

Special Tools and Equipment


Figure 1003
2.

Assembly of the Reduction Drive Housing Assembly


A.

If removed, install inserts (10, 20, and 50A, IPC 49-23-00 Figure 4) according to Standard
Practices Manual, Document HSPS 490001, REPAIR.

B.

If removed, install studs (40) and lockrings (30) according to Standard Practices Manual,
Document HSPS 490001, REPAIR.

C.

If removed, install grounding stud (60) (Pre SB-T-62T-49-173)


(1)

Install grounding stud (60) and torque 24 to 27 pound inches (2.7 to 3.1 Nm).

ASSEMBLY

49-23-00

Page 1002
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE MANGANESE DIOXIDE-CURED POLYSULFIDE RUBBER SEALANT
PR1440 B-2, CORRECTLY. THE SEALANT CONTAINS POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE SEALANT, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0189SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE SEALANT, PUT
ON SAFETY GLASSES OR CHEMICAL-SPLASH GOGGLES AND
SOLVENT-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(2)
D.

Apply sealant PR1440 B2 around stud.

If removed, install grounding stud (60A) (Post SB-T-62T-49-173).


WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL
ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(1)

Clean and degrease the surface around the base of the grounding stud (60A) on the
reduction drive using isopropyl alcohol and a clean, lint-free cloth.

(2)

Install grounding stud (60A) and washer (63). Torque stud 24 to 27 pound inches (2.7
to 3.1 Nm).

WARNING: USE MANGANESE DIOXIDE-CURED POLYSULFIDE RUBBER SEALANT


PR1440 B-2, CORRECTLY. THE SEALANT CONTAINS POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE SEALANT, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0189SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE SEALANT, PUT
ON SAFETY GLASSES OR CHEMICAL-SPLASH GOGGLES AND
SOLVENT-RESISTANT GLOVES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(3)

Apply sealant PR1440 B2 to the sides of grounding stud (60A) and washer (63).
NOTE: Do not cover threads or top surface of grounding stud.

ASSEMBLY

49-23-00

Page 1003
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
3.

Assembly of the Lube Oil Pump Assembly


A.

Make sure lube oil pump housing (20, IPC 49-23-00 Figure 3) and cover (30) have identical
serial numbers.
NOTE: The housing and cover must be assembled as a matched set.

B.

Insert pump driver shaft (60) and pump driven shaft (70) into the lube oil pump housing
(20). Make sure they are correctly located.

C.

Install one dowel pin (90) in each shaft and install gears (80).

D.

Install lube oil pump cover (30) and temporarily install two attaching screws (110) and nuts.
Make sure pump rotates freely.

E.

Press pins (40 and 50) into lube oil pump cover (30) and housing (20) until flush with cover
face. Check that pins protrude 0.123 to 0.166 inch (3.12 to 4.22 mm) from housing (20).

F.

Remove nuts and screws (110).

G.

Install dowel pin (90) in driver shaft (60).


NOTE: Keep retainer (100) with pump assembly for use when the pump is installed.

4.

Assembly of the Accessory Drive Assembly (ACCESS)


A.

If removed, install inserts (115, 150, and 160, IPC 49-23-00, Figure 2) according to
Standard Practices Manual, Document HSPS 490001, REPAIR.

B.

Install centrifugal separator plates (200) on each side of accessory gear (180).

WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE) CORRECTLY.
THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE DRY ICE, GET THE
MATERIAL SAFETY DATA SHEETMATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0088SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE DRY ICE, PUT ON INSULATED
GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE
ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
C.

Place accessory gear (180) and assembled centrifugal plates (200) in dry ice for
approximately 25 to 30 minutes.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE


PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
D.

Lubricate the bearing contact areas of accessory drive housing (170) and accessory cover
(120) with assembly fluid. Place accessory drive housing (170) and accessory cover (120)
in an oven for 10 to 15 minutes at 195F (90.6C).
ASSEMBLY

49-23-00

Page 1004
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE) CORRECTLY.
THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE DRY ICE, GET THE
MATERIAL SAFETY DATA SHEETMATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0088SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE DRY ICE, PUT ON INSULATED
GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE
ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
E.

