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[Chapter 72 TOC] ENGINE MAINTENANCE MANUAL SPAF–TB3EMM–1

TABLE OF CONTENTS

Title Section,
Sub-Section, Page
Subject
072.00.00

ENGINE - CLEANING/PAINTING ................................................................................................................. 1


1. GENERAL ............................................................................................................................................. 1
PROCEDURES FOR PERFORMING ADJUSTMENTS AND CHECKS ................................................................... 2
TASK CARD NO. 701.................................................................................................................................. 2
ROCEDURE: Engine Cleaning .............................................................................................................. 2
TASK CARD NO. 702.................................................................................................................................. 4
ROCEDURE: Removal of Corrosion From Engine Components ............................................................... 4
TASK CARD NO. 703.................................................................................................................................. 7
PROCEDURE: Reconditioning of Paint-and-Varnish Coatings .................................................................. 7
Figure 701 Locations of Paint-and-Varnish Coatings on Engine .............................................................. 8
TASK CARD NO. 704................................................................................................................................ 12
PROCEDURE: Reconditioning of Paint-and-Varnish Coatings On The Housing of The First Support
Assembly ......................................................................................................................................... 12
TASK CARD NO. 705................................................................................................................................ 14
ROCEDURE: Cleansing of Engine Flow Section ................................................................................... 14
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[Chapter 72 TOC] ENGINE MAINTENANCE MANUAL SPAF–TB3EMM–1

ENGINE - CLEANING/PAINTING

1. General

The present topic comprises the following Task Cards:


- Engine cleaning (Ref. Task Card No. 701).
- Removal of corrosion from engine components (Ref. Task Card No. 702).
- Reconditioning of paint-and-vanish coatings (Ref. Task Card No. 703).
- Reconditioning of paint-and-vanish coatings on the housing of the first support assembly (Ref. Task Card
No. 704).
-Cleansing of engine flow section (Ref. Task Card No. 705).

EFEECTIVITY:
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PROCEDURES FOR PERFORMING ADJUSTMENTS AND CHECKS

PAGES
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703/704

MS. ITEM ROCEDURE: Engine Cleaning

CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

CAUTION: DURING CLEANING TAKE STEPS TO PREVENT GASOLINE PROM COMING INTO CONTACT WITH
THE ELECTRIC WIRING OR GETTING ONTO THE AIR BLEED JETS AUD INTO THE PASSAGES
VENTING THE INNER CHAMBERS OP THE FUEL CONTROL UNIT AND AIR STARTER TO
ATMOSPHERE.

1. Using a cloth piece moistened with gasoline, remove dust, dirt, contamination, oil and fuel stains from the If a fuel or oil leakage is
engine external surfaces and then wipe with a clean dry cloth piece. detected, rectify the
Air dry for 10 to 15 min or blow off with moisture-free compressed air, making sure the surfaces have dried defect (Ref. Pig. 113)
and no gasoline has lodged in the engine inlet duct or elsewhere.

2. Verify that the paint-and-varnish coating is not damaged and there is no signs of corrosion. Restore the damaged
coating (Ref. Task Card
No. 703) and remove
corrosion (Ref. Task Card
No. 702).
3. If any clustered fungus are found on the engine external surfaces, remove them by wiping dry the affected
area with a dry cloth piece and then apply a thin layer of a preservation oil
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TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

1. Gasoline
2. Preservation oil
3. Cotton cloth piece
4. Abrasive cloth, grade 16 to 10
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PAGES
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705/708

MS. ITEM ROCEDURE: Removal of Corrosion From Engine Components

CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

1. General
1.1. Given below are indications of corrosion on components made of various metallic alloys:
(a) Corrosion of steel parts is evident aa an orange-brown coating which, when spreading, turns into a
solid mass of. outgrowth of a red-brown, brown or black color accompanied by breakdown of metal
surface in the form of pitting.
(b) Corrosion of parts made from Al -alloys is evidenced first by a white powdery coat which, when
growing further, is accompanied by pits filled with the products of corrosion of white and grey color.
(c) Corrosion of Mg-alloys is indicated by formation of a loose damp deposit of a dirty-whitish color,
covering the damaged metal.
(d) Corrosion of painted parts starts with the bulging of a paint-and-varnish film and then progresses to
the flaking of the film.
(e) Corrosion of oxidized steel parts is identified by ail orange-brown rust or by spots and dots barely
differing in color from the surface of the parts.

(f) Corrosion of cadmium-plated, parts is indicated by formation of a white, grey or black spots or a

powdery coating.

2. Removal of Corrosion from Engine Components


2.1. Remove corrosion from aluminum and steel components by dressing them with abrasive cloth, grade
16 to 10.
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OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

2.2. Remove corrosion from Mg-alloy parts by dressing them with the help of abrasive cloth of 16 to 10 grade
and then subjecting them to degreasing in gasoline and local dichromating.
Carry out the local dichromating by rubbing the cleaned surfaces with a brush moistened with a solution
of the following composition:
- Potassium dichromate/sodium dichromate 179 g
- Nitric acid (sp. g. = 1.4 g/cm3) 187 mltr
- Water 1 ltr
The time of dichromating is 30 to 40 s.

WARNING: IF SOME DICHROMATING SOLUTION HAS BEEN SPILLED ON HANDS, WASH IT OFF WITH
COLD WATER.
Immediately after dichromating, wipe the surfaces of parts with a wet cloth piece and then wipe dry.

CAUTION: NEVER ALLOW THE DICHROMATING SOLUTION TO GET ONTO SURFACES OF OTHER METALS
AND ALLOYS AS IT WILL CAUSE THEIR CORROSION.
KEEP THE DICHROMATING SOLUTION IN TIGHTLY SEALED VESSELS.
2.3. Following removal of corrosion, restore the damaged paint-and-varnish coating on the engine parts (Ref.
Task Card No. 703).
If the parts are unpainted, paint them with black enamel K0-818K (Ref. Step 3.3 and Para 4 of Task Card
No. 703).
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TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

1. Gasoline
2. Abrasive cloth, grade 16 to 10
3. Potassium dichromate or sodium dichrornate
4. Nitric acid
5. Water
6. Cotton cloth piece
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PAGES
TO M. S. TASK CARD No. 703
709 to 713/714

MS. ITEM PROCEDURE: Reconditioning of Paint-and-Varnish Coatings

CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

1. General

1.1. Recondition the paint-and-vanish coatings by applying the ЭП-140 enamel (of various colors) over the
preliminarily applied layer of the ЭП-076 primer and the KO-818K enamel.
1.2. For locations of the paint-and-varnish coatings on the engine, refer to Figure 701.
1.3. The paint-and-varnish coatings have adequate protective properties when they are applied onto a
preliminarily prepared surfaces.
1.4. It is prohibited to touch up corroded surfaces because in this case corrosion continues to progress under
the painted coating causing its subsequent bulging and flaking.
1.5. Store the paint-and-varnish materials in tightly sealed vessels.

2. Preparation of Surfaces for Painting

2.1. If a painted coating has been damaged to the layer of primer, degrease the surface by wiping it with a
cloth piece moistened with gasoline and let it dry in the open air for not less than 15 min.
2.2. If a painted coating has been damaged to the metal, remove corrosion (if any) (Ref. Task Card No. 702),
dress the surface with abrasive cloth of grit Nos 16 to 10, degrease it by wiping with a cloth moistened
with gasoline and let it dry in the open air for a minimum period of 15 min.
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CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY
A
2 D
1 2 2 2 2 D 2 2 2 2
A
1
2
2 2
В
E

F
version

1 1 2 2 2

В E
2 1 1. Areas coated with ЭП-076 primer with subsequent
2
coating with ЭП-140 enamel
2
2. Area coated with K.O-818K enamel

Temperature
controller

Figure 701 Locations of Paint-and-Varnish Coatings on Engine


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OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

3. Preparation of Paint-and-Varnish Materials

3.1. The epoxidized enamel ЭП-140 is prepared just before use by mixing the semi-finished enamel and a
hardener in the following proportion:
(a) To prepare the aluminum-filled (silvery) enamel, mix 70 weight parts of the semi-finished enamel and
30 weight parts of hardener No. 4 and then add 11 weight parts of the ПАП-2 aluminum powder to
100 weight parts of the just prepared base. The enamel is ready for use after 30 min from the moment
it was prepared. The pot life of the prepared enamel is not more than 5 h.
(b) To prepare the ЭП-140 enamel (of black color), mix 70 weight parts of the semi-finished enamel with
30 weight parts of hardener No. 2. The maximum pot life of the enamel is 5 days.
This the prepared enamel to the working viscosity with thinner P-5 and then filter the enamel through
three layers of gore.
3.2. Prepare the ЭП-076 primer immediately before use. The primer is prepared by mixing 75 weight parts of
the pigmented paste and 25 weight parts of hardener No. 2.
Thin the primer to the working viscosity with thinner P-5 or a ternary mixture consisting of 30 weight
parts of acetone, 30 weight parts of ethyl cellosolve and 40 weight parts of xylene.
The pot life of the prepared primer is 5 days.
3.3. To prepare the KO-818K enamel of black color, add 5 or 6 weight parts of hardener МФСН "B" and 80 to
100 weight parts of thinner P-5 or toluene to 100 weight parts of the KO-818 enamel.
After mixing with the hardener, the enamel may be used for a period of 24 h.