Remove accessory gear (180) and assembled centrifugal separator plates (200) from the
dry ice. Use an arbor press and install bearings (190) on both sides of accessory gear
(180), with thrust side facing away from gear.
NOTE: Make sure bearings are fully seated on shoulder of gear.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE


PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
CAUTION: THE PLUG IN THE ACCESSORY GEAR MUST FACE TOWARD THE FRONT OF
THE ACCESSORY DRIVE HOUSING (170) OR DAMAGE TO THE ACCESSORY
DRIVE MAY OCCUR.
F.

Remove the accessory drive housing (170) from the oven. Use an arbor press and
installation tool ST71241 and install accessory gear (180) and bearings (190) into
accessory drive housing (170).

G.

Place the accessory gear (180) in the accessory drive housing (170) with the shoulder of
the internal spline against the forward face of the housing.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE


PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
H.

Remove the accessory drive cover (120) from the oven. Install packing (130) on the
accessory drive cover (120).

I.

Install two threaded guide pins into the accessory drive housing (170) 180 apart. Press fit
the accessory drive cover (120) on the accessory drive housing (170) and secure with
washers (90) and screws (80). Torque screws 16 to 19 pound inches (1.8 to 2.1 Nm).

J.

Remove the two threaded guide pins from the accessory drive housing (170).

K.

Use guide and driver assembly ST90889 seal guide and install seals (210) in the
accessory drive housing (170) and the accessory drive cover (120). Remove and discard
seal guide.
NOTE: Lip seal edges should face in. Seals should be flush with outside face of the
accessory drive housing and the accessory drive cover.
ASSEMBLY

49-23-00

Page 1005
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
NOTE: A polypropylene seal guide is furnished with seal (210A) and is used for
installation of the seal.

5.

L.

Install gasket (60) and lifting plate (30) on the accessory drive housing (170) with screws
(40) and washers (50). Torque screws 24 to 27 pound inches (2.7 to 3.1Nm).

M.

Install packing (20) on union (10) and install union in lifting plate (30). Torque union 135 to
150 pound inches (15.2 to 16.9 Nm).

Assemble Carrier Assembly


A.

If removed, install inserts (340 and 350, IPC 49-23-00 Figure 1) according to Standard
Practices Manual, Document HSPS 490001, REPAIR.

B.

Pre SB-49-151:
(1)

Install retaining rings (420, IPC 49-23-00 Figure 1) in carrier (360).

(2)

Install bearings (410) from inside of carrier with thrust side against retaining ring.

(3)

Install carrier in support fixture ST93013 (refer to Figure 1004).


NOTE: Star gears are a matched set and must be kept together.

A-61518
Install Star Gears
Figure 1004
(4)

Install star gears (400, IPC 49-23-00 Figure 1) in carrier (360) with serial number
facing the small base of the carrier. Line up gear and bearing bores with L-pins of
support fixture ST93013.

ASSEMBLY

49-23-00

Page 1006
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING:

(5)

PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE


PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

Heat assembled carrier (360) 180 to 200F (82 to 93C) for 30 minutes.

WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE)


CORRECTLY. THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A
BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
DRY ICE, GET THE MATERIAL SAFETY DATA SHEETMATERIAL SAFETY
DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0088SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
DRY ICE, PUT ON INSULATED GLOVES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(6)

Cool pins (390) in dry ice for 30 minutes.

(7)

Remove L-pins (one at a time) and press in pins (390) using a 0.312 inch (7.925 mm)
diameter drift.
NOTE: Do not use L-pins of support fixture as a drift.

C.

Post SB-49-151:
(1)

Install three tabbed washers (425, IPC 49-23-00 Figure 1) and three bearings (410A)
in carrier (360A).
NOTE: The bearings must be installed with the counterbore facing up.
NOTE: Make sure the washer tab fits into the machined groove of the carrier
housing.
NOTE: Star gears are a matched set and must be kept together.

(2)

Install star gears (400) in carrier (360) with serial number facing the small base of the
carrier. Align gear and bearing bores with L-pins of support fixture.

(3)

Install the three remaining bearings (410A, IPC 49-23-00 Figure 1) and the three
tabbed washers (425).
NOTE: The bearing counterbores must face each other.
NOTE: Make sure the washer tab fits into the machined groove of the bearing.

(4)

Install carrier in support fixture AID-00494 (refer to Figure 1004A). Align gear and
bearing bores.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE


PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
(5)

Heat assembled carrier (360) 180 to 200F (82 to 93C) for 30 minutes.
ASSEMBLY

49-23-00

Page 1007
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE)
CORRECTLY. THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A
BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
DRY ICE, GET THE MATERIAL SAFETY DATA SHEETMATERIAL SAFETY
DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0088SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
DRY ICE, PUT ON INSULATED GLOVES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.
(6)

Let pins (390) cool in dry ice for 30 minutes.

(7)

Remove L-pins (one at a time) and press in pins (390) using a 0.312 inch (7.925 mm)
diameter drift.
NOTE: Do not use L-pins of support fixture as a drift.

(8)

Install three wavy washers (422) on top of tabbed washers (425).

(9)

Install three washers (427) on top of the wavy washers (422).

(10) Place three retaining rings (420A) on support fixture AID-00494. Compress the
wavey washers (422) and install the retaining rings (420A) into the carrier housing
(310A) groove. Remove carrier assembly from fixture AID-00494.
D.

Install ball (300), spring (290), and relief valve housing (260). Secure with washers (280)
and screws (270). Torque screws 20 to 25 pound inches (2.3 to 2.8 Nm) above selflocking torque.

ASSEMBLY

49-23-00

Page 1008
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

Install Star Gears


Figure 1004A
6.

Assemble Gear Train


WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
A.

Heat bearing (550) 180 to 200F (82 to 93C) for 30 minutes.

WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE) CORRECTLY.
THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE DRY ICE, GET THE
MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0088SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE DRY ICE, PUT ON INSULATED GLOVES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
B.

Let output shaft (530) cool in dry ice for 30 minutes.

C.

Install spacer (540) on output shaft.

D.

Install bearing (550) on output shaft using driver ST70282 (refer to Figure 1005).
ASSEMBLY

49-23-00

Page 1009
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
NOTE: Make sure the bearing outer race counterbore side faces the inside of the
reduction drive housing assembly.
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
E.

Heat reduction drive housing assembly (640, IPC 49-23-00 Figure 1) 140 to 150F (60 to
66C) for 30 minutes.

A-61519
Install Output Shaft Bearing
Figure 1005
F.

Remove housing from oven and install in assembly fixture ST70394 (refer to Figure 1006).

G.

Install assembled output shaft (530) using driver ST90133 (refer to Figure 1007).

ASSEMBLY

49-23-00

Page 1010
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES

A-61520
Install Reduction Drive Housing Assembly on Fixture
Figure 1006

A-61521-1
Install Output Shaft
Figure 1007
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
H.

Heat reduction drive housing assembly (640, IPC 49-23-00 Figure 1) 140 to 150F (60 to
66C) for 30 minutes.
ASSEMBLY

49-23-00

Page 1011
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE DRY ICE (ALSO KNOWN AS FROZEN CARBON DIOXIDE) CORRECTLY.
THE DRY ICE FUMES ARE POISONOUS. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE DRY ICE, GET THE
MATERIAL SAFETY DATA SHEETMATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0088SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE DRY ICE, PUT ON INSULATED
GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE
ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
I.

Cool shaft (590) in dry ice for 30 minutes.

J.

Remove housing from oven. Insert two aligning pins ST71248 in gear support shaft
attachment holes. Install pin in reduction drive housing assembly. Align match-marks and
install gear support shaft (590) using driver ST90675 (refer to Figure 1008).

A-61523
Install Gear Support Shaft
Figure 1008
K.

Remove aligning pins and install screws (600, IPC 49-23-00 Figure 1). Torque screws 20
to 25 pound inches (2.3 to 2.8 Nm) above self-locking torque.

L.

Install aligning pins ST71248 into pump assembly (560) attachment holes.

ASSEMBLY

49-23-00

Page 1012
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
M.

Heat reduction drive housing assembly (640) 140 to 150F (60 to 66C) for 30 minutes.

N.

Remove housing from the oven and install pump assembly (560) using driver ST90361
(refer to Figure 1009). Install ring (100, IPC 49-23-00 Figure 3). Secure with screws (570,
IPC 49-23-00 Figure 1). Torque screws 20 to 25 pound inches (2.3 to 2.8 Nm) above selflocking torque.

A-61524
Install Pump Assembly
Figure 1009
O.

Install shield (580).

P.

Align slots in gear (490) with pin in pump assembly drive shaft and install gear. Secure
with washer (510) and nut (500). Torque nut 20 to 25 pound inches (2.3 to 2.8 Nm).
NOTE: Make sure pin (90, IPC 49-23-00 Figure 3) is installed in pump assembly driver
shaft.

ASSEMBLY

49-23-00

Page 1013
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
Q.

Heat idler gear (460, IPC 49-23-00 Figure 1) 180 to 200F (82 to 93C).

R.

Remove gear from oven and install ball bearing (480) using driver ST70414-05 (refer to
Figure 1010). Install retaining ring (470, IPC 49-23-00 Figure 1).

A-61525
Install Idler Gear and Bearing
Figure 1010
S.

Install assembled gear (460) on gear support shaft (590) using driver ST71240. Install
retaining ring (450).

T.

Install ring gear (440) on output shaft (530).

U.

Install bearing (430), with thrust face of the bearing facing away from the shoulder of ring
gear (440), using driver ST71240.

ASSEMBLY

49-23-00

Page 1014
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
7.

Assemble Reduction Drive Assembly


WARNING: USE LOCQUIC PRIMER GRADE N OR T, CORRECTLY. THE PRIMER IS
FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE PRIMER, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0135SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
PRIMER, PUT ON CHEMICAL-SPLASH GOGGLES AND SOLVENT-RESISTANT
GLOVES (BUTYL RUBBER). MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE PRIMER FUMES BELOW THE MATERIAL SAFETY
DATA SHEET LIMIT.
A.

Apply Grade N or Grade T Primer to threads of diverter plug (610) and allow a minimum of
5 minutes to dry.

WARNING: USE PIPE SEALANT COMPOUND CORRECTLY. THE COMPOUND IS


COMBUSTIBLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY.
BEFORE YOU USE THE COMPOUND, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0069SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE COMPOUND, PUT ON
SAFETY GLASSES OR GOGGLES AND NEOPRENE, RUBBER, OR BUTYL
RUBBER GLOVES
B.

Apply pipe sealant to threads of plug (610) and install into front of reduction drive housing
assembly (640). Torque plug to 20-30 pound inches (2.3 to 3.4 Nm).
NOTE: Top of plug (610) should be 0.00 to 0.06 inches (0.00 to 0.15 mm) below surface
of reduction drive housing assembly (640).
NOTE: The long end of bypass elbow goes into carrier housing. Make sure the orifice of
elbow is aligned with oil passage.
NOTE: Do not apply pipe sealant to threads of plug (610A).

C.

Install bypass elbow (380) in carrier (360).

D.

Install gasket (370) on carrier (360).

E.

Install carrier (360) in reduction drive housing assembly (640) and secure with washers
(330) and screws (320). Torque screws in a clockwise pattern, in three steps, as follows:

F.

(1)

Torque screws 10 to 12 pound inches (1.1 to 1.4 Nm).

(2)

Torque screws 22 to 25 pound inches (2.5 to 2.8 Nm).

(3)

Torque screws 33 to 37 pound inches (3.7 to 4.2 Nm).

Apply a light coat of assembly fluid around inside diameter of seal (555) and seal guide.
Install seal using driver ST93228 into housing (640). Remove and discard seal guide.
ASSEMBLY

49-23-00

Page 1015
Mar 15/04

HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
NOTE: A polypropylene seal guide is furnished with seal (555) and is used for installation
of the seal.
G.

Place packing (250) and accessory drive assembly (200) on reduction drive housing
assembly (640). Secure with screws (210) and washers (240). Tighten screws evenly
using a criss-cross pattern from the middle and working outward. Torque screws 24 to 27
pound inches (2.7 to 3.1 Nm).

H.

Install packing (140) on bypass valve housing (130).

I.

Install bypass valve housing (130). Secure with retaining ring (120).

J.

Place packing (110) on plug and bleeder (100) and install plug and bleeder. Torque plug
and bleeder 40 to 50 pound inches (4.5 to 5.6 Nm).

K.

Place packing (90) on housing (78) and install housing (78) and screen (76).
Torque housing 60 to 80 pound inches (6.8 to 9.0 Nm).

L.

Place packing (80) on plug (74).

M.

Connect chain (72) from housing (78) to plug (74). Install plug (74).

N.

Place packings (60) on reducers (50) and plug and bleeder (55).

O.

Install reducers (50) and plug and bleeder (55). Torque reducers and plug and bleeder 25
to 35 pound inches (2.8 to 4.0 Nm).

P.

Place packing (20) on magnetic drain plug (10) and install magnetic drain plug. Torque
magnetic drain plug 40 to 60 pound inches (4.5 to 6.8 Nm).

Q.

Place packing (40) on magnetic plug (30) and install magnetic plug. Torque plug 20 to 30
pound inches (2.3 to 3.4 Nm).

WARNING: LUBRICANT, DRY FILM, IS TOXIC AND FLAMMABLE. DO NOT BREATHE


VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME,
OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT,
FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN
CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
R.

Spray solid film lubricant onto exposed splines of output shaft (530).

ASSEMBLY

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
WARNING: USE SILICONE ADHESIVE/SEALANT, DOW CORNING 3145, CORRECTLY.
KEEP THE SEALANT AWAY FROM WATER OR MOIST AIR. THE SEALANT
CAN REACT WITH WATER OR MOIST AIR TO MAKE METHYL ALCOHOL GAS.
METHYL ALCOHOL GAS IS VERY FLAMMABLE AND CAN BE EXPLOSIVE. DO
NOT SWALLOW THE SEALANT, IT CAN MAKE METHYL ALCOHOL THAT CAN
CAUSE DEATH OR BLINDNESS. BEFORE YOU USE THE SEALANT, GET THE
MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0202SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE SEALANT FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
S.
8.

If removed, bond new identification plate (620) or oil decal (630) to reduction drive
assembly, using adhesive RTV 3145.

Storage After Assembly


A.

This paragraph details the procedures for preservation, packaging, and storing the
reduction drive assembly. Equipment and materials required for packaging the reduction
drive assembly are listed in Figure 1011.
Name

Barrier material MIL-B-131


Cushioning material PPP-C-843/PPP-C-795
Desiccant MIL-D-3464
Fiberboard container
Label
Tape PPP-T-76/PPP-T-97

Source (Vendor Code)


Commercially Available (99167)
Commercially Available
Commercially Available
Commercially Available
Commercially Available
Commercially Available

Preservation and Storage Equipment and Materials


Figure 1011
B.

Storage Instructions
(1)

Clean reduction drive assembly in accordance with Standard Practices Manual,


Document HSPS 490001, CLEANING.
NOTE: Do not touch machined surfaces with bare hands after cleaning.

C.

(2)

Make sure that all ports are suitably capped.

(3)

Make sure that all openings are suitably covered to prevent entry of foreign objects.

Packing
(1)

Insert a layer of cushioning material in bottom of fiberboard container.

(2)

Wrap reduction drive assembly studs with barrier material.


ASSEMBLY

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HAMILTON SUNDSTRAND
ENGINE MANUAL
PART NUMBER 4501966 SERIES
(3)

Wrap reduction drive assembly with barrier material.

(4)

Place reduction drive assembly and eight units of desiccant in container and fill
remainder of space with cushioning material.

(5)

Close and seal container using tape, as necessary, to keep moisture out.

(6)

Attach a label to outside of container identifying component nomenclature, part


number, and date of repair.

(7)

Store reduction drive assembly in an indoor storage environment.

ASSEMBLY

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Minat Terkait