4. Touching up of Components on Engine

4.1. Prior to touching up, thoroughly mix all paint-and-varnish materials up to disappearance of the sediment.
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OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

4.2. Apply one coat of the enamel at a temperature within a range of plus 12 to 50 °C with the aid of a paint
blower or a brush.
It is not allowed to perform the touching-up operation in wet weather when the air humidity is higher
than 70 %.

NOTE: If a surface coated with the ЭП-140 enamel is found damaged to the metal, it is necessary prior
to applying the enamel, to spread a coat of primer ЭП-076 and to allow it to air dry until it is just
a little sticky to the touch, but for not less than 2 h.

4.3. Perform the touching-up by applying a thin uniform coat of a varnish with the aid of a paint blower or a
brush without runs and misses. A slight difference in color and thickness of the touch-up coating and the
original coating is acceptable.

4.4. Following the touching-up, allow the parts to air dry for not less than one hour.

4.5. It is recommended to carry out the touching-up operation shortly before starting the engine, as the
complete drying of the painted coating takes place during engine operation when the parts are heated.
Do not allow any moisture, oil or gasoline to get onto the freshly painted surfaces within 8 b after applying
the coating.
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CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

1. Flat brush 1. Gasoline


2. Abrasive cloth, grade 16 to 10
3. Primer ЭП-076
4. Enamel ЭП-140
5. Enamel KO-818K
6. Thinner P-5
7. Acetone
8. Ethyl cellosolve
9. Xylene
10. Cotton cloth piece
11. Gauze
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PAGES
TO M. S. TASK CARD No. 704
715 to 716

MS. ITEM PROCEDURE: Reconditioning of Paint-and-Varnish Coatings On The Housing of The First Support Assembly

CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

1. General
Recondition the painted coating on the housing of the first support assembly (on the struts and inner
surfaces) with the aid of the ЭП-586 enamel in case the coating is damaged up to the metal over more
than 50 % of the length of the strut front edge.
Perform the touching-up at the outside air temperature not below plus 15 °C.

2. Preparation of Enamel ЭП-586


Prepare epoxidized enamel ЭП-586 immediately before use by mixing 100 weight parts of the semi-finished
product of the ЭП-586 enamel with 10.5 weight parts of hardener No. 5. Should need be, thin the prepared
enamel to the working viscosity with the ternary mixture given in Step 3.2 of Task Card No. 702.

3. Touching-Up of First Support Assembly Housing Struts on Engine


3.1. Wash the affected areas with gasoline (grades Б-70, Бр-1 or "Нефрас") and a brush, a bristle brush or
a cloth piece dipped in gasoline. Air dry for a period not less than 15 min. Dress the defective places
having uneven, jagged edges of the damaged coating with abrasive cloth of grade 16 to 10.
3.2. Degrease the affected area with a brush or a cloth piece moistened in acetone.
Allow to air dry for a period of 10 to 15 min.
3.3. Touch up the affected area with the enamel, using a brush or a paint blower. A slight difference in a
shade of color and thickness of a coat applied to the damaged area and the original coating is acceptable.
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ACTIONS BY

3.4. Allow the applied coating to dry at a temperature of not less than plus 15 °C for a period of 24 h.
NOTE: If one coating is not sufficient, it is allowed to apply a second coat. In this case, the first coat
must be dried at a temperature not below 15 °C for a minimum period of 5 h while the final drying
must be carried out at a temperature of not less than 15 °C for 24 h. A reflector may be used to
assist drying.

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

1. Flat brush 1. Gasoline


2. Acetone
3. Enamel ЭП-586
4. Hardener No. 5
5. Ethyl cellosolve
7. Abrasive cloth, grade 16 to 10
8. Cotton cloth piece
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717/718

MS. ITEM ROCEDURE: Cleansing of Engine Flow Section

CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T. R.)
ACTIONS BY

1. The engine flow section cleansing operations are performed in the following cases:
- When performing the work associated with logging.
- When operating the helicopter at the low altitudes with content of great amount of dust and sand.
- When operating the helicopter at the low altitudes in the contaminated atmosphere (smog over a city,
smoke when extinguishing fire and the other factors).
The frequency of performing the work - every 100 operating hours.
- On detection of the power drop (reported by the flying personnel).

2. The engine flow section cleansing operations are performed as directed in Task Card No. 308, in this case:
2.1. As a cleansing composition, use is made of the ZOK-27 fluid diluted with water in ratio 1:4 (i.e. four parts
of water are added to one part of the ZOK-27 fluid).

NOTE: For preparing the composition, use is made of water in compliance with the instructions on use
of the ZOK-27 fluid.

2.2. For cleansing the engine flow section (at the outside air temperature ≥5 °C) it is required at least 10 ltr
of the prepared composition. At the outside air temperature <5 °C, the antifreeze solution is added to
the prepared composition in compliance with the instructions on use of the ZOK-27 fluid.
2.3. For better removal of the deposits, it is recommended to warm up the prepared composition to the
temperature of 45 to 80 °C.

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS