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Engines, Systems & Services

Phoenix, Arizona

TO: HOLDERS OF PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE OVERHAUL MANUAL,
ATA NO. 49-21-83, REVISED MARCH 3, 2003.

THIS REVISED PUBLICATION IS ISSUED FOR USE IN SUPPORT OF THE FOLLOWING AIRCRAFT.

ENGINE/
COMPONENT ENGINE AIRCRAFT
PART NO. MODEL NO. APPLICATION
381276-1 GTCP85-98DHF DC-9
381276-2 GTCP85-98DHF[A] MD-80

REVISION NO. 9 DATED FEBRUARY 14, 2006

This is a COMPLETE revision. The pages revised are listed below together with the Highlights of the revision.
Due to the extent of the changes, this publication has been reprinted in its entirety. Please discard the entire
manual of previous issue(s) and replace with this complete manual.

This publication is distributed by:

Honeywell Engines, Systems & Services


Technical Data Distribution
M/S 64-01/2101-201
P.O. Box 52170
Phoenix, AZ 85072-2170
To order a document, please go to our web-site at www.honeywelltechpubs.com

Inquires of a technical nature regarding this publication should be directed to:

Honeywell Engines, Systems & Services


Customer Support Center
M/S 26-06/2102-323
P.O. Box 29003
Phoenix, AZ 85038-9003
Phone: (Domestic) 800-601-3099
Phone: (International) 602-365-3099
Fax: 602-365-3343

HIGHLIGHTS Page 1 of 4
ATA NO. 49-21-83 Feb 14/06
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Engines, Systems & Services
Phoenix, Arizona

HIGHLIGHTS

Subject/Page Description of Change

49-21-83 Updated where applicable, all military standards and


federal specifications military, federal or industrial
standards. Updated all manufacturer's addresses.
Updated and added WARNINGs to latest Honeywell
specifications.
Title Page
Page T-1 Updated for Revision 9.

Safety/Warranty/Liability Advisory
Page SWLA-1/SWLA-2 Updated Warranty/Liability Advisory statement.

List of Effective Pages


Pages LEP-1 through LEP-5/LEP-6 Updated for Revision 9.

Record of Revisions
Page RR-1/RR-2 Added Revision 9.

Record of Temporary Revisions


Page TR-4 Added Temporary Revisions 49-75 through 49-79.

Table of Contents
Pages TC-1 through TC-4 Updated Table of Contents.

Introduction
Page INTRO-1 Updated Paragraph 1.

Pages INTRO-23 and INTRO-24 Updated Table 2.

49-20-00

Description and Operation


Page 3 Updated Table 2.

Assembly
Page 501 Updated Table 501.

Page 515 Updated Step 1.C.(4)(c).

Page 518 Updated Step 1.C.(4A)(c).

Page 521 Updated Step 1.C.(5)(b).

Page 522 Updated Steps 1.C.(5)(c) and (d).

Testing
Page 712 Updated Table 701 to incorporate TR 49-75.

Page 714 Updated Figure 704 (Sheet 1 of 4).

Page 724 Updated Table 702. Updated NOTE to incorporate


TR 49-76.

HIGHLIGHTS Page 2 of 4
49-21-83 Feb 14/06
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Engines, Systems & Services
Phoenix, Arizona

HIGHLIGHTS (CONT)

Subject/Page Description of Change

49-20-00 (Cont)

Page 725 Updated Table 702 to incorporate TR 49-77.

Page 743 Updated Step 1.G.(9)(b).

Storage Instructions
Page 901 Updated NOTE and Table 901.

Page 902 Updated Table 901.

49-20-01

Disassembly
Page 1 Updated Table 1.

49-20-02

Cleaning
Page 2 Updated Table 1.

49-20-04

Assembly
Page 501 Updated Table 501.

Page 507 Updated Step 1.C.(2)(d).

Page 509 Updated Step 1.C.(2)(f).

Page 513 Added NOTE.

Page 519 Updated Step 1.C.(4)(c).

Page 521 Updated Steps 1.C.(6)(c) and (d).

49-20-05

Assembly
Page 501 Updated Table 501.

Page 506 Updated NOTE.

Page 508 Updated Step 1.C.(2)(e).

49-26-02

Assembly
Page 501 Updated Table 501.

HIGHLIGHTS Page 3 of 4
49-21-83 Feb 14/06
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Engines, Systems & Services
Phoenix, Arizona

HIGHLIGHTS (CONT)

Subject/Page Description of Change

49-30-10

Cleaning
Page 1/2 Updated Table 1.

49-40-02

Cleaning
Page 1 Updated Table 1.

Page 2 Updated Figure 1 to incorporate TR 49-79.

49-60-05

Cleaning
Page 1 Updated Table 1.

49-70-01

Cleaning
Page 1 Updated Table 1.

49-70-03

Cleaning
Page 1 Updated Table 1.

49-70-05

Cleaning
Page 1 Updated Table 1.

49-70-06

Cleaning
Page 1 Updated Table 1.

49-70-07

Cleaning
Page 1/2 Updated Table 1.

49-70-08

Cleaning
Page 1 Updated Table 1.

HIGHLIGHTS Page 4 of 4
49-21-83 Feb 14/06
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Engines, Systems & Services
Phoenix, Arizona

PNEUMATIC AND SHAFT POWER GAS TURBINE ENGINE

PART NO.
381276-1
381276-2

OVERHAUL MANUAL

This document and all information and expression contained herein are the property of Honeywell
International Inc., are provided in confidence, and may be used by persons required by Federal Aviation
Regulation Part 21.50 to comply with any of the terms of these instructions. Except as set forth above, no
person may, in whole or in part, use, duplicate or disclose this information for any purpose without the prior
written permission of Honeywell International Inc.

This publication was prepared by


Honeywell International Inc.
Engines, Systems & Services
Cage Code (99193)
Technical Publications

For assistance call


Customer Support Center
800-601-3099
Outside North America call
602-365-3099

Page T-1
ATA NO. 49-21-83 Aug 1/78
Revised Feb 14/06 No. 9
Copyright 1978, 2006 Honeywell International Inc. All rights reserved.
OVERHAUL MANUAL
GTCP85-98DHF/[A]

SAFETY ADVISORY

WARNING: BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW THE
HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE
MANUFACTURER OR SUPPLIER. FAILURE TO OBEY THE MANUFACTURERS' OR
SUPPLIERS' RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR DISEASE.

This publication describes physical and chemical processes which can make it necessary to use chemicals,
solvents, paints, and other commercially available materials. The user of this publication must get the Material
Safety Data Sheets (OSHA Form 20 or equivalent) from the manufacturers or suppliers of the materials to be
used. The user must know the manufacturer/supplier data and obey the procedures, recommendations,
warnings and cautions set forth for the safe use, handling, storage, and disposal of the materials.

WARRANTY/LIABILITY ADVISORY

WARNING: HONEYWELL ASSUMES NO RESPONSIBILITY FOR ANY HONEYWELL EQUIPMENT


WHICH IS NOT MAINTAINED AND/OR REPAIRED IN ACCORDANCE WITH
HONEYWELL'S PUBLISHED INSTRUCTIONS AND/OR HONEYWELL'S FAA/SFAR 36
REPAIR AUTHORIZATION. NEITHER DOES HONEYWELL ASSUME RESPONSIBILITY
FOR SPECIAL TOOLS AND TEST EQUIPMENT FABRICATED BY COMPANIES OTHER
THAN HONEYWELL.

INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS OR


DECREASE THE LIFE OF THE COMPONENTS. INCORRECTLY FABRICATED SPECIAL
TOOLING OR TEST EQUIPMENT CAN RESULT IN DAMAGE TO THE PRODUCT
COMPONENTS OR GIVE UNSATISFACTORY RESULTS.

Page SWLA-1/SWLA-2
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page T-1 Feb 14/06 TC-3 Feb 14/06


TC-4 Feb 14/06
Safety/
Warranty/ Introduction INTRO-1 Feb 14/06
Liability INTRO-2 Feb 14/06
Advisory SWLA-1 Feb 14/06 INTRO-3 Feb 14/06
SWLA-2 Blank INTRO-4 Feb 14/06
INTRO-5 Feb 14/06
List of INTRO-6 Feb 14/06
Effective INTRO-7 Feb 14/06
Pages LEP-1 Feb 14/06 INTRO-8 Feb 14/06
LEP-2 Feb 14/06 INTRO-9 Feb 14/06
LEP-3 Feb 14/06 INTRO-10 Feb 14/06
LEP-4 Feb 14/06 INTRO-11 Feb 14/06
LEP-5 Feb 14/06 INTRO-12 Feb 14/06
LEP-6 Blank INTRO-13 Feb 14/06
INTRO-14 Feb 14/06
Record of INTRO-15 Feb 14/06
Revisions RR-1 Feb 14/06 INTRO-16 Feb 14/06
RR-2 Blank INTRO-17 Feb 14/06
INTRO-18 Feb 14/06
Record of INTRO-19 Feb 14/06
Temporary INTRO-20 Feb 14/06
Revisions TR-1 Feb 14/06 INTRO-21 Feb 14/06
TR-2 Feb 14/06 INTRO-22 Feb 14/06
TR-3 Feb 14/06 INTRO-23 Feb 14/06
TR-4 Feb 14/06 INTRO-24 Feb 14/06
TR-5 Feb 14/06 INTRO-25 Feb 14/06
TR-6 Feb 14/06 INTRO-26 Feb 14/06

Service 49-20-00 1 Feb 14/06


Bulletin List SB-1 Feb 14/06 2 Feb 14/06
SB-2 Feb 14/06 3 Feb 14/06
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SB-18 Blank 106 Feb 14/06
107 Feb 14/06
Table of 108 Feb 14/06
Contents TC-1 Feb 14/06 109 Feb 14/06
TC-2 Feb 14/06 110 Feb 14/06

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RECORD OF REVISIONS

REV ISSUE DATE REV ISSUE DATE


NO. DATE INSERTED BY NO. DATE INSERTED BY

ORIG Aug 1/78

1 Oct 15/81

2 Mar 30/83

3 Aug 31/84

4 Sep 26/86

5 Nov 12/92

6 Feb 28/96

7 Aug 31/99

8 Mar 3/03

9 Feb 14/06

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RECORD OF TEMPORARY REVISIONS

CHP/SEC INCORPO-
SUBJ RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
49-20-00
49-1 107 May 29/79 1
49-20-00
49-2 825/826 Aug 25/80 1
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49-3 1105 Aug 25/80 1
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49-23-04
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49-23-04
49-22 567 Feb 27/87 5

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RECORD OF TEMPORARY REVISIONS (CONT)

CHP/SEC INCORPO-
SUBJ RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
49-23-04
49-23 603 Jul 25/87 5
49-20-00
49-24 732 Jul 5/88 5
49-20-00
49-25 730 Jul 20/88 5
49-23-04
49-26 546 Aug 3/88 Replaced by TR 49-31 5
49-23-04
49-27 603 Aug 31/88 Replaced by TR 49-32 5
49-20-00
49-28 740 Oct 11/88 5
49-20-00
49-29 732 Jan 3/89 5
49-21-83
49-30 2T-R-REC Jan 31/89 5
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49-31 546 Jan 31/89 5
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49-20-00
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49-21-83
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RECORD OF TEMPORARY REVISIONS (CONT)

CHP/SEC INCORPO-
SUBJ RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
49-21-83
49-45 25 Feb 4/90 5
49-20-00
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RECORD OF TEMPORARY REVISIONS (CONT)

CHP/SEC INCORPO-
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GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST

SB DATE
NO. INCORPORATED TITLE

49-3516, Rev 6 Sep 26/86 Relocate Engine Identification Plate

49-3580, Rev 1 Mar 30/83 Repair of First Stage diffuser Part No. 698194-1
(Incorporation of Steel Tip Vanes)

49-3655, Rev 4 Feb 28/96 Availability of Reconditioned First Stage Impellers

49-3656, Rev 3 Mar 30/83 Availability of Reconditioned Second Stage


Impellers

49-3712, Rev 4 Oct 15/81 Incorporation of Combustor Unit (Atomizer and


Liner Assembly) Part Numbers

49-3914, Rev 5 Sep 26/86 Product Improvement - Containment Ring


Retention System

49-3926, Rev 3 Mar 30/83 Incorporation of Hooded Pcd Probe (Without Anti-
Moisture Orifice)

49-5030, Rev 1 Aug 31/99 Replace Input Shaft Part No. 892282-1 or
3603685-1 with Flexible Coupling Part No.
3607310-1

49-5070, Rev 2 Oct 15/81 Rework Electrical Engine Starters

49-5132 Oct 15/81 Availability of Improved Compressor Interstage


Seal Assembly

49-5173 Mar 30/83 Replace Compressor Bearing Part No. 693328 or


372435 with Compressor Bearing Part No. 358649

49-5181, Rev 2 Mar 30/83 Rework Electrical Engine Starter to Incorporate


Improved Clutch Plates

49-5192, Rev 3 Refer to ATA Incorporate Improved Automatic Start and Fuel
No. 49-23-67 Holding Relays, Part No. 306366-2

49-5196, Rev 6 Aug 31/99 Incorporate Timed Acceleration Fuel Control


Improvements in Existing FCU, Part No. 3602310,
3609150 and 3603100, Re-identify as Part No.
3608000

49-5199, Rev 3 Refer to ATA To Provide Stronger Second Stage Diffuser


No. 49-23-67 Housing to Prevent Cracking

49-5200, Rev 2 Mar 30/83 Provide Thicker Turbine Plenum Shim to Eliminate
Leakage

49-5209, Rev 1 Refer to ATA Centrifugal Switch Assembly - Removal of


No. 49-60-33 Retainer Pin Part No. 3601292-1

Page SB-1
49-21-83 Feb 14/06
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GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5210, Rev 2 Oct 15/81 Replace Packing With Retainer to Prevent Oil
Leakage

49-5230, Rev 2 Refer to ATA Expand Combustion Liner Assembly Exit Diameter
No. 49-21-73 to Reduce Hard Carbon Formation (Cancelled)

49-5233, Rev 1 Sep 26/86 Incorporation of Fuel Conservation EGT


Control System

49-5235 Refer to ATA Rework Multiple Centrifugal Switch and Wiring


No. 49-23-67 Harness Assembly to Incorporate Threaded
Connector

49-5236 Mar 30/83 Incorporate Strengthened Exhaust Flange


Assembly to Reduce Exhaust Gas Leakage

49-5304, Rev 2 Feb 28/96 Rework Oil Pump Assemblies to Pinned Pump
Configuration

49-5305, Rev 1 Aug 31/99 Incorporate Pinned Oil Pump Assembly

49-5307 Mar 30/83 Incorporation of Load Control Valve Part No.


109382-32

49-5309, Rev 2 Aug 31/99 Incorporate Improved Combustion Liner and Fuel
Atomizer Assembly

49-5334, Rev 1 No Effect One Time Inspection of Spare Rear Turbine Seals
Part No. 977898-1 and Part No. 899987-1

49-5393, Rev 2 No Effect Replacement of Centrifugal Multiple Switch


Pedestal Ball Bearing

49-5417, Rev 1 Refer to ATA Rework Fuel Control Unit Part No. 3602310-33 to
No. 49-30-49 Part No. 3609150-3

49-5418, Rev 1 Sep 26/86 Incorporate Fuel Control Unit with Improved
Acceleration Limiter

49-5436, Rev 6 Nov 12/92 Incorporate Improved Torus Assembly and Heat
Shield

49-5444 Refer to ATA Replacement of Fuel Atomizer Assembly Part No.


No. 49-23-67 3601193-3 with Part No. 3601193-2

49-5456, Rev 1 Feb 28/96 Replace/Rework Fan Seal Retainer, Part No.
695243-1 to Part No. 695243-4

49-5460, Rev 1 Aug 31/84 Incorporation of Improved Rear Turbine Seal

Page SB-2
49-21-83 Feb 14/06
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GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5471, Rev 2 Refer to ATA Incorporation of Improved Thermocouple Part No.


No. 49-23-67 692523-8

49-5472 Sep 26/86 Incorporation of Electrical Engine Starter Part No.


3605812-16 and 3605812-17

49-5477 Refer to ATA Rework Electrical Engine Starter Assembly, Part


No. 49-40-01 No. 3605812-13 to 3605812-16 and Part No.
3605812-14 to 3605812-17

49-5504, Rev 1 Refer to ATA Rework Multiple Centrifugal Switch Assembly, Part
No. 49-60-33 No. 3601030 to Part No. 3609480

49-5505 Refer to ATA Incorporate Multiple Centrifugal Switch Assembly,


No. 49-23-67 Part No. 3609480-13 in place of Part No.
3601030-13

49-5530, Rev 1 Nov 12/92 One Time Inspection of Combustion Chamber


Liner Assembly, Part No. 3605384-3 (Cancelled)

49-5550, Rev 2 Refer to ATA Rework Improved Combustion Liner Assembly


No. 49-23-67 Ring to Reduce Hard Carbon Formation

49-5583, Rev 1 Nov 12/92 Incorporation of Rear Turbine Seal, Part No.
3609143-3

49-5587, Rev 3 Aug 31/99 Incorporate Improved Accessory Cooling Fan


Assembly, Part No. 695227-19

49-5588, Rev 4 Refer to ATA Rework Accessory Cooling Fan Assembly, Part
No. 49-50-35 No. 695227-15 to 695227-19

49-5602, Rev 1 Refer to ATA Availability of Improved Pinion Bearing Part No.
No. 49-23-67 3609114-1 for use in Accessory Drive Gearcase
Assembly Part No. 3603701-1 through -6

49-5624 No Effect Rework of Spare Accessory Drive Gearcase


Housing, Part No. 3603708

49-5629 Refer to ATA Rework of Interstage Housing Assembly Part No.


No. 49-23-67 379518 to 698198-1

49-5630 Refer to ATA Rework Inlet Assembly, Part No. 379713 to


No. 49-23-67 698197-1

49-5631, Rev 1 Refer to ATA Rework Diffuser Housing, Part No. 379515 to
No. 49-23-67 698195-1

Page SB-3
49-21-83 Feb 14/06
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5658, Rev 1 Refer to ATA Incorporate Vent Scupper, Part No. 976703-1
No. 49-23-67 over Exhaust Pipe Vent on Exhaust Duct Flange
Part No. 695140-50/-100

49-5681 Refer to ATA Incorporate Oversize Turbine Nozzle, Part No.


No. 49-23-67 3601669-13/-14/-15/-16

49-5689, Rev 4 Nov 12/92 Incorporate Turbine Shroud Containment Ring.


Superseded by SB 49-A6707

49-5699, Rev 2 Refer to ATA Incorporation of MAR-M-247 Turbine Rotor and


No. 49-23-67 Shaft Assembly, Part No. 3842072-1

49-5700, Rev 3 Refer to ATA Incorporation of Hastelloy "S" Turbine Wheel


No. 49-23-67 Shroud, Part No. 3611904-1

49-5701, Rev 4 Refer to ATA Incorporate Improved Atomizer Assembly, Part


No. 49-23-67 No. 3601193-4/-5/-6 (Reduce Carbon Formation)

49-5709, Rev 2 Refer to ATA Incorporation of Tachometer Generator Seal, Part


No. 49-23-67 No. 3612194-1

49-5722, Rev 1 Refer to ATA Incorporation of Improved Igniter Plug Part No.
No. 49-23-67 3888210-1

49-5733 No Effect One-Time Inspection of Accessory Cooling Fan


Assembly Shaft Nut (Fan End) Part No. 3602177-2

49-5738 Refer to ATA Replace Existing Baffles with Enlarged Baffles


No. 49-23-67

49-5744, Rev 1 Feb 28/96 Incorporate Shock Mounted Bracket for Ignition
Unit

49-5751, Rev 9 Refer to ATA Incorporation of Non-Asbestos Gaskets


No. 49-23-67

49-5754, Rev 2 Refer to ATA Incorporation of Spring Loaded Turbine Seal


No. 49-23-67 Assembly, Part No. 693616-1 and 3609143-4

49-5762 Refer to ATA Authorize Use of Starter Clutch Plate Assembly,


No. 49-23-67 Part No. 3860692-1

49-5774, Rev 1 Refer to ATA Incorporate Improved Ignition Unit


No. 49-23-67

49-5809 Refer to ATA Incorporation of Non-Asbestos Gaskets


No. 49-23-67

Page SB-4
49-21-83 Feb 14/06
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5816 Refer to ATA Rework of Exhaust Duct Flange Assembly Part


No. 49-23-67 No. 695140-50 and -80

49-5834 Refer to ATA Incorporation of Improved Turbine Nozzle, Part


No. 49-23-67 No. 3846484-3 and 3846484-4

49-5851, Rev 2 Refer to ATA Authorize Use of Combustion Liner, Part No.
No. 49-23-67 3605384-8

49-5862 Refer to ATA Incorporation of Compressor Inlet Assembly,


No. 49-23-67 Part No. 698197-2 (for Commonality)

49-5882, Rev 4 Refer to ATA Rework Existing Second Stage Impeller, Part No.
No. 49-23-67 379548-50/966571-1 to Part No. 966569-2 or Part
No. 698193-4 to Part No. 966569-1

49-5901, Rev 1 No Effect Removal of MAR-M-247 Turbine Wheel and Shaft


Assembly, Part No. 3842072-1 Prior to Serial No.
8-01345-8951 (Suspected to Contain Hafnium
Oxide Inclusions)

49-5906, Rev 1 Refer to ATA Authorize Use of Second Stage Impeller, Part No.
No. 49-23-67 966569-2 in Lieu of Part No. 966569-1

49-5913 Refer to ATA Authorize Use of Torus Assembly, Part No.


No. 49-23-67 3830350-1/-2/-3/-4 in Lieu of Part No.
968959-28/-22/-23/-26

49-5914 Refer to ATA Replace Insert, Part No. M5932-1-29L with Insert
No. 49-23-67 Part No. 423-551-0126 on Gearcase Part No.
3603708

49-5919, Rev 1 Refer to ATA Rework of TAFCU Acceleration Control Assembly


No. 49-23-67 Part No. 3607680-5 to Part No. 3607680-6 (To
Provide Positive Acceleration Control)

49-5932 Refer to ATA Incorporation of Accessory Drive Housing Gear


No. 49-23-67 Pad Studs, Part No. 682-510-9107 in Place of Part
No. MS51989E107

49-5941, Rev 1 Refer to ATA Replacement of MAR-M-247 Turbine Rotor and


No. 49-23-67 Shaft Assembly, Part No. 3842072-1 with Part No.
3842072-2

49-5974, Rev 1 Refer to ATA Incorporation of Improved Plenum Inlet Screen


No. 49-23-67 Assembly, Part No. 695146-2

49-5996, Rev 1 Refer to ATA Rework Compressor Inlet Assembly, Part No.
No. 49-23-67 698197-1 to Part No. 698197-2

Page SB-5
49-21-83 Feb 14/06
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-6505 Refer to ATA Inspection and Rework of Interstage Seal


No. 49-21-73 Assembly, Part No. 378854-30 Change Letters L
and M to preclude Possible Interference

49-6508, Rev 1 Refer to ATA Replace Oil Temperature Switch, Part No. 375036
No. 49-23-67 with Part No. 305080-1

49-6534, Rev 2 Aug 31/99 Authorize Use of Turbine Rotor and Shaft
Assembly, Part No. 3842072-3

49-6563, Rev 2 Feb 28/96 Incorporate Improved Pinion Bearing, Part No.
3614920-1 in place of Part No. 3609114-1

49-6565, Rev 1 Feb 28/96 Incorporation of Load Control Valve, Part No.
109382-35-1

49-A6706, Rev 2 Mar 3/03 Incorporate Improved Turbine Shroud Containment


Augmentation Ring, Part No. 3616426-1. Supersedes
SB 49-5689.

49-6774 Feb 28/96 Incorporate Solid Mounted Bracket Part No.


696069-1 for Ignition Unit

49-6787 Feb 28/96 Replace/Rework Atomizer and Liner Assembly


Part No. 3604524-25 with Part No. 3604524-44

49-A6831, Rev 1 Refer to ATA Replace/Rework Exhaust Pipe, Part No. 976987-1,
No. 49-23-67 or Exhaust Duct, Part No. 3607748-1 to Exhaust
Duct, Part No. 3850089-1

49-6860 Refer to ATA Rework First Stage Compressor Impeller, Part Nos.
No. 49-23-67 966570-1 and 379547 to Part No. 966568-1

49-6861 Refer to ATA Replace Spring Washer, Part No. 791-502-9009


No. 49-23-67 with Part No. 3610875-23

49-6863, Rev 1 Refer to ATA Replace Turbine Nozzle, Part No. 3601669-1,
No. 49-23-67 3601669-7 or 3846484-3 with Part No. 3846484-7
and Part No. 3601669-2, 3601669-8 or 3846484-4
with Part No. 3846484-8

49-6864 Refer to ATA Rework Branched Wiring Harness, Part No.


No. 49-23-67 43959-3 to Part No. 43959-5 and Part No. 43959-4
to Part No. 43959-6

49-6865, Rev 1 Aug 31/99 Replace Retaining Nut, Part No. 379523 with
Part No. 379523-1

49-6866, Rev 1 Refer to ATA Replace or Rework Oil Pump, Part No. 379580-650
No. 49-23-67 with/to Part No. 379580-700

Page SB-6
49-21-83 Feb 14/06
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GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-6873 Feb 28/96 Rework Plumbing and Electrical Installation by


Replacing Elbow, Part No. 695165-1 with Part No.
695165-2

49-6875 Feb 28/96 Rework or Replace Driveshaft Assembly, Part No.


3601031-1 to Part No. 3601031-2

49-6898 Refer to ATA Replace Centrifugal Switch Assembly, Part No.


No. 49-23-67 3609480-5/-10/-13 with Part No. 3615700-5/-10/-13,
Respectively

49-6933, Rev 1 Refer to ATA Replace Nut, Part No. 525-580-9003 with Nut,
No. 49-23-67 Part No. S9424-4 which has Improved Retention
Properties

49-6928, Rev 2 Aug 31/99 Replace Timed Acceleration Fuel Control Unit (TAFCU),
Part Nos. 3608000-4/-6/-10 with Part Nos.
3608000-12/-13/-14

49-6934, Rev 1 Refer to ATA Replace/Rework Acceleration Control Assembly


No. 49-23-67 Part No. 3607680-6 with/to Part No. 3607680-8

49-6960, Rev 1 Refer to ATA Rework Centrifugal Switch Assembly, Part No.
No. 49-23-67 3609480-5/-10/-13 to Part No. 3615700-5/-10/-13
Respectively

49-7103 Aug 31/99 Rework/Replace Second Stage Diffuser Housing, Part No.
698195-1 to/with Part No. 698195-10 and Part No. 698195-8
to/with Part No. 698195-12

49-A7189, Rev 2 Mar 3/03 Incorporation of Turbine Wheel Shroud, Containment


Augmentation Ring, Part No. 3616426-3

49-7238 Aug 31/99 Remove and Replace Vent Tube Assembly, Part No.
695766-1 With Part No. 3617065-1

49-7301 Aug 31/99 Replace Compressor Interstage Seal, Part No. 378854-30
with Compressor Interstage Seal, Part No. 378854-50 on
Compressor and Turbine Assemblies, Part No. 3601835-All

49-7477 Aug 31/99 Replace Second Stage Impeller, Part Nos. 698193-2/-3/-4/-5,
or Part No. 3822481-3 with Second Stage Impeller, Part
No. 3822536-1

49-7484 Aug 31/99 Replace Fuel Control (FCU), Part No. 3609150-1/-2/-3 and
3608000-4/-6/-10/-12/-13/-14, with FCU Part No.
3617750-1/-2/-3 and Atomizer and Liner Assembly, Part Nos.
3604524-1/-19/-21/-25/-29/-44/-45/-46/-47/-48/-49/-50/-51
with Atomizer and Liner Assembly, Part Nos.
3604524-52/-53/-54/-55/-56/-57/-58

Page SB-7
49-21-83 Feb 14/06
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-7488 Refer to ATA Replace Turbine Rotor and Shaft Assembly Part Nos.
No. 49-23-04 3842072-1/-2/-3, or Part No. 3606982-1 with Turbine Rotor
and Shaft Assembly, Part No. 3842360-1

49-7495 Aug 31/99 Rework Fuel Control Assembly, Part No. 3609150-1/-2/-3 or
Part No. 3608000-4/-6/-10/-12/-13/-14 to Part No. 3617750-1/
-2/-3

49-7514 Aug 31/99 Rework/Replace of Compressor and Turbine Assembly, Part


No. 3601835-30 to/with Part No. 3601835-59

49-7542 Mar 3/03 Incorporation of External Shields, Part Nos. 3844911-1 and
3844911-2

49-7572 Refer to ATA Rework/Replace Compressor and Turbine Assembly, Part


No. 49-23-04 No. 3601835-30/-31/-33/-34/-39/-40/-41/-52/-53/-56/-59/-60
to/with Part No. 3601835-62

49-7664 Mar 3/03 Replaces Turbine Plenum Gasket, Part No. 3612631-4 with
Turbine Plenum Gasket, Part No 3618086-1

Page SB-8
49-21-83 Feb 14/06
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

GTE0165, Rev 1 Refer to ATA Improved Fan Shaft Bearings


No. 49-50-35

GTE0167 Refer to ATA Improved Second Stage Impeller


No. 49-23-67

GTE0170, Rev 1 Refer to ATA Replacement of Existing Washers


No. 49-23-67

GTE0172 Refer to ATA Parts Standardization


No. 49-30-38

GTE0192 Refer to ATA Improved Second Stage Diffuser


No. 49-23-67

GTE0226, Rev 1 Refer to ATA Alternate Oil Pump Filter Element


No. 49-90-33

GTE0253 Refer to ATA Replacement of Shims


No. 49-23-67

GTE0318 Refer to ATA Replacement of Fuel Nozzle Swirl


No. 49-23-67

GTE0357 Refer to ATA Authorizes Installation of Part No. 3601169-1/-2,


No. 49-23-67 Turbine Nozzle (Customer Option)

GTE0362 Refer to ATA Authorizes Replacement of Part No.


No. 49-23-67 NAS686-3 with MS21060-3

GTE0368 Refer to ATA Authorizes Installation of Part No. MS9489-24 in


No. 49-23-67 place of Part No. MS9489-25

GTE0531 Refer to ATA To provide a procurable repair part


No. 49-23-67

GTE0563 Refer to ATA To provide a procurable repair part


No. 49-23-67

GTE0581 Refer to ATA Authorize Use of Aluminum Oil Breather Tube


No. 49-23-67 in Lieu of CRES Tube

GTE0600 Refer to ATA Improved Screw for Lockwire


No. 49-23-67

GTE0648 Refer to ATA Identification Plate


No. 49-23-67

Page SB-9
49-21-83 Feb 14/06
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GTCP85-98DHF/[A]

(GTCP85-98DHF) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

GTE0696, Rev 1 Refer to ATA Terminal, Part No. 724-505-9013


No. 49-23-67

GTE0697, Rev 1 Refer to ATA Terminal, Part No. 724-505-9014


No. 49-23-67

GTE0813 Refer to ATA Connectors, Part No. 304805-1/-2/-3/-4/-5


No. 49-23-67

GTE0988 Refer to ATA Authorize use of Ring, Part No. MS16625-1100


No. 49-23-67 in place of Ring, Part No. NAS50-100

GTE0989 Refer to ATA Authorize use of Plug, Part No. AN814-6J in


No. 49-23-67 place of Plug, Part No. AN814-6C

GTE1089 Refer to ATA Authorize use of Turbine Rotor Shaft Assy,


No. 49-23-67 Part No. 3616256-1 In place of Turbine Rotor
Shaft Assy, Part No. 696161-13

Page SB-10
49-21-83 Feb 14/06
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST

SB DATE
NO. INCORPORATED TITLE

49-3580, Rev 1 Mar 30/83 Repair of First Stage diffuser Part No. 698194-1
(Incorporation of Steel Tip Vanes)

49-3655, Rev 4 Mar 30/83 Availability of Reconditioned First Stage Impellers

49-3656, Rev 3 Mar 30/83 Availability of Reconditioned Second Stage


Impellers

49-5132 Oct 15/81 Availability of Improved Compressor Interstage


Seal Assembly

49-5196, Rev 6 Aug 31/99 Incorporate Timed Acceleration Fuel Control


Improvements in Existing FCU, Part No. 3602310,
3609150 and 3603100, Re-identify as Part No.
3608000

49-5199, Rev 3 Refer to ATA To Provide Stronger Second Stage Diffuser


No. 49-23-67 Housing to Prevent Cracking

49-5304, Rev 2 Feb 28/96 Rework Oil Pump Assemblies to Pinned


Pump Configuration

49-5436, Rev 6 Nov 12/92 Incorporate Improved Torus Assembly and Heat
Shield

49-5472 Sep 26/86 Incorporation of Electrical Engine Starter Part No.


3605812-16 and 3605812-17

49-5477 Refer to ATA Rework Electrical Engine Starter Assembly, Part


No. 49-40-01 No. 3605812-13 to 3605812-16 and Part No.
3605812-14 to 3605812-17

49-5504, Rev 1 Refer to ATA Rework Multiple Centrifugal Switch Assembly, Part
No. 49-60-33 No. 3601030 to Part No. 3609480

49-5505 Refer to ATA Incorporate Multiple Centrifugal Switch Assembly,


No. 49-23-67 Part No. 3609480-13 in place of Part No.
3601030-13

49-5550, Rev 2 Refer to ATA Rework Improved Combustion Liner Assembly


No. 49-23-67 Ring for Reduced Hard Carbon Formation

49-5583, Rev 1 Nov 12/92 Incorporation of Rear Turbine Seal, Part No.
3609143-3

49-5587, Rev 3 Aug 31/99 Incorporate Improved Accessory Cooling Fan


Assembly, Part No. 695227-19

49-5588, Rev 4 Refer to ATA Rework Accessory Cooling Fan Assembly, Part
No. 49-50-35 No. 695227-15 to 695227-19

Page SB-11
49-21-83 Feb 14/06
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5602, Rev 1 Refer to ATA Availability of Improved Pinion Bearing Part No.
No. 49-23-67 3609114-1 for use in Accessory Drive Gearcase
Assembly Part No. 3603701-1 through -6

49-5624 No Effect Rework of Spare Accessory Drive Gearcase


Housing, Part No. 3603708

49-5629 Refer to ATA Rework of Interstage Housing Assembly Part No.


No. 49-23-67 379518 to 698198-1

49-5630 Refer to ATA Rework Inlet Assembly, Part No. 379713 to


No. 49-23-67 698197-1

49-5631, Rev 1 Refer to ATA Rework Diffuser Housing, Part No. 379515 to
No. 49-23-67 698195-1

49-5658, Rev 1 Refer to ATA Incorporate Vent Scupper, Part No. 976703-1
No. 49-23-67 over Exhaust Pipe Vent on Exhaust Duct Flange
Part No. 695140-50/-100

49-5681 Refer to ATA Incorporate Oversize Turbine Nozzle, Part No.


No. 49-23-67 3601669-13/-14/-15/-16

49-5689, Rev 4 Nov 12/92 Incorporate Turbine Shroud Containment Ring. Superseded
by SB 49-A6707.

49-5699, Rev 2 Refer to ATA Incorporation of MAR-M-247 Turbine Rotor and


No. 49-23-67 Shaft Assembly, Part No. 3842072-1

49-5700, Rev 2 Refer to ATA Incorporation of Hastelloy "S" Turbine Wheel


No. 49-23-67 Shroud, Part No. 3611904-1

49-5701, Rev 4 Refer to ATA Incorporate Improved Atomizer Assembly, Part


No. 49-23-67 No. 3601193-4/-5/-6 (Reduce Carbon Formation)

49-5709, Rev 2 Refer to ATA Incorporation of Tachometer Generator Seal, Part


No. 49-23-67 No. 3612194-1

49-5722, Rev 1 Refer to ATA Incorporation of Improved Igniter Plug Part No.
No. 49-23-67 3888210-1

49-5733 No Effect One-Time Inspection of Accessory Cooling Fan


Assembly Shaft Nut (Fan End) Part No. 3602177-2

49-5738 Refer to ATA Replace Existing Baffles with Enlarged Baffles


No. 49-23-67

49-5744, Rev 1 Nov 12/92 Incorporate Shock Mounted Bracket for Ignition
Unit

Page SB-12
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5751, Rev 9 Refer to ATA Incorporation of Non-Asbestos Gaskets


No. 49-23-67

49-5754, Rev 2 Refer to ATA Incorporation of Spring Loaded Turbine Seal


No. 49-23-67 Assembly, Part No. 693616-1 and 3609143-4

49-5762 Refer to ATA Authorize Use of Starter Clutch Plate Assembly,


No. 49-23-67 Part No. 3860692-1

49-5774, Rev 1 Refer to ATA Incorporate Improved Ignition Unit


No. 49-23-67

49-5809 Refer to ATA Incorporation of Non-Asbestos Gaskets


No. 49-23-67

49-5812, Rev 4 Refer to ATA Incorporation of Non-Asbestos Gaskets


No. 49-23-67

49-5816 Refer to ATA Rework of Exhaust Duct Flange Assembly Part


No. 49-23-67 No. 695140-50 and -80

49-5834 Refer to ATA Incorporation of Improved Turbine Nozzle, Part


No. 49-23-67 No. 3846484-3 and 3846484-4

49-5851, Rev 2 Refer to ATA Authorize Use of Combustion Liner, Part No.
No. 49-23-67 3605384-8

49-5862 Refer to ATA Incorporation of Compressor Inlet Assembly,


No. 49-23-67 Part No. 698197-2 (for Commonality)

49-5882, Rev 4 Refer to ATA Rework Existing Second Stage Impeller, Part No.
No. 49-23-67 379548-50/966571-1 to Part No. 966569-2 or Part
No. 698193-4 to Part No. 966569-1

49-5901, Rev 1 No Effect Removal of MAR-M-247 Turbine Wheel and Shaft


Assembly, Part No. 3842072-1 Prior to Serial No.
8-01345-8951 (Suspected to Contain Hafnium
Oxide Inclusions)

49-5906, Rev 1 Refer to ATA Authorize Use of Second Stage Impeller, Part No.
No. 49-23-67 966569-2 in Lieu of Part No. 966569-1

49-5913 Refer to ATA Authorize Use of Torus Assembly, Part No.


No. 49-23-67 3830350-1/-2/-3/-4 in Lieu of Part No. 968959-28/
-22/-23/-26

49-5914 Refer to ATA Replace Insert, Part No. M5932-1-29L with Insert
No. 49-23-67 Part No. 423-551-0126 on Gearcase Part No.
3603708

Page SB-13
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GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-5919, Rev 1 Refer to ATA Rework of TAFCU Acceleration Control Assembly


No. 49-23-67 Part No. 3607680-5 to Part No. 3607680-6
(To Provide Positive Acceleration Control)

49-5932 Refer to ATA Incorporation of Accessory Drive Housing Gear


No. 49-23-67 Pad Studs, Part No. 682-510-9107 in Place of Part
No. MS51989E107

49-5941, Rev 1 Refer to ATA Replacement of MAR-M-247 Turbine Rotor and


No. 49-23-67 Shaft Assembly, Part No. 3842072-1 with Part No.
3842072-2

49-5974, Rev 1 Refer to ATA Incorporation of Improved Plenum Inlet Screen


No. 49-23-67 Assembly, Part No. 695146-2

49-5996, Rev 1 Refer to ATA Rework Compressor Inlet Assembly, Part No.
No. 49-23-67 698197-1 to Part No. 698197-2

49-6505 No Effect Inspection and Rework of Interstage Seal


Assembly, Part No. 378854-30 Change Letters L

49-6508 Refer to ATA Replace Oil Temperature Switch, Part No. 375036
No. 49-23-67 with Part No. 305080-1

49-6534, Rev 1 Nov 12/92 Authorize Use of Turbine Rotor and Shaft
Assembly, Part No. 3842072-3

49-6563, Rev 2 Feb 28/96 Incorporate Improved Pinion Bearing, Part No.
3614920-1 in place of Part No. 3609114-1

49-6565, Rev 1 Feb 28/96 Incorporation of Load Control Valve


Part No. 109382-35-1

49-A6706, Rev 2 Mar 3/03 Incorporate Improved Turbine Shroud Containment


Augmentation Ring, Part No. 3616426-1. Supersedes
SB 49-5689.

49-6774 Feb 28/96 Incorporate Solid Mounted Bracket Part No.


696069-1 for Ignition Unit

49-6787 Feb 28/96 Replace/Rework Atomizer and Liner Assembly,


Part No. 3604524-25 with Part No. 3604524-44

49-A6831, Rev 1 Refer to ATA Replace/Rework Exhaust Pipe, Part No.


No. 49-23-67 976987-1, or Exhaust Duct, Part No. 3607748-1
to Exhaust Duct, Part No. 3850089-1

49-6860 Refer to ATA Rework First Stage Compressor Impeller, Part Nos.
No. 49-23-67 966570-1 and 379547 to Part No. 966568-1

Page SB-14
49-21-83 Feb 14/06
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GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-6861 Refer to ATA Replace Spring Washer, Part No. 791-502-9009


No. 49-23-67 with Part No. 3610875-23

49-6863, Rev 1 Refer to ATA Replace Turbine Nozzle, Part No. 3601669-1,
No. 49-23-67 3601669-7 or 3846484-3 with Part No. 3846484-7
and Part No. 3601669-2, 3601669-8 or 3846484-4
with Part No. 3846484-8

49-6864 Refer to ATA Rework Branched Wiring Harness, Part No.


No. 49-23-67 43959-3 to Part No. 43959-5 and Part No. 43959-4
to Part No. 43959-6

49-6865, Rev 1 Aug 31/99 Replace Retaining Nut, Part No. 379523 with
Part No. 379523-1

49-6866, Rev 1 Refer to ATA Replace or Rework Oil Pump, Part No.
No. 49-23-67 379580-650 with/to Part No. 379580-700

49-6873 Feb 28/96 Rework Plumbing and Electrical Installation by


Replacing Elbow, Part No. 695165-1 with Part No.
695165-2

49-6875 Feb 28/96 Rework or Replace Driveshaft Assembly, Part No.


3601031-1 to Part No. 3601031-2

49-6898 Refer to ATA Replace Centrifugal Switch Assembly, Part No.


No. 49-23-67 3609480-5/-10/-13 with Part No. 3615700-5/-10/-13,
Respectively

49-6928, Rev 2 Aug 31/99 Replace Timed Acceleration Fuel Control Unit (TAFCU),
Part Nos. 3608000-4/-6/-10 with Part Nos.
3608000-12/-13/-14

49-6933, Rev 1 Refer to ATA Replace Nut, Part No. 525-580-9003 with Nut,
No. 49-23-67 Part No. S9424-4 which has Improved Retention
Properties

49-6934, Rev 1 Refer to ATA Replace/Rework Acceleration Control Assembly


No. 49-23-67 Part No. 3607680-6 with/to Part No. 3607680-8

49-6960, Rev 1 Refer to ATA Rework Centrifugal Switch Assembly, Part No.
No. 49-23-67 3609480-5/-10/-13 to Part No. 3615700-5/-10/-13
Respectively

49-7103 Aug 31/99 Rework/Replace Second Stage Diffuser Housing, Part No.
698195-1 to/with Part No. 698195-10 and Part No. 698195-8
to/with Part No. 698195-12

49-A7189 Mar 3/03 Incorporation of Turbine Wheel Shroud, Containment


Augmentation Ring, Part No. 3616426-3

Page SB-15
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GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

49-7238 Aug 31/99 Remove and Replace Vent Tube Assembly, Part No.
695766-1 With Part No. 3617065-1

49-7301 Aug 31/99 Replace Compressor Interstage Seal, Part No. 378854-30
with Compressor Interstage Seal, Part No. 378854-50 on
Compressor and Turbine Assemblies, Part No. 3601835-All

49-7477 Aug 31/99 Replace Second Stage Impeller, Part Nos. 698193-2/-3/-4/-5,
or Part No. 3822481-3 with Second Stage Impeller, Part
No. 3822536-1

49-7484 Aug 31/99 Replace Fuel Control (FCU), Part No. 3609150-1/-2/-3 and
3608000-4/-6/-10/-12/-13/-14, with FCU Part No.
3617750-1/-2/-3 and Atomizer and Liner Assembly, Part Nos.
3604524-1/-19/-21/-25/-29/-44/-45/-46/-47/-48/-49/-50/-51
with Atomizer and Liner Assembly, Part Nos.
3604524-52/-53/-54/-55/-56/-57/-58

49-7488 Refer to ATA Replace Turbine Rotor and Shaft Assembly, Part Nos.
No. 49-23-04 3842072-1/-2/-3, or Part No. 3606982-1 with Turbine Rotor
and Shaft Assembly, Part No. 3842360-1

49-7495 Aug 31/99 Rework Fuel Control Assembly, Part No. 3609150-1/-2/-3 or
Part No. 3608000-4/-6/-10/-12/-13/-14 to Part No. 3617750-1/
-2/-3

49-7514 Aug 31/99 Rework/Replace of Compressor and Turbine Assembly, Part


No. 3601835-30 to/with Part No. 3601835-59

49-7542 Mar 3/03 Incorporation of External Shields, Part Nos. 3844911-1 and
3844911-2

49-7572 Refer to ATA Rework/Replace Compressor and Turbine Assembly, Part


No. 49-23-04 No. 3601835-30/-31/-33/-34/-39/-40/-41/-52/-53/-56-/59/-60
to/with Part No. 3601835-62

49-7664 Mar 3/03 Replaces Turbine Plenum Gasket, Part No. 3612631-4 with
Turbine Plenum Gasket, Part No. 3618086-1

Page SB-16
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GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) SERVICE BULLETIN LIST (CONT)

SB DATE
NO. INCORPORATED TITLE

GTE0192 Refer to ATA Improved Second Stage Diffuser


No. 49-23-67

GTE0226, Rev 1 Refer to ATA Alternate Oil Pump Filter Element


No. 49-90-33

GTE0318 Refer to ATA Replacement of Fuel Nozzle Swirl


No. 49-23-67

GTE0357 Refer to ATA Authorizes Installation of Part No. 3601169-1/-2,


No. 49-23-67 Turbine Nozzle (Customer Option)

GTE0362 Refer to ATA Authorizes Replacement of Part No.


No. 49-23-67 NAS686-3 with MS21060-3

GTE0368 Refer to ATA Authorizes Installation of Part No. MS9489-24 in


No. 49-23-67 place of Part No. MS9489-25

GTE0531 Refer to ATA To provide a procurable repair part


No. 49-23-67

GTE0563 Refer to ATA To provide a procurable repair part


No. 49-23-67

GTE0581 Refer to ATA Authorize Use of Aluminum Oil Breather Tube


No. 49-23-67 in Lieu of CRES Tube

GTE0600 Refer to ATA Improved Screw for Lockwire


No. 49-23-67

GTE0648 Refer to ATA Identification Plate


No. 49-23-67

GTE0696, Rev 1 Refer to ATA Terminal, Part No. 724-505-9013


No. 49-23-67

GTE0697 Refer to ATA Terminal, Part No. 724-505-9014


No. 49-23-67

GTE0813 Refer to ATA Connectors, Part No. 304805-1/-2/-3/-4/-5


No. 49-23-67

GTE0988 Refer to ATA Authorize use of Ring, Part No. MS16625-1100


No. 49-23-67 in place of Ring, Part No. NAS50-100

GTE0989 Refer to ATA Authorize use of Plug, Part No. AN814-6J in place
No. 49-23-67 of Plug, Part No. AN814-6C

GTE1089 Refer to ATA Authorize use of Turbine Rotor Shaft Assy, Part No.
No. 49-23-67 3616256-1 In place of Turbine Rotor Shaft Assy, Part No.
696161-13

Page SB-17/SB-18
49-21-83 Feb 14/06
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TABLE OF CONTENTS

CHAPTER/
SECTION/
SECTION SUBJECT PAGE

INTRODUCTION ............................................................................................................................INTRO-1
General .....................................................................................................................................INTRO-1
Equipment Identification System...............................................................................................INTRO-1
Arrangement of Exploded View Illustrations .............................................................................INTRO-2
Applicable Publications .............................................................................................................INTRO-2
Materials, Equipment, Compounds and Special Tools .............................................................INTRO-2
Shop Findings Report ...............................................................................................................INTRO-3
Geometric Tolerance Symbols..................................................................................................INTRO-5
Verification of Technical Data ...................................................................................................INTRO-5

ENGINE SECTION......................................................................................49-20-00
Description and Operation .................................................................................................................... 1
Disassembly...................................................................................................................................... 101
Cleaning ............................................................................................................................................ 201
Inspection/Check .............................................................................................................................. 301
Repair................................................................................................................................................ 401
Assembly........................................................................................................................................... 501
Fits and Clearances .......................................................................................................................... 601
Testing .............................................................................................................................................. 701
Troubleshooting ................................................................................................................................ 801
Storage Instruction ............................................................................................................................ 901
Special Tools, Fixtures and Equipment .......................................................................................... 1001

PLUMBING INSTALLATION.................................................................49-20-01
Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 3
Assembly ........................................................................................................................................ 3

ELECTRICAL INSTALLATION .............................................................49-20-02


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 2
Inspection/Check ............................................................................................................................ 3
Repair ............................................................................................................................................. 3
Assembly ........................................................................................................................................ 4

COMBUSTION AND EXHAUST SECTION..........................................49-20-04


Disassembly ............................................................................................................................... 101
Cleaning ..................................................................................................................................... 201
Inspection/Check ........................................................................................................................ 301
Repair ......................................................................................................................................... 401
Assembly .................................................................................................................................... 501
Fits and Clearances.................................................................................................................... 601
Special Tools, Fixtures and Equipment.................................................................................... 1001

Page TC-1
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TABLE OF CONTENTS (CONT)

CHAPTER/
SECTION/
SECTION SUBJECT PAGE

ENGINE POWER SECTION ................................................................49-20-05


Disassembly ............................................................................................................................... 101
Cleaning ..................................................................................................................................... 201
Inspection/Check ........................................................................................................................ 301
Repair ......................................................................................................................................... 401
Assembly .................................................................................................................................... 501
Fits and Clearances.................................................................................................................... 601

COMPRESSOR AND TURBINE ASSEMBLY .................................................................................. 101


(Deleted, refer to ATA No. 49-23-04)

ACCESSORY DRIVE GEARCASE ASSEMBLY ..................................49-26-02


Disassembly ............................................................................................................................... 101
Cleaning ..................................................................................................................................... 201
Inspection/Check ........................................................................................................................ 301
Repair ......................................................................................................................................... 401
Assembly .................................................................................................................................... 501
Fits and Clearances.................................................................................................................... 601
Special Tools, Fixtures and Equipment.................................................................................... 1001

ENGINE FUEL AND CONTROL SECTION ................................................49-30-00


Description and Operation .................................................................................................................... 1

ORIFICE - REDUCER (TURBINE PLENUM DRAIN FITTING)............49-30-10


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Assembly ........................................................................................................................................ 1

IGNITION/STARTING SECTION ................................................................49-40-00


Description and Operation .................................................................................................................... 1

PLUG - IGNITER ..................................................................................49-40-02


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Repair ............................................................................................................................................. 2
Assembly ........................................................................................................................................ 2

AIR SECTION..............................................................................................49-50-00
Description and Operation .................................................................................................................... 1

Page TC-2
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TABLE OF CONTENTS (CONT)

CHAPTER/
SECTION/
SECTION SUBJECT PAGE

ENGINE CONTROLS SECTION.................................................................49-60-00


Description and Operation .................................................................................................................... 1

RELAY - ARMATURE ..........................................................................49-60-05


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Assembly ........................................................................................................................................ 2

INDICATING SECTION...............................................................................49-70-00
Description and Operation .................................................................................................................... 1

THERMOCOUPLE - EXHAUST GAS TEMPERATURE ......................49-70-01


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Assembly ........................................................................................................................................ 2

METER - TIME TOTALIZING ...............................................................49-70-03


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Assembly ........................................................................................................................................ 2

BREAKER - CIRCUIT ...........................................................................49-70-05


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Assembly ........................................................................................................................................ 2

SWITCH - LOW OIL PRESSURE ........................................................49-70-06


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Assembly ........................................................................................................................................ 2

GENERATOR - TACHOMETER...........................................................49-70-07
Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Assembly ........................................................................................................................................ 1

SWITCH - OIL TEMPERATURE ..........................................................49-70-08


Disassembly ................................................................................................................................... 1
Cleaning ......................................................................................................................................... 1
Inspection/Check ............................................................................................................................ 1
Assembly ........................................................................................................................................ 2

Page TC-3
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TABLE OF CONTENTS (CONT)

CHAPTER/
SECTION/
SECTION SUBJECT PAGE

OIL SECTION..............................................................................................49-90-00
Description and Operation .................................................................................................................... 1

HEAVY MAINTENANCE (Deleted) ............................................................. 49-21-83................................. 1

Page TC-4
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INTRODUCTION

1. General

This publication gives maintenance instructions for the equipment shown in Tables 1 and 1A which is
made by:

- Honeywell Engines, Systems & Services, Phoenix, Arizona

This publication is written in agreement with the Air Transport Association of America Specification No.
100.

2. Equipment Identification System

The manufacturer's engine identification system provides for a model number, part number, series
number, and change number (if applicable which are stamped on the engine identification plate.

NOTE: When change numbers appear on the identification plate, these change numbers are use
with the engine part number and series number to determine the configuration.

A typical model number, part number, series number and change number is defined as follows. (Refer
to Tables 1 and 1A, Equipment Identification List.)

The model number defines the engine power class, significant features and specification
rating.

The part number defines the configuration. All engines having the same part number are
interchangeable.

The series number identifies internal product improvement changes incorporated in


production.

The change number is used to identify individual changes incorporated during overhaul, and to
identify out-of-sequence changes incorporated by field activities.

Work procedure differences between configurations of the equipment covered in this


publication are identified in the text by the insertion of the applicable service bulletin (Pre or
Post SB ____ ) or part number (PN ____ ), at the beginning of the paragraph or procedural
step which describes the changed procedure. Illustrations applicable to a particular
modification or configuration are identified by the insertion of the applicable service bulletin
(Pre or Post SB ____ ), part number PN ____ ), preceding the illustration title. Procedures and
illustrations not identified by service bulletins or part numbers are applicable to all
configurations of the equipment.

Page INTRO-1
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3. Arrangement of Exploded View Illustrations

Assembly instructions are arranged with an assembly illustration and the matching text on either the
same or on facing pages. All required information is provided, including torque values, tool numbers,
and materials so that the unit can be assembled without referencing any other part of the manual.

Identical exploded view illustrations are provided in the DISASSEMBLY, CLEANING, and
INSPECTION/CHECK sections of this manual and the IPC, ATA No. 49-23-67. These illustrations
appear in the same sequence in each of the sections, and are so numbered. For example, Figure 304
in INSPECTION/CHECK is the same as Figure 104 in DISASSEMBLY and Figure 4 in the IPC. Any
illustration not required in a particular section is not included, but a notation of the omission is provided
to maintain the figure number sequence. Reference to the Illustrated Parts Catalog (IPC) are provided
in ASSEMBLY section of this manual to provide a quick means of locating a particular part in the IPC if
replacement of that part is required. For example in section 49-20-04.

KEY TO FIGURE 502A

30. NUT (IPC FIG. 3) 45. BRACKET


40. WASHER 60A. CONTAINMENT RING

In this case, nut (30), washer (40), bracket (45) and containment ring (60A) are located in IPC Figure
3, Items 30, 40, 45 and 60A.

If it is desired to locate instructions pertaining to a specific detail part (by part number), simply locate
the part number, figure number and item number in the numerical index of the IPC.

4. Applicable Publications

The nomenclature, part number, and publication ATA number of these accessories covered in
separate publications are provided in Table 2. The Standard Practices Manual (SPM) is also listed in
Table 2. Reference to the SPM are contained in this manual for all standard procedures which are
applicable for the specific equipment covered in this manual.

5. Materials, Equipment, Compounds and Special Tools

Materials, equipment and compounds will be listed at the heading of each section. Special tools will be
listed in appropriate section as required. Consult these lists so that the materials, equipment,
compounds and special tools may be gathered prior to starting maintenance or repair.

Page INTRO-2
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6. Shop Findings Report

A minimum recommended standard for reporting APU and LRU findings is provided in the section
(Figure XX) to provide consistency and maximize usefulness of findings data across all repair and
overhaul facilities, effective the date of the manual revision. This key information should be highlighted
in a summary form either in the operators/repair facilities own shop findings report or as a cover page,
and submitted/distributed with the shop findings package. The data in the summary is critical to clearly
indentifying actions necessary for minimizing the cost of APU repair and maximizing the APU
reliability, and helps to establish effective work scopes, set realistic thresholds for inspection/text
intervals and requirements, and determine if design changes are justified.

Standard definitions used in the APU shop findings summary facilitate the collection, reporting analysis,
and use of the findings data:

A. Primary Failure is the specific part that caused the APU or LRU removal. Parts damaged by
the primary failure are called "secondary failures" and are not used in the shop findings
summary

B. Imminent Failure is an impending failure that would have happened relatively soon had the
primary failure not occurred.

C. Major Cost Drivers are those parts not included in the above that contribute significantly to the
cost of returning the APU to service. These are typically the more complex/critical/costly parts
that cannot be reused or economically repaired.

D. "Depth of Repair"- is the extent of APU or LRU disassembly and inspection required to make
the unit serviceable or reusable. It consists of three basic levels for the 85 model APU.

"Light repair"- external work only (electrical harness, LRUs, plumbing) or partial gearbox
disassembly. These have previously be called "quick turns" or "continue-time" units. Continue-
time inspection (Workscope Planning Guide) criteria applies.

"Medium repair"- complete gearbox disassembly and/or one of the following: partial or
complete compressor disassembly only, partial or complete turbine disassembly only. A
medium repair can also be a complete disassembly of any or all sections (gearbox,
compressor, and turbine) to repair a specific discrepancy affecting APU operation with all other
parts reused as removed. Medium Repairs have previously been called "repair" or "continue-
time units. Continue-time inspection (Workscope Planning Guide) criteria applies.

"Heavy repair"- at a minimum, complete compressor and turbine disassembly where exposed
detail parts are inspected per IRM requirements. This has previously been called an
"overhauled" or "heavy repair" unit.

NOTE: The test section release limits also refer to these depths of repair in lieu of terms
like "Repair" (now referred to as either "Light Repair" or "Medium Repair"),
"Overhaul" (now referred to as "Heavy Repair"), and "Continue-time" (now referred
to either "Light Repair" or "Medium Repair").

Similar depth of repair definitions apply to APU sections, modules and LRUs; with
the Heavy Repair designation implying inspection per IRM criteria and Light or
Medium Repair implying inspection per WPG criteria. For example, a
section/module can be dispositioned as a Light or Medium Repair (which allows
inspection to the WPG); but the APU is still classified as a Medium Repair at the
APU level.

Page INTRO-3
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Shop Findings Report Summary


Figure XX

Page INTRO-4
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7. Geometric Tolerance Symbols

If applicable, geometric symbols are used on illustrations in CHECK and REPAIR sections of the
manual. These symbols are shown in Table 3.

8. Verification of Technical Data

When possible the critical portions of the technical manuals are verified by the actual performance of
the procedures in the manual.

The sections shown below have been verified at the manufacturer's facility.

Section Date

49-20-04 (Assembly) Oct 11/88


49-20-05 (Assembly) Oct 11/88
49-23-04 (Assembly) Oct 11/88

Page INTRO-5
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Table 1. Equipment Identification List for Part No. 381276-1

The engines covered in this publication conform to Federal Aviation Administration Type Certificate No. TSO
C77, Category I, Class C.

Series Change Service


No. No. Description Bulletin

1 - Original Configuration -

2 2 Flight Test Configuration (Serial


No. P-1 only)

3 2, 10

10 Incorporation of Hooded Pcd Probe 49-3926


(Without Anti-Moisture Orifice)

4 2, 7, 10

7 Rework Electrical Engine Starter 49-5181


to Incorporate Improved Clutch Plates

5 2, 7, 10, 11

11 Rework Multiple Centrifugal Switch 49-5235


and Wiring Harness Assembly to In-
corporate Threaded Connector

6 2, 7, 10, 11, 12

12 Product Improved-Containment Ring 49-3914


Retention

7 2, 7, 10 thru 13

13 Incorporate Strengthened Exhaust 49-5236


Flange Assembly to Reduce Exhaust
Gas Leakage

8 2, 7, 10 thru 13,
19

19 Replace CRES Scavenge Tube with -


Aluminum

9 2, 7, 10 thru 13,
19, 21

21 Incorporation of Combustor Unit 49-5309


(Atomizer and Liner Assembly)
Part Numbers

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

10 2, 7, 10 thru 13,
19, 20, 21

20 Incorporation of Load Control 49-5307


Valve Part No. 109382-32

11 2, 7, 10 thru 13,
19, 21 and 25

25 Incorporate New Fuel Control 49-5418


Unit with Improved Acceleration
Limiter

12 2, 7, 10 thru 13,
19, 21, 24, 25
and 26

24 Incorporate Two-Piece Torus 49--5436


Assembly

26 Replace Fuel Atomizer Assembly 49-5444


Part No. 3601193-3 with Part
No. 3601193-2

13 2, 7, 10 thru 13,
19, 21, 24, 25,
26 and 28

28 Incorporate Improved Thermo- 49-5471


couple

14 2, 7, 10 thru 13,
19, 21, 24, 25,
26, 28 and 29

29 Incorporate Pinned Oil 49-5304/


Pump Assembly -5305

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

15 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29 and 31

31 To Provide Stronger Second 49-5199


Stage Diffuser Housing to
Prevent Cracking

16 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31 and 35

35 Incorporate Improved Torus 49-5436


Assembly and Heat Shield Part
No. 968959-22

17 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35 and
39

39 Incorporate Improved Accessory 49-5587


Cooling Fan Assemblies

18 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39
and 41

41 Incorporate Multiple Centrifugal 49-5505


Switch Assembly Part No. 3609480-
13 in place of Part No. 3601030-13

19 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41 and 43

43 Incorporate Improved Accessory 49-5587


Cooling Fan Assembly Part No.
695227-24

20 2, 7, 10 thru 131
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43 and 49

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

20 (Cont) 49 Incorporate Turbine Shroud 49-5689


Containment Augmentation Ring

21 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 49 and 52

52 Replace Existing Baffles with 49-5738


Enlarged Baffles

22 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49
and 52

48 Incorporation of Hastelloy "S" 49-5700


Turbine Wheel Shroud Part No.
3611904-1

23 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52
and 53

53 Incorporation of Customer- 49-5744


Requested Shock Mounting
of Ignition Units

24 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53 and 61

61 Incorporate New Bracket Assembly -

25 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62 and 64

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

25 (Cont) 62 Incorporate Improved Pump


Assembly

64 Incorporate Exhaust Duct Fan 49-5816


with Scupper at Oil Vent

26 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
and 69

67 Incorporate Improved Screen 49-5974


with resistance Welded Wire

69 Incorporate Improved Shut-off 49-6565


Valve

27 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68 and 69

68 Increase Temperature Set 49-6508


Point of Oil Temperature Switch

28 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69 and 72

72 Provide Hard Mount for Ignition 49-6774


Unit

29 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72 and 73

73 Provide Improved Altitude Starting 49-6787

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

30 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73
and 74

74 Reroute Thermocouple and Ignitor -


Lead to Protect from Combustor

31 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81 and 83

81 Provide Improved Hi-Speed 49-6563


Pinion Bearing

83 Provide T-Wheel Axial 49-6831


Retention

32 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81, 83, 84 and 88

84 Provide Improved Nut 49-6933


Part No. S9424-4

88 Incorporate Improved Housing 49-7514


Assembly Part No. 698195-12

34 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81, 83, 84, 88,
89, 93 and 94

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

34 (Cont) 93 Incorporate Improved Vent Tube 49-7238


Part No. 3617065-1

94 Incorporate Improved 49-A7189


Hastelloy "S" Augmentation Ring
Part No. 3616426-3

35 2, 7, 10 thru 13,
19, 21, 24, 25, 26,
28, 29, 31, 35, 39,
41, 43, 48, 49, 52,
53, 61, 62, 64, 67,
68, 69, 72, 73, 74
81, 83, 84, 88, 89
93, 94 and 95

95 Incorporate Improved Seal 49-7301


Assembly Part No. 378854-50

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 1 Rework Electrical Engine Starter 49-5070

3 Repair of First Stage Diffuser 49-3580


Part No. 698194-1 (Incorporation
of Steel Tip Vanes)

4 Availability of Reconditioned 49-3655


First Stage Impeller

5 Availability of Reconditioned 49-3656


Second Stage Impeller

6 Availability of Improved Compressor 49-5132


Interstage Seal Assembly

8 Incorporation of Fuel Conservation 49-5233


EGT Control System

14 Authorize Use of Turbine Wheel -


Assembly Part No. 3604604-3

15 Authorize Use of Second Stage -


Diffuser Part No. 892290-1

16 Authorize Use of Turbine Wheel -


Assembly Part No. 3604604-1

17 Authorize Use of Turbine Wheel -


Assembly Part No. 3604604-2

18 Incorporate Pinned Oil Pump 49-5305


Assembly (Refer to
Chg 29)

22 Authorize Use of Fuel Control -


Unit Part No. 3602310-10

23 Incorporate use of Gear Case -


Housing Part No. 977831-5

27 Incorporate Multiple Centrifugal 49-5505


Switch Assembly, Part No. 3609480-X (Refer to
in Place of Part No. 3601030-X Chg 41)

30 Authorize Use of Diffuser Housing 49-5199


Part No. 698195-7 or -8

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 33 Incorporation of Electrical Engine 49-5472


Starter, Part No. 3605812-16 and
3605812-17

34 Incorporate Improved Torus Part 49-5436


No. 968959-22 in Lieu of Torus,
Part No. 968959-16

37 Incorporate Improved Accessory 49-5587


Cooling Fan Assembly, Part No.
695227-24

38 Relocate Engine Identification 49-3516


Plate

40 Incorporation of Fuel Conserva- 49-5233


tion EGT Control System

42 Incorporate Improved Accessory 49-5587


Cooling Fan Assembly, Part No. (Refer to
695227-24 Chg 43)

44 Incorporate Turbine Shroud 49-5689


Containment Augmentation (Refer to
Ring Chg 49)

46 Incorporation of MAR-M-247 49-5699


Turbine Rotor and Shaft Assembly (Refer to
Part No. 3842072-1- Chg 45)

47 Incorporation of Hastelloy "S" 49-5700


Turbine Wheel Shroud Part No. (Refer to
3611904-1 Chg 48)

50 Incorporation of Improved Igniter 49-5722


Plug, Part No. 38882l0-1

56 Incorporate Improved Combustor 49-5851


Liner Part No. 3605384-8

57 Incorporate use of MAR-M-247 49-5834


Turbine Nozzles

60 Rework Atomizer by incorporating 49-5701


an Improved Shroud Nut

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 63 Authorizes use of Shims between -


the Torus and Shroud Support for
Units Modified by SB 49-5436 and
49-5689

65 Authorizes use of Torus Part No. -


3830350-2

71 Authorize use of Part No. 3616252-1 -

72 Authorize use of Ignition Unit Hard 49-6774


Mount Part No. 696069-1 in Lieu of
Shock Mount Part No. 3614647-1

75 Authorize use of Augmentation Ring -


Part No. 3616426-1

76 Authorize use of Composite Cooling -


Fan Part No. 3616496-1

77 Authorize use of Wiring Harness -


Part No. 43959

78 Authorize the MCP Upgrade VIA 49-6809


Parts Kit 3616233-1

79 Authorize the use of Ceramic Turbine -


Nozzles for Field Evaluation Program

82 Authorize use of T-Wheel/Shaft -


Assembly Part No. 3842072-3

84 Authorize use of Improved Nut 49-6933


Part No. S9424-4

85 Authorize use of Fuel Control 49-6928


Part No. 3608000-14 for Field
Evaluation Program

86 Authorize use of Switch Assembly 49-6898


Part No. 3615700-13

87 Authorize use of Turbine and -


Compressor Assembly
Part No. 3601835-60

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Table 1. Equipment Identification List for Part No. 381276-1 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 96 Authorize use of Improved Impeller 49-7477


Part No. 3822536-1

97 Authorize use of Fuel Control Unit 49-7484


Part No. 3617750-2

98 Provide ID for Units to Incorporate 49-7477


and Authorize use of Improved
HFC Life Impeller
Part No. 3822536-1

99 Provide ID for Units to Incorporate 49-7514


and Authorize use of Turbine and
Compressor Assembly
Part No. 3601835-59

100 Authorize the use of External Shields, 49-7542


Part Nos. 3844911-1 and 3844911-2

101 Turbine and Compressor Assembly, 49-7572


Part No. 3601835-62, replaces Turbine
and Compressor Assembly, Part No.
3601838-59.

102 Wheel and Shaft Assembly, Part No. 49-7488


3842360-1, replaces Wheel and Shaft
Assembly, Part No. 3842350-1

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Table 1A. Equipment Identification List for Part No. 381276-2

The engines covered in this publication conform to Federal Aviation Administration Type Certificate No. TSO
C77, Category I, Class C.

Series Change Service


No. No. Description Bulletin

1 - Original Configuration 49-5680

1 Incorporate Multiple Centrifugal 49-5505


Switch Assembly, Part No. 3609480-13
in Place of Part No. 3601030-13

2 1, 4

4 Incorporate Improved Torus, Part 49-5436


No. 968959-22 in Lieu of Torus,
Part No. 968959-16

3 1, 3, 4

3 Incorporate Improved Accessory 49-5587


Cooling Fan Assembly, Part No.
695227-19

4 8 Incorporate Multiple Centrifugal 49-5505


Switch Assembly, Part No. 3609480-
13 in Place of Part No. 3601030-13

5 9 Incorporate Improved Accessory 49-5587


Cooling Fan Assembly Part No.
695227-24

6 9, 15

15 Incorporate Turbine Shroud 49-5689


Containment Augmentation Ring

7 9, 14, 15,18

14 Incorporation of Hastelloy "S" 49-5700


Turbine Wheel Shroud Part No.
3611904-1

18 Replace Existing Baffles with 49-5738


Enlarged Baffles

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont)

Series Change Service


No. No. Description Bulletin

8 9, 14, 15,
18, 19
19 Incorporate Ignition Unit Shock 49-5744
Mount

9 9, 14, 15, 18,


19, and 24

24 Incorporate Bracket Assembly -


Part No. 3614647-1

10 9, 14, 15, 18,


19, 24, 27,
and 29

27 Incorporate Improved Pump -


Assembly Part No. 379580-700

29 Incorporate Exhaust Duct Flange 49-5816


with Scupper at Oil Vent

11 9, 14, 15, 18,


19, 24, 27,
29, 32 and 34

32 Incorporate Improved Screen with 49-5974


Resistance Welded Wire Part No.
695146-2

34 Incorporate Improved Shut-Off Valve 49-6565


Part No. 109382-35

12 9, 14, 15,18,
19, 24, 27,
29, 32, 33 and
34

33 Authorize the use of Oil Temp Switch 49-5699


Part No. 305080-1

13 9, 14, 15, 18,


19, 24, 27, 29,
32, 33, 34
and 37

37 Incorporate Hard Mount for 49-6774


Ignition Unit

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont)

Series Change Service


No. No. Description Bulletin

14 9, 14, 15, 18,


19, 24, 27, 29,
32, 33, 34, 37,
thru 39

38 Incorporate Improved Atomizer 49-6787


and Liner Assembly Part No.
3604524-44

39 Reroute Thermocouple and Ignitor -


Leads

15 9, 14, 15, 18,


19, 24, 27, 29,
32, 33, 34, 37,
thru 39,45,
and 47

45 Incorporate Improved Hi-Speed 49-6563


Pinion Bearing Part No. 3614920-1

47 Incorporate Improved Exhaust Duct 49-6831


Part No. 3850089-1

16 9, 14, 15, 18,


19, 24, 27, 29,
32, 33, 34, 37,
thru 39,45, 47,
and 48

48 Incorporate Improved Nut Part No. 49-6933


S9424-4

No Series 2 Incorporation of Electrical Engine 49-5472


Starter, Part No. 3605812-16 and
3605812-17

6 Incorporate Improved Accessory 49-5587


Cooling Fan Assembly, Part No.
695227-19

10 Incorporate Turbine Shroud 49-5689


Containment Augmentation (Refer to
Ring Chg 15)

12 Incorporation of MAR-M-247 49-5699


Turbine Rotor and Shaft Assembly (Refer to
Part No. 3842072-1 Chg 11)

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 13 Incorporation of Hastelloy "S" 49-5700


Turbine Wheel Shroud Part No. (Refer to
3611904-1 Chg 14)

16 Incorporation of Improved Igniter 49-5722


Plug, Part No. 3888210-1

20 Incorporate Improved Combustor 49-5851


Liner Part No. 3605384-8

21 Incorporate use of MAR-M-247 49-5834


Turbine Nozzles

23 Incorporate the use of Combustor 49-5851


Liner Part No. 3605384-8

25 Rework Atomizer Part No. 3601193-2 49-5701


to Part No. 3601193-5 by Replacing
Shrouded Nut

26 Incorporating the use of Shims 49-5436


Between the Torus and Shroud
Support

28 Incorporate use of Gear Case -


Housing Assembly Part No.
977831-5

30 Authorize the use of Torus Part -


No. 3830350-2

36 Incorporate the use of Part No. -


3616252-1

37 Authorize the use of Ignition Unit 49-6774


Hard Mount 696069-1

40 Authorize the use of Augmentation -


Ring Part No. 3616426-1

41 Authorize the use of Composite -


Cooling Fan Part No. 3616496-1

42 Authorize the use of Wiring Harness -


Part No. 43959-4

Page INTRO-20
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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 43 Authorize MCP Upgrade VIA Parts 49-6809


Kit 3616233-1

44 Authorize the use of Part No. 3616376-4 -


for Field Evaluation Only

46 Authorize the use of T-Wheel/Shaft -


Assembly Part No. 3842072-3

49 Authorize the use of Fuel Control 49-6928


Part No. 3608000-14

50 Authorize the use of Switch Assembly 49-6898


Part No. 3615700-13

51 Authorize the use of Turbine and -


Compressor Assembly Part No.
3601835-60

52 Incorporate Improved Housing -


Assembly Part No. 698195-12

53 Authorize the use of Seal 49-7173


Part No. 3863237-1 and
Rotor Part No. 3822479-1

56 Incorporate Improved Tube Assembly 49-7238


Part No. 3617065-1

57 Authorize the use of Hastelloy "S" 49-A7189


Augmentation Ring
Part No. 3616426-3

58 Authorize the use of Seal Assembly 49-7301


Part No. 378854-50

59 Authorize use of Improved Impeller 49-7477


Part No. 3822536-1

60 Provide ID for Units to Incorporate 49-7477


and Authorize use of Improved
HFC Life Impeller
Part No. 3822536-1

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Table 1A. Equipment Identification List for Part No. 381276-2 (Cont)

Series Change Service


No. No. Description Bulletin

No Series 61 Provide ID for Units to Incorporate 49-7514


and Authorize use of Turbine and
Compressor Assembly
Part No. 3601835-59

62 Provide identification for units incor- 49-7484


porating new FCU and Atomizer
and Liner Assembly

63 Authorize the use of External Shields, 49-7542


Part Nos. 3844911-1 and 3844911-2

64 Turbine and Compressor Assembly, 49-7572


Part No. 3601835-62, replaces Turbine
and Compressor Assembly, Part No.
3601838-59

65 Wheel and Shaft Assembly, Part No. 49-7488


3842360-1, replaces Wheel and Shaft
Assembly, Part No. 3842350-1

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Table 2. Applicable Publication List

Nomenclature Part No. Publication Type

Gas Turbine Engine 381276-1 49-21-81 MM


381276-2 49-21-73 IRM
49-23-67 IPC

Accessory Cooling Fan Assembly 695227-15 49-50-35 OHM/IPL


695227-19
695227-24

Air Pressure Regulator 108032-8 49-50-07 OHM/IPL

Centrifugal Multiple Switch 3601030-11-1 49-60-33 OHM/IPL


Assembly 3601030-13-1
3609480-13 49-60-47 CMM/IPL
3615700-13 48-60-63 CMM/IPL

Check Valve (Oil) 899766-1 49-90-41 OHM/IPL

Electrical Engine Starter 372697-21-1 49-40-01 OHM/IPL


3605812-10-1
3605812-14-1
3605812-17

Fuel Atomizer Assembly 3601193-2 49-30-38 OHM/IPL


3601193-3
3601193-4
3601193-5
3601193-7

Fuel Control Unit 3602310-14 49-30-49 OHM/IPL


3602310-33
3609150-3-1 49-30-69 OHM/IPL
3608000-10 49-31-17 CMM/IPL
3617750-2 49-31-83 CMM/IPL

Igniter Plug Lead 369259-20 49-41-05 OHM/IPL

Ignition Unit 3603281-3/-7 49-40-33 CMM/IPL

Load Control Valve 109382-28-1 49-50-40 OHM/IPL


109382-32-1

Oil Cooler Assembly 152050-5-1 49-20-10 CMM/IPL

Oil Tank Assembly 899320-1 49-90-35 OHM/IPL

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Table 2. Applicable Publication List (Cont)

Nomenclature Part No. Publication Type

Oil Pump Assembly 379580-300 49-90-33 OHM/IPL


379580-650
379580-700

Pneumatic Solenoid Valve (NC) 692993 49-60-41 OHM/IPL

Pneumatic Thermostat 129552-1-1 49-70-39 OHM/IPL

Pressure Relief Valve 373048-3 49-90-01 OHM/IPL


(Component of Oil Pump Assembly)

Sequencing Oil Pressure Switch 692525-9 49-60-06 OHM/IPL

Solenoid Shutoff Valve (NC) 692545-3 49-30-67 OHM/IPL


(Component of Fuel Control Unit)

Solenoid (Three-Way) Shutoff 320362-2-1 24-09-71 CMM/IPL


Valve

Standard Practices Manual - 20-00-02/ -


70-00-01

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Table 3. Geometric Tolerance Symbols

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Table 3. Geometric Tolerance Symbols (Cont)

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ENGINE SECTION

1. Description and Operation

A. General

The pneumatic and shaft power gas turbine engine is designed for both ground level and
airborne auxiliary power. The engine provides mechanical shaft power for driving aircraft
accessories such as an alternator, provides pneumatic bleed-air power for starting main
aircraft engines and for aircraft cabin air-conditioning and pressurization and provides cooling
air for engine lubricating oil and for the engine enclosure at all times.

B. Leading Particulars

The physical and operational characteristics of the pneumatic and shaft power gas turbine
engine are listed in Table 1. Refer to Table 2 for approved engine lubricating oils.

C. Description

The pneumatic and shaft power gas turbine engine is essentially a self-contained power
source and requires only a source of fuel and electrical power for operation. The starting,
acceleration, and operation of the engine is controlled by an integral system of automatic and
coordinated pneumatic and electro-mechanical controls. A minimum of customer-furnished
external controls are used for initiating engine starts and for observing engine operation.

Engine power is developed through compression of ambient air by a two-stage centrifugal


compressor. The compressed air, mixed with fuel and ignited, drives a radial inward-flow
turbine wheel. The rotating shaft power of the turbine wheel drives the compressor, the
accessories, and the output drive shaft.

(Post SB 49-5233/-98DHF[A]) The fuel conservation EGT control system enables the APU to
operate at a reduced bleed airflow load during "economy mode" operation while retaining full
bleed airflow capability. The system does not affect APU starting. Full bleed airflow is
maintained during aircraft main engine starting.

For convenient description, the engine is divided into seven main sections. The engine section
includes an accessory and gearcase assembly located at the front of the engine and a
compressor and a compressor and turbine assembly located at the rear. The remaining
sections are an engine fuel and control section, an ignition/starting section, an air section, an
engine control section, an indicating section, and an oil section. (Refer to Figure 1.)

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Table 1. Leading Particulars

Engine General
Weight (dry) (approx) .............................................................................................................................340 lb

Engine Ratings (min) at 620C (1150F) Turbine Discharge


Temperature (Ratings apply at the following conditions)
Inlet Air total Temperature ............................................................................................................ 39C (103F)
Inlet Air Total Pressure ......................................................................................................... 29.92 in. Hg abs
Turbine Discharge Static Pressure ....................................................................................... 29.92 in. Hg abs
Combined Mechanical and Pneumatic Power Output
Shaft Horsepower ....................................................................................................................... 60 +3/-0 shp
Bleed-air Flow ................................................................................................................................ 103.0 ppm
Bleed-air Total Pressure ....................................................................................................... 101.5 in. Hg abs
Bleed-air Total Temperature ................................................................................. 214 to 253C (418 to 488F)

Engine Speeds
Turbine Wheel
No-load, Steady-state .................................................................................................... 42,500 100 rpm
Full-bleed Load (Droop).............................................................................. 400 rpm min, 1,000 rpm max

Output Drive Shaft


(at 42,000 rpm turbine speed)......................................................................................................... 6,000 rpm
Tachometer-generator Drive Shaft
(at 42,000 rpm turbine speed)......................................................................................................... 4,200 rpm
Gear Ratio (turbine wheel speed to
tachometer-generator speed)............................................................................................................ 10:1
Fuel System
Fuel Specification...................................................................................................... MIL-G-5572, All Grades
MIL-DTL-5624, Grades JP4 or JP5;
ASTM D1655 Jet A, B, A1 aviation kerosene

Lubrication System
Lubrication Specification ..................................................................Refer to Table 2. Approved Engine Oils.
Electrical System
Voltage .............................................................................................................................................26 2 vdc
Amperage (Momentary) ............................................................................................................ 400 amp max

The engine section mounts and drives certain engine accessories, a cooling air fan assembly,
and the engine output drive shaft. The accessory and gearcase assembly consists of a
gearcase assembly and the following engine accessories; fuel control unit, oil pump assembly,
centrifugal switch assembly, starter and tachometer-generator.

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Table 2. Approved Engine Oils

Ambient Temperature
Minimum Maximum
Approved Lubricant Brand Name C F C F

CAUTION: ANY SUBSTITUTION OR USE OF NON-APPROVED LUBRICANTS, OR MIXING OF


BRANDS OR TYPES OF LUBRICANTS MAY CAUSE CONSIDERABLE ENGINE DAMAGE.

Group I
3 Centistoke Oils
(Lubricant Specification MIL-PRF-7808)

Aeroshell 390 -54 -65 54 130


BP/Exxon Turbo Oil 2389 -54 -65 54 130
Brayco 880 -54 -65 54 130
Castrol 325 or 399 -54 -65 54 130

Group II
5 Centistoke Oils
(Lubricant Specification MIL-PRF-23699)

Aeroshell or Royco Turbine Oil 500 -40 -40 54 130


Aeroshell or Royco 555 -40 -40 54 130
Aeroshell or Royco Turbine Oil 560 -40 -40 54 130
BP/Exxon Turbine Oil 2197 -40 -40 54 130
BP/Exxon Turbo Oil 2380 -40 -40 54 130
Castrol Aero 5000 -40 -40 54 130
Hatco 3611 -40 -40 54 130
Mobil Jet Oil II -40 -40 54 130
Mobil Jet Oil 254 -40 -40 54 130
Mobil Jet Oil 291 -40 -40 54 130
Royco 899 -40 -40 54 130

Group III

7.5 Centistoke Oil

Castrol 98 -40 -40 54 130

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1. C. The gearcase assembly encloses a reduction gear system. A torsion shaft couples the
compressor turbine main shaft to the main drive gear in the gearcase assembly. The main
drive gear transmits power through the reduction gear system to drive the accessories at the
required speed for each accessory. The arrangement of the accessory gear train permits the
starter to drive all the accessories in addition to driving the compressor impellers and turbine
wheel during engine starting.

The compressor and turbine assembly develops the pneumatic and shaft power absorbed
during operation of the engine. The assembly consists of a two-stage centrifugal compressor
and a single-stage turbine wheel assembly rotating on a common shaft. The compressor is
enclosed by a compressor inlet plenum assembly. The first and second stage compressor
impellers are pneumatically connected through interstage ducts. The turbine plenum
assembly encloses the turbine components and provides a receiver for compressed air from
the compressor discharge housing. A combustion chamber liner assembly provides a
combustion area and is perforated to provide the correct air-to-fuel mixture and burning rate.
A turbine torus assembly directs combustion products to a turbine nozzle assembly which
encompasses the turbine wheel blades. A shroud encloses the turbine wheel blades and
directs the exhaust gases to the turbine exhaust pipe. (Refer to Figure 2 for cross sectional
view with air flow schematic and location of accessory mounting pads.)

D. Operation

The engine incorporates control components which automatically control engine functions and
maintain required engine speed and safe temperature from initiation of start through operation
at full load. Some of the control components require interconnection with certain customer-
furnished switches and relays for proper operation.

When the starter is energized, the rotating starter drive pawls engage a jaw in the accessory
gearcase and start driving the gear train. The gear train drives the compressor and turbine
rotating parts, the oil pump assembly (and attached tachometer-generator), the fuel control
unit, and the centrifugal switch assembly. The low oil pressure switch electrical circuit remains
normally closed.

As the compressor and turbine rotating parts start turning, ambient air is drawn through the
inlet into the compressor assembly. The air is compressed by the compressor first stage
impeller, then passed through interstage ducts to the compressor second stage impeller for
further compression. The compressed air is discharged into a vaned deswirl assembly and
from there is directed into the turbine plenum. (Clean bleed-air may be withdrawn from an
outlet in the plenum through a bleed-air load control valve when the engine reaches governed
speed.) From the turbine plenum the compressed air enters the combustion chamber.

As engine speed increases, the rising oil pressure actuates the sequencing oil pressure switch,
which completes a circuit to the fuel solenoid valve and to the ignition unit. The fuel solenoid
valve is energized to open to permit fuel flow to the fuel atomizer assembly.

The fuel atomizer assembly sprays fuel into the combustion chamber where the fuel and
compressed air mix. The ignition unit causes the igniter plug to ignite the fuel and air mixture
in the combustion chamber.

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1. D. Combustion increases the energy content of the air-fuel mixture. The gases flow into the
turbine torus assembly and through the turbine nozzle assembly to the blades of the turbine
wheel. The energy of the gases is absorbed by the rotating of the turbine wheel. The spent
gases are discharged through the turbine exhaust. A portion of the power developed at the
turbine wheel is used to drive the compressor impellers, the accessory gear train, and the
driven accessories. The remainder of the power is available for output shaft power to drive
customer equipment when no-load governed speed is attained.

Acceleration of the engine continues through the combined force of the starter and energy of
the hot gases. When engine speed reaches its required value, the 35-percent switch in the
centrifugal switch assembly opens, this opens the circuit to the starter. Starter rotation ceases
and the starter driver pawls disengage from the accessory gear train. Engine oil pressure
increases until the low oil pressure switch electrical circuit is opened.

The engine continues to accelerate under turbine power. When engine speed reaches its
required value, the 95-percent switch in the centrifugal switch assembly closes. This opens a
circuit to the ignition unit and closes a circuit to the hourmeter. The igniter plug ceases firing,
and combustion is self-sustaining. The hourmeter starts recording operating time.
Acceleration continues until the no-load governed speed, is reached.

After steady state-no-load governed speed is attained, shaft power loads or bleed-air loads
may be imposed within the ranges specified in Table 1.

Engine speed and exhaust temperature are automatically controlled within established limits by
metering of fuel flow by the fuel control unit.

Smooth and proper acceleration is controlled by action of the acceleration limiter valve in the
fuel control unit. The valve references compressor air discharge pressure to fuel pressure,
then pressure-actuated diaphragm operate a poppet valve to bypass more or less fuel to
maintain the required ration of fuel flow to compressor air pressure. During starting, when
compressor air pressure is insufficient, the poppet valve is restrained from bypassing fuel by
an adjustable spring pressure against the actuating diaphragm. The fuel pressure at which the
spring pressure is overcome is the cracking pressure setting of the fuel control unit.

Turbine discharge temperature is controlled by action of a single dual purpose pneumatic


thermostat. If turbine discharge temperature exceeds a present value at any time during
acceleration or operation above 95 percent before actuation of the bleed-air switch, the ball
valve in the pneumatic thermostat opens to bleed some of the compressor air from the fuel
control unit limiter valve through the three way solenoid shutoff valve, which allows the poppet
valve to open and bypass fuel, thus reducing the turbine discharge temperature. When the
temperature is reduced below the preset value, the pneumatic thermostat closes and stops
bleeding the compressor air from the acceleration limiter valve. (Refer to Figure 2, Section
49-30-00.)

(Post SB 49-5233/-98DHF[A]) The fuel conservation system operation does not affect APU
starting. During a start the thermostat controls APU EGT to 630C (1166F) to retain maximum
start reliability and full bleed airflow capability for aircraft main engine starting. System
operation is initiated by selection of the cockpit "economy" switch to energize the 2-way
"economy" solenoid and vent LCV actuator pressure through the preset adjustable orifice.
EGT then is reduced, resulting in reduced fuel consumption and economical APU operation.

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1. D. Engine speed is controlled by action of the governor in the fuel control unit. The flyweight-type
governor is driven by the main fuel pump drive shaft, which in turn is driven through the
accessory gear train. When engine speed exceeds the present governed speed, the governor
flyweights move outward to open a slide valve to bypass fuel and so decrease engine speed.
When engine speed drops, as when load is applied, the governor flyweights move inward to
close the slide valve to permit greater fuel flow and so increase engine speed.

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Gas Turbine
Engine Sections
Figure 1

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1. D. Engine loading during bleed-air loading or combination shaft and bleed-air loading is
automatically controlled within established limits by modulation of the load control valve
butterfly position.

Overloading and consequent excessive turbine discharge temperature above 95-percent


speed with the bleed-air switch (customer furnished) actuated is controlled by action of a single
dual purpose pneumatic thermostat. Actuating the bleed-air switch in addition to opening the
load control valve, energizes the three-way solenoid shutoff valve which shuts off compressor
discharge pressure to the pneumatic thermostat. (Refer to Figure 2, Section 49-50-00.) If
turbine discharge temperature reaches a present value, the ball valve in the pneumatic
thermostat opens to bleed some of the control air from the load control valve actuator which
causes the actuator mechanism to move the butterfly valve toward the more closed position,
thus reaching the load and the discharge temperature. When the temperature is reduced
below the present value, the pneumatic thermostat closes and stops bleeding the control air
from the actuator.

The engine is provided with certain safety devices which shut down the engine or complete a
warning circuit in the event of overspeeding, excessively high oil temperature, or loss of oil
pressure. Other safety devices, operating in conjunction with the engine systems, may be
installed by the customer.

If engine speed starts to exceed governed speed and governing devices in the fuel control unit
have not metered fuel sufficiently to reduce speed, the flyweight-actuated overspeed switch in
the centrifugal switch assembly will open, which opens a circuit to the fuel solenoid valve.
When the fuel solenoid valve is de-energized, it closes and shuts off fuel flow to the
combustion chamber, thus stopping the engine.

If engine oil temperature exceeds a present value, the oil temperature switch electrical circuit
will close, completing a circuit to a customer-furnished warning indicator.

If engine oil pressure drops below a present value, the low oil pressure switch electrical circuit
will close, completing a circuit to a customer-furnished warning indicator.

The engine is stopped by actuation of the normally closed pneumatic solenoid valve, mounted
on top of the compressor inlet plenum. This valve is connected on the inlet port side to a
compressor air discharge port, and on the outlet port side to a port on the centrifugal switch
assembly. When the solenoid is energized the valve opens allowing flow of compressed air
into the centrifugal switch assembly. As the air pressure in the switch assembly builds up, the
switch actuating lever is forced into contact with the overspeed switch. When the overspeed
switch is actuated, it opens a circuit to the fuel solenoid valve and shuts off fuel flow to the
combustion chamber, thus stopping the engine.

KEY TO FIGURE 1

1. GAS TURBINE ENGINE 6. ENGINE CONTROLS SECTION


2. ENGINE SECTION (REFER TO SECTION 49-60-00)
(REFER TO 40-20-VARIOUS) 7. INDICATING SECTION
3. ENGINE FUEL AND CONTROL SECTION (REFER TO SECTION 49-70-00)
(REFER TO SECTION 49-30-00) 8. OIL SECTION (REFER TO
4. IGNITION/STARTING SECTION SECTION 49-90-00)
5. AIR SECTION (REFER TO
SECTION 49-50-00)

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Engine Cross Section


Figure 2

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ENGINE SECTION

1. Disassembly

NOTE: Refer to TESTING AND TROUBLESHOOTING to establish the condition of the unit or most
probable cause of malfunction. This is to determine the extent of disassembly without
completely disassembling and rebuilding the unit.

A. Preliminary Procedures

Before the engine can be dismantled, the following preparatory procedures should be
performed.

(1) If the engine is packed in a shipping container, crate, skid or other support, remove all
attaching hardware which secures engine.

(2) Attach 281513-3 sling or 2025131-1 lifting fixture to top of compressor turbine
assembly and to top of gearcase assembly. Adjust sling as required to support engine
in normal horizontal position.

(3) Attach a hoisting hook to 281513-3 sling or 2025131-1 lifting fixture on engine and lift
engine onto 281270-0-3, 833063-1 or 833565-2 stand.

(4) Support engine in 281270-0-3, 833063-1 or 833565-2 stand using 284125-1-1 or


2024502-1 mount on one side of engine, 284126-1-1 or 2024502-2 mount on other
side of engine, and 281893-1-1 or 834119-2 adapter to support the accessory end.

(5) Remove all shipping covers and plugs.

(6) If engine has been treated for preservation (a preservation notice tag will be attached
to engine), no further preliminary procedures are required. If engine has not been
treated for preservation, observe the following procedures.

(a) Remove all fuel and drain plugs from engine and from oil pump, fuel pump, or
other components as required.

(b) Drain all fuel into a container and discard.

(c) Drain all oil into a clean container and retain oil for inspection for evidence of
metal particles or other foreign matter.

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1. B. General Disassembly

Obvious steps or procedures necessary to disassemble the engine, such as removal of


lockwire, attaching parts, or simple components are omitted from the text. Removal of
plumbing, electrical and external parts installation may be accomplished whenever parts are
accessible. In general, disassembly should be accomplished in sequence of index numbers
assigned to individual exploded views. Variations from this sequence and special processes
or methods are specifically mentioned in the text. The following general procedures should be
observed throughout the disassembly operations.

(1) Place each part disassembled on a clean workbench in the order of removal 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 or 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 oil, using oil of specification used in the
engine lubrication system. Cover all parts with clean paper or suitable coverings
unless cleaning and inspection is to be accomplished immediately.

(5) Do not disassemble tube assemblies, hose assemblies, wiring harness assemblies,
riveted assemblies, or staked or press-fit parts (except seals and bearings) or remove
nameplates, modification plates, lubrication plates, decals, studs, or their 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 a manner consistent with
good shop practice.

(6) Always keep ports, bores, and passages of assemblies or components sealed with
tape or suitable closures between overhaul procedures. Cover large openings with
cardboard taped in place.

NOTE: Do not use tape to cover openings or connections on fuel or lubrication


system components.

(7) During various stages of disassembly, examine all parts and assemblies for signs of
scoring, burning, or other defects. Note physical conditions which will not be apparent
after cleaning. Tag involved parts before they are cleaned and laid out for detail
inspection. Check additionally for evidence of damage caused by improper
procedures at previous overhauls. Report such damage in accordance with current
practice.

(8) Record manner of lockwiring for duplication at assembly.

C. Detailed Disassembly Instructions

NOTE: Electrical connectors and plumbing lines to individual components shall be


disconnected prior to removal of the component from the engine. Refer to Sections
No. 49-20-01 and 49-20-02 for removal of plumbing and electrical installations.

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Disassemble Engine Section (Partial Breakdown)


Figure 102

NOTE: Figure 101 intentionally omitted.

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1. C. (1) Disassemble engine section components as follows. (Refer to Figure 102.)

(a) Remove attaching screw (20), then remove identification plate (10).

CAUTION: WHEN REMOVING TUBING FROM THERMOSTAT, USE BACK-UP


WRENCH ON HEX FLATS OF THERMOSTAT FITTING TO
PREVENT CHANGE OF SETTING AND DAMAGE TO
THERMOSTAT.

(b) Remove bolts (40, 80), washers (50, 90), retaining plate (100), pneumatic
thermostat (30), thermostat boss plug (70), and shim washers (60, 100).
Refer to ATA No. 49-70-39 for overhaul of pneumatic thermostat (30).

CAUTION: WHEN REMOVING SELF-LOCKING NUTS (140, 150) TO


DISCONNECT HARNESS ASSEMBLY, USE BACK-UP WRENCH
ON THERMOCOUPLE STUD NUTS TO PREVENT DAMAGE TO
THERMOCOUPLE.

(c) Remove attaching bolts (130) and washers (135), then remove
thermocouple (120). Refer to Section 49-70-01 for overhaul of
exhaust gas temperature thermocouple.

WARNING: OUTPUT VOLTAGE OF IGNITION UNIT IS DANGEROUS AND


COULD BE LETHAL. IT IS A CAPACITOR DISCHARGE-TYPE AND
CAN KEEP HIGH VOLTAGE. MAKE SURE IT IS DE-ENGERGIZED
AND GROUNDED BEFORE INPUT AND OUTPUT LEADS ARE
DISCONNECTED. DO NOT TOUCH CENTER CONTACT OF
OUTPUT TERMINAL.

(d) (Pre SB 49-5744) Remove attaching screws (210) and washers (220), then
remove bracket assembly (200) with assembled ignition unit (160). Remove
attaching nuts (170), washers (180) and screw (190), then remove ignition unit
(160) from bracket assembly. Refer to ATA No. 49-40-33 for functional test or
overhaul of ignition unit (160).

(Post SB 49-5744) Remove nuts (230, 240), clips (250, 260) and ignition unit
(160), then remove screws (210) and bracket assembly (200A) with bolts
(190B). Refer to ATA No. 49-50-33 for functional test or overhaul of the
ignition unit.

KEY TO FIGURE 102

10. IDENT PLATE (IPC FIG. 2) 110. SHIM WASHER 190B. BOLT
20. SCREW 120. THERMOCOUPLE 200. BRACKET ASSY
30. PNEU THERMOSTAT 130. BOLT 200A. BRACKET ASSY
40. BOLT 135. WASHER 210. SCREW
50. WASHER 140. LOCKNUT 220. WASHER
60. SHIM WASHER 150. LOCKNUT 230. NUT
70. THERMOSTAT BOSS PLUG 160. IGNITION UNIT 240. NUT
80. BOLT 170. NUT 250. CLIP
90. WASHER 180. WASHER 260. CLIP
100. RETAINING PLATE 190. SCREW

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(GTCP85-98DHF) Disassemble Engine Section (Partial Breakdown)


Figure 103

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1. C. (2) (GTCP85-98DHF) Disassemble engine section components as follows. (Refer to


Figure 103.)

(a) Remove attaching bolts (20) and washers (30), then remove solenoid valve
(10). Refer to ATA No. 49-60-41 for functional test or overhaul of solenoid
valve (10).

NOTE: Note orientation of load control valve for aid at assembly.

(b) Remove clamp (50), gasket (60), and load control valve (40). Refer to ATA
No. 49-50-40 for functional test or overhaul of load control valve (40).

(c) Remove attaching clamp (80) and air pressure regulator (70) from bracket
assembly (90). Refer to ATA No. 49-50-07 for functional test or overhaul of air
pressure regulator (70).

(d) Remove attaching nuts (100), washers (110), non-metallic washers (120) and
bolts (130), then remove bracket assembly (90).

KEY TO FIGURE 103

10. SOLENOID VALVE (IPC FIG. 3) 173. (POST SB 49-5233) BOLT


20. BOLT 174. (POST SB 49-5233) WASHER
30. WASHER 175. (POST SB 49-5233) WASHER
40. LOAD CONTROL VALVE 176. (POST SB 49-5233)
50. CLAMP ADJUSTABLE ORIFICE
60. GASKET 177. (POST SB 49-5233) PACKING
70. AIR PRESSURE REGULATOR 178. (POST SB 49-3516, REV 6)
80. CLAMP PLATE IDENT
90. BRACKET ASSY 179. (POST SB 49-3516, REV 6)
100. NUT SCREW
110. WASHER 180. WASHER
120. NON-METALLIC WASHER 190. WASHER
130. BOLT 200. VALVE MOUNTING BRACKET
140. THREE-WAY SHUTOFF VALVE ASSY
150. BOLT 210. NUT
160. WASHER 220. WASHER
170. (PRE SB 49-5233) HEAT SHIELD 230. NON-METALLIC WASHER
171. (POST SB 49-5233) BRACKET 240. BOLT
172. (POST SB 49-5233) 250. BOLT
PNEUMATIC SOLENOID VALVE

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1. C. (2) (e) (Pre SB 49-5233) Remove bolts (150), washer (160), heat shield (170),
washers (180), three-way shutoff valve (140), and washers (190) from valve
mounting bracket assembly (200). Refer to ATA No. 24-09-71 for functional
test or overhaul of three-way shutoff valve (140).

(Post SB 49-3516, Rev 6) Remove screws (179) and identification place


(178) from heat shield (170).

(Post SB 49-5233) Remove adjustable orifice (176) with packing (177) from
pneumatic solenoid valve (172). Remove bolts (173), washers (174),
pneumatic solenoid valve and washers (175) from bracket (171). Remove
bolts (150), washers (160), bracket, washers (180), three-way shutoff valve
(140) and washers (190) from valve mounting bracket assembly (200). Refer
to ATA No. 49-60-41 for functional test or overhaul of pneumatic solenoid
valve (172) and ATA No. 24-09-71 for functional test or overhaul of three-way
shutoff valve (140).

(f) Remove attaching nuts (210), washers (220), non-metallic washers (230),
bolts (240, 250), then remove valve mounting bracket assembly (200).

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(GTCP85-98DHF[A]) Disassemble Engine Section


(Partial Breakdown)
Figure 103A

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1. C. (2A) (GTCP85-98DHF[A]) Disassemble engine section components as follows. (Refer to


Figure 103A.)

(a) Remove attaching bolts (20) and washers (30), then remove solenoid valve
(10). Refer to ATA No. 49-60-41 for functional test or overhaul of solenoid
valve (10).

NOTE: Note orientation of load control valve for aid at assembly.

(b) Remove coupling (50), gasket (60), and load control valve (40). Refer to ATA
No. 49-50-40 for functional test or overhaul of load control valve (40).

(c) Remove attaching clamp (80) and air pressure regulator (70) from bracket
assembly (90). Refer to ATA No. 49-50-07 for functional test or overhaul of air
pressure regulator (70).

(d) Remove attaching nuts (100), washers (110), non-metallic washers (120) and
bolts (130), then remove bracket assembly (90).

KEY TO FIGURE 103A

10. SOLENOID VALVE (IPC FIG. 3A) 170. WASHER


20. BOLT 180. ADJUSTABLE ORIFICE
30. WASHER 190. PACKING
40. LOAD CONTROL VALVE 200. THREE-WAY SOLENOID VALVE
50. CLAMP 210. BOLT
60. GASKET 220. WASHER
70. AIR PRESSURE REGULATOR 230. SOLENOID BRACKET ASSY
80. CLAMP 240. WASHER
90. BRACKET ASSY 250. WASHER
100. NUT 260. BRACKET ASSY
110. WASHER 270. NUT
120. NON-METALLIC WASHER 280. WASHER
130. BOLT 290. NON-METALLIC WASHER
140. PNEUMATIC SOLENOID VALVE 300. BOLT
150. BOLT 310. BOLT
160. WASHER

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1. C. (2A) (e) Remove adjustable orifice (180) with packing (190) from pneumatic solenoid
valve (140). Remove bolts (150), washers (160), pneumatic solenoid valve
and washers (170) from solenoid bracket assembly (230). Remove bolts
(210), washers (220), solenoid bracket assembly, washers (240), three-way
shutoff valve (200) and washers (250) from valve mounting bracket assembly
(260). Refer to ATA No. 49-60-41 for functional test or overhaul of pneumatic
solenoid valve (140) and ATA No. 24-09-71 for functional test and overhaul of
three-way shutoff valve (200).

(f) Remove attaching nuts (270), washers (280), non metallic washers (290),
bolts (300, 310), then remove valve mounting bracket assembly (260).

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THIS PAGE INTENTIONALLY LEFT BLANK

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Disassemble Engine Section (Partial Breakdown)


Figure 104

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1. C. (3) Disassemble engine section components as follows. (Refer to Figure 104.)

(a) Remove clamps (20, 30), oil cooler assembly (10) and air duct hose
(40). Refer to ATA No. 49-20-10 for functional test or overhaul of oil cooler
assembly (10).

(b) Remove nuts (60), washers (70), spacer (80), bolts (90) and bracket (50).

(c) Remove bolts (110), washers (120), fan assembly (100) and packings (130).
Discard packings. Refer to ATA No. 49-50-35 for functional test or overhaul of
fan assembly (100).

(d) Remove screws (150), washers (160) and low oil pressure switch (140) from
oil tank assembly (170). Refer to Section 49-70-06 for overhaul of low oil
pressure switch.

(e) Remove bolts (180, 200), washers (190, 210) and oil tank assembly (170)
from left side of compressor inlet plenum. Refer to ATA No. 49-90-35 for
functional test or overhaul of oil tank assembly (170).

(f) Remove nuts (230), washers (240), spacers (250), bolts (260) and bracket
assembly (220).

KEY TO FIGURE 104

10. OIL COOLER ASSY (IPC FIG. 4) 140. LOW OIL PRESSURE SWITCH
20. CLAMP 150. SCREW
30. CLAMP 160. WASHER
40. AIR DUCT HOSE 170. OIL TANK ASSY
50. BRACKET 180. BOLT
60. NUT 190. WASHER
70. WASHER 200. BOLT
80. SPACER 210. WASHER
90. BOLT 220. BRACKET ASSY
100. FAN ASSY 230. NUT
110. BOLT 240. WASHER
120. WASHER 250. SPACER
130. PACKING 260. BOLT

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Disassemble Engine Section (Typical)


(Partial Breakdown)
Figure 105

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1. C. (4) Disassemble engine section components as follows. (Refer to Figure 105.)

(a) Remove nuts (20), tachometer-generator (10) and gasket (30) from oil pump
assembly (120). Refer to Section 49-70-07 for overhaul of
tachometer/generator.

(b) Remove oil temperature switch (40) with packing with retainer (50) from oil
pump assembly (120). Discard packing with retainer. Refer to Section
49-70-08 for overhaul of oil temperature switch.

(c) Remove clamp (70) and sequencing oil pressure switch (60) with plate (65)
from bracket (80). Remove screws (90), washer (100), packing with retainer
(110) and bracket (80). Refer to ATA No. 49-60-06 for functional test or
overhaul of sequencing oil pressure switch (60).

(d) Remove bolts (130, 150), washers (140) and oil pump assembly (120) with
packings (160). Discard packings. Refer to ATA No. 49-90-33 for functional
test or overhaul of oil pump assembly (120).

CAUTION: THE FUEL CONTROL DRIVE SHAFT SHALL BE KEPT WITH FUEL
CONTROL UNIT TO PREVENT LOSS OR DAMAGE.

(e) Remove nuts (180), then carefully remove fuel control unit (170). Determine
part number of fuel control unit (170). Refer to INTRODUCTION, Table 2 for
applicable manual number for functional test or overhaul.

NOTE: Exercise care to prevent damage to fuel control unit drive shaft
when removing fuel control unit from engine.

KEY TO FIGURE 105

10. TACHOMETER-GENERATOR 90. SCREW


(IPC FIG. 5) 100. WASHER
20. NUT 110. PACKING W/RTNR
30. GASKET 120. OIL PUMP ASSY
40. OIL TEMPERATURE SWITCH 130. BOLT
50. PACKING W/RTNR 140. WASHER
60. SEQUENCING OIL PRESSURE 150. BOLT
SWITCH 160. PACKING
65. PLATE 170. FUEL CONTROL UNIT
70. CLAMP 180. NUT
80. BRACKET

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Disassemble Engine Section (Partial Breakdown)


Figure 106

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1. C. (5) Disassemble engine section components as follows. (Refer to Figure 106.)

(a) Remove screws (20), washers (30), and time totalizing meter (10) from mount
assembly (60). Remove screws (40), washers (50) and mount assembly (60),
from panel assembly (170). Refer to Section 49-70-03 for overhaul of time
totalizing meter (10).

(b) Remove relay (70), nut (80), washer (90) and circuit breaker (100). Refer to
Section 49-60-05 for overhaul of relay (70) and Section 49-70-05 for overhaul
of circuit breaker (100). Remove nuts (110), screws (120), washers (130) and
disconnect electrical connector from panel assembly (170).

(c) Remove nuts (110), screws (120), washers (130) and disconnect electrical
connector from panel assembly (170).

NOTE: Do not disassemble items (180, 190) from panel assembly (170)
unless inspection reveals damage.

(d) Remove bolts (140, 160), washers (150) and panel assembly (170).

(e) Remove nuts (210), washers (220), bracket (200), spacer washers (240), link
(250) and bolts (260, 270).

(f) Remove nuts (290) and centrifugal switch assembly (280) with packing
(300). Discard packing. Determine part number of centrifugal switch
assembly (280). Refer to INTRODUCTION, Table 2 for applicable manual
number for functional test or overhaul.

(g) Remove nuts (320), starter assembly (310) with packing (330). Discard
packing. Refer to ATA No. 49-40-01 for functional test or overhaul of starter
assembly (310).

KEY TO FIGURE 106

10. TIME TOTALIZING 120. SCREW 250. LINK


METER (IPC FIG. 6) 130. WASHER 260. BOLT
20. SCREW 140. BOLT 270. BOLT
30. WASHER 150. WASHER 280. CENTRIFUGAL
40. SCREW 160. BOLT SWITCH ASSY
50. WASHER 170. PANEL ASSY 290. NUT
60. MOUNT ASSY 180. SCREW 300. PACKING
70. RELAY 190. PLATE 310. STARTER ASSY
80. NUT 200. BRACKET 320. NUT
90. WASHER 210. NUT 330. PACKING
100. CIRCUIT BREAKER 220. WASHER
110. NUT 240. SPACER WASHER

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1. D. Disassemble Combustion and Exhaust Section

Refer to Section 49-20-04 for instructions relative to disassembly of combustion and exhaust
section.

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ENGINE SECTION

1. Cleaning

A. Follow General Cleaning Instructions

(1) Perform all cleaning procedures in accordance with general cleaning instructions
provided in Standard Practices Manual (SPM), ATA No. 20-00-02/70-00-01.

(2) Protect all cleaned parts in accordance with instructions provided in SPM.

B. Clean Component Parts

NOTE: More than one cleaning method may be specified for a particular part or assembly,
e.g., a part may require removal of heavy grease deposits using a brush and
petroleum solvent followed by vapor degreasing for final cleaning. An additional
cleaning method may be required for corrosion removal. If a particular cleaning
method is not required due to the condition of the part, it may be omitted, however
only those cleaning methods specified for that part may be used.

(1) Refer to following figures for recommended cleaning methods for specific parts.

NOTE: Cleaning method numbers and alpha suffix shown in following figures
correspond to numbers and alpha suffix assigned to cleaning methods
described in the SPM. The cleaning methods instructions in the SPM refer
to additional instructions provided therein for preparation of solutions used
in performing the cleaning methods.

(2) Refer to Standard Practices Manual (SPM) for instructions pertaining to each of the
cleaning methods specified in cleaning methods listed presented herein.

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Engine Section (Partial Breakdown)


Figure 202

NOTE: Figure 201 intentionally omitted.

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Figure 202. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B E F J Q

All standard metallic hardware X X

200 Bracket Assy X X X

200A Bracket Assy X X X

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(GTCP85-98DHF) Engine Section (Partial Breakdown)


Figure 203

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Figure 203. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B E F J Q

All standard metallic hardware X X

90 Bracket Assy X X X

170 Heat Shield X X X X

171 Bracket Assy X X X X

200 Valve Mounting X X X


Bracket Assy

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(GTCP85-98DHF[A]) Engine Section (Partial Breakdown)


Figure 203A

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Figure 203A. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B E F J Q

All standard metallic hardware X X

90 Bracket Assy X X X

230 Bracket Assy X X X X

260 Valve Mounting X X X


Bracket Assy

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Engine Section (Partial Breakdown)


Figure 204

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Figure 204. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B E F J Q

All standard metallic hardware X X

40 Air Duct Hose X

50 Bracket X X X

220 Bracket Assy X X X

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Engine Section (Partial Breakdown)


Figure 206

NOTE: Figure 205 intentionally omitted.

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Figure 206. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B E F J Q

All standard metallic hardware X X

170 Panel Assembly X X X X

200 Bracket X X X X

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ENGINE SECTION

1. Inspection/Check

NOTE: Inspection/Check must be performed in accordance with instructions provided in the


Standard Practices Manual ATA No. 20-00-02/70-00-01. Reference to this manual
throughout this section will be indicated by the abbreviation SPM.

A. General Checks

(1) Check threaded parts for stripped, galled or crossed threads. Replace part if
damaged.

(2) Visually check hoses for evidence of damage. Frayed, worn, cut, kinked, deteriorated
or damaged hoses are not acceptable. Replace part that does not meet
Inspection/Check requirements.

(3) Visually check tubing for kinks, cracks, dents, excessive wear, and evidence of
corrosion or leakage. Check for cracked or galled tube flares and sleeves. Sharp
dents exceeding two percent of the tube diameter are not acceptable. Replace part
that does not meet Inspection/Check requirements.

(4) Visually check fittings for crossed, galled, peened or stripped threads. Check for
deterioration and contamination. Replace part that does not meet Inspection/check
requirements.

(5) Visually check brackets and support for physical damage that would impair function.
Replace part that does not meet Inspection/Check requirements.

B. Detailed Checks

NOTE: Items denoted by an X in Figures 302 through 306 under Detailed Check pertain to
ATA No. 49-21-73, Inspection/Repair Manual. All other references are specified as
required.

(1) Check oil pressure switch (140, Figure 304).

(a) Visually check threads for stripping, crossed, nicks, dents or other damage.

(b) Visually check connector for corrosion, bent, broken or missing pins.

(c) Visually check oil inlet for foreign material.

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1. B. (1) (d) Check operation of low oil pressure switch (90).

1 Apply oil (MIL-PRF-7808 or MIL-PRF-23699) to switch inlet port.

2 Increase pressure to 55 psig. Normally open circuits between Pins D


and A of receptacle shall close and normally closed circuit between
Pins C and B shall open.

3 Decrease pressure; switch shall reset at 45 3 psig minimum.

(2) Check tachometer generator (10, Figure 305).

(a) Visually check tachometer generator for cracks, dents, bent receptacle pins
and damaged threads.

(b) Check splines of drive shaft for damage.

(3) Check oil temperature switch (40, Figure 305) for actuation.

(a) Immerse oil temperature switch sensing probe in oil (MIL-PRF-7808 or


MIL-PRF-23699) at 116 to 121C (240 to 250F).

(b) Check circuit across oil temperature switch receptacle pins. Circuit must
close with temperature range of 116 to 121C (240 to 250F).

(c) Reduce oil temperature below 116C (240F). Circuit across pins must open.

(4) Check exhaust gas temperature thermocouple (120, Figure 302).

(a) Visually check the thermocouple for cracks or breaks, stripped threads, loose
or broken terminals or other obvious damage.

(b) Use a meter or light to check for continuity between thermocouple terminals.
There must be continuity.

(c) Use a multimeter and measure resistance from each terminal to body.
Resistance must be 20,000 ohms minimum at 20C (68F) or 10,000 ohms
minimum at 650C (1200F).

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1. B. (4) (d) Check exhaust gas temperature thermocouple using a lumnum oven
(Procedyne TH050).

NOTE: If lumnum oven (Procedyne TH050) is not available, check


Exhaust gas temperature thermocouple during engine testing.

1 Provide a surrounding temperature of 677C (1250F), exhaust gas


temperature thermocouple must register 28.00 to 28.30 millivolts at
0C (32F) reference junction or 27.05 to 27.35 at 24C (75F) reference
junction.

NOTE: The test fixture temperature indicator should be checked


against a calibrated temperature indicator to insure that
correct temperature is applied to the thermocouple.

(5) Check time totalizing meter (10, Figure 306).

(a) Visually check time totalizing meter for cracks or breaks, loose or broken
terminals, or other damage.

(b) Connect time totalizing meter to a test device for a comparable period of time.
Compare the indicated time from the time totalizing meter to a known
standard.

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Engine Section (Partial Breakdown)


Figure 302

NOTE: Figure 301 intentionally omitted.

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Figure 302. Check Requirements

Item
No. Nomenclature Detailed Check

30 Pneumatic Thermostat Refer to ATA No. 49-70-39.

120 Thermocouple Refer to Detail Check 1. B. (4).

160 Ignition Unit Refer to ATA No. 49-40-33.

NOTE: All other items of Figure 302 are limited to the requirements of the SPM or replacement.

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(GTCP85-98DHF) Engine Section (Partial Breakdown)


Figure 303

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Figure 303. Check Requirements

Item
No. Nomenclature Detailed Check

10 Pneumatic Shutdown Solenoid Refer to ATA No. 49-60-41.


Valve

40 Load Control Shutoff Valve Refer to ATA No. 49-50-40.

70 Air Pressure Regulator Refer to ATA No. 49-50-07.

140 Three Way Shutoff Solenoid Refer to ATA No. 24-09-71.


Valve

172 Pneumatic Solenoid Valve Refer to ATA No. 49-60-41.

NOTE: All other items of Figure 303 are limited to the requirements of the SPM or replacement.

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(GTCP85-98DHF[A]) Engine Section


(Partial Breakdown)
Figure 303A

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Figure 303A. Check Requirements

Item
No. Nomenclature Detailed Check

10 Pneumatic Shutdown Solenoid Refer to ATA No. 49-60-41.


Valve

40 Load Control Shutoff Valve Refer to ATA No. 49-50-40.

70 Air Pressure Regulator Refer to ATA No. 49-50-07.

140 Pneumatic Solenoid Valve Refer to ATA No. 49-60-41.

200 Three Way Shutoff Solenoid Refer to ATA No. 24-09-71.


Valve

NOTE: All other items in Figure 303A are limited to the requirements of the SPM or replacement.

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Engine Section (Partial Breakdown)


Figure 304

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Figure 304. Check Requirements

Item
No. Nomenclature Detailed Check

10 Oil Cooler Assy Refer to ATA No. 49-20-10.

100 Cooling Fan Assy Refer to ATA No. 49-50-35.

140 Low Oil Pressure Switch Refer to Detail Check 1. B. (1).

170 Oil Tank Assy Refer to ATA No. 49-90-35.

NOTE: All other items in Figure 304 are limited to the requirements of the SPM or replacement.

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Engine Section (Partial Breakdown)


Figure 305

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Figure 305. Check Requirements

Item
No. Nomenclature Detailed Check

10 Tachometer - Generator Refer to Detail Check 1. B. (2).

40 Oil Temperature Switch Refer to Detail Check 1. B. (3).

60 Oil Pressure Sequence Switch Refer to ATA No. 49-60-06.

120 Oil Pump Assy Refer to ATA No. 49-90-33.

170 Fuel Control Unit Refer to Introduction, Table 2.

NOTE: All other items in Figure 305 are limited to the requirements of the SPM or replacement.

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Engine Section (Partial Breakdown)


Figure 306

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Figure 306. Check Requirements

Item
No. Nomenclature Detailed Check

10 Time Totalizing Meter Refer to Detail Check 1. B. (5).

280 Centrifugal Switch Assy Refer to Introduction, Table 2.

310 Starter Assy Refer to ATA No. 49-40-01.

NOTE: All other items in Figure 306 are limited to the requirements of the SPM or replacement.

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ENGINE SECTION

1. Repair

Refer to Standard Practices Manual (SPM) ATA No. 20-00-02/70-00-01 and the Inspection and Repair
Manual ATA No. 49-21-73.

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ENGINE SECTION

1. Assembly

Table 501. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Anti-seize compound (C5-A Copper Based) Henkel Loctite Corp., 1001 Trout Brook Crossing,
Rocky Hill, CT 06067-3582

Anti-seize compound Bostik Consumer Division, Emhart Corp.,


(NS165) 221 Oley St., P.O. Box 3716, Reading,
PA 19605

Adhesive sealant (3145 RTV) Dow Corning Corp., 3901 S. Saginaw Rd.,
(MIL-A-46146) P.O. Box 995, Midland, MI 48640

Grease (Aeroshell No. 17) (MIL-G-21164C) Shell Oil Co., Aviation Sales Div., P.O. Box 910,
Lousiana St., Houston , TX 77252-2463

Grease (Mobil 29) (MIL-G-81827) Mobil Oil Corp. Beaumont Refinery, P.O. Box 331,
(Molybdenum Disulphide) Interstate 10, Beaumont, TX 77704

Grease (Royco 13D) (MIL-G-25013) Andersol, Inc., P.O. Box 518, 215 Merry Lane,
East Hanover, NJ 07936

Lubricant (OS-124 or Monsanto Co., Fibers Business Unit,


Santovac 5) 800 N. Linderbergh Blvd., St. Louis, MO 63167

Oil (MIL-PRF-7808, Type I or Commercially available


MIL-PRF-23699, Type II)

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1. A. General

NOTE: Assembly operations shall be performed with attention to details outlined in this
manual. Highest standards of precision shop procedures shall be employed
throughout the entire reassembly. Fits and tolerances shall be closely maintained.
the installation of plumbing, electrical and external parts installations shall be
accomplished when convenient during assembly. The following general
instructions shall be observed throughout the assembly procedures.

(1) Exercise extreme care to prevent dirt, dust, or foreign particles from entering the
engine. If any foreign particle enters the engine during assembly, stop assembly until
the foreign particle is located and removed, even if this causes considerable
disassembly.

(2) For added protection to the engine, cover large openings with tape and cardboard,
small openings with tape or a clean cloth. Cap or tape open tube ends. Do not tape
openings on fuel system components; use caps or similar coverings. If the unit is to
be left for even a short period in a partially disassembled state, cover all openings.

(3) If any parts were coated with corrosion-preventive compound, remove all traces of this
compound and any accumulated foreign matter. Clean all parts thoroughly before
assembly. Wipe all parts and surfaces with a clean, lint-free cloth.

(4) When special measurements for shimming or fitting are made on parts or on
assembled parts prior to their installation in the next higher assembly, tag these parts
as measured components of the high assembly and keep with that assembly. If
damage or other reason causes replacement of a measured component, repeat all
measurements which include the part, using the new part.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE AN


ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS
AN ASPHYXIANT; IT IS POISONOUS AND CAN BE ABSORBED THROUGH
THE SKIN.

(5) When bolts, studs, nut, or screws are assembled, coat all threaded surfaces with anti-
seize compound (NS165) unless otherwise specified. When splines or gear teeth are
to be mated, coat surfaces with oil (MIL-PRF-7808 or MIL-PRF-23699).

(6) When laminated shims are used, do not use the old shim if shim thickness is to be
increased. Use a new shim and peel off laminations as required. Old shims may be
continued in use of the required shim thickness is the same or is to be reduced and
laminations can be peeled off without damaging the shim.

(7) Never use extreme force in the assembly of the unit. If difficulty is encountered,
disassemble the unit and inspect for burrs or other interferences.

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1. A. (8) On through hole applications when extreme minimum stack conditions result in
excessive protrusion of the screw or bolt through either the threaded part or nut, a
shorter standard screw or bolt may be substituted providing the substitution results in a
minimum of one full thread protrusion beyond the face of the threaded part or nut.

NOTE: No substitutions of screw lengths are authorized for blind hole applications.

(9) On through hole applications when assembling parts which, through extreme stack
conditions, result in a screw or bolt protrusion of less than one full thread beyond the
face of the threaded part or nut, a longer standard screw or bolt may be substituted in
order to gain a minimum of one full thread protrusion.

(10) All packings are to be installed using a lubricant compatible with the system in which
the packing is located (i.e. packings used in oil systems are to be coated with oil). An
approved alternate method is to use lubricant (OS-124 or Santovac 5) on all packings
prior to installation.

B. Safety Fastening Methods

Attaching parts may be locked using various methods as applicable to the part. these
methods include use of self-locking nuts, and use of lockwire. The following general
instructions shall be observed when installing locking devices.

(1) Duplicate the locking method as noted during the disassembly.

NOTE: During the "run-down" of a self-locking nut the run-down resistance


(frictional torque) shall be noted on the last rotation just before removing
clearance between parts. The self-locking nut then shall be tightened to
the specified torque value plus the noted frictional torque.

(2) Install self-locking nuts using standard shop procedures for the type nut being used.

(3) When lockwire is used, install lockwire per SAE-AS567.

C. Assemble Engine Section Components

NOTE: Be sure all assembly procedures for the compressor and turbine section
(49-23-04), accessory drive gearcase section (49-26-02), combustion and exhaust
section (49-20-04) and engine power section (49-20-05) have been completed
before accomplishing engine section assembly. Electrical connectors and plumbing
lines shall be connected after or in conjunction with installation of the component
onto the engine. Refer to Sections No. 49-20-01 and 49-20-02 for installation of
plumbing and electrical installations.

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Assemble Starter Assembly, Centrifugal Switch


Assembly and Time Totalizing Meter
Figure 501

Page 504
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GTCP85-98DHF/[A]

1. C. (1) Assemble starter assembly, centrifugal switch assembly and time totalizing meter.
(Refer to Figure 501.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(a) Apply a thin coat of oil (MIL-PRF-7808 or MIL-PRF-23699) or lubricant


(OS-124 or Santovac 5) to new packing (330). Install starter assembly (310)
with new packing (330) and secure with nuts (320). Tighten nuts to a torque
value of 70 to 90 inch-pounds.

(b) Apply light coat of grease (MIL-G-21164, Mobile 29 or Royco 13D) to female
splined area of gearshaft. Apply a thin coat of oil (MIL-PRF-7808 or MIL-PRF-
23699) or lubricant (OS-124 or Santovac 5) to new packing (300). Install
centrifugal switch assembly (280) with new packing (300) and secure with nuts
(290). Tighten nuts to a torque value of 70 to 90 inch-pounds.

(c) Install bracket (200), link (250), and spacer washers (240). Secure with bolts
(260, 270), washers (220), and nuts (210). Tighten bolts to a torque value of
20 to 25 inch-pounds.

(d) Install panel assembly (170) and secure with bolts (140, 160) and washers
(150).

KEY TO FIGURE 501

10. TIME TOTALIZING 120. SCREW 250. LINK


METER (IPC FIG. 6) 130. WASHER 260. BOLT
20. SCREW 140. BOLT 270. BOLT
30. WASHER 150. WASHER 280. CENTRIFUGAL
40. SCREW 160. BOLT SWITCH ASSY
50. WASHER 170. PANEL ASSY 290. NUT
60. MOUNT ASSY 180. SCREW 300. PACKING
70. RELAY 190. PLATE 310. STARTER ASSY
80. NUT 200. BRACKET 320. NUT
90. WASHER 210. NUT 330. PACKING
100. CIRCUIT BREAKER 220. WASHER
110. NUT 240. SPACER WASHER

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1. C. (1) (e) Install plate (190) on panel assembly (170) and secure with screws (180).

(f) Install wiring harness assembly onto panel assembly (170) and secure with
nuts (110), washers (130) and screws (120).

(g) Install circuit breaker (100) into panel assembly (170) and secure with nuts
(80) and washer (90). Install relay (70).

(h) Install mount assembly (60) onto panel assembly (170) and secure with
screws (40) and washers (50).

(i) Install time totalizing meter (10) and secure with screws (20) and washers
(30).

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10. TACHOMETER-GENERATOR 90. SCREW


(IPC FIG. 5) 100. WASHER
20. NUT 110. PACKING W/RTNR
30. GASKET 120. OIL PUMP ASSY
40. OIL TEMPERATURE SWITCH 130. BOLT
50. PACKING W/RTNR 140. WASHER
60. SEQUENCING OIL PRESSURE 150. BOLT
SWITCH 160. PACKING
65. PLATE 170. FUEL CONTROL UNIT
70. CLAMP 180. NUT
80. BRACKET

Assemble Fuel Control Unit (Typical),


Oil Pump Assembly, Tachometer-Generator,
Oil Temperature Switch and Oil Pressure Switch
Figure 502

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GTCP85-98DHF/[A]

1. C. (2) Assemble fuel control unit, oil pump assembly, tachometer-generator, oil temperature
switch and oil pressure switch as follows. (Refer to Figure 502.)

(a) Apply light coat of grease (MIL-G-21164, Mobile 29 or Royco 13D) to square
flats and splined teeth of fuel control unit (170) drive shaft. Install fuel control
unit and secure with nuts (180). Tighten nuts to a torque value of 70 inch-
pounds.

NOTE: The oil pump assembly (120) prior to installation on the engine, is
held together by four (4) screws and one 1/4 inch bolt. The pump
is secured to the gearcase with three (3) 3/8 inch bolts. It is
recommended that the mechanic, when installing the oil pressure
switch, loosen only the two (2) screws necessary to retain the oil
pressure switch bracket. If this procedure is followed, there should
be no relative movement that would result in misalignment.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(b) Apply a thin coat of oil (MIL-PRF-7808 or MIL-PRF-23699) or lubricant


(OS-124 or Santovac 5) to new packings (160). Install oil pump assembly
(120) with new packings (160). Secure with bolts (130, 150) and washers
(140). Tighten bolts to a torque value of 70 inch-pounds.

NOTE: Do not cover vent hole in sequencing oil pressure switch when
attaching clamp.

(c) Install bracket (80) on oil pump assembly (120). Secure using existing screw
(90), washer (100) and packing with retainer (110). Install sequencing oil
pressure switch (60) on bracket (80) and secure with clamp (70).

(d) Install oil temperature switch (40) with new packing with retainer (50) on oil
pump assembly (120). Tighten oil temperature switch to a torque value of 50
inch-pounds.

(e) Install tachometer-generator (10) with new gasket (30) on oil pump assembly
(120). Secure with nuts (20). Tighten nuts to a torque vale of 25 inch-pounds.

Page 509
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OVERHAUL MANUAL
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Assemble Oil Tank Assembly, Low Oil


Pressure Switch, Fan Assembly
and Oil Cooler Assembly
Figure 503

Page 510
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GTCP85-98DHF/[A]

1. C. (3) Assemble oil tank assembly, low oil pressure switch, fan assembly and oil cooler
assembly as follows. (Refer to Figure 503.)

(a) Install bracket assembly (220) with spacer washers (250) and secure with
bolts (260), washers (240) and nuts (230). Tighten bolts to a torque value of
20 to 25-inch-pounds.

(b) Install oil tank assembly (170) on left side of compressor inlet plenum
assembly and on bracket assembly (220). Secure with bolts (180, 200) and
washers (190, 210). Tighten bolts to a torque value of 20 to 25-inch-pounds.

CAUTION: DO NOT OVERTIGHTEN ELECTRICAL HARNESS CONNECTOR


OR DAMAGE TO LOW OIL PRESSURE SWITCH MAY RESULT.

(c) Install low oil pressure switch (140) on oil tank assembly (170). Secure with
screws (150) and washers (160).

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(d) Apply a thin coat of oil (MIL-PRF-7808 or MIL-PRF-23699) or lubricant


(OS-124 or Santovac 5) to new packings (130). Install fan assembly (100)
with new packings (130). Secure with bolts (110) and washers (120). Tighten
bolts to a torque value of 50 to 70 inch-pounds.

(e) Install bracket (50) with spacer (80) and secure with bolts (90), washers (70)
and nuts (60). Tighten bolts to a torque value of 20 to 25 inch-pounds.

NOTE: Locate clamps (20, 30) at ends of oil cooler assembly (10) with
bolts pointing as shown.

(f) Install oil cooler assembly (10) and air duct hose (40). Secure with clamps
(20, 30). Tighten nut on clamps to a torque value of 20 inch-pounds.

KEY TO FIGURE 503

10. OIL COOLER ASSY 100. FAN ASSY 180. BOLT


(IPC FIG. 4) 110. BOLT 190. WASHER
20. CLAMP 120. WASHER 200. BOLT
30. CLAMP 130. PACKING 210. WASHER
40. AIR DUCT HOSE 140. LOW OIL 220. BRACKET ASSY
50. BRACKET PRESSURE 230. NUT
60. NUT SWITCH 240. WASHER
70. WASHER 150. SCREW 250. SPACER WASHER
80. SPACER 160. WASHER 260. BOLT
90. BOLT 170. OIL TANK ASSY

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(GTCP85-98DHF) Assemble Solenoid Valves, Air Pressure


Regulator and load Control Valve
Figure 504

Page 512
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GTCP85-98DHF/[A]

1. C. (4) (GTCP85-98DHF) Assemble solenoid valves, air pressure regulator and load control
valve as follows. (Refer to Figure 504.)

(a) Install valve mounting bracket assembly (200) at location shown in Figure
504A. Secure bracket assembly with bolts (240, 250, Figure 504), washers
(220), non-metallic washers (230), and nuts (210). Tighten nuts (210) to a
torque value of 90 to 100 inch-pounds.

NOTE: If mounting bracket assembly was previously installed in Section


49-20-04, disregard instruction relating to installation of mounting
bracket assembly.

KEY TO FIGURE 504

10. SOLENOID VALVE (IPC FIG. 3) 172. (POST SB 49-5233)


20. BOLT PNEUMATIC SOLENOID VALVE
30. WASHER 173. (POST SB 49-5233) BOLT
40. LOAD CONTROL VALVE 174. (POST SB 49-5233) WASHER
50. CLAMP 175. (POST SB 49-5233) WASHER
60. GASKET 176. (POST SB 49-5233)
70. AIR PRESSURE REGULATOR ADJUSTABLE ORIFICE
80. CLAMP 177. (POST SB 49-5233) PACKING
90. BRACKET ASSY 178. (POST SB 49-3516, REV 6)
100. NUT PLATE-IDENT
110. WASHER 179. (POST SB 49-3516, REV 6) SCREW
120. NON-METALLIC WASHER 180. WASHER
130. BOLT 190. WASHER
140. THREE-WAY SHUTOFF VALVE 200. VALVE MOUNTING BRACKET ASSY
150. BOLT 210. NUT
160. WASHER 220. WASHER
170. (PRE SB 49-5233) HEAT SHIELD 230. NON-METALLIC WASHER
171. (POST SB 49-5233) 240. BOLT
SOLENOID BRACKET ASSY 250. BOLT

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Location of Bracket Assemblies


Figure 504A

Page 514
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

1. C. (4) (b) (Pre SB 49-5233) Position three-way shutoff valve (140) with heat shield
(170) and secure to valve mounting bracket assembly (200) with bolts (150),
washers (160, 180, 190). Tighten bolts (150) to a torque value of 20 to 25
inch-pounds.

(Post SB 49-3516, Rev 6) Install identification plate (178). Secure


Identification Plate with screws (179).

(Post SB 49-5233) Position three-way shutoff valve (140) with solenoid


bracket assembly (171) and secure to valve mounting bracket assembly (200)
with bolts (150), washers (160, 180, 190). Tighten bolts (150) to a torque
value of 20 to 25 inch-pounds. Install adjustable orifice (176) with packing
(177) on pneumatic solenoid valve (172) and secure assembled pneumatic
solenoid valve to solenoid bracket assembly (171) with bolts (173) and
washers (174, 175).

NOTE: If mounting bracket assembly was previously installed in Section


49-20-04, disregard instruction relating to installation of mounting
bracket assembly.

(c) Install bracket assembly (90) at position shown on Figure 504A. Apply
anti-seize compound (C5-A Copper Based) to threads of bolts before
installation. Secure bracket assembly with bolts (130, Figure 504), non-
metallic washers (120), washers (110) and nuts (100). Tighten nuts (100) to a
torque value of 90 to 100 inch-pounds.

(d) Install air pressure regulator (70) on bracket assembly (90) and secure with
clamp (80). Position clamp as shown in Figure 504A.

NOTE: Clamp (50) should be located with the nut at bottom or six o'clock
position of the load control valve (40).

(e) Install load control valve (40, Figure 504), with gasket (60). Secure valve with
clamp (50). Tighten clamp to a torque value of 25 to 35 inch-pounds.

(f) Install solenoid valve (10) on inlet plenum assembly. Secure solenoid valve
with washers (30) and bolts (20). Tighten bolts to a torque value of 20 to 25
inch-pounds.

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(GTCP85-98DHF[A]) Assemble Solenoid Valves, Air Pressure


Regulator and Load Control Valve
Figure 504B

Page 516
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

1. C. (4A) (GTCP85-98DHF[A]) Assemble solenoid valves, air pressure regulator and load
control valve as follows. (Refer to Figure 504B.)

(a) Install valve mounting bracket assembly (260) at location shown in Figure
504A. Secure bracket assembly with bolts (300, 310, Figure 504B), washers
(280), non-metallic washers (290), and nuts (270). Tighten nuts (270) to a
torque value of 90 to 100 inch-pounds.

NOTE: If mounting bracket assembly was previously installed in Section


49-20-04, disregard instruction relating to installation of mounting
bracket assembly.

(b) Position three-way shutoff valve (200) with solenoid bracket assembly (230)
and secure to valve mounting bracket assembly (260) with bolts (210),
washers (220, 240, 250). Tighten bolts (210) to a torque value of 20 to 25
inch-pounds. Install adjustable orifice (180) with packing (190) on pneumatic
solenoid valve (140) and secure assembled pneumatic solenoid valve to
solenoid bracket assembly (230) with bolts (150), and washers (160, 170).

NOTE: If mounting bracket assembly was previously installed in Section


49-20-04, disregard instruction relating to installation of mounting
bracket assembly.

KEY TO FIGURE 504B

10. SOLENOID VALVE (IPC FIG. 3A) 170. WASHER


20. BOLT 180. ADJUSTABLE ORIFICE
30. WASHER 190. PACKING
40. LOAD CONTROL VALVE 200. THREE-WAY SOLENOID VALVE
50. CLAMP 210. BOLT
60. GASKET 220. WASHER
70. AIR PRESSURE REGULATOR 230. SOLENOID BRACKET ASSY
80. CLAMP 240. WASHER
90. BRACKET ASSY 250. WASHER
100. NUT 260. BRACKET ASSY
110. WASHER 270. NUT
120. NON-METALLIC WASHER 280. WASHER
130. BOLT 290. NON-METALLIC WASHER
140. PNEUMATIC SOLENOID VALVE 300. BOLT
150. BOLT 310. BOLT
160. WASHER

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1. C. (4A) (c) Install bracket assembly (90) at position shown on Figure 504A. Apply
anti-seize compound (C5-A Copper Based) to threads of bolts before
installation. Secure bracket assembly with bolts (130, Figure 504B), non
metallic washers (120), washers (110) and nuts (100). Tighten nuts (100) to a
torque value of 90 to 100 inch-pounds.

(d) Install air pressure regulator (70) on bracket assembly (90) and secure with
clamp (80). Position clamp as shown in Figure 504A.

NOTE: Locate the clamp (50) with the nut at the bottom or six o'clock
position on the load control valve.

(e) Install load control valve (40, Figure 504B), with gasket (60). Secure valve
with clamp (50). Tighten clamp to a torque value of 25 to 35 inch-pounds.

(f) Install solenoid valve (10) on inlet plenum assembly. Secure solenoid valve
with washers (30) and bolts (20). Tighten bolts to a torque value of 20 to 25
inch-pounds.

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Assemble Thermostats, Thermocouple and Ignition Unit


Figure 505

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1. C. (5) Assembly thermostats, thermocouple and ignition unit as follows. (Refer to Figure
505.)

(a) (Pre SB 49-5744) Install ignition unit (160) on bracket assembly (200) and
secure with screws (190), washers (180) and nuts (170). Tighten screws
(190) to a torque value of 20 to 25 inch-pounds. Install assembled ignition unit
and bracket assembly on compressor inlet plenum assembly and secure with
washers (220) and screws (210). Tighten screws to a torque value of 20 to 25
inch-pounds.

(Post SB 49-5744) Install the ignition unit (160) on bracket assembly (200A)
and attach with bolts (190B), clips (250, 260) and nuts (230, 240). Tighten the
nuts to a torque value of 20 to 25 inch-pounds. Install the assembled ignition
unit and attach with screws (210), tighten the screws to a torque value of 20 to
25 inch-pounds.

CAUTION: DO NOT EXCEED 25 INCH-POUNDS TIGHTENING TORQUE AT


AL TERMINAL AND 15 INCH-POUNDS TIGHTENING TORQUE AT
CR TERMINAL WHEN RECONNECTING HARNESS ASSEMBLY
LEADS TO THERMOCOUPLE.

(b) Install thermocouple (120) in exhaust duct flange assembly, apply anti-seize
compound (C5-A Copper Based) to threads of bolts before installation.
Secure thermocouple with bolts (130) and washers (135). Tighten bolts to a
torque value of 50 to 70 inch-pounds.

NOTE: (Post SB 49-A6831) The thermocouple (120) should be


approximately centered between the vanes of exhaust pipe
assembly. Refer to Section 49-20-04.

KEY TO FIGURE 505

10. IDENT. PLATE (IPC FIG. 2) 110. SHIM WASHER 190B. BOLT
20. SCREW 120. THERMOCOUPLE 200. BRACKET ASSY
30. THERMOSTAT 130. BOLT 200A. BRACKET
40. BOLT 135. WASHER 210. SCREW
50. WASHER 140. LOCKNUT 220. WASHER
60. SHIM WASHER 150. LOCKNUT 230. NUT
70. THERMOSTAT BOSS PLUG 160. IGNITION UNIT 240. NUT
80. BOLT 170. NUT 250. CLIP
90. WASHER 180. WASHER 260. CLIP
100. RETAINING PLATE 190. SCREW

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CAUTION: WHEN INSTALLING TUBING ON THERMOSTAT, USE BACK-UP


WRENCH ON HEX FLATS OF THERMOSTAT FITTING TO
PREVENT CHANGED OF SETTING AND DAMAGE TO
THERMOSTAT.

1. C. (5) (c) Install pneumatic thermostat (30) in exhaust duct flange assembly with slots
facing gas stream. Apply anti-seize compound (C5-A Copper Based) to
threads of bolt before installation. Install shim washers (60) as required to
obtain 0.010 to 0.020 inch pinch on thermostat. Secure thermostat with
washer (50) and bolt (40). Tighten bolts to a torque value of 40 to 50 inch-
pounds.

(d) Apply anti-seize compound (C5-A Copper Based) to threads of bolts


before installation. Coat thermostat boss plug (70) with adhesive (RTV3145).
Install shim washer (110) as required to obtain 0.005 to 0.030 inch pinch
between plug and retainer. Secure plug with retaining plate (100), washer (90)
and bolt (80). Tighten bolt to a torque value of 40 to 50 inch-pounds.

(e) Install identification plate (10) on plenum assembly. Secure with screws (20).

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ENGINE SECTION

1. Fits and Clearances

A. Assembly Fits and Clearances Instructions

(1) All assembly Fits and Clearances are called out in the text of ASSEMBLY procedures.
Fits and Clearances are listed in Table 601 and referenced to item and figure number
and may be used as an aid in determining overhaul requirements. Torque values are
listed in Table 602.

NOTE: Whenever non-standard torque values are required for individual parts, the
parts are identified and the torque requirements are listed in the applicable
assembly procedures covering the part. These specified torque values do
not include frictional torques developed by self locking devices or "run-
down" resistance. The frictional resistance or "run-down" torque must be
added to the specified torque. Torque tolerances are not provided for nuts
and bolts since this tolerance is assumed to be the nominal tolerance of a
properly calibrated torque wrench. Where two torque values are included,
the lower value shall be used when torque is applied to the nut and the bolt
is held stationary. When torque is applied to the bolt and the nut is held
stationary, the higher value shall be used. When torque values are not
specified, conform to standard shop practice or sources such as FAA
Manual AC65-9, Airframe and Powerplant Mechanics General Handbook.

(2) Follow general guidelines listed below for tightening small fasteners.

NOTE: Fasteners installed through essentially inelastic boundaries will first be


tightened to remove visible clearance between parts. During this initial
tightening of the fastener, the "run-down" resistance shall be noted on the
last rotation just before establishment of a tensile preload in the fastener.
The fastener shall then be given an additional tightening movement by a
steady sweep of the wrench to produce a final torque, as determined by
feel, that is approximately equal to the "run-down" torque plus the values
shown in Step (2)(a) for the respective thread size. This procedure will
produce 35 percent accuracy which is adequate for all items not listed
under torque values below. As a further assistance, Step (2)(b) gives
general guidelines for obtaining the final torque.

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1. A. (2) (a)

Torque (in.-lb)

Thread Size Aluminum Fastener CRES Fastener

6 5 10
8 10 20
10 15 35
1/4 45 75
5/16 80 160
3/8 140 275

(b)

Thread Size Approximate Rotation After Run-Down

6-32 45 deg
8-32 60 deg
10-24 40 deg
1/4-20 40 deg
5/16-18 40 deg
3/8-24 60 deg

(c) Fasteners installed through elastic boundaries (sealed by means of a


diaphragm or similar elastomeric gasket) shall be tightened uniformly to effect
a pressure-tight seal.

Table 601. Fits and Clearances

Figure Item Limits


No. No. Nomenclature Description (Inches)

505 60 Shim Washer (Pneumatic Thermostat) 0.010 to 0.020


Provide pinch between
thermostat (30) and boss

110 Shim Washer Provide pinch between 0.005 to 0.030


retaining plate (100) and
boss

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Table 602. Torque Values

Figure Item Torque


No. No. Nomenclature (in.-lbs)

501 260, 270 Bolt 20 to 25


290, 320 Nut 70 to 90

502 20 Nut 25
40 Oil Temperature Switch 50
130, 150 Bolt 70
180 Nut 70

503 20, 30 Clamp 20


90, 180, 200, 260 Bolt 20 to 25
110 Bolt 50 to 70

504 20 Bolt 20 to 25
50 Clamp 25 to 35
100 Nut 90 to 110
150 Bolt 20 to 25
210 Nut 90 to 100

504B 20 Bolt 20 to 25
50 Clamp 25 to 35
100 Nut 90 to 110
210 Bolt 20 to 25
270 Nut 90 to 100

505 40, 80 Bolt 40 to 50


130 Bolt 50 to 70
190, 210 Screws 20 to 25

Page 603/604
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ENGINE SECTION

1. Testing

A. General Instructions

(1) Test setup requirements are specified in the text in Steps B.(1) through (7) and are
illustrated in Figures 701, 702, and 703. Test equipment instrumentation requirements
are listed in Table 701.

(2) Complete and accurate records of all test information shall be maintained on a test
data sheet such as shown in Figure 704.

(3) Calculations may be required to correct observed values to standard values. When
such calculations are required, the necessary instructions, charts, curves, tables, or
other data are provided in the text.

NOTE: In order to ensure accuracy of readings obtained during test and calibration
of equipment, it is recommended that all instrumentation and gages to be
used be checked on a periodic basis.

(4) All instrumentation shall be carefully checked against recognized standards.


Manometers shall be zeroed or set to barometer reading, as applicable, at least once
a day. Any errors in excess of accuracy limits given in Table 701 shall be corrected
before the equipment can be used.

(5) Limited Testing is allowable based on depth of repair and shop experience. Testing
may be limited to validation of work performed. Refer to Table II-1 for Limited Test
Requirements and definitions of depth of repair below.

(6) "Depth of Repair"-is the extent of APU or LRU disassembly and inspection required to
make the unit serviceable or reusable. It consists of three basic levels for the 85
model APU.

Table II-1. Limit Test Requirements-Typical

Test Section/Check Light Medium Heavy


Preliminary Procedures & Instructions
Precautionary Requirements
Run-in-Checks
Combination Load Acceptance Check * **
Bleed Load Only Acceptance Check * **
Engine Operational Checks
Notes:
* Optional, based on experience and judgement of repair facility.
** Optional, unless turbine or compressor is completely disassembled

Page 701
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Fuel and Lubrication System Test Setup (Typical)


Figure 701

Page 702
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1. A. (6) "Light repair"- external work only (electrical harness, LRUs, plumbing) or partial
gearbox disassembly. These have previously be called "quick turns" or "continue-
time" units. Continue-time inspection (Workscope Planning Guide) criteria applies.

"Medium repair"- complete gearbox disassembly and/or one of the following: partial or
complete compressor disassembly only, partial or complete turbine disassembly only.
A medium repair can also be a complete disassembly of any or all sections (gearbox,
compressor, and turbine) to repair a specific discrepancy affecting APU operation with
all other parts reused as removed. Medium Repairs have previously been called
"repair" or "continue-time units. Continue-time inspection (Workscope Planning
Guide) criteria applies.

"Heavy repair"- at a minimum, complete compressor and turbine disassembly where


exposed detail parts are inspected per IRM requirements. This has previously been
called an "overhauled" or "heavy repair" unit

NOTE: Similar depth of repair definitions apply to APU sections, modules and
LRUs; with the Heavy Repair designation implying inspection per IRM
criteria and Light or Medium Repair implying inspection per WPG criteria.
For example, a section/module can be dispositioned as a Light or Medium
Repair (which allows inspection to the WPG); but the APU is still classified
as a Medium Repair at the APU level.

B. Test Setup Requirements

(1) The engine shall be mounted for testing in accordance with the following instructions.

KEY TO FIGURE 701

1. SEQUENCING OIL 15. OIL TEMPERATURE BULB (MS28034-1)


PRESSURE SWITCH 16. OIL PRESSURE CONNECTION
2. DRAIN CONNECTION (9/16-18 THD FOR 3/8 INCH LINE)
(1/2-20 THD FOR 5/16 INCH LINE) 17. FUEL BOOST PUMP
3. TURBINE PLENUM DRAIN CONNECTION 18. PRESSURE REGULATOR
(1/2-20 THD FOR 5/16 INCH LINE 19. SHUTOFF VALVE
4. FUEL BYPASS PORT CONNECTION 20. FUEL FILTER
(7/16-20 THD FOR 1/4 INCH LINE) 21. FUEL FLOWMETER
5. FUEL INLET CONNECTION 22. TEST SETUP FUEL SHUTOFF VALVE
(9/16-18 THD FOR 3/8 INCH LINE) 23. TEMPERATURE INDICATOR
6. FUEL SOLENOID VALVE (FUEL INLET) (0 TO 150F)
7. FUEL FILTER 24. PRESSURE GAGE (FUEL INLET)
8. FUEL DISCHARGE CONNECTION (0 TO 20 PSIG)
(TO FUEL ATOMIZER ASSY) 25. MANUAL FUEL BYPASS VALVE
9. FUEL DRAIN CONNECTION 26. PRESSURE GAGE (FUEL DISCHARGE)
(7/16-20 THD FOR 1/4 INCH LINE) (0 TO 600 PSIG)
10. CONTROL AIR LINE 27. PRESSURE GAGE (LIMITER
11. ACCELERATION LIMITER ADJUSTMENT CRACKING) (0 TO 100 PSIG)
SCREW 28. PRESSURE GAGE (OIL
12. GOVERNOR ADJUSTMENT SCREW DISCHARGE) (0 TO 120 PSIG)
12A. GOVERNOR ADJUSTMENT NUT 29. TEMPERATURE INDICATOR (OIL
13. OIL FILTER DISCHARGE) (0 TO 300F)
14. PRESSURE RELIEF VALVE ASSY 30. GOVERNOR ADJUSTMENT JAM NUT

Page 703
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NOTE: Leave one mount loose in stand to allow for thermal expansion movement.

1. B. (1) (a) Install engine in 281270-0-3, 833063-1 or 833565-2 stand using 284125-1-1 or
2024502-1 mount on one side of engine, 284126-1-1 or 2024502-2 mount on
other side of engine, and 281893-1-1 or 834119-2 adapter to support the
accessory end.

(b) Install mounted engine in a test setup facility so that all sides, tops, and
bottom of engine are readily accessible. Compressor air inlet (9, Figure 703)
and cooling fan air inlet (5) shall be unobstructed.

(c) Connect fuel and lubrication systems, electrical system, air ducts, and
instrumentation as specified in the following paragraphs.

(2) A fuel supply, together with the necessary plumbing, controls, and instrumentation
shall be provided in the test setup in accordance with the following. (Refer to Figure
701; refer to Table 701.)

Page 704
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THIS PAGE INTENTIONALLY LEFT BLANK

Page 705
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Electrical System, Speed, Power,


and Vibration Test Setup
Figure 702

Page 706
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1. B. (2) (a) Provide the source of fuel as specified in Table 701 and provide a fuel supply
line from the fuel source to fuel inlet connection (5).

(b) Install fuel boost pump (17) in the fuel supply line, if required, to maintain inlet
fuel pressure specified in Table 702.

(c) Install pressure regulator (18), shutoff valve (19), fuel filter (20), fuel flowmeter
(21), and test setup fuel shutoff valve (22) in the fuel supply line to control and
measure fuel flow. Make certain the appropriate graphs or curves for the
particular flowmeter being used are available for determining correct fuel flow.

(d) Connect a tee into the fuel supply line and install a thermocouple probe in the
tee to measure fuel inlet temperature. Connect the thermocouple to
temperature indicator (23).

(e) Connect the cross fitting at fuel control unit fuel inlet connection (5) to the fuel
supply line, the line from manual fuel bypass valve (25) and to pressure gage
(24) to measure inlet fuel pressure.

KEY TO FIGURE 702

1. STARTER NEGATIVE TERMINAL 16. HARNESS RECEPTACLE


(1/4-28 THD) 17. NON-RAM DOOR INTERLOCK
2. STARTER POSITIVE TERMINAL RECEPTACLE
(1/4-28 THD) 18. RAM DOOR ACTUATOR
3. SHAFT POWER MOUNTING FLANGE RECEPTACLE
(AND20006, TYPE SV1-B) 19. AMMETER (0 TO 50 AMP)
4. VIBRATION MOUNT SUPPORT 20. SHUNT
CONNECTION 21. STARTER RELAY (500 AMP)
5. VIBRATION MOUNT SUPPORT 22. PNEUMATIC SOLENOID SWITCH
CONNECTION (3/8-24 THD) 23. HIGH OIL TEMPERATURE LIGHT
6. TACHOMETER-GENERATOR (YELLOW)
7. ENGINE HARNESS INPUT 24. LOW OIL PRESSURE LIGHT (WHITE)
RECEPTACLE 25. LOW OIL PRESSURE LIGHT (BLUE)
8. ENGINE RAM DOOR ACTUATOR 26. BLEED-AIR SWITCH
RECEPTACLE 27. READY-TO-LOAD LIGHT (GREEN)
9. ENGINE NON-RAM DOOR 28. RECEPTACLE
INTERLOCK RECEPTACLE 29. AUX START RELAY
10. EPUT METER AND COUNTER 30. START SWITCH
11. WATER DYNAMOMETER (250 31. MASTER ON LIGHT (AMBER)
SHAFT HORSEPOWER) 32. MASTER STOP SWITCH
12. TORQUE METER 33. CIRCUIT BREAKER
13. VIBRATION PICKUP (MODEL NO. 34. RECEPTACLE
4382) 35. (POST SB 49-5233 (98DHF[A])
14. HIGH PASS FILTER (COMPONENT LAB SWITCHING DEVICE (FUEL
OF VIBRATION METER) ECONOMY SOLENOID SWITCH)
15. VIBRATION METER (MODEL 1-117)

Page 707
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Air Systems Test Setup (Typical)


Figure 703

Page 708
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

1. B. (2) (f) Install a tee fitting at fuel bypass port connection (4) on the fuel control unit to
provide a connection to a bypass line and to pressure gage (26) to measure
fuel discharge pressure. Install manual fuel bypass valve (25) in the bypass
line between the tee fitting and the fitting at fuel inlet connection (5) for manual
control of engine speed.

(g) When checking fuel control unit acceleration limiter valve cracking pressure,
remove pressure gage (26) and temporarily install pressure gage (27).

(h) Connect drain lines at drain connection (2, 3, 9).

KEY TO FIGURE 703

1. GEARCASE NEGATIVE PRESSURE CONNECTION


2. TEE ASSY
3. NUT
4. ORIFICED CAP (0.035 TO 0.040 INCH) CAP
5. COOLING FAN AIR INLET
6. LOAD CONTROL VALVE BLEED-AIR DISCHARGE FLANGE
(QUICK-DISCONNECT)
7. METERING SCREW (VALVE ADJUSTMENT)
8. TURBINE BEARING CAVITY NEGATIVE PRESSURE CONNECTION
9. COMPRESSOR AIR INLET
10. ENGINE THERMOCOUPLE
11. PNEUMATIC THERMOSTAT
12. CONTROL AIR LINE FROM PNEUMATIC THERMOSTAT
13. TURBINE EXHAUST FLANGE (QUICK-DISCONNECT TYPE, 9 INCH DIA)
14. PNEUMATIC SHUTDOWN SOLENOID VALVE
15. COMPOUND GAGE (TURBINE BEARING CAVITY NEG PRESS)
(+15 PSIG TO -30 INCH HG G)
16. MERCURY MANOMETER (BAROMETER) (AMBIENT AIR) (0 TO 30 INCH HG)
17. TEMPERATURE INDICATOR (AMBIENT AIR) (0 TO 150F)
18. TAILPIPE ADAPTER (PART NO. 2024745-2)
*19. TEMPERATURE INDICATOR (TURBINE EXHAUST) (50 TO 1500F)
20. BLEED-AIR DUCT ASSY (PART NO. 281407-2)
21. HOSE ASSY (PART NO. 258616)
22. AIR FLOW MEASURING SECTION
23. BLEED-AIR SHUTOFF VALVE (REMOTE CONTROL ADJUSTABLE)
24. TEMPERATURE INDICATOR (BLEED-AIR) (0 TO 600F)
25. MERCURY MANOMETER (BLEED-AIR) (0 TO 100 INCH HG)
26. TEMPERATURE INDICATOR (FLOW ORIFICE AIR) (0 TO 600F)
27. MERCURY MANOMETER (FLOW ORIFICE AIR) (0 TO 100 INCH HG)
28. WATER MANOMETER (FLOW ORIFICE DIFFERENTIAL)
(0 TO 100 INCH WATER)
29. COMPOUND GAGE (GEARCASE NEGATIVE PRESS.)
(+15 PSIG TO -30 INCH HG G)
*30. TEMPERATURE INDICATOR (ENGINE THERMOCOUPLE) (50 TO 1500F)

* INDICATORS MUST BE THE SAME OR IDENTICAL UNITS

Page 709
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1. B. (3) An oil supply, together with the necessary plumbing, controls, and instrumentation
shall be provided in the test setup in accordance with the following. (Refer to Figure
701; refer to Table 701.)

(a) Provide lubrication oil as specified in Section 49-20-00, Table 2. Fill oil tank
to FULL mark on sight gage.

(b) Connect a pressure gage at the oil pressure connection (16) on the oil pump
assembly to measure oil discharge pressure.

(c) Replace high oil temperature switch with oil temperature bulb (15). Connect
temperature indicator (29) to measure oil discharge temperature.

Table 701. Instrumentation Requirements

Application Range Accuracy

TEMPERATURE

Compressor inlet air total 0 to 150F 2F

Bleed-air discharge total 0 to 600F 2F

Bleed-air measuring section 0 to 600F 2F


orifice

Turbine exhaust total 50 to 1500F 10F


Turbine exhaust (from engine 50 to 1500F 10F
thermocouple)

Fuel pump inlet 0 to 150F 2F

Oil pump discharge 0 to 300F 2F

PRESSURE

Air pressure regulator 0 to 50 Inch Hg Ga 0.10 Inch Hg

Compressor inlet air 28 to 31 Inch Hg Abs 0.10 Inch Hg


(Barometric)

Accessory gearcase +15 Psig to -30 Inch Hg Ga 0.10 Inch Hg

Page 710
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Table 701. Instrumentation Requirements (Cont)

Application Range Accuracy

PRESSURE (Cont)

Turbine bearing cavity +15 Psig to -30 Inch Hg Ga 0.10 Inch Hg

Bleed-air discharge total 0 to 100 Inch Hg Ga 0.10 Inch Hg

Bleed-air measuring section 0 to 100 Inch Hg Ga 0.10 Inch Hg


orifice (upstream)

Bleed-air measuring section 0 to 100 Inch water Ga 0.10 Inch water


orifice (differential)

Fuel Pump Inlet 0 to 35 psig 0.25 psi

Fuel pump discharge 0 to 600 psig 5.0 psi

Fuel pump limiter bypass 0 to 100 psig 0.6 psi


valve cracking

Oil pump discharge 0 to 120 psig 2.0 psi

FLOW

Bleed-air Weight 0 to 200 pm 2.0 pm

Fuel 80 to 300 phr 1.0 phr

SPEED

*Turbine Wheel 0 to 46,000 rpm 100 rpm

ELECTRIC

Starter Motor Current 0 to 500 amp 5.0 amp

*Turbine wheel speed to tachometer-generator shaft speed ratio; 10 to 1.

Page 711
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Table 701. Instrumentation Requirements (Cont)

Application Range Accuracy

VIBRATION

Engine Total 0 to 3.0 mil 0.01 mil

POWER

Shaft Output 0 to 200 hp 2.0 hp

FUEL SYSTEM Fuel MIL-G-5572, Grade All, MIL-DTL-5624,


Grade JP-4 and JP-5 or
ASTM D1655 Jet A, B, A1
aviation kerosene

Inlet Press. 30 2 psig

Inlet Temp 57C (135F) max

LUBRICATION SYSTEM Lubricant Type I MIL-PRF-7808, Section 49-20-00,


(3 Centistoke) Table 2

Lubricant Type II MIL-PRF-23699 Section 49-20-00,


(5 Centistoke) Table 2

7.5 Centistoke Refer to Section 49-20-00, Table 2

ELECTRICAL SYSTEM Voltage 26 2 vdc

Current 400 amp (momentary max)

Page 712
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1. B. (4) An electrical system with necessary wiring, switches, and controls shall be installed in
the test setup in accordance with the following. (Refer to Figure 702; refer to Table
701.)

(a) Provide a source of electrical power as specified in Table 701.

(b) Provide a control panel with master stop switch (32), start switch (30), bleed-
air switch (26), green ready-to-load light (27), starter relay (21) and ammeter
(19) and shunt (20).

(c) Provide a harness assembly to connect the control panel to engine harness
receptacle (16). Provide a lead to connect starter relay (21) to starter positive
terminal (2).

(d) Provide jumper wires for receptacles (17, 18).

(e) (Post SB 49-5233/98DHF[A]) Connect J & P, engine harness receptacle (16)


to lab switching device (fuel economy solenoid switch) to operate fuel
economy solenoid.

(5) Instrumentation and equipment for measurement of engine speed, output shaft
horsepower, and engine vibration shall be installed in the test setup in accordance with
the following. (Refer to Figure 702; refer to Table 701.)

(a) Install water dynamometer (11) at shaft power mounting flange (3) and
connect torque meter (12) to the water brake to measure shaft output
horsepower.

NOTE: The load performance tests herein are based on the use of a water
dynamometer to apply shaft loading. Operators have the option of
utilizing a generator and load bank in lieu of a water dynamometer.
The only variable in the computation for shaft horsepower
conversion is the generator efficiency. Users will have to get this
information from the generator manufacturer. The calculation
required is: (Required S.H.P.) x (0.746) x (Generator Efficiency) =
Required Generator KVA Loading.

Page 713
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Date Technician
Part No. Cmpsr Inlet Temperature Start Time
Model No. Barometric Pressure Stop Time
Serial No. Total This Run

Condition Test/Check Observation Requirement Actual


Engine Run- Acceleration Fuel Pressure 57 to 63 psig psig
in Limiter Valve (Boost Pump on)

Manual Start Vibration at 0.6 mil max mil


Gearcase End
Vibration at 0.4 mil max mil
Turbine End
No-Load 42,500 100 rpm rpm
Governed Speed
Turbine Bearing 0 to -25 in. HgG in. HgG
Cavity Pressure at rated speed
with cavity ports for Overhauled/
capped. Repaired Units
+4 psig to -25 in. psig/in.
Hg G for Continue - HgG
Time Units (HSI or
repairs that do not
include compressor
and turbine disassembly)
Fuel Pump Inlet 30 2 psig psig
Pressure
Fuel Pump Dis- Check psig
charge Pressure
Oil Pump Dis- 95 5 psig psig
charge Pressure
Oil Pump Dis- 3 psig max psig
charge Pressure
Fluctuation
Oil Pump Dis 140C (285F) max C
charge Tempera- or 51C (125F) ( F)
ture higher than ambi-
ent temperature
Accessory Gear- -3 to -10 in. in.
case Cavity Nega- Hg G Hg G
tive Pressure

Oil Filter Ele- Check Oil Filter None permitted If contam-


ment check Element for Con- inated, Re-
tamination place Filter

Test Data Sheet


Figure 704 (Sheet 1 of 4)

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Condition Test/Check Observation Requirement Actual


Engine Run-in Centrifugal or 35 Percent SW 14,500 to rpm
(Cont) Speed Switch Actuation Speed 16,500 rpm rpm
Check (Check rpm
Two Actuations)
95 Percent SW 37,300 to rpm
Actuation Speed 38,900 rpm rpm

110 Percent SW 44,750 250 rpm


Actuation Speed rpm

No-Load Gov- No-Load Governed 42,500 100 rpm rpm


erned Speed Speed
Adjustment
Pneumatic Actua- 110 Percent Engine shall
tion of 100 Per- Switch Actuation shut down
cent Switch
No-Load Gov- No-Load Governed 42,500 100 rpm rpm
erned Speed Speed
Recheck
Full-Load Gov- Full-Load Governed 400 to 1000 rpm rpm
erned Speed Speed Droop to full
Check load
No-Load Gov- No-Load Governed 42,500 100 rpm rpm
erned Speed Speed
Recheck
Air Pressure Air Pressure 37.6 to 39.7 in.
Regulator Out- in. Hg G Hg G
put Pressure (18.5 to 19.5 psig) ( psig)
Engine Combination Bleed-Air Flow, Record data lb/min
Acceptance Load Perform- Pressure and Bleed-air flow
ance Check Temperature Bleed-air pres- ________in.
(60SHP) indications sure Hg abs
Bleed-air temper- ________C
ature (Refer to ( F)
Table 703)

Test Data Sheet


Figure 704 (Sheet 2)

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Condition Test/Check Observation Requirement Actual


Engine Ac- Bleed Bleed-Air flow, Record data. _______lb/min
ceptance Load perform- Pressure and Bleed-air flow
(Cont) ance Check Temperature Bleed-air pres- ________in.
(0 SHP) indications sure Hg abs
Bleed-air temper- C
ature (Refer to ( F)
Table 704)
Orifice Inlet Orifice Inlet Record data in.
Air Pressure Air Pressure Hg G
Indicator
Orifice Inlet Orifice Air Record Data C
Air Temperature Inlet Temperature ( F)
Indicator
Orifice Delta Orifice Inlet Record data in.
Pressure Air Pressure Hg G
Indicators in.
H2 O

Compare Test Engine Thermo- Engine thermo- + C


Setup Thermo- couple and Test couple Indica- ( F)
couple Indicator Setup Thermo- tion shall be:
with Engine couple Tempera- not more than - C
Thermocouple ture Indicators 34C (62F) higher ( F)
Indicator or 14C (25F)
lower than test
setup thermo-
couple indication
Engine Op- Pneumatic (Load Temperature on Temperature shall C
eration Control) Thermo- Test Setup Thermo- be: 630C (1166F) ( F)
stat Check couple Indicator maximum
574C (1066F)
recommended
(Refer to Table 705)
Pneumatic (Load Temperature on Controlling C
Control) Thermo- Test Setup Ther- temperature ( F)
stat Recheck mocouple Indi- shall recheck C
cator within 3C (5F) ( F)
for two succes-
sive checks

Test Data Sheet


Figure 704 (Sheet 3)

Page 716
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Condition Test/Check Observation Requirement Actual


Engine Load Control Fuel Pressure From No-Load to sec
Operation Valve Rate Con- Indicator full bleed load
(Cont) trol Check within 9 to 10
seconds
Bleed-Air Pres- Bleed-Air Pres- Oscillation shall in. Hg
sure Oscillation sure Indicator be dampened
within 1.0 inch
Hg within 10
seconds after
engine speed
reaches min value
Fuel Economy To assure 2 cycles
Solenoid system "On - Off"
operability
Overload and Time, Test Cell After 2 minutes rpm
Bleed-Air Ambient Tempera- or a test cell
Contamination ture and Engine ambient tempera-
Check Speed ture of 39C (103F)
engine speed shall
be 41,000 rpm min
Acceleration Fuel Pressure 57 to 63 psig psig
Limiter Valve (Boost Pump On)
Recheck

Automatic Start Starting Se- Starter de-


Check (2 Suc- quence energizes at
cessive Checks) 14,500 to 16,500
rpm. Ready to
load light illuminates
at 37,300 to 38,900
rpm. Engine shall
accelerate to no-load
governed speed within
allowable time limits

Engine Status Accept Reject

Remarks

Test Data Sheet


Figure 704 (Sheet 4)

Page 717
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NOTE: For water brake calibration, the horsepower factor is 441,000. The
horsepower formula is:

Indicated Torque (in.-lbs) X Turbine Wheel Speed =


441,000
Horsepower.

1. B. (5) (b) Connect tachometer-generator (6) to EPUT meter and counter (10) to
measure engine turbine wheel speed. (Refer to Figure 702.)

NOTE: Ratio of turbine wheel speed to tachometer-generator drive shaft


speed is 10 to 1. The speed factor when using a ten-pole
tachometer-generator is 60. The tachometer calibration point is
750 cps which equals a turbine wheel speed of 45,000 rpm.

(c) Install 265846-1 mount at connection (4) on gearcase assembly and 265846-2
mount on connection (5) on compressor. Install vibration pickup (13) on each
mount. Connect vibration meter (15) with high pass filter (14) to each pickup
to measure engine vibration.

(6) Air ducts and instrumentation for measuring turbine and bleed-air discharge air shall
be provided in the test setup in accordance with the following. (Refer to Figure 703;
refer to Table 701.)

NOTE: Test facility exhaust provisions shall discharge all exhaust air and gas to
the same conditions of temperature and pressure as exist at the
compressor and fan inlets.

(a) Install tailpipe adapter (18) on turbine exhaust flange (13). Connect opposite
end of adapter to test facility exhaust provisions. The test facility shall exhaust
to same conditions of ambient temperature and pressure as exist at the
compressor air inlet.

Page 718
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1. B. (6) (b) (Tailpipe Adapter, Part No. 2024745-2) Install 834320-1 and 834320-2
thermocouples (component of adapter) in the fittings provided on tailpipe
adapter (18). Connect thermocouples to temperature indicator (19) to
measure turbine exhaust temperatures.

NOTE: Tailpipe Adapter, Part No. 2024745-2 replaces Tailpipe Adapters,


Part Nos. 281915-2-1 and 285148-2-1.

(Tailpipe Adapter, Part No. 281915-2-1) Install 290255-1-1 and 290255-2-1


thermocouple in the fittings provided on tailpipe adapter (18). Connect
thermocouples to temperature indicator (19) to measure turbine exhaust
temperature.

(Tailpipe Adapter, Part No. 285148-2-1) Install three 283880-1 and one
283880-2 thermocouples (component of adapter) in the fittings provided on
tailpipe adapter (18). Connect thermocouples to temperature indicator (19) to
measure turbine exhaust temperatures.

CAUTION: DO NOT EXCEED 25 INCH-POUNDS TIGHTENING TORQUE AT


AL TERMINAL AND 15 INCH-POUNDS TIGHTENING TORQUE AT
CR TERMINAL WHEN CONNECTING INDICATOR LEADS TO
ENGINE THERMOCOUPLE.

(c) Connect engine thermocouple (10) to temperature indicator (30) to check


thermocouple readings against test setup thermocouples temperature
readings.

NOTE: Engine thermocouple heat readings shall not be used for engine
test procedures.

(d) Install bleed-air duct assembly (20) on load control valve bleed-air discharge
flange (6). Connect bleed-air duct assembly thermocouples to temperature
indicator (24) to measure bleed-air discharge temperature.

(e) Connect bleed-air duct assembly (20) total pressure probes to mercury
manometer (25) to measure bleed-air discharge pressure.

(f) Connect one end of hose assembly (21) to bleed-air duct assembly (20) and
connect other end to air flow measuring section (22). The measuring section
shall contain a 4.000 to 6.000 inch square edge orifice plate in accordance
with ASME Power Test Code, Part 5, Chapter 4 (1949), "Flow Measurement".
Make certain the appropriate graphs or curves for the particular measuring
section being used are available for determining correct actual air weight flow.

(g) Install two iron-constantan thermocouples upstream of the flow measuring


section orifice plate and connect to a temperature indicator (26) to measure
orifice air temperature for flow calculations.

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1. B. (6) (h) Install two static pressure probes upstream of the flow measuring section
orifice plate and two static pressure probes downstream of the orifice plate.

(i) Install a tee in the upstream pressure probe line and connect one end to
mercury manometer (27) to read upstream pressure. Connect other end of
tee to bottom of a water manometer. Connect downstream pressure probes
to top of water manometer (28) to measure orifice differential pressure for flow
calculations.

(j) Install bleed-air shutoff valve (23) downstream of the flow measuring section.
The valve shall be capable of handling air weight flow from 9 to 150 pounds
per minute at a maximum temperature of 249C (480F). Connect the valve to
the test facility exhaust provisions.

(k) Install a duct at the oil cooler air discharge flange. Connect the duct to the test
facility exhaust provisions.

(7) Instrumentation for measuring accessory gearcase negative pressure, turbine bearing
cavity negative pressure, and control air pressure shall be provided in the test setup in
accordance with the following. (Refer to Figure 703; refer to Table 701.)

(a) Install 2024743-1 inlet duct on the compressor air inlet (9) and centered in the
air stream to measure inlet air temperature for engine performance
calculations.

(b) Install mercury manometer (barometer) (16) adjacent to the engine to


measure ambient air pressure for engine performance calculations.

(c) Remove orificed vent plug from gearcase assembly and install tee assembly
(2) and nut (3). Fabricate orificed cap (4) containing on 0.035 to 0.040 inch
diameter orifice and install cap on tee assembly.

(d) Connect compound gage (29) to gearcase negative pressure connection (1) to
measure case negative pressure.

(e) Connect compound gage (15) to turbine bearing cavity negative pressure
connection (8) to measure turbine bearing cavity negative pressure. Cap off
disconnected turbine bearing cavity vent line.

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1. C. Preliminary Procedures and Instructions

(1) The following preparations shall be made prior to testing.

(a) Mount engine in the maintenance stand, install in test setup, and connect
instrumentation in accordance with instructions outlined in Paragraph 2.

(b) Check all plumbing and ducts for correct routing and security of connections.
Check thermocouple probes for security and correct polarity, check electrical
system for correct routing and security of connections. Make certain that
entire test setup is secure and accurate.

(c) Set all test setup switches and valves in OFF position.

(d) Open engine hourmeter circuit breaker.

(e) Observe and record barometric pressure readings at intervals indicated on


test data sheet (Figure 704). Adjust manometer as necessary.

CAUTION: CAPPING OFF THE LOAD CONTROL VALVE TEE FITTING


ALLOWS THE LOAD CONTROL VALVE TO REMAIN FULL OPEN
DURING BLEED LOADING OF THE ENGINE. THEREFORE
EXERCISE CARE NOT TO EXCEED TURBINE DISCHARGE
TEMPERATURE LIMITS SPECIFIED IN TABLE 702, WHEN USING
THE TEST SETUP BLEED-AIR SHUTOFF VALVE TO BLEED LOAD
THE ENGINE.

(f) Disconnect tube assembly (control air line between three-way solenoid valve
and load control valve), at load control valve tee fitting. Cap off load control
valve tee fitting.

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1. C. (2) Observe the following priming procedures before the initial start of the engine. (Refer
to Figure 701.)

CAUTION: ENGINE SHALL NEVER BE PERMITTED TO ROTATE UNLESS


THERE IS ADEQUATE FUEL SUPPLIED TO FUEL CONTROL UNIT.
FUEL CONTROL UNIT LUBRICATION IS PROVIDED BY FUEL.

(a) Open shutoff valve (19) and actuate test setup fuel shutoff valve (22) to supply
fuel to fuel control unit. Bleed all air from fuel control unit through FUEL-LOW
fitting on ground checkout panel.

(b) Make certain oil tank and plumbing lines are clean. If required, flush and drain
oil tank and lines.

(c) Fill oil tank to FULL mark on indicator sight gage with oil specified in Section
49-20-00, Table 2. Check oil filter to ensure paper element is installed.

(d) Remove electrical connector from sequencing oil pressure switch (1) to
prevent switch from actuating fuel solenoid valve (6). Do not reconnect
receptacle until priming is completed and fuel control unit acceleration limiter
bypass cracking pressure has been checked. Jumper Pins A and C on non-
ram door interlock receptacle (17, Figure 702) and Pins C and H on ram door
actuator receptacle (18).

(e) Attach an oil line from a pre-oil boost pump serviced with oil specified in Table
701, to oil pressure connection (16, Figure 701). Apply approximately five psig
pressure with boost pump, roll engine over by hand several times to pre-oil
engine.

CAUTION: DO NOT EXCEED STARTER DUTY CYCLE. (REFER TO TABLE


702.)

(f) Close master-stop switch (32, Figure 702) and press start switch (30); rotate
engine by starter action.

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1. C. (2) (g) Allow engine to rotate until oil pressure is indicated on pressure gage (28,
Figure 701). If oil pressure is not indicated within ten seconds, stop engine
and correct trouble before proceeding.

CAUTION: DO NOT EXCEED STARTER DUTY CYCLE. (REFER TO TABLE


702.)

(h) If oil pressure is indicated, continue rotating engine for a total of 30 seconds.
Record starter current, oil pressure, and engine speed on test data sheet
(Figure 704).

(i) Check oil level in oil tank and replenish if required.

Table 702. Operating Limits

Observation Condition Limit Requirements

CAUTION: STOP UNIT IF INDICATED VALUES EXCEED OR PERSIST AT THESE LIMITS.

Compressor Inlet Air Continuous operation 54C (130F) max


Temperatures

Bleed-air Temperature Continuous operation 253C (488F) max

Cooling Fan Air Inlet Continuous operation 54C (130F) max


Temperature

Turbine Discharge Continuous operation 630C (1166F) max


Temperature

Never exceed (Governed 662C (1225F) max


Speed Condition)

NOTE: Maximum temperatures may be exceeded during engine start and acceleration, provided that start
time does not exceed normal limits.

Fuel Economy Solenoid With fuel economy solenoid 90.55 to 96.11C (195 to
energized 205F) max decrease in EGT

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Table 702. Operating Limits (Cont)

Observation Condition Limit Requirements

Turbine Wheel Speeds Continuous operation 42,600 rpm max

Never exceed 45,000 rpm max

Fuel Temperature at Any operating condition 43C (110F) max


Pump Inlet

Oil Temperature Any operating condition 140C (285F) max or 51C (125F)
higher than ambient temperature

Oil Pressure (at oil No load governed speed 95 5


pump pressure tap)

Allowable fluctuation 3 psi max


at steady-state

Oil Consumption At rated speed 0.25 lb/hr max

CAUTION: MAXIMUM PEAK VIBRATIONS GREATER THAN THE LIMITS SHOWN MAY
OCCUR AT CERTAIN CRITICAL TURBINE WHEEL SPEEDS FROM 17,000 TO
23,000 RPM. DO NOT OPERATE THE UNIT CONTINUOUSLY AT ANY SPEED
WHERE VIBRATION EXCEEDS THESE LIMITS OR UNDER CONDITIONS THAT
CREATE SPEED DWELLINGS BETWEEN 17,000 AND 23,000 RPM.

NOTE: Momentary vibration amplitudes in excess of specified limits are acceptable during
start and acceleration cycles, however, the magnitude of the observed amplitude
excursions should not exceed 2.0 mil at the turbine end or at the gearcase end. If
transient vibrations exceed 1.5 mil at the turbine end or gearcase end, perform an
additional four starts. If vibrations stay within the 2.0 mil limit and do not show an
increasing trend during the four starts, the engine is acceptable. If the vibration
trend increases during the extra four starts, reject engine. Check engine
vibration at a minimum oil temperature of 104C (220F) and under a combination
load.

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Table 702. Operating Limits (Cont)

Observation Condition Limit Requirements

Vibration Amplitude Gearcase end 0.6 mil max

Turbine end 0.4 mil max

Gearcase Negative At rated speed -3 to -10 in. Hg gage


Pressure

Turbine Bearing Cavity At rated speed with


Pressure with cavity port capped

Overhauled/Repaired Units 0 to -25 in. Hg G

Continue - Time Units (HSI +4 psig to -25 in. Hg G


or repairs that do not include
compressor and turbine
disassembly)

Starter Duty cycle One minute on max,


four minutes off min

NOTE: A cooling period of 30 minutes is required after four


starter duty cycles.

Light-off Time Refer to Figure 706

Leakage Oil leakage from any shaft None allowed


seal (during operation)

Oil leakage from first stage None allowed


compressor seal during or
after shutdown

Fuel leakage from fuel One drop per minute max


control unit drain

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Table 702. Operating Limits (Cont)

Observation Condition Limit Requirements

Leakage (Cont) Air leakage (other than valve None allowed


bleed holes, pressure
regulator, acceleration limiter
valve cap and plenum drain
orifice)

Turbine Wheel Speed Continuous operation 42,500 100 rpm


(No-load governed speed)

Continuous operation (400 to 1,000 rpm droop


(full-load governed speed) to full load)

10-second operation (during 43,900 to 46,000 rpm


check of speed or centrifugal
switch operation only)

Never exceed 46,000 rpm max

1. D. Precautionary Requirements

CAUTION: SHUTDOWN ENGINE IF IGNITION AND FULL NO LOAD GOVERNED


SPEED DOESN'T OCCUR WITHIN TIME LIMIT SHOWN IN FIGURE 706.
ENSURE FUEL HAS DRAINED (IF FUEL FLOW HAS OCCURRED) FROM
PLENUM BEFORE RESTART IS INITIATED. FAILURE OF FUEL TO DRAIN
COULD CAUSE A HOT START.

NOTE: Engine noise is acceptable as long as compressor discharge pressure variation


does not exceed 10 psig.

(1) The engine shall be shut down immediately and the cause of trouble determined and
corrected if operation limits tabulated in Table 702 are exceeded, or if seizing, unusual
noise, smoke, fuel or oil leakage, or other obvious malfunction is observed.

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WARNING: DURING OPERATION OF THE ENGINE, PERSONNEL SHALL STAND


CLEAR OF THE COMPRESSOR AIR INLET, TURBINE EXHAUST, AND
PLANES OF ROTATION OF THE HIGH SPEED TURBINE AND
COMPRESSOR. EXTREME CARE SHALL BE TAKEN TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE AIR INLET. TURBINE OR
COMPRESSOR FAILURE, WHICH MAY BE CAUSED BY FOREIGN
MATERIAL ENTERING THE ENGINE, CAN BE VIOLENT AND COULD
RESULT IN DAMAGE TO EQUIPMENT OR INJURY TO NEARBY
PERSONNEL.

1. D. (2) Do not operate engine under conditions that cause speed dwellings between 10,000
and 13,000 rpm or at speeds where vibration exceeds 0.6 mil at the accessory end
pickup or 0.4 mil at the turbine end pickup.

NOTE: The use of the hot section components will be extended by operating the
engine at no-load governed speed for at least one minute prior to
application of a bleed-air load.

(3) Allow engine to operate at no-load governed speed for one minute (minimum) prior to
application of a bleed-air load.

(4) Allow engine to operate at zero bleed load for 1 minute (minimum) prior to a shutdown.

E. Engine Run-in Checks

(1) Check fuel control unit acceleration limiter valve cracking pressure as follows.

NOTE: Connection of gas turbine engine tester is not required for this check.
Make sure that the fuel control unit has been primed and air has been bled
prior to operation.

(a) Check battery to ensure that a fully charged battery is available for electrical
power.

(b) Disconnect control air line (10, Figure 701) at fuel control unit to vent control
air line to ambient pressure.

(c) Disconnect electrical connector at fuel solenoid valve (6) and close manual
fuel bypass valve (25).

(d) Disconnect fuel pressure gage (6) and connect pressure gage (27) (limiter
cracking) to fuel bypass port connection (4).

(e) Make sure that test cell boost pump supplying fuel to APU is ON.

CAUTION: DO NOT EXCEED STARTER DUTY CYCLE. (REFER TO TABLE


702.)

(f) Close master stop switch (32, Figure 702) and press start switch (30) to rotate
engine by starter action.

NOTE: A fuel inlet pressure of 5 psig minimum is required when checking/


setting acceleration limiter valve cracking pressure.

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OVERHAUL MANUAL
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1. E. (1) (g) (Pre SB 49-5196 and Post SB 49-7484) (FCU) While engine is rotating at
approximately 8000 to 9000 rpm, check and record acceleration limiter valve
cracking pressure at gage from 282645 pressure gage and case set
assembly. Cracking pressure shall be 57 to 63 psig.

1 If cracking pressure is 60 3 psig, do not adjust.

2 If cracking pressure requirement is not met, adjust cracking


pressure to 58 to 62 psig using a wrench to loosen locknut while
holding acceleration limiter valve adjustment screw (11, Figure 701)
with screwdriver. Turn adjustment screw clockwise to increase
cracking pressure, counterclockwise to decrease cracking pressure.

NOTE: 1/2 turn of adjustment screw (11) equals 5 psig change.

3 When adjustment is complete, hold adjustment screw (11) with


screwdriver and tighten locknut with wrench.

4 Recheck acceleration limiter valve cracking pressure per


instructions outlined in Steps (e) through (g).

(Post SB 49-5196) (TAFCU) While engine is rotating at approximately 8000


to 9000 rpm, check cracking pressure of limiter valve as indicated at
cracking pressure gage. Cracking pressure must be 57 to 63 psig with
boost pump ON.

1 If cracking pressure is 57 to 63 psig, do not adjust.

2 If cracking pressure requirement is not met, but greater than 55


psig adjust cracking pressure to 58 to 62 psig using a wrench to
loosen locknut while holding acceleration limiter valve adjustment
screw (11, Figure 701) with screwdriver. Turn adjustment screw
clockwise to increase cracking pressure, counterclockwise to
decrease cracking pressure.

NOTE: 1/2 turn of adjustment screw (11) equals 5 psig change.

3 If cracking pressure is less than 55 psig, replace fuel control


(TAFCU).

(h) Record cracking pressure and fuel inlet pressure on test data sheet (Figure
704).

(i) Remove pressure gage (limiter cracking) (27, Figure 701) from fuel bypass
port connection (4) and reinstall pressure gage (fuel discharge) (26).

(j) Reconnect control air line (10) at fuel control unit.

(k) Reconnect electrical receptacle at sequencing oil pressure switch (1).

(l) Wipe any surface oil, grease, or fuel from engine.

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1. E. (2) Perform manual starting procedure and run-in as follows.

NOTE: Manual control of engine operation shall be used until engine controls are
adjusted for automatic operation. Manual control of engine speed is
accomplished by operating test setup manual fuel bypass valve (25, Figure
701) to bypass fuel from fuel pump outlet to fuel pump inlet. Observe
precautionary requirement outlined in Step 1.D.(2) when controlling engine
speed with bypass valve.

(a) Ensure that shutoff valves (19, 22, Figure 701) are open and manual bypass
valve (25) is closed. Close master stop switch (32, Figure 702) and press
start switch (30) to initiate engine rotation. Observe engine start and
acceleration operation. Starting cycle shall commence immediately and
continue after start switch is released. Check engine vibration and cavity
pressures during operation check; values shall be within limits given in Table
702. If engine starts and accelerates properly, open manual fuel bypass valve
to control turbine wheel speed and turbine inlet temperature. Both low oil
pressure light (24, 25, Figure 702) circuits shall be energized when starting
cycle continues after start switch is released and engine accelerates.

(b) Observe engine acceleration operation. At approximately 4000 rpm engine


speed, rising oil pressure (five to seven inches Hg gage) shall actuate
sequencing oil pressure switch. Sequencing oil pressure switch actuation
shall energize ignition unit and open fuel solenoid valve. At approximately
4000 to 5000 rpm engine speed, engine shall light off and continue to
accelerate. As engine reaches a speed of 15,000 to 15,500 rpm, immediately
open master stop switch to shut down engine.

(c) Close master stop switch and press start switch. As engine accelerates,
observe actuation of engine 35-percent switch. At approximately 14,500 to
16,500 rpm engine speed, the 35-percent switch shall operate and de-
energize starter, as indicated on ammeter by current drop. Low oil pressure
light circuits shall be de-energized and lights go off. If vibration does not
exceed 0.6 mil, allow engine to continue to accelerate at approximately 37,000
rpm, open master stop switch to shut engine down.

NOTE: If oil pressure is not within limits specified in Table 702, adjust oil
pump relief valve adjustment screw to obtain specified 100 10
psig pressure.

CAUTION: IF AT ANY TIME THE ENGINE EXCEEDS VIBRATION LIMITS


SPECIFIED IN TABLE 702, IMMEDIATELY SHUT DOWN ENGINE
TO PREVENT DAMAGE.

(d) Close master stop switch and press start switch. As engine accelerates,
observe actuation of engine 95-percent switch. At approximately 37,300 to
38,900 rpm engine speed, the 95-percent switch shall operate and de-
energize ignition. Load light shall come on. Check engine vibration, which
shall not exceed limits specified in Table 702. Adjust manual fuel bypass
valve to maintain an engine speed of 42,500 100 rpm maximum. Operate at
this speed for sufficient time to record data. Check engine vibration, which
shall not exceed limits specified in Table 702. Record turbine bearing cavity
pressure. Shut down engine.

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1. E. (2) (e) Remove and check oil filter (13, Figure 701). If filter is contaminated, change
filter and recheck after approximately 15 minutes of engine operation.

(3) Check automatic controls as follows.

(a) Check and adjust centrifugal switch assembly as follows.

1 Start engine and accelerate under manual control.

2 At approximately 14,500 to 16,500 rpm, engine speed, check that


35-percent switch operates, de-energizing starter. Adjust switch
setting, if necessary, by removing plate and adjusting screw located
farthest from electrical connector. A clockwise rotation of the
adjustment screw will increase engine rpm. A counterclockwise
rotation of the adjustment screw will decrease engine rpm.

3 At approximately 37,300 to 38,900 rpm engine speed, check that


95-percent switch operates, de-energizing ignition unit and
energizing bleed-load switch and green ready-to-load light. Adjust
switch setting, if necessary, by removing plate and adjusting center
screw. A clockwise rotation of the adjustment screw will increase
engine rpm. A counterclockwise rotation of the adjustment screw
will decrease engine rpm.

(b) Check and adjust fuel control unit governor speed setting.

CAUTION: (PRE SB 49-5196 AND POST SB 49-7484) DO NOT


EXCEED TWO FULL TURNS OF ADJUSTMENT ON
GOVERNOR SPRING IF A DISENGAGEMENT OCCURS
BETWEEN THE SPRING RETAINER NUT AND
ADJUSTMENT SCREW OR IF MORE THAN TWO FULL
TURNS ARE REQUIRED TO ATTAIN DESIRED RPM.
REFER TO FUEL CONTROL UNIT PUBLICATION (ATA NO.
49-30-49 OR 49-31-83) FOR GOVERNOR SPRING
REPLACEMENT INSTRUCTIONS.

DO NOT EXCEED 46,000 RPM AT ANY TIME.


DO NOT EXCEED 43,900 RPM FOR PERIODS LONGER
THAN TEN SECONDS.

1 Start and allow engine to accelerate to no-load governed speed.

2 With no-load applied, check steady-state no-load governed speed


indicated on tester tachometer indicator. Steady-state no-load
governed speed shall be within limits of 101.0 to 101.4 percent
(42,400 to 42,600 rpm).

3 (Pre SB 49-5196 and Post SB 49-7484) Remove lockwire and


loosen locknut with wrench while holding the governor adjustment
screw (12, Figure 701) with screwdriver. Turn the governor
adjustment screw with screwdriver to obtain the desired engine
speed. Clockwise adjustment increases engine speed,
counterclockwise adjustment decreases engine speed.

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OVERHAUL MANUAL
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CAUTION: (PN 3608000-ALL) TIMED ACCELERATION FUEL


CONTROL (TAFCU) GOVERNOR ADJUSTMENT NUT CAN
BE MADE IF THE ENGINE SPEED CHANGE IS SMALL
(REDUCING ENGINE SPEED BY NO MORE THAN 300
RPM OR INCREASING SPEED NO MORE THAN 600 RPM).
DO NOT OVER ADJUST. ONLY ADJUST ENOUGH TO
REACH THE REQUIRED SPEED SETTING. EXCESSIVE
ADJUSTMENTS WILL RESULT IN MIS-ADJUSTMENT OF
THE INTERCEPT GOVERNOR THAT CANNOT BE
CORRECTED ON THE ENGINE.

1. E. (3) (b) 3 (Post SB 49-5196) Remove lockwire and use the 833274-1 sleeve
adjustor wrench to hold the governor adjustment nut (12A) while
loosening jamnut (30) with the 833275-1 jamnut wrench. Adjust
governor nut to obtain the desired engine speed. Clockwise
adjustment increases engine speed, counterclockwise adjustment
decreases engine speed.

4 (Pre SB 49-5196 and Post SB 49-7484) Repeat Step 2. When


adjustment is satisfactory, hold governor adjustment screw (12) with
screwdriver and tighten locknut with wrench. Lockwire.

(Post SB 49-5196) Repeat Step 2. When adjustment is


satisfactory, hold governor adjustment nut (12A) with the 833274-1
sleeve adjustor wrench and tighten jamnut (30) with the 833275-1
jamnut wrench. Lockwire.

(c) Check pneumatic operation of centrifugal switch as follows.

1 With engine operating at no-load governed speed, actuate


pneumatic solenoid switch (22, Figure 702) to open pneumatic
solenoid valve located on top of compressor inlet plenum.

2 Check that valve opens to pressurize and actuate overspeed switch


in centrifugal switch assembly and engine shuts down.

(d) Check no-load governed speed. Start and allow engine to accelerate at no-
load governed speed. No-load governed speed shall fall within limits specified
in Table 702 with manual fuel bypass valve (25, Figure 701) completely
closed.

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OVERHAUL MANUAL
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1. E. (3) (e) Check full-load governed speed.

1 Set water dynamomter (11, Figure 702) to apply corrected shaft


horsepower load specified in Table 706 with engine operating at no-
load governed speed.

CAUTION: ENSURE THAT TEST SETUP BLEED-AIR SHUTOFF


VALVE IS CLOSED PRIOR TO OPENING ENGINE LOAD
CONTROL VALVE TO PREVENT OVER TEMP CONDITION.

2 Actuate bleed-air switch (26, Figure 702) to open engine load


control valve, then slowly open test setup bleed-air shutoff valve
(23, Figure 703) to bleed load engine, until a turbine discharge
temperature specified in Table 703 is reached. Full-load governed
speed shall be within limits specified in Table 702 with manual fuel
bypass valve (25, Figure 701) completely closed.

3 If droop is not within specified limits, change fuel control unit


governor spring in accordance with instructions outlined in fuel
control unit publication (ATA No. 49-30-49). Use weaker spring to
decrease droop. Reaccomplished Steps (b) through (e) if spring
change is required.

4 Remove shaft and pneumatic loads.

(f) Recheck no-load governed speed. No-load governed speed shall be within
limits specified in Table 702.

(g) Check and adjust air pressure regulator output pressure.

1 Remove cap from tee fitting located at air pressure regulator.


(Refer to Figure 705.)

2 Connect one end of control air pressure hose assembly to tee fitting
and other end to 0 to 50 inches Hg gage.

3 Start engine and allow to accelerate at no-load governed speed.


Operate engine for two minutes at no-load stabilize operation.

4 Observe pressure indicated on gage. Pressure shall be 37.6 to


39.7 inches Hg gage (18.5 to 19.5 psig allowable).

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1. E. (3) (g) 5 If regulated outlet pressure is not within specified limits, shut down
engine, loosen locknut on opposite end of air pressure regulator and
turn adjustment screw clockwise to increase outlet pressure,
counterclockwise to decrease outlet pressure. Tighten locknut and
repeat check procedure. Lockwire the nut.

(h) Check pneumatic thermostat (acceleration mode) (11, Figure 703) controlling
temperature and adjust, if required as follows.

CAUTION: CAPPING OFF THE LOAD CONTROL VALVE FITTING


ALLOWS THE LOAD CONTROL VALVE TO REMAIN FULL
OPEN DURING BLEED LOADING OF THE ENGINE,
THEREFORE EXERCISE CARE NOT TO EXCEED
TURBINE DISCHARGE TEMPERATURE LIMITS
SPECIFIED IN TABLE 702 WHEN USING THE TEST
SETUP BLEED-AIR SHUTOFF VALVE TO BLEED LOAD
THE ENGINE.

1 Check that tube assembly (control air line) to load control valve tee
fitting is disconnected and tee fitting is capped off.

2 Disconnect wiring harness assembly connector from pneumatic


shutdown solenoid valve (14, Figure 703.)

3 Start and manually accelerate engine to no-load governed speed


limits specified in Table 702.

Air Pressure Regulator Adjustment Screw


Figure 705

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CAUTION: DO NOT EXCEED TURBINE DISCHARGE TEMPERATURE


LIMIT SPECIFIED IN TABLE 702. IMMEDIATELY CLOSE
TEST SETUP BLEED-AIR SHUTOFF VALVE UPON
ATTAINING ACCELERATION CONTROL THERMOSTAT
CONTROLLING TEMPERATURE.

1. E. (3) (h) 4 Actuate bleed-air switch (26, Figure 702) to open engine load control
valve, then slowly open test setup bleed-air shutoff valve (23, Figure
703). Continue to open valve very slowly, at a rate of approximately
3C (5F) increase in turbine discharge temperature per second until
speed and fuel flow start dropping. Turbine discharge temperature at
this point is the acceleration control thermostat controlling
temperature. The acceleration control thermostat controlling
temperature shall be 537 to 630C (100 to 1166F).

5 If thermostat does not control within specified limits, adjust


thermostat as follows, then record data on the Test Data Sheet.

NOTE: There are two self-locking helicoil inserts located in the


adjustable collar to prevent the collar from rotating and
changing calibration in service. To ensure integrity of this
locking device the torque on the adjustment collar should
be observed during adjustment. If the running torque on
the adjustment collar is less than 20 inch-pounds the
thermostat must be removed from service for repair.

6 Calibrate adjustable thermostat to required setting as follows.

a Observing that each index mark on the adjustment head


equals 2C (4F), rotate adjustment collar in a clockwise
direction (viewed from fitting end) to increase temperature
setting.

b Rotate adjustment collar in a counterclockwise direction to


decrease temperature setting.

7 Recheck controlling temperature two successive times after correct


setting of thermostat is obtained. Controlling temperature shall
repeat within 3 (5F) for each check.

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1. F. Engine Acceptance Check

NOTE: Prior to starting acceptance test, check that turbine plenum assembly bolts are
tightened to a torque value of 90 to 100 inch-pounds plus frictional torque.

(1) Check combination load performance as follows.

NOTE: Results of check and values observed shall be entered on the test record
sheets. If any symptoms of a malfunction or defect are observed during
check, the engine shall be shut down immediately. Refer to Paragraph I for
required action in such instances.

(a) Start engine and allow to reach no-load governed speed limits specified in
Table 702.

(b) Operate engine for five minutes at no-load.

(c) Apply shaft horsepower specified in Table 703 to engine using water
dynamometer (11, Figure 702).

(d) Actuate bleed-air switch (26, Figure 702) to open engine load control valve
and slowly open test setup bleed-air shutoff valve (23, Figure 703) to load
engine to a turbine discharge temperature specified in Table 703.

(e) Operate engine for five minutes to allow conditions to stabilize. Note and
record bleed-air total pressure and bleed-air total temperature. Note and
record temperature, pressure, and pressure differential at bleed-air measuring
section, then use these figures to calculate bleed-air flow, using the graph or
chart for the particular air flow measuring section being used. Record
calculated bleed-air flow.

Page 735
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Table 703. Combination Load Performance Requirements (60 SHP)

Heavy Repair Continue Time


Condition (Overhaul) (Light/Medium Repair)

Bleed-air flow 106.7 lb/min 100.2 lb/min

Bleed-air 99.6 inch 96.5 inch Hg


Pressure Hg Abs min Abs min

Bleed-air 234 20C 234 20C


Total (453 35F) (453 35F)
Temperature

Shaft SHP +3 SHP +3


Horsepower Delta Correction Factor = 60 Delta Correction Factor = 60
(SHP) -0 -0

Turbine 630C (1166F) (max) 630C (1166F) (max)


Discharge
Temperature

NOTE: Requirements are based on 39C (103F) compressor inlet air temperature and 29.92 inch
Hg abs ambient air pressure. Use correction factors as directed in Paragraph H for other
inlet air temperatures and ambient pressures.

Table 704. Bleed Air Performance Requirement (0 SHP)

Heavy Repair Continue Time


Condition (Overhaul) (Light/Medium Repair)

Bleed-air flow 126 lb/min 118.3 lb/min

Bleed-air 94.6 inch Hg Abs min 94.6 inch Hg Abs min


Pressure

Bleed-air 234 20C 234 20C


Total (453 35F) (453 35F)
Temperature

Turbine 630C (1166F) (max) 630C (1166F) (max)


Discharge
Temperature

NOTE: Requirements are based on 39C (103F) compressor inlet air temperature and 29.92 inch
Hg abs ambient air pressure. Use correction factors as directed in Paragraph H. for other
inlet air temperatures and ambient pressures.

Page 736
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

1. F. (1) (f) Engine shall meet or exceed performance requirements given in Tables 703
or 704. Values in Tables 703 or 704 are based on compressor inlet air
temperature of 39C (103F), ambient air pressure of 29.92 inches Hg absolute,
and bleed load at specified turbine discharge temperature. If conditions of
inlet air temperature and ambient pressure are other than specified, observed
values shall be corrected in accordance with instructions outlined in Paragraph
10.

(g) Remove load, operate engine for one minute, then shut down.

G. Engine Operational Checks

NOTE: Results of checks and values observed shall be entered on the test record sheets.
If any symptoms of a malfunction or defect are observed during checks, the engine
shall be shut down immediately. Refer to Step (9) for required action in such
instances.

(1) Check pneumatic thermostat (11, Figure 703) (load control mode) controlling
temperature and adjust, if required, as follows.

(a) Remove cap from load control tee fitting, then reconnect tube assembly
(control air line between three-way solenoid valve and load control valve).

(b) Start and allow engine to accelerate to no-load governed speed.

(c) Actuate bleed-air switch (26, Figure 702) to open engine load control valve.
Set water brake to obtain 63 shaft horsepower corrected for ambient pressure
(63 SHP=SHP/Delta Correction Factor), then slowly open test setup bleed-air
shutoff valve (23, Figure 703) while observing turbine discharge temperature.
With test setup bleed-air shutoff valve (23) full open, the engine load control
valve shall control the turbine discharge temperature within 574 to 630C (1066
to 1166F). If thermostat does not control within specified limits, adjust
thermostat. (Refer to Paragraph E, Step (3)(h) then record data on Test Data
Sheet.

(d) Recheck controlling temperature after correct setting thermostat is obtained.


Controlling temperature shall repeat within 3C (5F) for two successive
checks.

(2) Check operation of load control valve as follows.

(a) Start engine and allow to accelerate to no-load governed speed. Actuate
bleed-air switch (26, Figure 702) to open engine load control valve, then open
test setup bleed-air shutoff valve (23, Figure 703) as required to maintain
turbine discharge temperature at 8 to 10C (15 to 20F) below setting of load
control thermostat.

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OVERHAUL MANUAL
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1. G. (2) (b) Close bleed-air switch (26, Figure 702) to close engine load control valve
completely, then actuate bleed-air switch (26) to open position and observe
fuel pressure gage (26, Figure 701). The time between switch actuation and
first peak observed on fuel pressure gage (indicating full-load has been
reached) shall be nine to ten seconds.

(c) If required, adjust metering screw (7, Figure 703) to bring load control valve
actuation time within limits. Clockwise adjustment of metering screw
increases actuation time, counterclockwise adjustment decreases operating
time.

(2A) (Post SB 49-5233) Check fuel economy system.

NOTE: Ensure fuel economy solenoid is closed (de-energized) except during


systems operational checks.

(a) With unit at full-load (no shaft load) energize fuel economy solenoid.

(b) Adjust fuel economy orifice until EGT decreases 90.55 to 96.11C (195 to
205F) and lock.

(c) Cycle fuel economy solenoid two times to assure system operability.

(3) Check engine cycling as follows.

(a) Start the engine and allow to accelerate to no-load governed speed.

(b) Open test setup bleed-air shutoff valve (23, Figure 703), then actuate bleed-air
switch (26, Figure 702) to open engine load control valve; all cycling (bleed-air
pressure oscillation) shall be completely dampened to within 1 inch Hg within
ten seconds after differential pressure reaches the first peak. Speed shall
remain above 41,000 rpm.

(4) Check pneumatic thermostat reliability by operating engine for ten minutes at full bleed
load (zero shaft load) under control of the load control thermostat.

(5) Perform overload and bleed-air contamination check as follows.

NOTE: After completion of engine operation checks, test setup bleed-air ducting
must be reconnected to load control valve if recalibration of thermostat is
desired in accordance with Step 1.G.(8)(f).

(a) Remove test setup bleed-air ducting from load control valve.

Page 738
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OVERHAUL MANUAL
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1. G. (5) (b) Start and allow engine to accelerate to no-load governed speed.
Record speed.

(c) With engine operating at no-load governed speed, actuate bleed-air switch
(26, Figure 702) to open engine load control valve. Operate engine for a
minimum of two minutes or until ambient temperature in test cell reaches 39C
(103F). Minimum engine speed (momentary) shall not be less than 41,000
rpm. Maximum speed droop (stabilized) shall not exceed 1000 rpm. Observe
bleed-air for evidence of smoke or oil spray. No oil spray or smoke allowed
during operation.

(d) Record turbine discharge temperature indicated on test setup temperature


indicator (19, Figure 703) and temperature indicator (30). (Engine
thermocouple.)

(6) Dynamically check engine thermocouple as follows.

NOTE: This check is to be performed with the engine operating at a combination


load condition.

(a) Compare test setup thermocouple indication to engine thermocouple


indication recorded in Step (5)(b). Engine thermocouple indication shall not be
more than 34C (62F) higher or 14C (25F) lower than test setup thermocouple
indication.

(b) Replace engine thermocouple and/or check test setup instrumentation if


comparison is not within limits.

(c) Reaccomplish Steps (5) and (6) if replacement of engine thermocouple and/or
maintenance of test setup instrumentation is required.

(7) Recheck acceleration limiter valve cracking pressure with boost on and reset to 57 to
63 psig, if necessary. Refer to Paragraph E.(1). Record data.

Page 739
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OVERHAUL MANUAL
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1. G. (8) Perform automatic start test as follows.

NOTE: This test is unnecessary if two successful automatic starts were made
earlier.

(a) Disconnect manual fuel bypass valve at fuel bypass port connection (4, Figure
701).

CAUTION: DO NOT EXCEED STARTER DUTY CYCLE. (REFER TO TABLE


702.)

NOTE: Engines with timed acceleration fuel control units acceleration time
is 40 to 70 seconds.

(b) Momentarily press start switch and observe engine operation. Engine shall
start, light off, and accelerate to no-load governed speed within time limit
shown in Figure 706 without any external control. Check that both low oil
pressure circuit lights are on below 40 psig oil pressure. Check that above 65
psig oil pressure, both switch lights go off.

(b1) Recheck turbine cavity pressure at no load governed speed and record.
Compare reading to that taken during run-in as recorded on the Test Data
Sheet (Figure 704). Reject engine if pressure has decayed 50 percent or
more.

(c) When engine reaches no-load governed speed, shut down engine.

NOTE: If sequence of two automatic starts is interrupted because of failure


or malfunction, rerun the complete sequence after correcting
cause.

(d) Repeat automatic start procedure for a total of two consecutive successful
fully automatic starts and accelerations to no-load governed speed.

(e) Record required data on the Test Data Sheet (Figure 704), including
maximum average turbine discharge temperature and length of time required
to accelerate to no-load governed speed.

NOTE: Bleed-air ducting must be reconnected prior to recalibration of


thermostat.

(f) Recalibrate thermostat, if desired, to obtain exhaust gas temperature limits


specified in Table 705 in accordance with Step 1.E.(3)(h)6.

(g) Remove compound gage (15, Figure 703) at turbine bearing cavity negative
pressure connection (8) and plug or cap from line. Connect vent line.

Page 740
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OVERHAUL MANUAL
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THIS PAGE INTENTIONALLY LEFT BLANK

Page 741
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Starting Time Vs APU Oil Temperature


Figure 706

Page 742
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Table 705. Engine Exhaust Gas Temperature (EGT) Settings

EGT Measurement Pneumatic (Load Mode)


Thermostat

Max *Recommended

Test Set 630C 574 - 0 + 10C


Thermocouple (1166F) (1066 - 0 + 20F)

* The manufacturer recommends these lowered temperature settings to increase the service life of the engine
"hot" section. These temperatures may be adjusted as necessary to meet each individual operators'
requirements. Operators are advised that a reduction of EGT will reduce bleed airflow and can affect cabin
temperatures under warmer ambient conditions.

1. G. (9) Perform final check as follows.

(a) Upon satisfactory completion of all test procedures, lockwire or seal with red
Glyptal all controls and thermostats.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE, AND LUNG
DAMAGE. THE DANGER AND CAUTIONS FOR EACH CHEMICAL
IS DIFFERENT.

(b) Check all plumbing lines, openings and shaft seals for leakage and correct as
required. Wash engine with solvent, (MIL-PRF-680) to clean any excess fuel,
oil, or grease from exterior of engine. Reset hour meter circuit breaker.

(c) Start engine and operate at no-load governed speed for five minutes. Check
hour meter for proper operation during run.

(d) Shut down engine and check for fuel and oil leaks, particularly around joints,
B-nuts and seals. The use of Jet-Light or similar type flashlight is helpful to
show even small amounts of moisture. There is to be no moisture after a five-
minute run anywhere on the engine, gearbox, accessories or plumbing. If any
moisture is apparent, identify leak, fix if possible, and rerun for five minutes;
other wise, reject the unit.

(e) If engine performance is satisfactory, remove temperature bulb and install oil
temperature switch in oil pump assembly.

Page 743
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

NOTE: Prior to placing engine in service or storage, retighten the following


bolts and clamps to the torque value listed.

Turbine Plenum Assy 90 to 110 inch-pounds


attaching bolts plus frictional torque

Exhaust Flange Assy 90 to 110 inch-pounds


attaching bolts plus frictional torque

Igniter Plug 50 to 70 inch-pounds


attaching bolts plus frictional torque

1. G. (9) (f) If engine is not to be placed in service at once, proceed immediately with
preservation procedure in accordance with Storage Instructions.

H. Performance Calculations

(1) Engine performance requirements specified in Table 703 are based on compressor
inlet temperature of 39C (103F), ambient air pressure of 29.92 inches Hg absolute.
When engine performance is checked under other conditions, the observed
performance values shall be corrected to standard conditions.

(2) Correction factors for performance calculations are given in Tables 706 and 706A.
Definitions of symbols used in formulas and calculations are given in Table 707.
Formulas and sample calculations are given in Steps (3), (4), and (5).

(3) Flow correction formula is WB std = WB/Delta Correction Factor +WB chng. Assume
measured bleed-air flow is 120.0 PM, inlet air temperature is 80F, and ambient
pressure is 28.87 inches Hg. From Table 706, flow correction factor WB chng = -13.7.
Substituting in formula:

WB std = 120.0 - 13.7 = 120.0 -13.7 = 124.4 - 13.7 = 110.7


28.87 0.965
29.92

WB std = 110.7 PPM

(4) Pressure correction formula is PB std = PB/Delta Correction Factor +PB chng.
Assume observed bleed-air pressure is 100.5 inches Hg, inlet air temperature is 80F
and ambient pressure of 28.87 inches Hg. From Table 706, pressure correction factor
PB chng = 2.3. Substituting in formula:

PB std = 100.5 -2.3 = 100.5 -2.3 = 104.1 -2.3 = 101.8


28.87 0.965
29.92

PB std = 101.8 inches Hg abs.

Page 744
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Table 706. Performance Correction Factors


(Combined 60 SHP Shaft and Bleed-Air Loads)

Tcl WB chng PB chng TB chng Tcl WB chng PB chng TB chng


(F) (lb/min) (in. Hg A) (F) (F) (lb/min) (in. Hg A) (F)

-4 -66.1 -13.0 +112.0 30 -44.8 -8.2 +75.6


-3 -65.4 -12.9 110.0 1 -44.2 -8.1 74.5
-2 -64.7 -12.8 109.6 2 -43.6 -7.9 73.5
-1 -64.0 -12.7 108.4 3 -43.0 -7.8 72.4
4 -42.3 -7.7 71.3
0 -63.3 -12.6 +107.2
1 -62.6 -12.5 106.0 35 -41.7 -7.6 +70.3
2 -61.9 -12.4 104.9 6 -41.1 -7.5 69.2
3 -61.2 -12.2 103.8 7 -40.5 -7.4 68.2
4 -60.6 -12.1 102.6 8 -39.9 -7.3 67.2
9 -39.3 -7.2 66.1
5 -59.9 -12.0 +101.5
6 -59.3 -11.0 100.4 40 -38.6 -7.1 +65.1
7 -58.6 -11.7 99.4 1 -38.0 -6.9 64.1
8 -58.0 -11.5 98.3 2 -37.4 -6.8 63.0
9 -57.4 -11.4 97.2 3 -36.8 -6.7 62.0
4 -36.1 -6.6 61.0
10 -56.8 -11.2 +96.2
1 -56.1 -11.0 95.1 45 -35.5 -6.5 +60.0
2 -55.5 -10.9 94.1 6 -34.9 -6.4 59.0
3 -54.9 -10.7 93.0 7 -34.2 -6.3 58.1
4 -54.3 -10.6 92.0 8 -33.6 -6.2 57.1
9 -32.9 -6.1 56.1
5 -53.7 -10.4 +91.0
6 -53.1 -10.2 90.0 50 -32.3 -6.0 +55.1
7 -52.5 -10.0 89.1 1 -31.7 -5.9 54.2
8 -52.0 -9.8 88.1 2 -31.0 -5.7 53.2
9 -51.4 -9.7 87.1 3 -30.4 -5.6 52.2
4 -29.8 -5.5 51.2
20 -50.8 -9.5 +86.1
1 -50.2 -9.3 85.1 55 -29.1 -5.4 +50.2
2 -49.6 -9.2 84.1 6 -28.5 -5.3 49.2
3 -49.0 -9.0 83.1 7 -27.9 -5.2 48.2
4 -48.4 -8.9 82.1 8 -27.3 -5.0 47.2
9 -26.6 -4.9 46.1
25 -47.8 -8.7 +81.0
6 -47.2 -8.6 80.0 60 -26.0 -4.8 +45.1
7 -46.6 -8.5 78.9 1 -25.4 -4.7 44.1
8 -46.0 -8.4 77.8 2 -24.8 -4.6 43.1
9 -45.4 -8.3 76.7 3 -24.1 -4.4 42.1
4 -23.5 -4.3 41.0

Page 745
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Table 706. Performance Correction Factors


(Combined 60 SHP Shaft and Bleed-Air Loads) (Cont)

Tcl WB chng PB chng TB chng Tcl WB chng PB chng TB chng


(F) (lb/min) (in. Hg A) (F) (F) (lb/min) (in. Hg A) (F)

65 -22.9 -4.2 +40.0 100 -1.8 -0.3 +3.2


6 -22.3 -4.1 39.0 1 -1.2 -0.2 2.1
7 -21.7 -3.9 37.9 2 -0.6 -0.1 1.1
8 -21.1 -3.8 36.9 3 0.0 0.0 0.0
9 -20.4 -3.7 35.8 4 +0.6 +0.1 -1.1

70 -19.8 -3.5 +34.8 105 +1.2 +0.2 -2.1


1 -19.2 -3.4 33.7 6 1.7 0.3 -3.2
2 -18.6 -3.3 32.7 7 2.3 0.4 -4.2
3 -18.0 -3.2 31.6 8 2.9 0.5 -5.3
4 -17.4 -3.0 30.6 9 3.5 0.6 -6.3

75 -16.8 -2.9 +29.5 110 +4.1 +0.7 -7.4


6 -16.2 -2.8 28.5 11 4.6 0.8 -8.4
7 -15.6 -2.7 27.4 12 5.2 0.9 -9.5
8 -14.9 -2.6 26.4 13 5.8 1.0 -10.5
9 -14.3 -2.5 25.3 14 6.3 1.1 -11.6

80 -13.7 -2.3 +24.3 115 +6.9 +1.2 -12.6


1 -13.1 -2.2 23.2 16 7.5 1.3 -13.6
2 -12.5 -2.1 22.2 17 8.0 1.4 -14.7
3 -11.9 -2.0 21.1 18 8.6 1.5 -15.7
4 -11.3 -1.9 20.1 19 9.2 1.6 -16.8

85 -10.7 -1.8 +19.0 120 +9.7 +1.7 -17.8


6 -10.1 -1.7 17.9 21 10.3 1.8 -18.9
7 -9.5 -1.6 16.9 22 10.8 2.0 -19.9
8 -8.9 -1.5 15.8 23 11.4 2.1 -20.9
9 -8.3 -1.4 14.8 24 11.9 2.2 -22.0

90 -7.7 -1.3 +13.7 125 +12.5 +2.3 -23.0


1 -7.1 -1.2 12.7
2 -6.5 -1.1 11.6
3 -5.9 -1.0 10.6
4 -5.3 -0.9 9.5

95 -4.7 -0.8 +8.4


6 -4.1 -0.7 7.4
7 -3.5 -0.6 6.3
8 -2.9 -0.5 5.3
9 -2.3 -0.4 4.2

Page 746
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OVERHAUL MANUAL
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Table 706A. Performance Correction Factors


(0 SHP Shaft Load)

Tcl WB chng PB chng TB chng Tcl WB chng PB chng TB chng


(F) (lb/min) (in. Hg A) (F) (F) (lb/min) (in. Hg A) (F)

26.0 -45.0 -9.5 80.2 61.0 -24.2 -4.7 45.2


27.0 -44.4 -9.3 79.3 62.0 -23.0 -4.6 44.2
28.0 -43.8 -9.2 78.3 63.0 -23.0 -4.4 43.1
29.0 -43.2 -9.0 77.3 64.0 -22.4 -4.3 42.1
30.0 -42.6 -8.9 76.4 65.0 -21.8 -4.2 41.0

31.0 -42.0 -8.7 75.4 66.0 -21.3 -4.1 39.9


32.0 -41.4 -8.6 74.4 67.0 -20.7 -4.0 38.8
33.0 -40.8 -8.4 73.5 68.0 -20.1 -3.8 37.8
34.0 -40.2 -8.3 72.5 69.0 -19.5 -3.7 36.7
35.0 -39.6 -8.2 71.5 70.0 -18.9 -3.6 35.6

36.0 -39.0 -8.0 70.6 71.0 -18.3 -3.5 34.4


37.0 -38.0 -7.9 69.6 72.0 -17.7 -3.4 33.5
38.0 -37.0 -7.7 68.6 73.0 -17.2 -3.3 32.4
39.0 -37.3 -7.6 67.6 74.0 -16.6 -3.2 31.4
40.0 -36.7 -7.4 66.6 75.0 -16.0 -3.1 30.3

41.0 -36.1 -7.3 65.6 76.0 -15.4 -2.9 29.3


42.0 -35.5 -7.2 64.6 77.0 -14.8 -2.8 28.1
43.0 -34.9 -7.0 63.6 78.0 -14.3 -2.7 27.0
44.0 -34.3 -6.9 62.6 79.0 -13.7 -2.6 26.0
45.0 -33.7 -6.7 61.6 80.0 -13.1 -2.5 24.9

46.0 -33.1 -6.6 60.6 81.0 -12.5 -2.4 23.8


47.0 -32.5 -6.5 59.6 82.0 -12.0 -2.3 22.7
48.0 -31.9 -6.3 58.6 83.0 -12.0 -2.1 21.6
49.0 -31.3 -6.2 57.6 84.0 -10.8 -2.0 20.6
50.0 -30.7 -6.1 56.6 85.0 -10.2 -1.9 19.5

51.0 -30.1 -5.9 55.6 86.0 -9.7 -1.8 18.4


52.0 -29.5 -5.8 54.5 87.0 -9.1 -1.7 17.3
53.0 -28.9 -5.7 53.5 88.0 -8.5 -1.6 16.2
54.0 -20.3 -5.5 52.5 89.0 -7.9 -1.5 15.1
55.0 -27.8 -5.4 51.5 90.0 -7.4 -1.4 14.1

56.0 -27.2 -5.3 50.4 91.0 -6.8 -1.3 13.0


57.0 -26.6 -5.2 49.4 92.0 -6.2 -1.2 11.9
58.0 -26.0 -5.0 48.4 93.0 -5.7 -1.1 10.8
59.0 -25.4 -4.9 47.3 94.0 -5.1 -1.0 9.7
60.0 -24.8 -4.8 46.3 95.0 -4.5 - .9 8.7

Page 747
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Table 706A. Performance Correction Factors


(0 SHP Shaft Load) (Cont)

Tcl WB chng PB chng TB chng Tcl WB chng PB chng TB chng


(F) (lb/min) (in. Hg A) (F) (F) (lb/min) (in. Hg A) (F)

96.0 -4.0 - .7 7.6


97.0 -3.4 - .6 6.5
98.0 -2.8 - .5 5.4
99.0 -2.3 - .4 4.3
100.0 -1.7 - .3 3.2

101.0 -1.1 - .2 2.2


102.0 - .6 - .1 1.1
103.0 0.0 0.0 0.0
104.0 .6 .1 -1.1
105.0 1.1 .2 -2.2

106.0 1.7 .3 -3.2


107.0 2.2 .4 -4.3
108.0 2.8 .5 -5.4
109.0 3.4 .6 -6.5
110.0 3.9 .8 -7.5

111.0 4.5 .9 -8.6


112.0 5.0 1.0 -9.7
113.0 5.6 1.1 -10.7
114.0 6.1 1.2 -11.8
115.0 6.7 1.3 -12.9

116.0 7.2 1.4 -13.9


117.0 7.8 1.5 -15.0
118.0 8.3 1.6 -16.1
119.0 8.9 1.8 -17.1
120.0 9.4 1.9 -18.2

121.0 10.0 2.0 -19.2


122.0 10.5 2.1 -20.3
123.0 11.1 2.2 -21.4
124.0 11.6 2.3 -22.4
125.0 12.2 2.5 23.5

Page 748
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Table 707. Symbol Definitions

Symbol Definition

Tcl Actual inlet temperature in degrees Fahrenheit

Delta Correction Actual barometer pressure in inches Hg divided by 29.92


Factor

WB Actual bleed-air flow in pounds per minute

PB Actual bleed-air pressure in inches Hg absolute

TB Actual bleed-air temperature in degrees Fahrenheit

WB std Calculated bleed-air flow for a 39C (103F), 29.92 in. Hg day

PB std Calculated bleed-air pressure for a 39C (103F), 29.92 in. Hg day

TB std Calculated bleed-air temperature for a 39C (103F), 29.92 in. Hg day

WB chng Flow correction factor at Tcl

PB chng Pressure correction factor at Tcl

TB chng Temperature correction factor at Tcl

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OVERHAUL MANUAL
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1. H. (5) Temperature correction formula is TB std = TB + TB chng. Assume observed bleed-


air temperature is 235C (455.7F) and inlet air temperature is 27C (80F). From Table
706 temperature
correction factor TB chng = +24.3. Substituting in formula:

TB std = 235C (455.7F) +24.3 = 249C (480F)


TB std = 249C (480F)

I. Rejection and Rerun

(1) RERUN IN EVENT OF FAILURE. Engines rejected because of failure or malfunction


shall have cause of failure or malfunction corrected and all or part of acceptance test
rerun. The class of failure or malfunction and the point of occurrence during the
acceptance test will determine the amount of rerun required. Failures and
malfunctions are classified into three categories as follows.

(a) CLASS ONE: FAILURE OF ANY ROTATING PART. Class One parts include
turbine wheel, compressor impellers and associated shafts and splines, all
shafts, gears, compressor, and turbine sections. After repair or replacement
of any Class One item, engine shall undergo complete run in, automatic
controls check and adjustment, and acceptance test.

(b) CLASS TWO: FAILURE OF FUNCTIONAL COMPONENT. Class Two parts


include oil pressure switch, fuel pump, thermostats, centrifugal switch, and oil
pump. In the event of a Class Two failure, the faulty component shall be
removed from the engine and repaired. Before installation, the repaired
component shall be tested and calibrated as specified in accordance with the
applicable publication for the component. Testing of the engine may be
resumed at the point of failure if the failure occurred before the component
was calibrated on the engine, or if replacement of the component does not
affect calibration of another component. If failure occurred after calibration of
the component, the test may be resumed at the point of calibration. A
component may be removed and replaced without re-calibration if only its
point of attachment is disturbed, for example, replacement of a packing or
gasket acting as seal between component and engine.

(c) CLASS THREE: FAILURE OF MINOR PART AND EXPENDABLE ITEMS


AND PARTS. Class Three parts include plumbing, electrical harness and
fittings, igniter plug, gaskets, nuts, bolts, etc. Failed parts shall be replaced
with acceptable parts and testing may be resumed from the point at which
failure occurred, unless its replacement involves disturbing a component of a
higher class. If so, testing may be resumed at the point in which the higher
class component would be tested.

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1. J. Post Run Requirement

Retorquing of turbine plenum bolts after test cell run is also required when Seal Part, No.
3605771-1 is used.

NOTE: Compressor shroud contour paint is applied in a thick layer for the purpose of
allowing minimum operating clearance for maximum APU performance.
Compressor section paint rubs from first or second stage impellers are acceptable
as long as the paint is not rubbed through to the point of having metal-to-metal
contact between an impeller blade and shroud.

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ENGINE SECTION

1. Troubleshooting

A. General

The following troubleshooting procedures are based on performance of the engine operational
test and are presented in a tree-type format. When all steps in the OK condition path check
out, the engine is operable.

When a test does not check out, follow the NOT OK line to the box containing the trouble
symptom. Turn to the procedure indicated and continue to follow a single line by analyzing the
results of each test until the required corrective action is determined. Perform the specified
corrective action, then repeat the test at which the failure was encountered.

All troubleshooting procedures are based on the assumption that wiring is OK and that
electrical power is available. If the corrective action in the procedure does not correct the
problem, check wiring using wiring diagrams (Figure 801 or 802). Refer to Table 801 or 802
for electrical data.

Use schematic diagrams provided for aid in performing engine troubleshooting. (Refer to
Sections 49-30-00, 49-50-00 and 49-90-00.)

B. Engine Troubleshooting

Engine troubleshooting is divided into two parts; start, and governed-speed operation.

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1. C. Engine Start Troubleshooting

INITIATE ENGINE START. IF -

STARTER DOES NOT OPERATE


STARTER OPERATES WHEN STARTER SW
WHEN START SW IS PRESSED -
IS PRESSED. CHECK OPERATION. IF -
PROCEDURE 1.

STARTER OPERATES ONLY UNTIL


START SW IS RELEASED -
PROCEDURE 2.

OK - OBSERVE FOR ENGINE LIGHT OFF AT STARTER OPERATES BUT CRANKS


2.5 TO 3.5 OIL PRESS. IF - ENGINE SLOWLY OR NOT AT ALL -
PROCEDURE 3.

OK - OBSERVE FOR ACCELERATION TO NO - LIGHT OFF DOES NOT OCCUR -


LOAD GOVERNED SPEED. IF - PROCEDURE 4, 5.

FLAMES EMIT FROM EXHAUST


DURING ACCELERATION -
PROCEDURE 6.
CONT

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CONT

ALL START INDICATIONS NORMAL ACCELERATION SLOW OR SPEED


ENGINE START OK. DOES NOT REACH NO-LOAD
GOVERNED SPEED - PROCEDURE 7.

1. D. Engine Governed Speed Operation Troubleshooting

OPERATE ENGINE AT NO-LOAD GOVERNED


SPEED. IF -

ENGINE HAS HIGH OIL


CONSUMPTION OR NOTICEABLE
SMOKE FROM EXHAUST -
PROCEDURE 8.

ENGINE EXCEEDS NO-LOAD


GOVERNED SPEED THEN SHUTS
DOWN. ADJUST GOVERNOR OR
REPLACE FUEL CONTROL.

CONT

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OK-APPLY BLEED OR COMBINATION


(BLEED AND SHAFT) LOAD. IF -

BLEED LOAD CANNOT BE


APPLIED - PROCEDURE 9.

EXCESSIVE EGT OR NO CONTROL


DURING BLEED LOAD APPLICA-
TION - PROCEDURE 10.

EXCESSIVE SPEED DROOP


DURING LOAD APPLICATION -
PROCEDURE 11.

ALL GOVERNED SPEED INDICATIONS NO DROP IN EGT


NORMAL, GOVERNED SPEED OPERATION DURING FUEL
OK. ECONOMY SYSTEM
CHECK, CHECK FUEL
ECONOMY
SOLENOID VALVE
FOR OPEN
POSITION-
PROCEDURE 12.

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GTCP85-98DHF/[A]

PROCEDURE 1

STARTER DOES NOT OPERATE WHEN START SW


IS PRESSED, MOVE MASTERSTOP SW TO STOP
THEN TO RUN POSITION. PRESS START SW.

CHK - VOLTAGE AT STARTER. IF - REMOVE CONN FROM CNTFGL SW.


CONNECT A JUMPER WIRE
BETWEEN PINS B AND C OF CONN
REMOVED FROM SW. PRESS
START SW. IF -

OK-REPL STARTER. NOT OK-REPLACE STARTER OPERATES STARTER DOES


STARTER MOTOR. REPL CNTFGL SW. NOT OPERATE,
CHK VOLTAGE
TO START SW.
IF -

OK- REPL START NOT OK -


SW. REPLACE
MASTER-STOP
SW.

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GTCP85-98DHF/[A]

PROCEDURE 2

STARTER OPERATES ONLY UNTIL START SW


IS RELEASED. CHECK OPERATION OF HOLDING
RELAY. PRESS AND RELEASE START SWITCH.
IF -

RELAY IS ENERGIZED, REPLACE STARTER RELAY IS NOT ENERGIZED, REPLACE


MOTOR RELAY. HOLDING RELAY.

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OVERHAUL MANUAL
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PROCEDURE 3

STARTER OPERATES BUT CRANKS ENGINE


SLOWLY OR NOT AT ALL, CHK VOLTAGE AT
STARTER MOTOR. IF -

OK-CHK STARTER MOTOR CLUTCH AND NOT OK- CORRECT POWER SUPPLY.
PAWL. IF -

OK-CHK ACCESSORY DRIVE GEARCASE


NOT OK- REPAIR OR REPLACE STARTER.
ASSY GEAR TRAIN. IF -

OK - CHK TORSION SHAFT BETWEEN GEAR- NOT OK - REPR OR REPL GEARCASE


CASE ASSY AND THE COMPRESSOR AND ASSY.
TURBINE ASSY. IF -

OK - CHK FOR DEFECTIVE COMPRESSOR


NOT OK - REPLACE SHAFT.
AND TURBINE ASSY. IF -

NOT OK - REPR OR REPL CPRSR - TURB


ASSY.

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PROCEDURE 4

LIGHT OFF DOES NOT OCCUR, CHK FIRING


OF IGNITER. IF -

OK - CHK FUEL SUPPLY PRESSURE NOT OK - CHK VOLTAGE AT IGNITION


TO FUEL CONTROL UNIT. IF - UNIT PRIMARY TERMINAL WITH ENGINE
MOTORING. IF -

OK - CHK FUEL NOT OK - CHK TEST


PRESS. THROUGH SETUP FUEL SUPPLY. OK - REPL IGNITOR NOT OK - CHK OIL
FUEL ATOMIZER. IF - PLUG, IGN LEAD PRESS. WITH
OR IGN UNIT AS ENG MOTORING.
REQUIRED. IF -

OK - CHK FOR NOT OK - REFER TO


DEFECTIVE TURB PROCEDURES 5.
ASSY.

OK - CHK VOLTAGE AT SEQ OIL PRESS.


SW. IF - NOT OK - REPAIR OR REPLACE OIL
PUMP ASSY.

OK - REPLACE SEQ OIL PRESS SW.


NOT OK - REPAIR OR REPLACE CENTRIF-
UGAL SWITCH.

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GTCP85-98DHF/[A]

PROCEDURE 5

IMPROPER FUEL PRESSURE THROUGH LEVEL


ATOMIZER, CHK FUEL FLOW TO FUEL ATOMIZER.
IF -

OK - CHK FUEL PRESSURE TO FUEL NOT OK - CHK VOLTAGE TO FUEL


ATOMIZER. IF - SOLENOID VALVE. IF -

OK - CHK FUEL NOT OK - (PRE SB OK - REPLACE FUEL NOT OK - CHK


ATOMIZER SCREEN. 49-5196) ADJ SOLENOID VALVE. SEQ OIL PRESS
IF - ACCELERATION SW. IF -
LIMITER CRACKING
PRESS. IF CRACK-
ING PRESS CANNOT
BE ADJ, OR (POST SB
49-5196), CHK FUEL
CONTROL UNIT FUEL
FILTER. IF - OK - REPLACE SE- NOT OK - REPAIR
QUENCING OIL OR REPLACE OIL
PRESS SWITCH. PUMP ASSY.

OK- REPAIR OR NOT OK -


OK- REPLACE NOT OK- CLEAN OR
REPLACE FUEL REPLACE FUEL
FUEL REPLACE FUEL
CONTROL UNIT. FILTER.
ATOMIZER. ATOMIZER SCREEN.
UNIT

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GTCP85-98DHF/[A]

PROCEDURE 6

FLAMES EMIT FROM EXHAUST DURING


ACCELERATION, CHK FUEL SUPPLY
PRESSURE TO FUEL CONTROL UNIT.
IF -

OK - CHK ACCELERATION LIMITER NOT OK - (PRE 49-5196) ADJ


CRACKING PRESS SETTING. IF - ACCELERATION LIMITER CRACKING
PRESS SETTING. IF SETTING CAN
NOT BE ADJ OR (POST SB 49-5196)
REPLACE FUEL CONTROL UNIT.

OK - REPLACE FUEL ATOMIZER ASSY.

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PROCEDURE 7

ACCELERATION SLOW OR ENGINE DOES


NOT REACH NO LOAD GOVERNED SPEED,
CHECK VOLTAGE TO STARTER MOTOR.
IF -

OK - CHK FUEL SUPPLY PRESS TO FUEL NOT OK - VOLTAGE IS BELOW 14 VDC


CONTROL INLET. IF - DURING IN RUSH OF CURRENT,
CORRECT POWER SUPPLY.

OK - CHK CONTROL AIR PRESS, FUEL NOT OK - CHK TEST SETUP FUEL
PRESS AND TURB DISCH TEMP ON SUPPLY.
START. IF -

CONTROL AIR AND FUEL PRESS NORM CONTROL AIR AND FUEL PRESS NORM
BUT TURB DISCH TEMP HIGH, CHK FOR AND TURB DISCH TEMP LOW, CHK FUEL
UNUSUAL NOISE OR RAPID DECELER- ATOMIZER SCREEN. IF -
ATION, IF NOT OK, CHK FOR DEFECTIVE
COMPRESSOR AND TURBINE ASSY.

OK - REPLACE FUEL NOT OK - CLEAN OR


ATOMIZER. REPLACE SCREEN.

CONT

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PROCEDURE 7 (CONT)

CONT

CONTROL AIR PRESS. FUEL PRESS AND


TURB DISCH TEMP LOW. CHK ACCELER-
ATION LIMITER VALVE CRACKING PRESS.
IF -

OK - CHK CONTROL AIR PRESS LINES. IF - NOT OK - RESET CRACKING PRESS.

OK - CHK PNEUMATIC THERMOSTAT NOT OK - TIGHTEN OR REPLACE LINES.


SETTING. IF -

OK - CHK CONTROL AIR PICKUP TEE ASSY; NOT OK - ADJUST THERMOSTAT


FOR CORRECT ORIFICE SIZE OR CON- SETTING.
TAMINATION; ORIFICE SIZE SHALL BE
0.030 TO 0.034 IN. DIA. IF -

OK - REPLACE THREE-WAY VALVE. NOT OK - CLEAN OR REPLACE TEE ASSY.

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PROCEDURE 8

ENGINE HAS HIGH OIL CONSUMPTION OR


NOTICEABLE SMOKE FROM EXHAUST, CHK
OIL LEVEL IN TANK. IF -

OK - DISCONNECT OIL TANK VENT LINE AT NOT OK - SERVICE OIL TANK.


EXHAUST VENT PROBE AND PLACE LINE
IN CONTAINER, OPERATE ENGINE. IF -

SMOKING CONTINUES FROM EXHAUST, SMOKING STOPS AND OIL IS BLOWN


CHK ACCESSORY CASE PRESS PORT INTO CONTAINER, REPLACE PACKINGS
PLUG AND PACKING. IF - ON OIL AND BREATHER FITTING ASSY.

OK - CHK ACCESS DR NOT OK - TIGHTEN SMOKING CONTINUES FROM EXHAUST,


GEARCASE CAVITY PLUG OR REPLACE CHK TURBINE BEARING CAVITY
PRESS. IF - PACKING. PRESSURE. IF -

OK - CHK ACCESS NOT OK-REPR


DR GEARCASE. OR REPL COMP
AND TURB ASSY.

OK - CHK TURBINE BEARING CAVITY NOT OK - CHK STARTER SEAL, GEN MTG
PRESS. PAD SEAL, FAN ASSY SEAL, OIL PUMP
ASSY SEAL OR FUEL CONTROL UNIT
SEAL LEAKAGE. REPLACE DEFECTIVE
SEAL.

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PROCEDURE 9

BLEED LOAD CANNOT BE APPLIED, CHECK


ACTUATION OF 95% SW (LOAD LIGHT ON).
IF -

OK - CHK BLEED LOAD SYSTEM AIR


NOT OK - REPLACE CNTFGL SW ASSY.
PRESS LINES. IF -

OK - CHK VOLTAGE TO LOAD CONTROL NOT OK - REPAIR OR REPLACE FAULTY


VALVE. IF - LINE.

OK - CHK AIR PRESS REGULATOR OUTPUT NOT OK - CHK LOAD SWITCH. IF -


PRESS. IF -

OK - REPAIR OR NOT OK - RE-


REPLACE WIRING. PLACE LOAD
SWITCH.

CONT CONT

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PROCEDURE 9 (CONT)

CONT CONT

OK - REPAIR OR REPLACE LOAD CONTROL NOT OK - CHK AIR PRESS REG PICKUP
VALVE. CONNECTOR OR TEE ASSY; ASSEMBLY
SHALL BE FREE OF FOREIGN MATTER.
IF -

OK - CHK PRESS REGULATOR FILTER NOT OK - CLEAN CONNECTOR OR TEE


ELEMENT. IF - ASSEMBLY.

OK - ADJUST OR REPLACE PRESSURE NOT OK - CLEAN OR REPLACE FILTER


REGULATOR. IF - ELEMENT.

LOAD CANNOT BE APPLIED, REPLACE


LOAD CONTROL VALVE.

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GTCP85-98DHF/[A]

PROCEDURE 10

EXCESSIVE EGT OR NO CONTROL DURING


BLEED LOAD APPLICATION. CHK -

INSTALLATION AND OPERATION OF


THREE-WAY VALVE. IF -

OK - CALIBRATE OR REPLACE PNEUMATIC NOT OK - REINSTALL OR REPLACE


THERMOSTAT. THREE-WAY VALVE.

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PROCEDURE 11

EXCESSIVE SPEED DROOP DURING LOAD


APPLICATION, CHK -

IF TURB DISCH TEMP EXCEEDS LOAD CONTROL VALVE OPENING RATE.


SPECIFIED LIMIT; CHK AIR
PRESSURE REGULATOR OUTPUT
PRESSURE. IF -

NOT OK - ADJ
RATE OR
OK - ADJ OR REPL NOT OK - ADJ OR REPLACE VALVE.
PNEUMATIC REPL REGULATOR
THERMOSTAT.

IF TURB DISCH TEMP IS BELOW SPECI-


FIED LIMIT WHEN SPEED DROOPS; CON-
NECT PRESS. GAGE TO MEASURE CONT
AIR PRESS. AT FUEL CONT UNIT LIMITER,
THEN WITH ENG OPERATING ACTUATE
BLEED-LOAD SW AND CHK CONTROL AIR
PRESS. IF -

CONT AIR PRESS. LOW, CHK LINES IN


CONT AIR SYS FOR LEAKS. IF -

CONT

CONT

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PROCEDURE 11 (CONT)

CONT CONT

OK - CHK CONT AIR NOT OK - REPLACE CONTROL AIR PRESS. NORM AND FUEL
PICKUP TEE ASSY FAULTY LINE. PRESS INCREASES WHEN RPM
FOR CORRECT ORI- DROOPS CHK FUEL ATOMIZER SCREEN.
FICE SIZE OR IF -
CONTAMINATION;
ORIFICE SIZE
SHALL BE 0.030
TO 0.034 INCH
DIAMETER. IF -

OK - CHK THREE- NOT OK - CLEAN OR OK - REPLACE FUEL NOT OK - CLEAN


WAY VALVE. IF - REPLACE PICKUP ATOMIZER. OR REPLACE
TEE ASSY. SCREEN.

NOT OK - REPLACE
VALVE.

CONTROL AIR PRESS, AND FUEL PRESS.


REMAIN CONSTANT WHEN RPM DROOPS,
CHK FUEL SUPPLY PRESS. IF -

CONT CONT

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PROCEDURE 11 (CONT)

CONT CONT

OK - CHK FUEL FILTER ELEMENT. IF - NOT OK - CORRECT FUEL SUPPLY


PRESS.

OK - CHK FUEL SHUTOFF SOL VALVE FOR NOT OK - REPLACE ELEMENT.


OBSTRUCTION AND OPERATION. IF -

NOT OK - REPLACE FUEL SHUTOFF SOL


OK - REPLACE FUEL CONTROL UNIT. VALVE.

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PROCEDURE 12
(POST SB 49-5233/DHF[A])

NO DROP IN EGT DURING FUEL ECONOMY


SYSTEM CHK, CHK FUEL ECONOMY SOLENOID
VALVE FOR OPEN POSITION. IF -

OK - CHK ADJUSTABLE ORIFICE NOT OK - REPLACE FUEL ECONOMY


FOR OBSTRUCTION. IF - SOLENOID VALVE.

NOT OK - REPLACE ADJUSTABLE


ORIFICE ASSEMBLY.

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OVERHAUL MANUAL
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Wiring Diagram for Wiring Harness Assembly


PN 43959-2/-3
Figure 801 (Sheet 1 of 2)

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Wiring Diagram for Wiring Harness Assembly


PN 43959-2/-3
Figure 801 (Sheet 2)

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OVERHAUL MANUAL
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Table 801. Electrical Wiring Data (Refer to Figure 801)

From To
Wire Awg Length Location Term or Location Term or Wire
No. Size (in.) No. Pin No. No. Pin No. Specification

3X8K18 18 32.75 P1-1108 D T1-29 X1 MS17411


3X8L18 18 10.25 T1-28 X1 T1-29 X1 MS17411
3X8M18 18 6.50 T1-27 X1 T1-28 X1 MS17411
3X9G18 18 31.50 P1-1108 A T1-29 X2 MS17411
3X10G18 18 28.75 P1-1108 B T1-28 X2 MS17411
3X11G18 18 27.75 P1-1108 C T1-27 X2 MS17411
E576C18 18 83.25 P1-1108 B P1-126 B MS17411
E577C18 18 83.25 P1-1108 H P1-126 A MS17411
E579A18 18 83.25 P1-1108 G P1-126 C MS17411
E605G16 16 18.75 P1-264 E S3-44 2 MS17411
E605H16 16 51.25 P1-1108 E S3-44 2 MS17411
E605J18 18 51.25 P1-1108 F S3-44 2 MS17411
E605K20 20 61.75 P1-149 E S3-44 2 MS17411
* E605K20 20 61.75 P1-149 3 S3-44 2 MS17411
E606A16 16 19.25 P1-264 D S3-44 1 MS17411
E606B20 20 62.25 P1-149 B S3-44 1 MS17411
* E606B20 20 62.25 P1-149 4 S3-44 1 MS17411
E606D18 18 51.75 P1-1108 C S3-44 1 MS17411
E607B20 20 58.75 S3-44 7 P1-149 0 MS17411
* E607B20 20 58.75 S3-44 7 P1-149 5 MS17411
E607C18 18 67.00 S3-44 7 P1-101 E MS17411
E607D20 20 15.75 S3-44 7 P1-264 B MS17411
E608A18 18 17.00 P1-264 A S3-44 5 MS17411
E608B18 18 71.00 P1-148 A S3-44 5 MS17411
E608C18 18 39.50 P1-150 A S3-44 5 MS17411
E608D16 16 72.50 P1-156 A S3-44 5 MS17411
E608E18 18 18.75 HR-MTR NEG(-) S3-44 6 MS17411
E608F18 18 45.00 P1-262 B S3-44 6 MS17411
E608G16 16 49.50 P1-1108 M S3-44 6 MS17411
E608J20 20 43.25 S3-44 6 P1-155 H MS17411
E608L18 18 77.75 S3-44 4 P1-490 A MS17411
**E608N18 18 78.25 P1-767 A S3-44 4 MS17411
E609A18 18 35.50 P1-1108 D P1-116 C MS17411
E618A16 16 39.75 P1-1108 X SPLICE - MS17411
* E618J20 20 52.50 P1-149 1 CB - MS17411
E618J20 20 50.25 P1-149 A SPLICE - MS17411
E618K16 16 3.50 SPLICE - CB LINE MS17411

*Denotes wiring harness assembly Part No. 43959-3.


**Denotes Post SB 49-5233

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Table 801. Electrical Wiring Data (Refer to Figure 801) (Cont)

From To
Wire Awg Length Location Term or Location Term or Wire
No. Size (in.) No. Pin No. No. Pin No. Specification

E621C16 16 93.50 P1-1108 V P1-263 E MS17411


E622A18 18 88.00 P1-263 B P1-155 C MS17411
E624C20 20 42.00 P1-155 A PL-1108 N MS17411
E625020 20 42.75 P1-1108 U P1-155 B MS17411
E628G16 16 48.50 P1-1108 P S3-44 8 MS17411
E628H18 18 70.50 S3-44 8 P1-156 B MS17411
E628J18 18 75.50 S3-44 8 P1-490 B MS17411
**E631D18 18 101.25 P1-1108 J P1-767 B MS17411
E633C18 18 69.00 P1-1108 M P1-262 A MS17411
E640A18 18 93.50 P1-1108 T P1-263 C MS17411
E641A18 18 12.00 HR-MTR P0S(+) CB LOAD MS17411
E643A18 18 85.75 P1-1108 K P1-265 B MS17411
* E644A20 20 77.00 P1-149 7 P1-116 A MS17411
E644A20 20 77.00 P1-149 C P1-116 A MS17411
E645A18 18 64.75 P1-265 A S3-44 3 MS17411
E645B18 18 18.50 P1-264 H S3-44 3 MS17411
E645C18 18 50.50 P1-1108 K S3-44 3 MS17411
E646A18 18 67.25 P1-264 G P1-263 D MS17411
E650A18 18 68.25 P1-101 B P1-150 B MS17411
E651A20 20 28.25 P1-149 F P1-101 A MS17411
* E651A20 20 28.25 P1-149 2 P1-101 A MS17411
E652A18 18 18.50 P1-101 C P1-148 B MS17411
CR-WHITE 18 104.00 P1-1108 S TCPL CR MIL-W-5846
AL-GREEN 18 104.00 P1-1108 A TCPL AL MIL-W-5846

*Denotes wiring harness assembly Part No. 43959-3


**Denotes Post SB 49-5233.

Page 824
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Wiring Diagram for Wiring Harness Assembly


PN 43959-4
Figure 802 (Sheet 1 of 2)

Page 825
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GTCP85-98DHF/[A]

Wiring Diagram for Wiring Harness Assembly


PN 43959-4
Figure 802 (Sheet 2)

Page 826
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Table 802. Electrical Wiring Data


(Refer to Figure 802)

From To
Wire Awg Length Location Term or Location Term or Wire
No. Size (in.) No. Pin No. No. Pin No. Specification

3X8K18 18 32.75 P1-1108 D T1-29 X1 MS17411


3X8L18 18 10.25 T1-28 X1 T1-29 X1 MS17411
3X8M18 18 6.50 651-27 X1 T1-28 X1 MS17411
3X9G18 18 31.50 P1-1108 A T1-29 X2 MS17411
3X10G18 18 28.75 P1-1108 B T1-28 X2 MS17411
3X11G18 18 27.25 P1-1108 C T1-27 X2 MS17411
E576C18 18 83.75 P1-1108 B P1-126 B MS17411
E577C18 18 83.25 P1-1108 H P1-126 A MS17411
E579A18 18 83.25 P1-1108 G P1-126 C MS17411
E605G16 16 18.75 P1-264 E S3-44 2 MS17411
E605H16 16 51.25 P1-1108 E S3-44 2 MS17411
E605J18 18 51.25 P1-1108 F S3-44 2 MS17411
E605K20 20 61.75 P1-149 3 S3-44 2 MS17411
E606A16 16 19.25 P1-264 D S3-44 1 MS17411
E606B20 20 62.25 P1-149 4 S3-44 1 MS17411
E606D18 18 51.75 P1-1108 C S3-44 1 MS17411
E607B20 20 58.75 S3-44 7 P1-149 5 MS17411
E607C18 18 67.00 S3-44 7 P1-101 E MS17411
E607D20 20 15.75 S3-44 7 P1-264 B MS17411
E608A18 18 17.00 P1-264 A S3-44 5 MS17411
E608B18 18 71.00 P1-148 A S3-44 5 MS17411
E608C18 18 39.50 P1-150 A S3-44 5 MS17411
E608D16 16 72.50 P1-156 A S3-44 5 MS17411
E608E18 18 18.75 HR-MTR NEG(-) S3-44 6 MS17411
E608F18 18 45.00 P1-262 B S3-44 6 MS17411
E608G16 16 49.50 P1-1108 M S3-44 6 MS17411
E608J20 20 43.25 S3-44 6 P1-155 H MS17411
E608L18 18 77.75 S3-44 4 P1-490 A MS17411
E608N18 18 78.25 P1-767 A S3-44 4 MS17411
E609A18 18 35.50 P1-1108 D P1-116 C MS17411
E618A16 16 39.75 P1-1108 X SPLICE - MS17411
E618J20 20 52.50 P1-149 1 CB LINE MS17411
E618K16 16 3.50 SPLICE - CB LINE MS17411
E621C16 16 93.50 P1-1108 V P1-263 E MS17411
E622A18 18 88.00 P1-263 B P1-155 C MS17411
E624C20 20 42.00 P1-155 A PL-1108 N MS17411
E625D20 20 42.75 P1-1108 U P1-155 B MS17411

Page 827
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GTCP85-98DHF/[A]

Table 802. Electrical Wiring Data


(Refer to Figure 802) (Cont)

From To
Wire Awg Length Location Term or Location Term or Wire
No. Size (in.) No. Pin No. No. Pin No. Specification

E628G16 16 48.50 P1-1108 P S3-44 8 MS17411


E628H18 18 70.50 S3-44 8 P1-156 B MS17411
E628J18 18 75.50 S3-44 8 P1-490 B MS17411
E631D18 18 101.25 P1-1108 J P1-767 B MS17411
E633C18 18 69.00 P1-1108 M P1-262 A MS17411
E640A18 18 93.50 P1-1108 T P1-263 C MS17411
E641A18 18 12.00 HR-MTR POS(+) CB LOAD MS17411
E643A18 18 85.75 P1-1108 K P1-265 B MS17411
E644A20 20 77.00 P-149 7 P1-116 A MS17411
E645A18 18 64.75 P1-265 A S3-44 3 MS17411
E645B18 18 18.50 P1-264 H S3-44 3 MS17411
E645C18 18 50.50 P1-1108 K S3-44 3 MS17411
E646A18 18 67.25 P1-264 G P1-263 D MS17411
E650A18 18 P1-101 B P1-150 B MS17411
E651A20 20 28.25 P1-149 2 P1-101 A MS17411
E652A18 18 18.50 P1-101 C P1-148 B MS17411
CR-WHITE 18 104.00 P1-1108 S TSPL CR MIL-W-5846
AL-GREEN 18 104.00 P1-1108 A TCPL AL MIL-W-5846

Page 828
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ENGINE SECTION

1. Storage Instruction

NOTE: The APU storage/preservation procedures are guidelines only and represent best practices
for the protection of stored units against damage from worst-case exposure to moisture,
debris, and other environmental conditions during extended periods storage. The manual
should be used as a baseline to establish what precautions should be taken at and/or after
storage based on each operator's region and experience.

The majority of parts produced today do not require any form of age control. Control does
not apply to assemblies, silicon rubber, fluorocarbon rubber, fuel tank synthetics, or static
seals used with fasteners.

SAE AS 1933 specifies the "Age Controls of Age-Sensitive Elastomeric Material for
Aerospace Applications". This standard is used for all military and commercial use as
defined by Honeywell. Assemblies containing age-sensitive material defined in this
specification are limited by failure rates in service use and remaining system life determined
by the user.

Adverse environmental conditions may cause degradation of various parts. Such


conditions are, but not limited to, the following:

1. Moisture
2. High temperature (generally of 125F)
3. Swelling agents such as fuel or solvents
4. Corrosive vapors
5. Mechanical stresses
6. Ultraviolet light

Items which are suspected of being exposed to an adverse environment should be checked
for evidence of deterioration and replaced as necessary prior to incorporation into service.

Table 901. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed item.

Desiccant (MIL-D-3464, Type I & II) Commercially available

Humidity Indicator Driaire Inc., P.O. Box 569, 26 Fitch St.,


(Cobaltous chloride card, Norwalk, CT 06856
Type MS 301)

Humidity Indicator (Alternate) Humidial Corp., P.O. Box 610, 926 S 8th St.,
(Humidial 2) Colton, CA 92324-0610

Page 901
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Table 901. Materials and Compounds (Cont)

Material or Compound Manufacturer

Oil (MIL-PRF-6081, Grade 1010 or 1005) Commercially available

Water-Vapor Proof Bag Commercially available


(MIL-PRF-117D, Type 1,
Class E, or MIL-PRF-131E,
Class E)

CAUTION: THE COMPRESSOR SECTION SHALL NOT BE SPRAYED WITH ANY


CORROSION-PREVENTIVE COMPOUNDS. NO HYDROCARBONS OR OIL
SHOULD EVER BE INTRODUCED INTO THE COMPRESSOR SECTION; A
POSSIBILITY OF UNCONTROLLED COMBUSTION MIGHT RESULT.

1. A. Follow Procedure for Preservation of Engine

(1) Disconnect high pressure fuel line at ground checkout panel and connect a line to
drain overboard.

(2) Disconnect fuel supply line at fuel inlet connection of fuel control unit and connect a
source of oil (MIL-PRF-6081, Grade 1010 or 1005). Supply oil under slight pressure if
necessary.

(3) Disconnect ignition unit primary lead, depress start switch momentarily, and rotate
engine by use of starter for 15 to 20 seconds. the fuel solenoid valve will automatically
open, allowing oil to flow overboard. Maintain flow until clean oil flows overboard.

(4) Remove drain plug from oil tank and allow all oil to drain. Disconnect scavenge oil-in
line to oil tank and allow all excess oil to drain from engine. Allow oil to drain from fuel
control unit and fuel lines.

(5) Connect fuel line to ground checkout panel, connect oil scavenge line to oil tank, install
oil tank drain plug, and connect ignition.

(6) Remove fuel and oil filters. Dip new oil filter in lubrication system oil specified in Table
702. Flush fuel filter with oil (MIL-PRF-6081, Grade 1010 or 1005), then install filters
in fuel control unit and oil pump assembly.

(7) Disconnect all test setup equipment and remove engine from test installation.

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1. A. (8) Wash all excess fuel and oil from engine.

CAUTION: DO NOT USE TAPE ON FUEL SYSTEM COMPONENTS.

(9) Plug, cap or seal all external pressure taps, ports fittings and other openings on the
engine. (See Figure 901.)

(10) Lockwire all controls per SAE AS567.

(11) Secure warning tags to engine.

(12) Install engine in original shipping container, in accordance with MIL-E-5595 and
MIL-E-5607.

B. Procedure for Storage of Engine

(1) Secure two pounds of desiccant MIL-D-3464 in the engine exhaust and compressor
inlet sections of the engine.

(2) Secure one pound of desiccant MIL-D-3464 in a suitable location in front of the
accessory assembly.

(3) Secure a humidity indicator to the engine in a location readily visible with the engine in
its stored position.

NOTE: Make sure that engine is thoroughly enclosed in bag and that bag is free of
tears. Check for sharp corners which could cause rips or tears.

(4) Enclose the engine completely in a water-vapor proof bag (MIL-PRF-117D or


MIL-PRF-131E). Exhaust 70 to 80 percent of air from the bag using a commercial
vacuum cleaner, or by folding and taping the bag to approximate contour of the
engine.

C. Periodic Check of Storaged Engine

(1) Visually check container each 30 days to verify that the humidity indicator is fully
activated and that the relative humidity inside the vapor-proof bag is less than 40
percent.

(2) If humidity indicator reflects humidity above the 40 percent level the engine shall be
opened and inspected for serviceability. If engine is serviceable repeat Preservation
and Storage procedures.

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Installation of Shipping Covers, Tags,


and Lockwire (Typical)
Figure 901

Page 904
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GTCP85-98DHF/[A]

ENGINE SECTION

1. Special Tools, Fixtures and Equipment

A. General

Procedures outlined in this publication, requiring special tools, fixtures and equipment, can be
accomplished with the use of special tools, fixtures and equipment listed in Table 1001. The
items listed may be obtained from Honeywell Engines, Systems & Services, Ground Support
Equipment, 717 N. Bendix Dr., South Bend, IN 46628-1000, Telephone: 574-231-3987, unless
otherwise noted.

Table 1001. Special Tools, Fixtures and Equipment

Item Source/
No. Nomenclature Use Part No.

NOTE: Equivalent substitutes may be used for listed items.

1. Metal Hose Assembly Provides means of ducting bleed-air 258616


(Replaced by P/N from engine to a flow measuring
834485-1) section.

2. Vibration Pickup Mounts vibration pickup to compressor 265846-1


Mount and turbine assembly mount pad.

3. Vibration Pickup Mounts vibration pickup to compressor 265846-2


Mount and turbine assembly mount pad.

4. Screwdriver and Holds and prevents rotation of nuts 280353


Wrench Assembly while adjusting screw on fuel control
governor.

5. Portable Engine Secures and holds engine in various 281270-0-3


Stand (Replaced by positions during assembly, dis-
833063-1) assembly and testing. Also used to
transport engine.

6. Gas Turbine Provides means to direct and sense 281407-2


Bleed-Air Duct bleed-air pressure and temperature
during testing.

7. Beam Type Sling Provides means of lifting engine 281513-3


during overhaul.

8. Engine Adapter Adapts and supports accessory 281893-1-1


(Replaced by drive gearcase housing assembly
PN 834119-2) to Stand, PN 281270-0-3 or
833063-1.

Page 1001
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Table 1001. Special Tools, Fixtures and Equipment (Cont)

Item Source/
No. Nomenclature Use Part no.

9. Tailpipe Adapter Provides means of directing exhaust 281915-2-1


(Replaced by gases to facility exhaust stack and
PN 2024745-2) provides mounting bosses for exhaust
gas temperature instrumentation.

10. Pressure Gage and Monitors engine run-in checks. 282645


Case Set Assembly

11. Thermocouple Provides means of sensing exhaust 283880-1


gas temperature during testing. (3 Req'd)
Component of PN 285148-2-1.

12. Thermocouple Provides means of sensing exhaust 283880-2


gas temperature during testing.
Component of PN 285148-2-1.

13. Engine Mount Supports engine on Stand, PN 284125-1-1


(Replaced by 281270-0-3 or 833063-1.
PN 2024502-1)

14. Engine Mount Supports engine on Stand, PN 284126-1-1


(Replaced by 281270-0-3 or 833063-1.
PN 2024502-1)

15. Tailpipe Adapter Provides means of directing exhaust 285148-2-1


(Replaced by gases to facility exhaust stack and
PN 2024745-2) provides mounting bosses for exhaust
gas temperature instrumentation.
Alternate for PN 281915-2-1.

16. Immersion Provides means of sensing 290115-1


Thermocouple compressor inlet temperature
(2 Req'd) during testing.
(Replaced by
PN 2024743-1)

17. Portable Engine Secures and holds engine in various 833063-1


Stand (Replaced positions during assembly, dis-
by PN 833565-2) assembly and testing. Also used to
transport engine.

18. Sleeve Adjustor Holds governor adjustment nut. 833274-1


Wrench

19. Jamnut Wrench Holds governor jamnut. 833275-1

Page 1002
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Table 1001. Special Tools, Fixtures and Equipment (Cont)

Item Source/
No. Nomenclature Use Part no.

20. Portable Engine Secures and holds engine in various 833565-2


Stand (Replaces positions during assembly, dis-
PN 833063-1) assembly and testing. Also used to
transport engine.

21. Thermocouple Provides means of sensing exhaust 834320-1


Assembly gas temperature during testing.
Component of PN 2024745-2.

22. Thermocouple Provides means of sensing exhaust 834320-2


Assembly gas temperature during testing.
Component of PN 2024745-2.

23. Metal Hose Assembly Provides means of ducting bleed-air 834485-1


(Replaces P/N from engine to a flow measuring
258616) section.

24. Engine Adapter Adapts and supports accessory 834119-2


(Replaces PN drive gearcase housing assembly
281893-1-1) to Stand, PN 833565-2.

25. Engine Mount Supports engine on Stand, PN 2024502-1


(Replaces PN 833565-2.
284125-1-1)

26. Engine Mount Supports engine on Stand, PN 2024502-2


(Replaces PN 833565-2.
284126-1-1)

27. Inlet Duct Provides means of sensing 2024743-1


compressor inlet temperature during
testing.

28. Tailpipe Adapter Provides means of directing exhaust 2024745-2


gases to facility exhaust stack and
provides mounting bosses for
exhaust gas temperature
instrumentation. (Replaces PNs
285148-2-1 and 281915-2-1.)

29. Lifting Fixture Provides means of lifting engine 20255131-1


during overhaul. Alternate for PN
281513-3.

30. Immersion Provides means of sensing exhaust 290255-1-1


Thermocouple gas temperature during testing. Use
with PN 281915-2-1 tailpipe adapter.

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Table 1001. Special Tools, Fixtures and Equipment (Cont)

Item Source/
No. Nomenclature Use Part no.

31. Immersion Provides means of sensing exhaust 290255-2-1


Thermocouple gas temperature during testing. Use
with 281915-2-1 tailpipe adapter.

32. Vibration Meter, Provides means of measuring Sensortronics Inc,


Type 1-117 (1 engine vibration within a specified Vibration Products
Req'd) with High amplitude. Div, 746 Arrow
Pass Filter Catalog Grand Cir, Covina,
No. 1-003-110 CA 91722
(1 Req'd) (Replaced
by Model No. 203G8)

33. Vibration Pickup, Mounts to engine to provide Sensortronics Inc,


Model No. 4-103-0001 means of registering vibration at Vibration Products
(2 Req'd) (Replaced engine turbine and engine Div, 746 Arrow
by Model No. 4382) accessory gearcase. Grand Cir, Covina,
CA 91722

34. Vibration Meter, Provides means of measuring Trig-Tek Inc,


Model 203G8 engine vibration within a specified 423 S Brookhurst,
amplitude. (Replaces Type 1-117.) Anaheim, CA
92804-2450

35. Vibration Pickup, Mounts to engine to provide Bruel & Kajer


Model 4382 means of registering vibration at Instruments Inc,
engine turbine and engine 721 N Eckhoff St,
accessory gearcase. (Replaces Orange, CA
Model No. 4-103-001.) 92668

Page 1004
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

PLUMBING INSTALLATION

1. Disassembly

Table 1. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Aqueous alkaline cleaner Magnaflux, A Division of Illinois Tool Works Inc.,


(Daraclean 282) 3624 W. Lake Ave., Glenview, IL 60025

Degreasing solvent Commercially available


(MIL-PRF-680)

A. General

(1) Disassembly of details of the plumbing installation shall be accomplished as


accessible and feasible during removal of component items from the engine as
defined in Section 49-20-00. Note routing to tubing and location and manner of
attaching clamps. Tag tubing as necessary to aid in assembly. Discard packings and
gaskets. (Refer to Figures 1 through 5.)

NOTE: Refer to ATA No. 49-90-41 for overhaul of check valve (250, Figure 2).
Tag check valve to identify location on engine for assembly.

2. Cleaning

A. Follow Detailed Methods of Cleaning

(1) Degrease parts with petroleum solvent as follows:

WARNING: USE THE CORRECT PERSONAL PROTECTION. THIS


CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND LUNG
DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS
FOR EACH CHEMICAL.

(a) Place degreasing solvent (MIL-PRF-680) in a dip tank or use as a spray in a


positive outside ventilated spray booth.

WARNING: SPRAY VAPORS ARE TOXIC AND SHALL NOT BE INHALED.


OBSERVE ALL FIRE PRECAUTIONS.

(b) Dip, soak, agitate or spray parts to be cleaned until oil and grease have been
removed.

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2. A. (2) Degrease parts using Daraclean 282 cleaning solution.

(a) Prepare Daraclean 282 cleaning solution.

WARNING: DARACLEAN IS AN EYE IRRITANT. WEAR EYE


PROTECTION WHEN MIXING THE CLEANING
COMPOUND.

1 Mix Daraclean 282 with tap water in a dip tank to a concentration of 8


parts of water to 1 part Daraclean, to make a 12% solution.

2 Set the water temperature at 140 to 160F (60 to 71C) and maintain at
this temperature.

(b) Remove grease from parts with a Daraclean 282 cleaning solution.

1 Dip, soak or agitate parts to be cleaned until all oil and grease are
removed.

2 Spray clean parts with curvics.

WARNING: USE THE CORRECT PERSONAL PROTECTION.


COMPRESSED AIR WILL CAUSE LOOSE PARTICLES
THAT CAN GET IN YOUR EYES. THE AIRSTREAM CAN
CAUSE CUTS, DO NOT POINT IT AT YOUR SKIN.

3 Dry the parts with compressed air.

4 Apply a layer of rust/corrosion preventative if parts are to be stored.

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3. Inspection/Check

A. Perform General Checks

(1) Visually check all tube assemblies for nicks, cracks, excessive wear, signs of
corrosion, or other damage.

(2) Visually check all hose assemblies for nicks, cracks, excessive wear, cuts, or other
damage.

(3) Visually check all fittings for crossed threads, cracks, or other damage.

(4) Visually check clamps and brackets for damage.

(5) Check orificed tee assemblies (560, Figure 4) and (140, Figure 5) for freedom from
obstructions. Dimensionally check orificed tee assembly (560, Figure 4) to ensure that
the orifice Diameter is 0.030 to 0.034 inch, and orificed tee assembly (140, Figure 5)
orifice Diameter is 0.138 to 0.142 inch.

4. Assembly

A. Assemble Plumbing Installation

(1) Assembly of the plumbing installation may be accomplished as accessible and


feasible during installation of accessory items as defined in Section 49-20-00. Install
new packings and gaskets during assembly.

B. Orificed Tee Assembly Installation

(1) Install orificed tee assembly (560, Figure 4) and (140, Figure 5) so that arrow on each
orifice tee assembly body points toward rear of engine.

C. Packing With Retainer Set (20, 25, Figure 4)

(1) Packing with retainer (20) with yellow marked rim shall be located next to bolt head.
Packing with retainer (25) with knurled rim shall be located at opposite location.

D. Check Valve Installation

(1) Install check valve (250, Figure 2) with arrow on check valve pointing in the direction of
the oil cooler assembly and with word "HINGE" stamped on hex flat in the upward
position.

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Plumbing Installation (Partial Breakdown)


Figure 1

Page 4
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KEY TO FIGURE 1

10. HOSE ASSY (IPC FIG. 1, 49-20-01) 360. CLAMP


20. TEE 370. BOLT
30. NUT 380. TEE
40. PACKING 390. TUBE ASSY
50. BOLT 400. TEE
60. CLAMP 410. NUT
70. NUT 420. PACKING
80. WASHER 430. NUT
90. CLAMP 440. ELBOW
100. CLAMP 450. PACKING
110. BOLT 460. TEE
120. TUBE ASSY 470. PACKING
130. ELBOW 480. NUT
140. NUT 490. TUBE ASSY
150. PACKING 500. UNION
160. TUBE ASSY 510. PACKING
170. UNION 520. TEE
180. PACKING 530. NUT
190. ELBOW 540. TUBE ASSY
200. NUT 550. ELBOW
210. PACKING 560. NUT
220. NUT 570. PACKING
230. WASHER 580. NUT
240. CLAMP 590. WASHER
245. CLAMP 600. CLAMP
250. BOLT 610. BOLT
260. NUT 620. CLAMP
270. WASHER 630. TUBE ASSY
280. CLAMP 640. ELBOW
290. BOLT 650. NUT
300. TUBE ASSY 660. PACKING
310. TUBE ASSY 670. PLUG
320. UNION 680. PACKING
330. PACKING 690. ELBOW
340. NUT 700. NUT
350. WASHER 710. PACKING

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Plumbing Installation (Partial Breakdown)


Figure 2

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KEY TO FIGURE 2

10. HOSE ASSY (IPC FIG. 2, 49-20-01) 170. NUT


20. UNION 180. WASHER
30. PACKING 190. BOLT
40. TEE 200. CLAMP
50. CAP 210. NUT
60. PIN 220. WASHER
70. CHAIN 230. BOLT
80. RING 240. CLAMP
90. TUBE ASSY 250. SWING CHECK VALVE
100. NUT 260. UNION
110. WASHER 270. PACKING
120. BOLT 280. TUBE ASSY
130. CLAMP 290. NUT
140. REDUCER 300. WASHER
150. PACKING 310. BOLT
160. TUBE ASSY 320. CLAMP

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(GTCP85-98DHF) Plumbing Installation (Partial Breakdown)


Figure 3

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KEY TO FIGURE 3

10. TUBE ASSY (IPC FIG. 3, 49-20-01) 320. BOLT


20. NUT 330. CLAMP
30. WASHER 340. CLAMP
40. BOLT 350. TEE
50. CLAMP 360. PACKING
60. ELBOW 370. CAP
70. PACKING 380. NUT
80. NUT 390. HOSE ASSY
90A. TEE 400. NUT
100. PACKING 410. WASHER
110. NUT 420. BOLT
120. CAP 430. CLAMP
130. TUBE ASSY 440. UNION\
140. TUBE ASSY 450. CAP
150. NUT 460. NUT
160. WASHER 470. WASHER
170. BOLT 480. TUBE ASSY
180. CLAMP 490. UNION
190. TEE 500. CAP
200. CAP 510. WASHER
-201. TUBE ASSY (POST SB 49-5233) 520. NUT
-201A. TUBE ASSY (POST SB 49-5233, REV 1) 530. TUBE ASSY
-202. CAP (POST SB 49-5233) 540. NUT
-203. TEE (POST SB 49-5233) 550. WASHER
-204. NUT (POST SB 49-5233) 560. BOLT
-205. PACKING (POST SB 49-5233) 570. CLAMP
210. TUBE ASSY 580. TUBE ASSY
220. NUT 590. NUT
230. WASHER 600. WASHER
240. BOLT 610. BOLT
250. CLAMP 620. CLAMP
260. REDUCER 630. UNION
270. PACKING 640. PACKING
280. TUBE ASSY 650. HOSE ASSY
290. TUBE ASSY 660. TEE
-291. NUT (POST SB 49-5233) 670. CAP
-292. WASHER (POST SB 49-5233) 680. WASHER
-292A. WASHER (POST SB 49-5233, REV 1) 690. NUT
-293. BOLT (POST SB 49-5233) 700. TEE
-293A BOLT (POST SB 49-5233, REV 1) 710. CAP
-294. SPACER (POST SB 49-5233) 720. WASHER
-294A. SPACER (POST SB 49-5233, REV 1) 730. NUT
-295. CLAMP (POST SB 49-5233) 740. ELBOW
300. NUT 750. PACKING
310. WASHER 760. NUT

- ITEM NOT ILLUSTRATED

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) Plumbing Installation (Partial Breakdown)


Figure 3A

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

KEY TO FIGURE 3A

10. TUBE ASSY (IPC FIG. 3A, 49-20-01) 440. TEE


20. NUT 450. PACKING
30. WASHER 460. CAP
40. BOLT 470. NUT
50. CLAMP 480. HOSE ASSY
60. ELBOW 490. NUT
70. PACKING 500. WASHER
80. NUT 510. BOLT
90. TEE 520. CLAMP
100. PACKING 530. UNION
110. NUT 540. CAP
120. CAP 550. NUT
130. TUBE ASSY 560. WASHER
140. TUBE ASSY 570. TUBE ASSY
150. NUT 580. UNION
160. WASHER 590. CAP
170. BOLT 600. WASHER
180. CLAMP 610. NUT
190. TEE 620. TUBE ASSY
200. TUBE ASSY 630. NUT
210. CAP 640. WASHER
220. TEE 650. BOLT
230. NUT 660. CLAMP
240. PACKING 670. TUBE ASSY
250. TUBE ASSY 680. NUT
260. NUT 690. WASHER
270. WASHER 700. BOLT
280. BOLT 710. CLAMP
290. CLAMP 720. UNION
300. REDUCER 730. PACKING
310. PACKING 740. HOSE ASSY
320. TUBE ASSY 750. TEE
330. TUBE ASSY 760. CAP
340. NUT 770. WASHER
350. WASHER 780. NUT
360. BOLT 790. TEE
370. SPACER 800. CAP
380. CLAMP 810. WASHER
390. NUT 820. NUT
400. WASHER 830. ELBOW
410. BOLT 840. PACKING
420. CLAMP 850. NUT
430. CLAMP

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Plumbing Installation (Partial Breakdown)


Figure 4

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

KEY TO FIGURE 4

10. BOLT (IPC FIG. 4, 49-20-01) 370. NUT


20. PACKING W/RTNR 380. WASHER
30. PACKING W/RTNR 390. CLAMP
40. ELBOW 400. CLAMP
50. PLUG 410. SPACER
60. TUBE ASSY 420. BOLT
70. NUT 430. CLAMP
80. WASHER 440. CLAMP
90. CLAMP 450. TUBE ASSY
100. BOLT 460. UNION
110. TUBE ASSY 470. CLAMP
120. NUT 480. CLAMP
130. WASHER 490. NUT
140. CLAMP 500. ELBOW
150. SPACER 510. PACKING
160. CLAMP 520. TUBE ASSY
170. BOLT 530. CLAMP
180. TUBE ASSY 540. TEE
190. CLAMP 550. NUT
200. CLAMP 560. TUBE ASSY
210. TUBE ASSY 570. PACKING
220. NUT 580. TUBE ASSY
230. WASHER 590. NUT
240. CLAMP 600. WASHER
250. SPACER 610. CLAMP
260. BOLT 620. BOLT
270. TEE 630. NUT
280. TEE 640. ELBOW
290. NUT 650. PACKING
300. PACKING 660. HOSE ASSY
310. TUBE ASSY 670. NUT
320. CLAMP 680. ELBOW
330. NUT 690. PACKING
340. WASHER 700. PACKING
350. CLAMP 710. ELBOW
360. BOLT 720. NUT

Page 13
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Plumbing Installation (Partial Breakdown)


Figure 5

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

KEY TO FIGURE 5

10. TUBE ASSY (IPC FIG. 5, 49-20-01) 190. CLAMP


20. NUT 200. HOSE ASSY
30. WASHER 210. NUT
40. CLAMP 220. WASHER
50. BOLT 230. BOLT
60. CLAMP 240. CLAMP
70. BOLT 250. CLAMP
80. ELBOW 260. NUT
90. PACKING 270. WASHER
100. UNION 280. CLAMP
110. PACKING 290. CLAMP
120. TUBE ASSY 300. BOLT
130. NUT 310. NUT
140. TEE ASSY 320. ELBOW
150. PACKING 330. PACKING
160. NUT 340. CAP ASSY
170. WASHER 350. UNION
180. BOLT 360. PACKING

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

ELECTRICAL INSTALLATION

1. Disassembly

A. General

WARNING: IGNITION SYSTEM HIGH CURRENT AND VOLTAGE CAN BE FATAL. MAKE
CERTAIN ELECTRICAL POWER IS REMOVED FROM IGNITION SYSTEM FOR A
MINIMUM OF 5 MINUTES BEFORE ANY DISCONNECTIONS ARE MADE. AFTER
DISCONNECTING IGNITER PLUG LEAD ENSURE COMPLETE DISCHARGE OF
CAPACITORS IN IGNITION UNIT BY IMMEDIATELY SHORTING IGNITER LEAD TO
GROUND; TO AVOID EXPLOSION MAKE CERTAIN NO VOLATILE FLUIDS OR
GASES ARE PRESENT.

Disassembly of the electrical installation may be accomplished as accessible and feasible


during removal of component items from the engine as defined in 49-20-00. Note routing of
wiring harness and manner of attaching clamps. Tag connectors, as necessary to aid in
assembly. (Refer to Assembly Section, Figures 1, 1A and 2.)

B. Remove electrical connectors

(1) Remove threaded connector.

(a) Use connector pliers to loosen coupling rings which are too tight to be
loosened by hand.

NOTE: Do not use excessive force, and do not pull on attached wires.

(b) Alternately pull on the plug body and unscrew the coupling ring until the
connector is separated.

(c) Protect disconnected plugs and receptacles with caps or plastic bags to keep
debris from entering and causing faults.

(2) Remove bayonet connector.

(a) Remove connector by rotating the coupling ring in a counterclockwise


direction.

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

2. Cleaning

Table 1. Materials and Compounds

Material or Compound Manufacturer

Methyl-ethyl-ketone (MEK) Commercially available


(ASTM D740)

Retention test tool Astro Tool Corp., 21615 SW. Tualatin Valley
Hwy., Beaverton, OR 97006-1329

Sn60 Solder Commercially available


(EIA J-STD-00)

Degreasing solvent Commercially available


(MIL-PRF-680)

A. General

WARNING: USE DEGREASING SOLVENT (MIL-PRF-680) IN A WELL-VENTILATED


AREA. KEEP AWAY FROM FLAME. AVOID BREATHING FUMES.

(1) Clean electrical components using cloth dampened in degreasing solvent


(MIL-PRF-680).

(2) Clean receptacles with dry, soft bristled brush; remove oil type soil with cotton swab
dampened in methyl-ethyl-ketone (ASTM D740).

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

3. Inspection/Check

A. General

(1) Check wiring for worn insulation, broken wires, terminals, or evidence of corrosion.
Inspect plugs and connectors for damaged contacts, bent or broken pins, crossed or
peened threads.

(2) Check locked condition of all connector pins and sockets.

(a) Use a suitable retention test tool, capable of producing an axial load of two to
three pounds, to check pin and socket locked condition.

(3) Visually check igniter plug lead (280, Figure 1) shielding for evidence of fraying,
terminals for cracks and security, fitting for crossed or stripped threads and wrenching
flats for roundness. Refer to ATA No. 49-41-05 for overhaul of igniter plug lead.
4. Repair

A. General

Replace defective components or defective wiring using Figure 801. Section 49-20-00 as a
guide to wire connections. Solder all connections in accordance with MIL-S-6872, using Sn60
solder (EIA J-STD-00).

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

5. Assembly

A. General

Assembly of the electrical installation may be accomplished as accessible and feasible during
installation of accessory items as defined in Section 49-20-00.

B. Install Electrical connectors.

(1) Threaded connector installation.

(a) Locate the proper position of the plug in relation to the receptacle by aligning the
key of one part with groove or keyway of other part.

(b) Start the plug into the receptacle with a slight forward pressure and engage the
threads of the coupling ring and receptacle.

NOTE: Never use force to mate connectors to receptacles. Do not hammer


a plug into its receptacle, and never use a torque wrench or pliers to
lock coupling rings.

Use connector pliers to tighten coupling rings beyond finger tight if


space around the connector is too small to obtain a good finger grip.

(c) Alternately push in the plug and tighten the coupling ring until the plug is
completely seated.

(2) Bayonet connector installation.

NOTE: Use of connector pliers prohibited.

(a) Locate the proper position of the plug in relation to the receptacle by aligning the
key of one part with the groove or keyway of the other part.

(b) Start the plug into the receptacle with a slight forward pressure and engage the
coupling.

(c) Completed coupling shall be accomplished by clockwise rotation of the coupling


ring and will be indicated by an audible sound at the completion of the coupling
cycle.

(d) Visual indication of complete coupling is accomplished when:

1 Three axial stripes on the coupling ring align with three corresponding
stripes on the receptacle; or

2 Coupling pins on the receptacle are visible through holes in the coupling
ring.

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GTCP85-98DHF/[A]

THIS PAGE INTENTIONALLY LEFT BLANK

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GTCP85-98DHF/[A]

(GTCP85-98DHF) Electrical Installation


(Partial Breakdown)
Figure 1

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

KEY TO FIGURE 1

10. NUT (IPC FIG. 1, 49-20-02) 240. WASHER


20. WASHER 250. BOLT
30. BOLT 260. CLAMP
40. CLAMP 270. CLIP
50. NUT 280. LEAD (IGNITER PLUG)
60. WASHER 290. NUT
70. BOLT 300. WASHER
80. CLAMP 310. BOLT
90. NUT 320. CLAMP
100. WASHER 330. NUT
110. BOLT 340. WASHER
120. CLAMP 350. BOLT
130. NUT 360. CLAMP
140. WASHER 370. NUT
150. BOLT 380. WASHER
160. CLAMP 390. BOLT
170. BRACKET 400. CLAMP
180. NUT 410. NUT
190. WASHER 420. WASHER
200. BOLT 430. BOLT
210. CLAMP 440. CLAMP
220. BRACKET 450. NUT
225. BOLT 460. WASHER
226. WASHER 470. BOLT
230. NUT 480. CLAMP

Page 7
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

(GTCP85-98DHF[A]) Electrical Installation


(Partial Breakdown)
Figure 1A

Page 8
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

KEY TO FIGURE 1A

10. NUT (IPC FIG. 1A, 49-20-02) 260. CLAMP


20. WASHER 270. CLIP
30. BOLT 280. LEAD (IGNITER PLUG)
40. CLAMP 290. NUT
50. NUT 300. WASHER
60. WASHER 310. BOLT
70. BOLT 320. CLAMP
80. CLAMP 330. NUT
90. NUT 340. WASHER
100. WASHER 350. BOLT
110. BOLT 360. CLAMP
120. CLAMP 370. NUT
130. NUT 380. WASHER
140. WASHER 390. BOLT
150. BOLT 400. CLAMP
160. CLAMP 410. NUT
170. BRACKET 420. WASHER
180. NUT 430. BOLT
190. WASHER 440. CLAMP
200. BOLT 450. NUT
210. CLAMP 460. WASHER
220. BRACKET 470. BOLT
225. BOLT 480. CLAMP
226. WASHER 490. NUT
230. NUT 500. WASHER
240. WASHER 510. BOLT
250. BOLT 520. CLAMP

Page 9
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

Electrical Installation
(Partial Breakdown)
Figure 2

Page 10
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OVERHAUL MANUAL
GTCP85-98DHF/[A]

KEY TO FIGURE 2

10. COVER ASSY (IPC FIG. 2, 49-20-02) 270. WASHER


20. SCREW 280. BOLT
30. BOLT 290. CLAMP
40. WASHER 300. BRACKET
50. RELAY 310. NUT
60. SCREW 320. WASHER
70. NUT 330. BOLT
80. WASHER 340. CLAMP
90. CIRCUIT BREAKER 345. BOLT
100. TIME TOTALIZING METER 346. WASHER
110. SCREW 350. NUT
120. WASHER 360. WASHER
130. MOUNT 370. BOLT
140. SCREW 380. CLAMP
150. WASHER 390. BOLT
160. NUT 400. LINK
170. WASHER 415. SPACER WASHER
180. BOLT 420. NUT
190. CLAMP 430. WASHER
200. CLAMP 440. BOLT
210. BOLT 450. CLAMP
220. NUT 460. BOLT
230. WASHER 480. LINK
240. BOLT 490. SPACER WASHER
250. CLAMP 500. HARNESS ASSY
260. NUT

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GTCP85-98DHF/[A]

COMBUSTION AND EXHAUST SECTION

1. Disassembly

A. Perform General Disassembly

Obvious steps or procedures necessary to disassemble the engine, such as removal of


lockwire, attaching parts, or simple components are omitted from the text. Removal of
plumbing and electrical installations may be accomplished whenever parts are accessible. In
general, disassembly should be accomplished in sequence of index numbers assigned to
individual exploded views. Variations from this sequence and special processes or methods
are specifically mentioned in the text. The following general procedures should be observed
throughout the disassembly operations.

(1) Place each part disassembled on a clean workbench in the order of removal 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 or 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 oil, using oil of specification used in the
engine lubrication system. Cover all parts with clean paper or suitable coverings
unless cleaning and inspection is to be accomplished immediately.

(5) Do not disassemble tube assemblies, hose assemblies, wiring harness assemblies,
rivet assemblies, or staked or press-fit parts (except seals and bearings) or remove
nameplates, modification plates, lubrication plates, decals, studs, or their 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 a manner consistent with
good shop practice.

(6) Always keep ports, bores, and passages of assemblies or components sealed with
tape or suitable closures between overhaul procedures. Cover large openings with
cardboard taped in place.

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GTCP85-98DHF/[A]

CAUTION: DO NOT USE TAPE TO COVER OPENINGS OR CONNECTIONS ON FUEL


OR LUBRICATION SYSTEM COMPONENTS.

1. A. (7) During various stages of disassembly, examine all parts and assemblies for signs of
scoring, burning, or other defects. Note physical conditions which will not be apparent
after cleaning. Tag involved parts before they are cleaned and laid out for detail
inspection. Check additionally for evidence of damage caused by improper
procedures at previous overhauls. Report such damage in accordance with current
practice.

(8) Record manner of lockwiring for duplication at assembly.

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THIS PAGE INTENTIONALLY LEFT BLANK

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Disassemble Combustion and Exhaust Section


(Partial Breakdown)
Figure 101

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

1. B. Disassemble Combustion and Exhaust Section

(1) Disassemble combustion and exhaust section components as follows. (Refer to


Figure 101.)

NOTE: Engine is mounted in 281270-0-3, 833063-1 or 833565-2 stand using


284125-1-1 or 2025402-1 mount on one side of engine, 284126-1-1 or
2024502-2 mount on other side of engine, and 281893-1-1 or 834119-2
adapter to support the accessory end.

(a) Remove coupling (10) and combustor unit (-30) with packing (20) from engine.
Discard packing.

(b) Remove bolts (50), washers (60), retainer (70) and igniter plug (40) with
gasket (80). Discard gasket.

(c) Remove reducer orifice (90) with packing (100) and tags (110, 120). Discard
packing.

(d) Remove bolts (140), washers (150), plate (180) and fuel atomizer assembly
(130) with packings (160A) and washer (170C). Discard packing.

(e) Loosen nut (210) and remove elbow (190) with packing (200) and nut (210)
from fuel atomizer assembly (130). Refer to ATA No. 49-30-38 for functional
test or overhaul of fuel atomizer assembly (130). Discard packing.

(f) Remove combustion liner assembly (230A) from combustor cap (220).

KEY TO FIGURE 101

10. COUPLING (IPC FIG. 1) 130. FUEL ATOMIZER ASSY


20. PACKING 140. BOLT
-30. COMBUSTOR UNIT 150. WASHER
40. IGNITER PLUG 160A. PACKING
50. BOLT 170C. WASHER
60. WASHER 180. PLATE
70. RETAINER 190. ELBOW
80. GASKET 200. PACKING
90. REDUCER ORIFICE 201. NUT
100. PACKING 210. NUT
110. TAG 220. COMBUSTOR CAP
120. TAG 230A. COMBUSTION LINER ASSY

- ITEM NOT ILLUSTRATED

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Disassemble Combustion and Exhaust Section


Figure 102

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

1. B. (2) Disassemble combustion and exhaust components as follows. (Refer to Figure 102.)

(a) Remove bolts (10), washers (20) and fitting (30) from exhaust duct flange
assembly (70).

(b) Remove bolts (40), screws (60), washers (50) and exhaust duct flange
assembly (70). Discard bolts.

(c) (Pre SB 49-7542) Remove nuts (80), washers (90), non-metallic washer (100),
bolts (110, 120), washers (130, 140) and bracket (150). Remove turbine
plenum assembly (160), gasket (170) and shims (180).

(Post SB 49-7542) Remove nuts (80), washers (90), non metallic washer
(100), bolts (110, 120, 120A), washers (130, 140) and bracket (150). Remove
nut (230), washer (220) and bolts (120B, 210). Remove external shield upper
half (190) and lower half (200). Remove turbine plenum assembly (160),
gasket (170) and shims (180).

KEY TO FIGURE 102

10. BOLT (IPC FIG. 2) 120B. BOLT


20. WASHER 130. WASHER
30. FITTING 140. WASHER
40. BOLT 150. BRACKET
50. WASHER 160. TURBINE PLENUM ASSY
60. SCREW 170. GASKET
70. EXHAUST DUCT FLANGE ASSY 180. SHIM
80. NUT 190. EXTERNAL SHIELD UPPER HALF
90. WASHER 200. EXTERNAL SHIELD LOWER HALF
100. NON-METALLIC WASHER 210. BOLT
110. BOLT 220. WASHER
120. BOLT 230. NUT
120A. BOLT

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Disassemble Combustion and Exhaust Section


(Partial Breakdown)
Figure 103

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OVERHAUL MANUAL
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1. B. (3) Disassemble combustion and exhaust components as follows. (Refer to Figure 103.)

NOTE: Exhaust pipe assembly has left-hand threads.

(a) Use 280333 spanner wrench to remove exhaust pipe assembly (10).

(Pre SB 49-5436) Remove and discard gasket (20).

CAUTION: REUSE OF NUTS (30) WITH WASHERS (40) COULD RESULT IN


PREMATURE ENGINE FAILURE.

(b) (Pre SB 49-3914/-5436) Remove attaching nuts (30) and washers (40).
Separate turbine torus assembly (50) and containment ring (60) from engine.
Discard nuts and washers.

(Post SB 49-3914; Pre SB 49-5436) Remove nuts (30), washers (40) and
brackets (45). Remove turbine torus assembly (50) and containment ring
(60A) from engine. Discard nuts and washers.

(Post SB 49-5436; Pre SB 49-3914) Remove attaching nuts (30) and washers
(40). Remove turbine torus assembly (50A), heat shield (55) and containment
ring (60) from engine. Discard nuts and washers.

(Post SB 49-5436/-3914) Remove nuts (30), washers (40) and brackets (45).
Remove turbine torus assembly (50A), heat shield (55) and containment ring
(60A) from engine. Discard nuts and washers.

(Post SB 49-A6706) Remove nuts (30), washers (40), and brackets (45).
Remove turbine torus assembly (50A), heat shield (55) and containment rings
(60, 65) from engine. Discard nuts and washers.

(Post SB A7189) Remove nuts (30), washers (40), and brackets (45).
Remove turbine torus assembly (50A), heat shield (55) and containment rings
(60, 65B) from engine. Discard nuts and washers.

KEY TO FIGURE 103

10. EXHAUST PIPE ASSY (IPC FIG. 3) 55. HEAT SHIELD


20. EXHAUST PIPE GASKET (POST SB 49-5436)
(PRE SB 49-5436) 60. CONTAINMENT RING
30. NUT (PRE SB 49-3914)
40. WASHER -60A. CONTAINMENT RING
45. BRACKET (POST SB 49-3914)
(POST SB 49-3914) 65. CONTAINMENT RING
50. TURBINE TORUS ASSY (POST SB 49-5689)
(PRE SB 49-5436) -65B. CONTAINMENT RING
50A. TORUS ASSY (POST SB 49-A7189)
(POST SB 49-5436)

- ITEM NOT ILLUSTRATED

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1. C. Disassemble Engine Section

Refer to 49-20-05 for instructions relative to disassembly of the engine power section.

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COMBUSTION AND EXHAUST SECTION

1. Cleaning

A. Follow General Cleaning Instructions

(1) Perform all cleaning procedures in accordance with general cleaning instructions
provided in Standard Practices Manual (SPM), ATA No. 20-00-02/70-00-01.

(2) Protect all cleaned parts in accordance with instructions provided in SPM.

B. Clean Component Parts

NOTE: More than one cleaning method may be specified for a particular part or assembly,
e.g., a part may require removal of heavy grease deposits using a brush and
petroleum solvent followed by vapor degreasing for final cleaning. An additional
cleaning method may be required for corrosion removal. If a particular cleaning
method is not required due to the condition of the part, it may be omitted, however
only those cleaning methods specified for that part may be used.

(1) Refer to following figures for recommended cleaning methods for specific parts.

NOTE: Cleaning method numbers and alpha suffix shown in following lists
correspond to numbers and alpha suffix assigned to cleaning methods
described in the SPM. The cleaning methods instructions in the SPM refer
to additional instructions provided therein for preparation of solutions used
in performing the cleaning methods.

(2) Refer to SPM for instructions pertaining to each of the cleaning methods specified in
cleaning methods lists presented herein.

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Combustion and Exhaust Section


Figure 201

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Figure 201. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B C

All standard metallic hardware. X X

220 Combustor Cap X X X

230A Combustion X X X
Liner Assy

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Combustion and Exhaust Section


(Partial Breakdown)
Figure 202

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Figure 202. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B C

All standard metallic hardware X X

70 Exhaust Duct X X
Flange Assy

160 Turbine Plenum X X X


Assy

190, 200 External Shield X X

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Combustion and Exhaust Section


(Partial Breakdown)
Figure 203

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Figure 203. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B C

All standard metallic hardware X X

10 Exhaust Pipe Assy X X X

50, 50A Turbine Torus Assy X X X

55 Heat Shield X X

60, 65 Containment Ring X X X

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COMBUSTION AND EXHAUST SECTION

1. Inspection/Check

NOTE: Inspection/Checks shall be performed in accordance with instructions provided in Standard


Practices Manual ATA No. 20-00-02/70-00-01. Reference to this manual throughout this
section will be indicated by the abbreviation SPM.

A. General Checks

(1) Check threaded parts for stripped, galled or crossed threads. Replace part if
damaged.

(2) Visually check fittings for crossed, galled, peened or stripped threads. Check for
deterioration and contamination. Replace part that does not meet Inspection/Check
requirements.

(3) Visually check brackets and supports for physical damage that would impair function.
Replace part that does not meet Inspection/Check requirements.

B. Detailed Inspection/Check

Items denoted by an X in the following figures under Detail Inspection/Check pertain to ATA
No. 49-21-73, Inspection/Repair Manual. All other references are specified as required.

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Combustion and Exhaust Section


(Partial Breakdown)
Figure 301

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Figure 301. Inspection/Check

Item Detailed
No. Nomenclature Inspection/Check

40 Igniter Plug Refer to ATA


No. 49-40-02

90 Turbine Plenum Drain (Reducer) Refer to ATA


No. 49-30-10

130 Fuel Atomizer Assy Refer to ATA


No. 49-30-38

220 Combustor Cap X

230A Combustion Liner Assy X

NOTE: All other items of Figure 301 are limited to the requirements of the SPM or replacement.

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Combustion and Exhaust Section


(Partial Breakdown)
Figure 302

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Figure 302. Inspection/Check

Item Detailed
No. Nomenclature Inspection/Check

70 Exhaust Duct Flange Assy X

160 Turbine Plenum Assy X

NOTE: All other items of Figure 302 are limited to the requirements of the SPM or replacement.

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Combustion and Exhaust Section


(Partial Breakdown)
Figure 303

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Figure 303. Inspection/Check

Item Detailed
No. Nomenclature Inspection/Check

10 Exhaust Pipe Assy X

50, 50A Turbine Torus Assy X

55 Heat Shield X

60, 65 Containment Ring X

NOTE: All other items of Figure 303 are limited to the requirements of the SPM or replacement.

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COMBUSTION AND EXHAUST SECTION

1. Repair

Refer to ATA No. 49-21-73.

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COMBUSTION AND EXHAUST SECTION

1. Assembly

Table 501. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Anti-seize compound Henkel Loctite Corp.,


(C5-A Copper Based) 1001 Trout Brook Crossing,
Rocky Hill, CT 06067

Adhesive sealant (RTV 106) General Electric Co., GE Silicones


260 Hudson River Rd.,
Waterford, NY 12188

Grease (Aeroshell No. 5) Commercially available.

Marking compound (Dykem The Dykem Co., 8501 Delport Dr., St. Louis,
Hi-Spot Blue, No. 107) MO 63114-5905

Primer (P-415-66-611BC with Griggs Paint Inc., 3635 S. 16th St.,


Catalyst C1178-66) Phoenix, AZ 85040-1305

A. General Assembly Instructions

Assembly operations shall be performed with attention to details outlined in this manual. Highest
standards of precision shop procedures shall be employed throughout the entire reassembly.
Fits and tolerances shall be closely maintained. The following general instructions shall be
observed throughout the assembly procedures.

(1) Exercise extreme care to prevent dirt, dust, or foreign particles from entering the engine.
If any foreign particle enters the engine during assembly, stop assembly until the foreign
particle is located and removed, even if this causes considerable disassembly.

(2) When measurements for shimming for fitting are made on parts or on assembled
parts prior to their installation in the next higher assembly, tag these parts as
measured components of the higher assembly and keep with that assembly. If
damage or other reason causes replacement of a measured component, repeat all
measurements which include the part, using the new part.

(3) Never use extreme force in the assembly of the unit. If difficulty is encountered,
disassemble the unit and inspect for burrs or other interferences.

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1. A. (4) On through hole applications when extreme minimum stack conditions result in
excessive protrusion of the screw or bolt through either the threaded part or nut, a
shorter standard screw or bolt may be substituted providing the substitution results in a
minimum of one full thread protrusion beyond the face of the threaded part or nut.

NOTE: No substitutions of screw lengths are authorized for blind hole applications.

(5) On through hole applications when assembling parts which, through extreme stack
conditions, result in a screw or bolt protrusion of less than one full thread beyond the
face of the threaded part or nut, a longer standard screw or bolt may be substituted in
order to gain a minimum of one full thread protrusion.

B. Safety Fastening Instructions

Attaching parts may be locked using various methods as applicable to the part. These
methods include use of self-locking nuts, and use of lockwire. The following general
instructions shall be followed when installing locking devices.

(1) Duplicate the locking method as noted during the disassembly.

NOTE: During the "run-down" of a self-locking nut the run-down resistance


(frictional torque) shall be noted on the last rotation just before removing
clearance between parts. The self-locking nut then shall be tightened to
the specified torque value plus the noted frictional torque.

(2) Install self-locking nuts using standard shop procedures for the type nut being used.

(3) When lockwire is used, install lockwire per SAE-AS567.

NOTE: Electrical connectors and plumbing lines to individual components shall be


connected after installation of the component on the engine. Refer to
Sections 49-20-01 and 49-20-02 for installation of plumbing and electrical
installation components.

C. Assemble Combustion and Exhaust Section

NOTE: Refer to ATA No. 49-23-04 for assembly of the compressor and turbine assembly.
Be sure all assembly procedures for the compressor and turbine assembly have
been completed before assembling the combustion and exhaust section.

(1) With engine installed in 281270-0-3, 833063-1 or 833565-2 stand using 284125-1-1 or
2024502-1 mount on one side of engine, 284126-1-1 or 2024502-2 mount on other
side of engine, and 281893-1-1 or 834119-2 adapter to support the accessory end.

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10. EXHAUST PIPE ASSY 55. HEAT SHIELD


(IPC FIG. 3) (POST SB 49-5436)
20. GASKET (PRE SB 49-5436) 60. CONTAINMENT RING
30. NUT (PRE SB 49-3914)
40. WASHER -60A. CONTAINMENT RING
50. TORUS ASSY (PRE SB 49-5436) (POST SB 49-3914)
50A. TORUS ASSY 410. TURBINE WHEEL SHROUD
(POST SB 49-5436) (ATA NO. 49-23-04, IPC FIG. 1)

- ITEM NOT ILLUSTRATED

Assemble Containment Ring, Turbine Torus


Assembly and Exhaust Pipe Assembly
Figure 501 (Sheet 1 of 3)

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1. C. (2) Install containment ring, turbine torus assembly and exhaust pipe assembly as follows.

CAUTION: PRIOR TO POSITIONING CONTAINMENT RING ON ENGINE,


CHECK THICKNESS OF CONTAINMENT RING FLANGE AND
MATING THICKNESS OF SHROUD SUPPORT. THE
CONTAINMENT RING FLANGE THICKNESS SHALL BE EQUAL TO
OR LESS THAN MATING SHROUD SUPPORT THICKNESS. IF
CONTAINMENT RING FLANGE THICKNESS EXCEEDS MATING
SHROUD SUPPORT THICKNESS, AN UNDESIRABLE PRELOAD
ON THE RETAINING WASHERS CAN RESULT. IF THIS
CONDITION EXISTS, REWORK OF CONTAINMENT RING IS
RECOMMENDED. (REFER TO ATA NO. 49-21-73 FOR
REWORKING CONTAINMENT RING FLANGE THICKNESS.)

NOTE: Containment ring may be loose after tightening nuts. This condition is
acceptable.

(a) Temporarily position containment ring (60 or 60A, Figure 501) with wide lip
facing as shown on to engine, allowing containment ring to slip past turbine
shroud support.

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10. EXHAUST PIPE ASSY (IPC FIG. 3) 60. CONTAINMENT RING


20. GASKET 65. CONTAINMENT AUGMENTATION
30. NUT RING (POST SB 49-A6707)
40. WASHER -65B. CONTAINMENT AUGMENTATION
50. TORUS ASSY RING (POST SB 49-A7189)
50A. TORUS ASSY 410. TURBINE WHEEL SHROUD
(POST SB 49-5436) (ATA NO. 49-23-04 IPC FIG 1)

- ITEM NOT ILLUSTRATED

Assemble Containment Ring, Turbine Torus


Assembly and Exhaust Pipe Assembly
Figure 501 (Sheet 2)

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NOTE: Refer to Figure 502 for orientation of torus assembly.

1. C. (2) (b) (Pre SB 49-5436) Position torus assembly (50, Figure 501, Sheet 1) onto
engine.

NOTE: Tabs on the heat shield must fit between the turbine nozzle bolts.
Turn the heat shield to get the correct installation.

(Post SB 49-5436) Position heat shield (55) on turbine wheel shroud (410).
Position torus assembly (50A) onto engine.

(Post SB 49-A6707) Position containment augmentation ring (65, Figure 501,


Sheet 2) on turbine wheel shroud (410). Position torus assembly (50A) onto
engine.

(c) Position wide lip of containment ring (60, Figure 501) around outer
circumference and flush with flange of turbine shroud support and contacting
mating surface of turbine shroud support and contacting mating surface of
turbine torus assembly (50 or 50A) at all contact points. Containment portion
of ring will extend over outer circumference of torus assembly. Orient torus
assembly on engine in position shown in Figure 502.

(d) (Pre SB 49-3914) Apply anti-seize compound (C5-A Copper Based) to


threads of attaching nuts (30, Figure 501). Install washers (40) and nuts (30),
ensuring that washers are flush with flange of turbine shroud support and
overlap onto wide lip of containment ring (60) securing it in place. Tighten
nuts (30) to a torque value of 50 to 70 inch-pounds plus frictional torque.

(Post SB 49-3914) Apply anti-seize compound (C5-A Copper Based) to


threads of nuts (30, Figure 501, Sheet 3). Install seven washers (40) and
seven nuts (30) noting positions shown on Figure 501, Sheet 3, ensuring that
washers (40) are flush with flange of turbine shroud support and overlap onto
wide lip of containment ring (60A) securing it in place. Tighten nuts (30) to a
torque value of 50 to 70 inch-pounds plus frictional torque.

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(Post SB 49-3914) Install Brackets


Figure 501 (Sheet 3)

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1. C. (2) (e) (Post SB 49-3914) Position bracket (45, Figure 501, Sheet 3) onto torus studs
(3 locations) and containment ring (60A) as shown. Secure with nuts (30).
Tighten nuts to a torque value of 50 to 70 inch-pounds plus frictional torque.

Check Point 10: 1. Make sure that torus nuts are tightened to a torque
value of 50 to 70 inch-pounds.

2. Verify orientation of torus assembly.

CAUTION: EXERCISE CARE WHEN TIGHTENING EXHAUST PIPE


ASSEMBLY. IF EXCESSIVE FORCE IS EXERTED WHEN
TIGHTENING THE EXHAUST PIPE ASSEMBLY IT IS POSSIBLE TO
FORCE THE TURBINE WHEEL SHROUD OUT OF POSITION. AN
IMPROPERLY POSITIONED TURBINE WHEEL SHROUD COULD
RESULT IN TURBINE WHEEL RUB.

(f) (Pre SB 49-5436) Apply anti-seize compound (C5-A Copper Based) to mating
threads of turbine wheel shroud (410, Figure 501, Sheet 2) and exhaust pipe
assembly (10). Install exhaust pipe gasket (20). Screw exhaust pipe
assembly on turbine wheel shroud using 280333 spanner wrench until a snug
fit is obtained.

(Post SB 49-5436) Apply anti-seize compound (C5-A Copper Based) to


mating threads of turbine shroud (410, Figure 501, Sheet 2) and exhaust pipe
assembly (10). Screw exhaust pipe assembly on turbine wheel shroud using
280333 spanner wrench until a snug fit is obtained.

(Post SB 49-A6831) Apply anti-seize compound (C5-A Copper Based) to


mating threads of turbine shroud (410, Figure 501, Sheet 2) and exhaust pipe
assembly (10). Mark the location of the thermocouple hole at bottom of
engine assembly with marking compound (Dykem, Hi-Spot Blue, No. 107).
Screw exhaust pipe assembly on turbine wheel shroud using 280333 spanner
wrench until a snug fit is obtained. Make sure the exhaust pipe assembly is
positioned with the mark at the bottom of the engine centered approximately
between the vanes.

NOTE: Exhaust pipe assembly has left hand threads.

KEY TO FIGURE 501 (SHEET 3)

30. NUT (IPC FIG. 3) 45. BRACKET


40. WASHER 60A. CONTAINMENT RING

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Orientation of Turbine Torus and Plenum Assemblies


Figure 502

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KEY TO FIGURE 502

110. BOLT (IPC FIG. 2) 150. BRACKET


120. BOLT 160. TURBINE PLENUM ASSY

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10. EXHAUST PIPE ASSY (IPC FIG. 3) 160. TURBINE PLENUM ASSY
120. PLENUM BOLT (IPC FIG. 2) 170. TURBINE PLENUM GASKET

Determine Thickness of Turbine Plenum Shims


(Typical)
Figure 503

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1. C. (3) Determine thickness of turbine plenum shims as follows.

CAUTION: EXERCISE CARE WHEN TIGHTENING EXHAUST PIPE


ASSEMBLY. IF EXCESSIVE FORCE IS EXERTED WHEN
TIGHTENING THE EXHAUST PIPE ASSEMBLY IT IS POSSIBLE TO
FORCE THE TURBINE WHEEL SHROUD OUT OF POSITION. AN
IMPROPERLY POSITIONED TURBINE WHEEL SHROUD COULD
RESULT IN TURBINE WHEEL RUB.

NOTE: If the turbine plenum gasket (170) is not used in the final assembly, do not
install gasket (170) for these calculations.

(a) Install alignment two studs (Figure 503), 180 degrees apart in exhaust pipe
assembly (10). Install new turbine plenum gasket (170). Position turbine
plenum assembly (160) on studs 20 degrees clockwise from position noted at
disassembly. Using 280333 spanner wrench, rotate turbine plenum assembly
counterclockwise until positioned as shown in Figure 502.

(b) Temporarily secure turbine plenum assembly (160, Figure 503) using eight
plenum bolts (120).

NOTE: A maximum of two of any thickness of exhaust pipe shims shall be


used.

(c) With a depth micrometer, measure and record Dimension A at a minimum of


six places. Determine the average dimension and subtract 0.020 inch and the
thickness of the turbine plenum assembly (160) from average dimension
obtained. Result is thickness of exhaust pipe shims (180, Figure 504)
required between exhaust pipe assembly (10, Figure 503) and turbine plenum
assembly.

Check Point 15: Verify calculations and shims to obtain 0.020 interference fit
between the exhaust pipe and the plenum assembly.

(d) Remove turbine plenum assembly (160) and alignment studs.

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10. BOLT (IPC FIG. 2) 120B. BOLT


20. WASHER 130. WASHER
30. FITTING 140. WASHER
40. BOLT 150. BRACKET
50. WASHER 160. TURBINE PLENUM ASSY
60. SCREW 170. GASKET
70. EXHAUST DUCT FLANGE ASSY 180. TURBINE PLENUM SHIM
80. NUT 190. EXTERNAL SHIELD UPPER HALF
90. WASHER 200. EXTERNAL SHIELD LOWER HALF
100. NON-METALLIC WASHER 210. BOLT
110. BOLT 220. WASHER
120. BOLT 230. NUT
120A. BOLT

Install Turbine Plenum and Exhaust


Duct Flange Assembly
Figure 504

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1. C. (4) Install turbine plenum and exhaust flange duct assembly as follows.

NOTE: Install non-metallic washers adjacent to second stage diffuser


housing.

Care must be taken to ensure that turbine plenum assembly


attaching bolts do not bottom out. If bolts are found to be
bottoming, use thicker washers and/or shorter bolts. (Refer to
Figure 503 for bracket and bolt installation.)

(a) (Preferred Method) Install turbine plenum gasket (170), turbine plenum shims
(180) and turbine plenum assembly (160), position plenum assembly as
shown in Figure 502. Coat bolts (110, 120, 120A, Figure 504) with primer
(P- 415-66-611 BC with catalyst 178-66). Coat both sides of washers (90)
with grease (Aeroshell No. 5). Apply grease (Aeroshell No. 5) to the outer bolt
holes of the second stage diffuser housing. Install bolts while primer is wet,
with brackets (150), washers (90, 130, 140) and nuts (80).

(Pre SB 49-7664) Tighten plenum bolts to a torque value of 90 to 110 inch-


pounds plus frictional torque.

(Post SB 49-7664) Tighten plenum bolts to a torque value of 110 to 125 inch-
pounds plus frictional torque.

(Alternate Method) Apply a thin even layer of adhesive (RTV106) to the


mounting surface of the second stage diffuser housing. Install turbine plenum
shims (180) and plenum assembly, positioning turbine plenum assembly as
shown in Figure 502. Coat bolts (110, 120, Figure 504) with primer
(P- 415-66-611BC with Catalyst C1178-66). Coat both sides of washers (90)
with grease (Aeroshell No. 5). Apply grease (Aeroshell No. 5) to the outer bolt
holes of the second stage diffuser housing. Install bolts, (110, 120) while
primer is wet, with brackets (150), washers (90, 130, 140) and nuts (80).
Tighten plenum bolts to a torque value of 90 to 110 inch-pounds plus frictional
torque. Remove all excess adhesive on inner diameter of second stage
diffuser housing mounting surface.

(a) (POST SB 49-7542) (Preferred Method) Install turbine plenum gasket (170),
turbine plenum shims (180) and turbine plenum assembly (160), position
plenum assembly as shown in Figure 502. Coat bolts (110, 120, 120A, Figure
504) with primer (P- 415-66-611 BC with catalyst 178-66). Coat both sides of
washers (90) with grease (Aeroshell No. 5). Apply grease (Aeroshell No. 5) to
the outer bolt holes of the second stage diffuser housing. Install the external
shield upper half (190) and lower half (200) and install bolts (120B, 210).
Install washers (220) and nuts (230) onto bolts (210). Install bolts (110,120,
120B) while primer is wet, with brackets (150), washers (90, 130, 140) and
nuts (80). Install the external shield upper half (190), lower half (200) and
install bolts (120B, 210). Install washers (220) and nuts (230) onto bolts (210).

(Pre SB 49-7664) Tighten plenum bolts to a torque value of 90 to 110 inch-


pounds plus frictional torque.

(Post SB 49-7664) Tighten plenum bolts to a torque value of 110 to 125 inch-
pounds plus frictional torque.

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1. C. (4) (a) (Alternate Method) Apply a thin even layer of adhesive (RTV106) to the
mounting surface of the second stage diffuser housing. Install turbine plenum
shims (180) and plenum assembly, positioning turbine plenum assembly as
shown in Figure 502. Coat bolts (110, 120, 120A, Figure 504) with primer
(P- 415-66-611BC with Catalyst C1178-66). Coat both sides of washers (90)
with grease (Aeroshell No. 5). Apply grease (Aeroshell No. 5) to the outer bolt
holes of the second stage diffuser housing. Install the external shield upper
half (190) and lower half (200) and install bolts (120B, 210). Install washers
(220) and nuts (230) onto bolts (210). Install bolts, (110, 120, 120B) while
primer is wet, with brackets (150), washers (90, 130, 140) and nuts (80).
Tighten plenum bolts to a torque value of 90 to 110 inch-pounds plus frictional
torque. Remove all excess adhesive on inner diameter of second stage
diffuser housing mounting surface.

NOTE: Make sure adhesive (RTV 106) is applied in a thin even layer. This
will help prevent too much collection of adhesive on the inner
diameter of the second stage diffuser housing mounting surface.

(b) Coat mating surface of exhaust duct flange assembly (70) with adhesive
(RTV106). Make sure there are no voids or gap in adhesive. Position
exhaust duct flange assembly on plenum assembly (160) with the exhaust gas
temperature thermocouple and pneumatic thermostat mount positioned as
shown in Figure 502. Check alignment of flange bolt holes. Movement of
exhaust pipe assembly may be required to obtain alignment.

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Recheck Radial Clearance between Turbine


Wheel and Turbine Wheel Shroud
Figure 505

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CAUTION: AFTER TIGHTENING FLANGE ASSEMBLY, WIPE EXCESS


COMPOUND (APPLIED IN PREVIOUS STEP (a)) FROM ENDS OF
INSTALLED BOLTS BY REACHING THROUGH THE COMBUSTOR
UNIT OPENING IN THE PLENUM.

1. C. (4) (c) Coat threads of bolts (40, Figure 504) and screws (60) with anti-seize
compound (C5-A Copper Based), then install bolts, screws and washers (50)
as shown. Tighten bolts and screws to a torque value of 90 to 110 inch-
pounds plus frictional torque.

(d) Recheck radial clearance between turbine wheel and shroud as outlined in
ATA No. 49-23-04.

(e) Apply a layer of adhesive (RTV 106) between fitting (30) and mating surface.
Install fitting and attach with washers (20) and bolts (10). Tighten bolts to a
torque value of 70 inch-pounds.

(5) Recheck radial clearance between turbine wheel and shroud as follows. (Refer to
Figure 505.)

NOTE: Misalignment of shroud, exhaust pipe and turbine plenum may cause
change in radial clearance.

(a) Place engine in the horizontal running position (6 o'clock down) and check
radial clearance between turbine wheel and turbine wheel shroud. Radial
clearance in any direction between turbine wheel and turbine wheel shroud
with all radial play removed shall be 0.015 inch minimum and within 0.005 inch
of the clearance measured 180 degrees away with all radial play removed. If
clearance measured 180 degrees away with all radial play removed. If
clearance is not within limits, disassemble combustion and exhaust section as
required to determine cause.

Check Point 20: Verify 0.015 inch minimum radial clearance between wheel
and turbine wheel shroud with the engine in the running
position (6 o'clock down).

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Assemble Combustor Unit


Figure 506

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1. C. (6) Assemble combustor unit as follows. (Refer to Figure 506.)

(a) Install elbow (190) with nut (210) and new packing (200) into fuel atomizer
assembly (130).

(b) Place combustion liner assembly (230A) in combustor cap (220) and align
mounting holes for igniter plug (40) and fuel atomizer assembly (130).

CAUTION: ENSURE PACKING GROOVE IN ATOMIZER WASHER IS


INSTALLED FACING COMBUSTOR CAP.

(c) Install one packing (160A) into groove of washer (170C) and remaining
packing (160A) into packing groove of fuel atomizer assembly (130). Install
fuel atomizer assembly and washer with new packings on combustor cap
(220) and combustion liner assembly (230A). Coat threads of attaching bolts
(140) with anti-seize compound (C5-A Copper Based). Install washers (150)
and bolts. Tighten bolts enough to allow fuel atomizer assembly to shift on
combustor cap.

(d) Install igniter plug (40) and new gasket (80) into combustor cap (220) and
through combustion liner assembly (230A). Coat threads of bolts (50) with
anti-seize compound (C5-A Copper Based). Secure igniter plug with retainer
(70), washers (60) and bolts (50). Tighten bolts enough to allow igniter plug to
shift on combustor cap.

(e) Install reducer orifice (90) with new packing (100). Tighten reducer orifice to a
torque value of 75 inch-pounds. Install tags (110, 120).

KEY TO FIGURE 506

10. COUPLING (IPC FIG. 1) 130. FUEL ATOMIZER ASSY


20. PACKING 140. BOLT
-30. COMBUSTOR UNIT 150. WASHER
40. IGNITER PLUG 160A. PACKING
50. BOLT 170C. WASHER
60. WASHER 180. PLATE
70. RETAINER 190. ELBOW
80. GASKET 200. PACKING
90. REDUCER ORIFICE 210. NUT
100. PACKING 220. COMBUSTOR CAP
110. TAG 230A. COMBUSTION LINER ASSY
120. TAG

- ITEM NOT ILLUSTRATED

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NOTE: (Pre SB 49-3914) Perform containment ring (60A, Figure 501


(Sheet 3)) security check by reaching into the combustor liner
opening in the turbine plenum assembly to make sure that the
containment ring cannot be moved to a "cocked" position.
Freedom of the ring to "float" is normal, however, axial movement
shall not exceed one-eighth inch.

(Post SB 49-3914) Perform containment ring (60A, Figure 501


(Sheet 3)) security check by reaching into the combustion liner
opening in the turbine plenum assembly to make sure that the
containment ring cannot be moved with bracket installed.

Make sure that fuel atomizer and igniter plug bolts are loose
enough to allow self alignment of combustion liner assembly
(230A) and torus opening.

1. C. (6) (f) Install new packing (20) and combustor unit (40 through 230A) into turbine
plenum assembly. Install new coupling (10) with nut on coupling pointing
downward. Tighten nut on coupling to a torque value of 50 to 70 inch-pounds
plus frictional torque, then lockwire coupling nut, per SAE-AS567.

(g) Tighten bolts (50) to a torque value of 70 inch-pounds plus frictional torque
and lockwire, per SAE-AS567.

(h) Tighten bolts (140) to a torque value of 50 inch-pounds and lockwire per
SAE-AS567. Install plate (180).

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COMBUSTION AND EXHAUST SECTION

1. Fits and Clearances

A. Observe Dimensional Values

(1) Fits, clearances and build dimensions are provided in Table 601.

(2) A description of, and limits for, these fits and clearances are located in the table.

Table 601. Fits and Clearances

Figure Limit
No. Nomenclature/Description (inches)

503 Clearance between plenum assembly 0.015 to 0.025


and shims before tightening bolts.

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1. B. Assembly Torque Values

NOTE: Fasteners installed through essentially in elastic boundaries will first be tightened to
remove visible clearance between parts. During this initial tightening of the
fastener, the "run-down" resistance shall be noted on the last rotation just before
establishment of a tensile preload in the fastener. The fastener shall then be given
an additional tightening movement by a steady sweep of the wrench to produce a
final torque, as determined by feel, that is approximately equal to the run-down
torque plus the values shown in Table A for the respective thread size. This
procedure will produce 35 percent accuracy which is adequate for all items not
listed under torque values below. As a further assistance, Table B gives general
guidelines for obtaining the final torque.

Table A:

Torque (in.-lb)
Thread Size Aluminum Fastener CRES Fastener

6 5 10
8 10 20
10 15 35
1/4 45 75
5/16 80 160
3/8 140 275

Table B:

Thread Size Approximate Rotation After Run-Down

6-32 45 deg
8-32 60 deg
10-24 40 deg
1/4-20 40 deg
3/8-24 60 deg

Fasteners installed through elastic boundaries (sealed by means of a diaphragm or similar


elastomeric gasket) shall be tightened uniformly to effect a pressure-tight seal.

(1) Special torque values are provided in Table 602.

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Table 602. Special Torque Values

Figure Item Torque


No. No. Nomenclature/Description (In.-lb)

501 320 Nozzle Nuts 15 to 20

502, 30 Torus Attaching Nuts 50 to 60


502A

505 110 Plenum Bolts PN MS9490-22 90 to 110


120 Plenum Bolts PN NAS1004-3A 70
40 Flange Bolts 90 to 110
60 Flange Screws 90 to 110

507 10 Coupling 50 to 70
50 Bolt 70
90 Reducer Orifice 75
140 Bolt 50

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COMBUSTION AND EXHAUST SECTION

1. Special Tools, Fixtures and Equipment

A. General

Procedures shown in this publication, that need special tools, fixtures and equipment, can be
done with the use of special tools, fixtures and equipment shown in Table 901. The items can
be purchased from Honeywell Engines, Systems & Services, Ground Support Equipment, 717
N. Bendix Dr., South Bend, IN 46628-1000, Telephone: 574-231-3987.

Table 1001. Special Tools, Fixtures and Equipment

Item Source/
No. Nomenclature Use Part No.

NOTE: Equivalent substitutes may be used for listed items.

1. Spanner Wrench Provides leverage to remove 280333


or install threaded tailpipe.

2. Portable Engine Facilitate disassembly, assembly 281270-0-3


Stand or transportation of engine.
(Replaced by 833063-1)

3. Engine Mount Support engine during 284125-1-1


(Replace by maintenance. (Replaced by
PN 2024502-1) 2024502-1)

4. Engine Mount Support engine during 284126-1-1


(Replaced by maintenance. (Replaced by
PN 2024502-1) 2024502-1)

5. Engine Adapter Adapts and supports 281893-1


(Replaced by accessory drive gearcase
PN 834119-2) housing assembly to stand
PN 281270-0-3.

6. Portable Engine Secures and holds engine in 833063-1


Stand (Replaced by various positions during
PN 833565-2) assembly, disassembly and
testing. Also used to transport
engine.

7. Portable Engine Secures and holds engine in 833565-2


Stand (Replaces various positions during
PN 833063-1) assembly, disassembly and
testing. Also used to transport
engine.

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Table 1001. Special Tools, Fixtures and Equipment (Cont)

Item Source/
No. Nomenclature Use Part No.

8. Engine Adapter Adapts and supports 834119-2


(Replaces PN accessory drive gearcase
281893-1) housing assembly to stand
PN 833565-2.

9. Engine Mount Support engine during 2024502-1


(Replaces PN maintenance.
284125-1-1 and
284126-1-1)

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ENGINE POWER SECTION

1. Disassembly

A. Perform General Disassembly

Obvious steps or procedures necessary to disassemble the engine, such as removal of


lockwire, attaching parts, or simple components are omitted from the text. Removal of
plumbing, electrical and external parts installation may be accomplished whenever parts are
accessible. In general, disassembly should be accomplished in sequence of index numbers
assigned to individual exploded views. Variations from this sequence and special processes
or methods are specifically mentioned in the text. The following general procedures should be
observed throughout the disassembly operations.

(1) Place each part disassembled on a clean workbench in the order of removal 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 or 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 oil, using oil of specification used in the
engine lubrication system. Cover all parts with clean paper or suitable coverings
unless cleaning and inspection is to be accomplished immediately.

(5) Do not disassemble tube assemblies, hose assemblies, wiring harness assemblies,
rivet assemblies, or staked or press-fit parts (except seals and bearings) or remove
nameplates, modification plates, lubrication plates, decals, studs, or their 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 a manner consistent with
good shop practice.

(6) Always keep ports, bores, and passages of assemblies or components with tape or
suitable closures between overhaul procedures. Cover large openings with cardboard
taped in place.

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NOTE: Do not use tape to cover openings or connections on fuel or lubrication


system components.

1. A. (7) During various stages of disassembly, examine all parts and assemblies for signs of
scoring, burring, or other defect. Note physical conditions which will not be apparent
after cleaning. Tag involved parts before they are cleaned and laid out for detail
inspection. Check additionally for evidence of damage caused by improper
procedures at previous overhauls. Report such damage in accordance with current
practice.

(8) Record manner of lockwiring for duplication at assembly.

B. Disassemble Engine Power Section

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Engine Power Section


(Partial Breakdown)
Figure 101

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1. B. (1) Disassemble engine power section components as follows. (Refer to Figure 101.)

(a) Remove nuts (10) and washers (20), then remove gearcase assembly (30),
packing (40), torsion shaft (50) and spring (60). Discard packing. Refer to
ATA No. 49-26-02 for overhaul of gearcase assembly.

(b) Remove screws (150) and inlet plenum screen assembly (160).

(c) Remove nut (137), bolts (70, 90), screws (120, 125, 135) and washers (80,
100, 110, 130, 136), then remove compressor inlet plenum assembly (170)
from compressor and turbine assembly (180). Discard packing (140). Refer
to ATA No. 49-23-04 for overhaul of compressor and turbine assembly.

KEY TO FIGURE 101

10. NUT (IPC FIG. 1) 125. SCREW


20. WASHER 130. WASHER
30. GEARCASE ASSY 135. SCREW
40. PACKING 136. WASHER
50. TORSION SHAFT 137. NUT
60. SPRING 140. PACKING
70. BOLT 150. SCREW
80. WASHER 160. INLET PLENUM SCREEN
90. BOLT ASSY
100. WASHER COMPRESSOR INLET
110. WASHER 170. PLENUM ASSY
120. SCREW 180. COMPRESSOR AND
-120A. SCREW TURBINE ASSY

- ITEM NOT ILLUSTRATED

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1. B. (2) Remove baffle assemblies as follows. (Refer to Figure 103.)

NOTE: Do not disassemble items (70, 80) unless inspection reveals damage.

(a) Remove screws (20, 100), washers (30, 120) and baffle assemblies (40
through 90 and 100) from compressor and turbine assembly.

20. SCREW (IPC FIG. 3) 80. ANCHOR NUT


30. WASHER 90. BAFFLE
40. BOLT 100. BAFFLE ASSY
50. WASHER 110. SCREW
60. BRACKET 120. WASHER
70. RIVET

Engine Power Section


(Partial Breakdown)
Figure 103

NOTE: Figure 102 intentionally omitted.

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ENGINE POWER SECTION

1. Cleaning

A. Follow General Cleaning Instructions

Table 201. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Corrosion-preventive compound Commercially available


(MIL-C-6529, Type III)

(1) Perform all cleaning procedures in accordance with general cleaning instructions
provided in Standard Practices Manual (SPM), ATA No. 20-00-02/70-00-01.

(2) Protect all cleaned parts in accordance with instructions provided in SPM.

B. Clean Component Parts

NOTE: More than one cleaning method may be specified for a particular part or assembly,
e.g., a part may require removal of heavy grease deposits using a brush and
petroleum solvent followed by vapor degreasing for final cleaning. An additional
cleaning method may be required for corrosion removal. If a particular cleaning
method is not required due to the condition of the part, it may be omitted, however
only those cleaning methods specified for that part may be used.

(1) Refer to following figures for recommended cleaning methods for specific parts.

NOTE: Cleaning method numbers and alpha suffix shown in following lists
correspond to numbers and alpha suffix assigned to cleaning methods
described in the SPM. The cleaning method instructions in the SPM refer
to additional instructions provided therein for preparation of solutions used
in performing the cleaning methods.

(2) Refer to Standard practices Manual (SPM) for instructions pertaining to each of the
cleaning methods specified in cleaning methods lists presented herein.

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1. B. (3) Heat discoloration of metal surface is not objectionable; however, scale which may
become loose and damage the unit shall be removed. Carbon residue and
combustion products shall be removed.

(4) Corrosion products wherever they appear shall be removed and the base metal
treated to prevent further corrosion before reassembly.

(5) Steel and 400 series stainless steel parts require the application of corrosion-
preventive compound (MIL-C-6529, Type III) after cleaning to prevent rust and
corrosion.

CAUTION: AN ASSEMBLY SHALL NOT BE CLEANED IN A SOLUTION THAT IS


DETRIMENTAL TO ONE OF THE PARTS IN THE ASSEMBLY.

(6) Clean dissimilar metals as follows:

(a) Analyze assemblies that combine dissimilar metals carefully and determine
types of materials.

(b) Clean assemblies containing brass, bronze, steel, and cadmium, using
methods applicable to the base metal involved. Assemblies containing these
materials are not affected by chromic acid or hydrofluoric acid.

(7) Place parts in clean plastic bags or equivalent containers after cleaning, for protection
from contaminants. Ports and orifices shall be capped, plugged, or sealed.

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Engine Power Section


(Partial Breakdown)
Figure 201

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Figure 201. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B J

All standard metallic hardware X X

50 Torsion Shaft X

170 Compressor Inlet X


Plenum Assy

NOTE: Figure 202 intentionally omitted.

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Figure 203. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B J

90, 100 Baffle Assy X X X

Engine Power Section


(Partial Breakdown)
Figure 203

NOTE: Figure 202 intentionally omitted.

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ENGINE POWER SECTION

1. Inspection/Check

NOTE: Inspection/Checks shall be performed in accordance with instructions provided in Standard


Practices Manual ATA No. 20-00-02/70-00-01. Reference to this manual throughout this
section will be indicated by the abbreviation SPM.

A. Perform General Checks

(1) Check threaded parts for stripped, galled or crossed threads. Replace part if
damaged.

(2) Visually check fittings for crossed, galled, peened or stripped threads. Check for
deterioration and contamination. Replace part that does not meet Inspection/Check
requirements.

(3) Visually check brackets and supports for physical damage that would impair function.
Replace part that does not meet Inspection/Check requirements.

B. Detailed Inspection/Check

Items denoted by an X in the following figures under Detail Inspection/Check pertain to ATA
No. 49-21-73, Inspection/Repair Manual.

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Engine Power Section


(Partial Breakdown)
Figure 301

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Figure 301. Inspection/Check

Item Detailed
No. Nomenclature Inspection/Check

50 Torsion Shaft X

60 Spring X

160 Inlet Plenum Screen Assy X

170 Compressor Inlet Plenum Assy X

NOTE: All other items of Figure 301 are limited to the requirements of the SPM or replacement.

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Figure 303. Inspection/Check

Item Detailed
No. Nomenclature Inspection/Check

90, 100 Baffle Assy X

NOTE: All other items of Figure 303 are limited to the requirements of the SPM or replacement.

Engine Power Section


(Partial Breakdown)
Figure 303

NOTE: Figure 302 intentionally omitted.

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ENGINE POWER SECTION

1. Repair

Refer to ATA No. 49-21-73.

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ENGINE POWER SECTION

1. Assembly

Table 501. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Adhesive sealant (Silastic 732 RTV) Dow Corning Corp, P.O. Box 995, 3901 S.,
(MIL-A-46146) Saginaw Rd., Midland, MI 48640

Lubricant (OS-124 or Santovac 5) Monsanto Co., Fibers Business Unit,


800 N. Linderbergh Blvd., St. Louis,
MO 63167

Oil (MIL-PRF-7808, Type I or Commercially available


MIL-PRF-23699, Type II)

A. General Assembly Instructions

Assembly operations shall be performed with attention to details outlined in this manual.
Highest standards of precision shop procedures shall be employed throughout the entire
assembly. Fits and tolerances shall be closely maintained. The following general instructions
shall be observed throughout the assembly procedures.

(1) Exercise extreme care to prevent dirt, dust, or foreign particles from entering the
engine. If any foreign particle enters the engine during assembly, stop assembly until
the foreign particle is located and removed, even if this causes considerable
disassembly.

(2) When special measurements for shimming or fitting are made on parts or on
assembled parts prior to their installation in the next higher assembly, tag these parts
as measured components of the higher assembly and keep with that assembly. If
damage or other reason causes replacement of a measured component, repeat all
measurements which include the part, using the new part.

(3) Never use extreme force in the assembly of the unit. If difficulty is encountered,
disassemble the unit and inspect for burrs or other interferences.

(4) On through hole applications when extreme minimum stack conditions result in
excessive protrusion of the screw or bolt through either the threaded part or nut, a
shorter standard screw or bolt may be substituted providing the substitution results in a
minimum of one full thread protrusion beyond the face of the threaded part or nut.

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NOTE: No substitutions of screw lengths are authorized for blind hole applications.

1. A. (5) On through hole applications when assembling parts which, through extreme stack
conditions, result in a screw or bolt protrusion of less than one full thread beyond the
face of the threaded part of nut, a longer standard screw or bolt may be substituted in
order to gain a minimum of one full thread protrusion.

B. Safety Fastening Instructions

Attaching parts may be locked using various methods as applicable to the part. Thee methods
include use of self-locking nuts, and use of lockwire. The following general instructions shall
be observed when installing lockwire devices.

(1) Duplicate the locking method as noted during the disassembly.

NOTE: During the "run-down" of a self-locking nut the run-down resistance


(frictional torque) shall be noted on the last rotation just before removing
clearance between parts. The self-locking nut then shall be tightened to
the specified torque value plus the noted frictional torque.

(2) Install self-locking nuts using standard shop procedures for the type nut being used.

(3) When a lockwire is used, install lockwire per SAE-AS567.

C. Assemble Engine Power Section

NOTE: Perform assembly procedures for compressor and turbine assembly (ATA 49-23-
04), accessory drive gearcase assembly (Section 49-26-02) and the combustion
and exhaust section (Section 49-20-04) before assembling the engine power
section. Install components from the engine section (Section 49-20-00) as
applicable or feasible during assembly of engine power section.

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20. SCREW (IPC FIG. 1) 100. BAFFLE ASSY


30. WASHER 110. SCREW
90. BAFFLE 120. WASHER

Installation of Baffle Assemblies


Figure 501

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1. C. (1) Install baffle assemblies as follows. (Refer to Figure 501.)

(a) Install bracket (60) on baffle assembly (70) and secure with washer (50) and
bolt (40). Position baffle assembly (40 through 90) between inlet housing
assembly and diffuser assembly and secure with screws (20) and washers
(30).

(b) Position baffle assembly (100) between inlet housing assembly and diffuser
assembly and secure with screws (110) and washers (120). Tighten screws
(20, 100) to a torque value of 30 to 35 inch-pounds.

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Installation of Compressor Inlet Plenum Assembly


Inlet Screen Assembly and Gearcase Assembly
Figure 502

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1. C. (2) Assemble compressor and turbine assembly, compressor inlet plenum assembly, inlet
screen assembly and gearcase assembly as follows. (Refer to Figure 502.)

NOTE: Install washers (110) as required between compressor inlet plenum


assembly (170) and compressor and turbine assembly (180) to prevent
damage to plenum attaching brackets.

If Part No. 698195-7 is used, apply a thin coating of adhesive (RTV 732) to
the contact areas of the diffuser housing and inlet plenum. (Packing is not
required for this installation.)

(a) Install new packing (140) and compressor inlet plenum assembly (170).
Secure compressor inlet plenum assembly with bolts (70, 90), screws (120,
125, 135), washers (80, 100, 110, 130, 136) and nuts (137). Tighten bolts
(70) to a torque value of 160 to 190 inch-pounds. Tighten bolts (90) and
screws (120, 125, 135) to a torque value of 20 to 25 inch-pounds. Lockwire
nut (137) to screw (125), per SAE-AS567.

KEY TO FIGURE 502

10. NUT (IPC FIG. 1) 125. SCREW


20. WASHER 130. WASHER
30. GEARCASE ASSY 135. SCREW
40. PACKING 136. WASHER
50. TORSION SHAFT 137. NUT
60. SPRING 140. PACKING
70. BOLT 150. SCREW
80. WASHER 160. INLET PLENUM SCREEN ASSY
90. BOLT 170. COMPRESSOR INLET PLENUM
100. WASHER ASSY
110. WASHER 180. COMPRESSOR AND TURBINE
120. SCREW ASSY
-120A. DELETED

- ITEM NOT ILLUSTRATED

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1. C. (2) (b) Install inlet plenum screen assembly (160) to compressor inlet plenum
assembly (170) and secure with screws (150). Tighten screws to a torque
value of 20 to 25 inch-pounds.

CAUTION: DETERMINATION OF TURBINE WHEEL SHAFT PLUG DEPTH IS


MANDATORY AS USE OF INCORRECT TORSION SHAFT COULD
RESULT IN DISENGAGEMENT OF ACCESSORY GEARCASE
FROM COMPRESSOR AND TURBINE ASSEMBLY.

(c) Determine depth of plug in turbine wheel shaft; measure distance from end of
shaft to plug located inside shaft. If distance is less than four inches use
Torsion Shaft, Part No. 968696-1; if more than four inches use Torsion Shaft,
Part No. 296291-2.

Check Point 10: 1. Verify correct part number and acceptance of


accessory assembly.

2. Verify cleanliness and condition of pilot diameters of


accessory assembly and compressor inlet housing.

3. Verify spring, shaft and presence of packing in


compressor and turbine shaft.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(d) Coat splines or torsion shaft (50) Part No. 969291-2 or 968696-1 with oil
(MIL-PRF-7808 or MIL-PRF-23699).

(e) Insert spring (60) and lubricated torsion shaft into shaft of compressor and
turbine assembly (180). Apply a thin film of oil (MIL-PRF-7808 or
MIL-PRF-23699) or lubricant (OS-124 or Santovac) to new packing (40), then
install packing.

(f) Install gearcase assembly (30). Make certain external splines on torsion shaft
(50) are aligned with internal splines of shaft in gearcase assembly. Secure
gearcase assembly in place with washers (20) and nuts (10). Tighten nuts to
a torque value of 40 to 50 inch-pounds.

D. Assemble Engine Section

Refer to Section 49-20-00 for instructions relative to assembly of engine section.

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ENGINE POWER SECTION

1. Fits and Clearances

Tightening torque of specific screws, nuts and bolts is listed in Table 601.

NOTE: Where two torque values are listed for bolts with nuts, the lower value is used when nut is
tightened and bolt is held stationary and the higher value is used when bolt is tightened and
nut is held stationary. Torque values listed do not include frictional torques developed from
self-locking devices. All other torque values represent a minimum to maximum range.

Table 601. Torque Values

Figure Item Torque


No. No. Nomenclature/Description (in.-lb)

501 20, 110 Screw 30 to 35

502 10 Nut 40 to 50

70 Bolt 160 to 190

90 Bolt 20 to 25

120, 125 Screw 20 to 25


135, 150

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COMPRESSOR AND TURBINE ASSEMBLY

1. Deleted. (Refer to ATA No. 49-23-04)

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ACCESSORY DRIVE GEARCASE ASSEMBLY

1. Disassembly

A. General Disassembly

Disassembly should be accomplished in sequence of index numbers assigned to individual


exploded views. Variations from this sequence and special processes or methods are
specifically mentioned in the text. The following general procedures should be observed
throughout the disassembly operations.

(1) Place each part disassembled on a clean workbench in the order of removal in
preparation for cleaning and inspection. Keep hardware and small parts together in
trays.

(2) Provide proper coverings or supports to protect shaft, gears, and studs, and projecting
parts from damage.

(3) Do not use steel or lead hammers directly on assemblies or their parts. Use cellulose-
tipped hammers or 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 cover all parts with clean paper or suitable coverings unless
cleaning and inspection is to be accomplished.

(5) Do not disassemble riveted assemblies, or staked or press-fit parts (except seals and
bearings) or remove nameplate, studs, or their 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 a manner consistent with good shop practice.

NOTE: Do not use tape to cover openings or connections.

(6) Always keep ports, bores, and passages of assemblies or components sealed with
suitable closures between overhaul procedures.

(7) During various stages of disassembly, examine all parts and assemblies for signs of
scoring, burning, or other defects. Note physical conditions which will not be apparent
after cleaning. Tag involved parts before they are cleaned and laid out for detail
inspection. Check additionally for evidence of damage caused by improper
procedures at previous overhauls. Report such damage in accordance with current
practice.

NOTE: Discard all packings, seals and bearings at disassembly, regardless of


condition.

(8) Record manner of lockwiring for duplication at assembly.

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1. B. Disassemble Accessory Drive Gearcase Assembly

(1) Disassemble bearing and seal retainers as follows: (Refer to Figure 101.)

NOTE: Do not disassemble bushings, inserts, pins, studs or sleeves from matched
housing assembly set unless otherwise instructed in the text or
necessitated by replacement of a part.

(a) Remove screws (10), washers (20), and bearing retainer (30) with assembled
parts. Remove packing (40) and press seal stator (60) from bearing retainer.
Discard seal stator and packing.

Gearcase Assembly (Partial Breakdown)


(Bearing and Seal Retainers)
Figure 101

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1. B. (1) (b) Straighten tab of key (80). Hold output shaft using 285418-1-1 wrench
adapter, and remove nut (90) using 253562-1 spanner wrench. Remove
spacer (100), key (80), shim washer (70), seal rotor (110) and washer (120).
Discard key and seal rotor.

(c) Remove nut (130), washer (140), seal retainer (150) with assembled parts.
Remove ring (160), and press seal (170) from bearing retainer. Remove
packing (180). Discard packing and seal.

(d) Remove screw (190), bearing retainer (200). Remove plug (210) and packing
(220) from bearing retainer (250). Remove bolts (230), washers (240) and
bearing retainer (250) with packing (260). Remove screws (270) and bearing
retainer (280). Discard packings.

(e) Remove screws (290), bearing retainer (300), shim (310), spring washer (320)
and guide (330).

(f) Remove bolts (340), washers (350), bearing retainer (360) with packing (370).
Remove screws (380), washers (390), oil nozzle assembly (400) with packing
(410). Discard packings.

KEY TO FIGURE 101

10. SCREW 210. PLUG


20. WASHER 220. PACKING
30. BEARING RETAINER 230. BOLT
40. PACKING 240. WASHER
-50. BEARING SEAL 250. BEARING RETAINER
60. SEAL STATOR 260. PACKING
70. SHIM WASHER 270. SCREW
80. KEY 280. BEARING RETAINER
90. NUT 290. SCREW
100. SPACER 300. BEARING RETAINER
-105. BEARING SEAL 310. SHIM
110. SEAL ROTOR 320. SPRING WASHER
120. WASHER 330. GUIDE
130. NUT 340. BOLT
140. WASHER 350. WASHER
150. SEAL RETAINER 360. BEARING RETAINER
160. RING 370. PACKING
170. SEAL 380. SCREW
180. PACKING 390. WASHER
190. SCREW 400. OIL NOZZLE ASSY
200. BEARING RETAINER 410. PACKING

- ITEM NOT ILLUSTRATED

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Gearcase Assembly (Partial Breakdown)


(Gears and Gearshaft Assemblies)
Figure 102

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1. B. (2) Disassemble gears and gearshaft assemblies as follows. (Refer to Figure 102.)

CAUTION: EXERCISE CARE WHEN SEPARATING MATCHED HOUSING


ASSEMBLIES (570, 580) TO AVOID DISPLACEMENT OF
BUSHINGS.

(a) Place accessory drive gearcase assembly on workbench with input housing
assembly (570) face up.

(b) Remove nuts (10), washers (20, 70) and bolts (30, 80).

NOTE: Do not disassemble bushings, inserts, pins, studs or sleeves from


matched housing assembly set unless otherwise instructed in the
text or necessitated by replacement of a part.

CAUTION: EXERCISE CARE WHEN REMOVING PINS (490) TO AVOID


DISPLACEMENT OF BUSHINGS.

(c) Use the 835668-1 removal fixture and remove alignment pins (490) from input
and output housing assemblies (570, 580).

(d) Install two jack screws, having 1/4-20NC-3B threads, in threaded holes of
input housing assembly (570).

(e) Separate input and output housing assemblies (570, 580) by threading each
jack screw down equally into blind holes in output housing assembly (580).

(f) Carefully separate matched housing assembly set.

(g) Remove jack screws.

KEY TO FIGURE 102

10. NUT 230. BEARING 410. IDLER GEAR SHAFT


20. WASHER 250. PLUG 420. BEARING
30. BOLT 260. MULTI-SPEED 440. PLUG
40. NUT GEARSHAFT 450. OUTPUT DRIVE
50. WASHER 290. BEARING GEARSHAFT ASSY
60. PACKING W/RTNR 300. IDLER GEAR ASSY 460. BEARING
70. WASHER 310. NUT 470. ANTI-ROTATION PIN
80. BOLT 320. PAWL DRIVE JAW 480. PINION GEAR
90. PACKING 330. BEARING 490. ALIGNMENT PIN
100. TUBE 340. STARTER DRIVE 500. SCREW
110. NOZZLE CLUSTER GEAR 510. PACKING
120. GASKET 350. BEARING 520. LUBRICATING NOZZLE
130. BEARING 360. FAN IDLER SPUR 530. BEARING
150. GEARSHAFT GEAR 540. BEARING
180. PLUG 370. SPACER 550. PACKING
190. BEARING 380. BEARING 570. INPUT HOUSING ASSY
210. PLUG 390. WASHER 580. OUTPUT HOUSING ASSY
220. GEARSHAFT 400. IDLER SPUR GEAR

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1. B. (2) (h) Remove tube (100) and nozzle (110) with packings (90). Remove gasket
(120). Discard packings and gasket.

NOTE: Do not remove plugs (180, 210, 250) from gearshafts (150, 220,
260) unless required by inspection.

(i) Lift gearshafts (150, 220), multi-speed gearshaft (260), idler gear assembly
(300), and fan idler spur gear (360), with attached bearings (130, 190, 230,
290, 350) out of output housing assembly (580). Press bearings from
gearshafts and gear.

1 Remove bearing (290) from gear (300) using puller plate 2024501-3
and adapter 2024500-3 on stub shaft end of shaft and adapter
2024500-4 on splined end.

2 Remove bearings (130,190) from gearshafts (150, 220) using puller


plate 2024501-6 and adapter 2024500-8 on stub end of shaft and
adapter 2024500-6 on splined end.

3 Remove bearing (350) from gearshaft (360) using puller plate


2024501-5 and adapter 2024500-7.

4 Remove bearing (230) from gearshaft (260) using puller plate


2024501-4 and adapter 2024500-5 on stub end of shaft and adapter
2024500-6 on splined end.

(j) Lift starter drive cluster gear (340) with assembled parts from output housing
assembly (580). Hold pawl drive jaw (320) using 285090-1-1 spanner wrench
and remove nut (310). Remove pawl drive jaw (320) and bearings (330) from
gear. Using puller plate 2024501-3 and adapter 2024500-3 on stub shaft end,
and adapter 2024500-4 on splined end. Discard nut.

(k) Remove nut (40), washer (50), packing with retainer (60), and slide idler gear
shaft (410) with assembled parts out of output housing assembly (580).
Remove spacer (370), bearings (380), washer (390) and idler spur gear (400)
from idler gear shaft (410). Discard packing with retainer and bearings.

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CAUTION: MAKE SURE THAT PINION GEAR (480) WITH ATTACHED


OUTPUT DRIVE BEARINGS (460) REMAINS WITH GEARSHAFT
AS GEARSHAFT ASSEMBLY IS PRESSED FROM OUTPUT
HOUSING ASSEMBLY (580).

NOTE: Do not remove plug (440) from output drive gearshaft assembly
(450) unless required by inspection.

1. B. (2) (l) Press output drive gearshaft assembly (450) out of bearing (530). Using
support fixture 2024499-1 and adapter 2024500-5 with arbor press.

(m) Remove bearing (420) from gearshaft. Use puller plate 2024501-1 and
adapter 2024500-1.

(n) Remove bearings (460) with anti-rotational pins (470) from pinion gear (480).
Using puller plate 2024501-2 and adapter 2024501-2.

(o) Remove screw (500), lubricating nozzle and stud assembly (520) with packing
(510). Discard packing.

(p) Remove bearing retainer (540) with bearing (530) and packing (550) from
output housing assembly (580). Press bearing from retainer. Discard
packing.

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ACCESSORY DRIVE GEARCASE ASSEMBLY

1. Cleaning

A. General Cleaning Instructions

(1) Perform all cleaning procedures in accordance with general cleaning instructions
provided in Standard Practices Manual (SPM), ATA No. 20-00-02/70-00-01.

(2) Protect all cleaned parts in accordance with instructions provided in SPM.

B. Clean Component Parts

NOTE: More than one cleaning method may be specified for a particular part or
assembly, e.g., a part may require removal of heavy grease deposits using
a brush and petroleum solvent followed by vapor degreasing for final
cleaning. An additional cleaning method may be required for corrosion
removal. If a particular cleaning method is not required due to the condition
of the part, it may be omitted, however only those cleaning methods
specified for that part may be used.

(1) Refer to following figures for recommended cleaning methods for specific parts.

NOTE: Cleaning method numbers and alpha suffix shown in following lists
correspond to numbers and alpha suffix assigned to cleaning methods
described in the SPM. The cleaning methods instructions in the SPM, refer
to additional instructions provided therein for preparation of solutions used
in performing the cleaning methods.

(2) Refer to Standard Practices Manual (SPM) for instructions pertaining to each of the
cleaning methods specified in cleaning methods lists presented herein.

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Accessory Drive Gearcase Assembly


(Bearing and Seal Retainers)
(Partial Breakdown)
Figure 201

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Figure 201. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B C D E F H J P

All standard metallic hardware X X

30 Retainer X X X X

90 Nut X X X

150, 250, Retainer X X X X


300, 360

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Accessory Drive Gearcase Assembly (Partial Breakdown)


(Gears and Gearshaft Assemblies)
Figure 202

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Figure 202. Cleaning Methods

Cleaning Methods - Refer to Method 203


Item (Alpha Suffix) in SPM
No. Nomenclature A B C D E F H J P

All standard metallic hardware X X

All bearings X

100 Tube X X X X

110 Nozzle X X X X

150, 220, Gearshaft X X X X


260, 450

300 Gear Assy X X X

320 Jaw X X X

340, 360, Gear X X X


400, 480

410 Shaft X X X

520 Nozzle Assembly X X X

540 Retainer X X X X

570, 580 Housing Assy X X X X

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ACCESSORY DRIVE GEARCASE ASSEMBLY

1. Inspection/Check

NOTE: Inspection/Check shall be performed in accordance with instructions provided in Standard


Practices Manual ATA No. 20-00-02/70-00-01. Reference to this manual throughout this
section will be indicated by the abbreviation SPM.

A. Perform General Checks

(1) Check threaded parts for stripped, galled or crossed threads. Replace part if
damaged.

(2) Check thread inserts for security and condition of threads. Refer to ATA No. 49-21-73,
Inspection/Repair Manual if inserts are loose or damaged.

(3) Check anodized or plated parts for wear through to base metal. Refer to ATA No.
49-21-73, Inspection/Repair Manual for repair of anodized or plated parts.

(4) Visually check parts for cracks. No cracks, other than those specifically allowed, are
permitted. If cracks are suspected, refer to ATA No. 49-21-73, Inspection/Repair
Manual for magnetic particle or fluorescent penetrant check on part.

B. Detailed Inspection/Check

Items denoted by an X in the following figures under Detail Inspection/Check pertain to ATA
No. 49-21-73, Inspection/Repair Manual. All other references are specified as required.

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Accessory Drive Gearcase Assembly


(Bearing and Seal Retainers)
(Partial Breakdown)
Figure 301

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Figure 301. Inspection/Check

Detailed
Item Inspection/
No. Nomenclature Check

30, 250, 200 Retainer X


250, 280, 300,
360

90 Nut X

100 Spacer X

210 Plug and Bleeder X

400 Oil Nozzle Assy X

NOTE: All other items of Figure 301 are limited to the requirements of the SPM or replacement.

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Accessory Drive Gearcase Assembly


(Gears and Gearshaft Assemblies)
(Partial Breakdown)
Figure 302

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Figure 302. Inspection/Check

Detailed
Item Inspection/
No. Nomenclature Check

110 Nozzle X

150, 220, Gearshaft X


260

360, 400 Gear X

320 Jaw X

410 Shaft X

540 Retainer X

570, 580 Matched Housing Set X

130, 190, *Bearing X


230, 290,
330, 350,
530

* Refer to SPM, Section III, 20-00-02/70-00-01,


for inspection of bearings.

NOTE: All other items of Figure 302 are limited to the requirements of the SPM or replacement.

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ACCESSORY DRIVE GEARCASE ASSEMBLY

1. Repair

A. Repair Instructions

Refer to ATA No. 49-21-73.

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ACCESSORY DRIVE GEARCASE ASSEMBLY

1. Assembly

Table 501. Materials and Compounds

Material or Compound Manufacturer

NOTE: Equivalent substitutes may be used for listed items.

Adhesive cement (Glyptal 1276) Glyptal Inc., 305 Eastern Ave.,


Chelsea, MA 02150

Compound, retaining (Loctite 75, conforming Henkel Loctite Corp., 1001 Trout Brook
to MIL-R-46082, Type II) Crossing, Rocky Hill, CT 06067

Compound (ASTM D 5363, Commercially available


AN0111 through AN0171)

Compound (MIL-S-46163, Type 1, Grade K) Commercially available

Dry ice Commercially available

Oil (MIL-PRF-7808, Type I or


MIL-PRF-23699, Type II) Commercially available

Vacuum gage Commercially available


(0 to 30 inches mercury)

Vacuum pump Commercially available


(2.1 Cubic feet per minute
approximate capacity)

Zinc chromate primer Commercially available


(Federal Specification TT-P-1757)

A. General Assembly Instructions

NOTE: Assembly instructions are arranged with an assembly illustration and the matching
text on either the same or on facing pages. All required information is provided,
including torque values, tool numbers, and materials so that the component can be
assembled without referencing any other part of the manual.

(1) Refer to Standard Practices Manual (SPM ATA No. 20-00-02/70-00-01, Section V) for
shop procedures during assembly.

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1. A. (2) Refer to Fits and Clearances for location of critical fits, clearances, and tightening
torque requirements.

(3) Never use extreme force during assembly of the unit. If difficulty is encountered,
disassemble unit and inspect for burrs or other interferences. Fits and clearances and
special torque values involved in assembly are specified at the applicable points of
assembly.

(4) The manufacturer has included suggested Check Points for observance during and/or
after critical build operations. Observance of these check points is suggested to
ensure quality assembly results.

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Gearcase Assembly (Partial Breakdown)


(Bearing, Seal Retainers and Oil Nozzle Assy)
Figure 501

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1. B. Assemble Accessory Drive Gearcase Assembly

(1) Assemble bearing, seal retainers and oil nozzle assembly as follows: (Refer to Figure
501.)

Check Point 10: 1. Make sure housing assemblies are a matched set.

2. Make sure oil passages are open and clean.

NOTE: Check housing assemblies (570, 580) for cleanliness and foreign matter.
Visually check studs for proper installation.

(a) Install two guide pins into output housing assembly (580) to aid in installation of
lubricating nozzle and stud assembly (520).

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(b) Install packing (510) on lubricating nozzle and stud assembly (520). Squirt oil
(MIL-PRF-7808 or MIL-PRF-23699) through lubricating nozzle and stud
assembly to make sure oil passage is not plugged.

KEY TO FIGURE 501

10. SCREW 220. PACKING 510. PACKING


(IPC FIG. 1) 230. BOLT 520. LUBRICATING
20. WASHER 240. WASHER NOZZLE AND STUD
30. BEARING RETAINER 250. BEARING RETAINER ASSY
130. NUT 260. PACKING 530. BEARING
140. WASHER 270. SCREW 540. BEARING RETAINER
150. SEAL RETAINER 280. BEARING CARRIER 550. PACKING
160. RING 340. BOLT 570. INPUT HOUSING
170. SEAL 350. WASHER ASSY
180. PACKING 360. BEARING 580. OUTPUT HOUSING
190. SCREW 370. PACKING ASSY
200. BEARING 500. SCREW
210. PLUG (IPC FIG. 2)

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WARNING: USE THE CORRECT PERSONAL PROTECTION. THE HEATED


PARTS WILL CAUSE BURNS.

NOTE: Freeze lubricating nozzle and stud assembly (520) in dry ice for
later installation.

Heat output housing assembly (580) in oven at 149C (300F) for 30


minutes for aid in installation of retainer (540) and lubricating
nozzle and stud assembly (520).

1. B. (1) (c) Using previously installed guide pins press lubricating nozzle and stud
assembly (520) with assembled packing (510) into output housing assembly
(580) using 2024495-1 press fixture. Make sure lubricating nozzle and stud
assembly flange is bottomed out against housing assembly.

(d) Coat threads of screws (500) with compound (MIL-S-46163, Type 1, Grade
K). Install screws in lubricating nozzle and stud assembly and tighten to a
torque value of 20 to 25 inch-pounds.

(e) Assemble packing (550) to inner bearing retainer (540), then install inner
bearing retainer in output housing assembly (580) (output side). Install
bearing (530) in inner bearing retainer. Make sure bearing is bottomed in bore.
Temporarily install outer bearing retainer (30), washers (20) and screws (10).

(f) Install packing (370) on bearing retainer (360). Install assembled parts in
input housing assembly (570). Secure with washers (350) and bolts (340).
Tighten bolts to a torque value of 20 to 25 inch-pounds.

(g) Install bearing retainers (280, 200) in output housing assembly (580). Secure
bearing retainers with screws (270, 190). Tighten screws to a torque value of
15 to 20 inch-pounds.

(h) Install packing (260) on bearing retainer (250). Install assembled parts in
output housing assembly (580). Secure with washers (240) and bolts (230).
Tighten bolts to a torque value of 20 to 25 inch-pounds. Install packing (220)
and plug (210) into bearing retainer.

(i) Install seal (170) in seal retainer (150) using 285793-1-1 seal driver. Orient
seal as shown. Secure seal to seal retainer with ring (160). Install packing
(180) on seal retainer with assembled parts, then install seal retainer in output
housing assembly (580). Temporarily secure with washers (140) and nuts
(130) until fuel control unit is installed.

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Gearcase Assembly (Partial Breakdown)


(Idler Spur Gear, Idler Gear Shaft and Bearings)
Figure 502

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1. B. (2) Assemble idler spur gear, idler gear shaft and bearings as follows: (Refer to Figure
502.)

(a) Install one bearing (380), idler spur gear (400), washer (390), second bearing
(380) and spacer (370) onto idler gear shaft (410).

Check Point 20: 1. Make sure bearings are installed on gear shaft.

NOTE: Output housing assembly (580) may require localized heating to


aid installation of idler gear shaft (410) with assembled parts.

(b) Install the assembled idler gear shaft (410) in output housing assembly (580)
and install packing with retainer (60), washer (50), and nut (40). Tighten nut to
a torque value of 270 to 300 inch-pounds.

Check Point 20: 2. Make sure packing with retainer (60) is installed under
nut and washer adjacent to starter motor pad.

KEY TO FIGURE 502

40. NUT (IPC FIG. 2) 390. WASHER


50. WASHER 400. IDLER SPUR GEAR
60. PACKING W/RTNR 410. IDLER GEAR SHAFT
370. SPACER 580. OUTPUT HOUSING ASSY
380. BEARING

Page 509
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Gearcase Assembly (Partial Breakdown) (High Speed Pinion


Gear, Output Drive Gearshaft and Bearings)
Figure 503

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1. B. (3) Assemble high speed pinion gear, output drive gearshaft and bearings as follows:
(Refer to Figure 503.)

NOTE: Make sure bearings (460) are installed on pinion gear (480) with anti-
rotation grooves at outer ends.

(a) Measure inside diameter of bearings (460) and outside diameter of bearing
journals of pinion gear (480); difference shall be 0.0002 to 0.0008 inch. Fit
shall be tight. Press bearings on gear using 834440-1 bearing installation set.

Check Point 30: 1. Make sure bearings are installed on the gear.

(b) Press bearing (420) on unthreaded end of output drive gearshaft (450) using
bearing installation tool 2024447-1.

Check Point 30: 2. Make sure the plug and bearing are installed on the
gearshaft.

(c) Apply heavy coat of compound (ASTM D 5363, AN0111 through AN0171) to
hold anti-rotation pin (470) in place during assembly.

(d) Install anti-rotation pin (470) in anti-rotation groove of output housing


assembly (580).

Check Point 30: 3. Make sure the anti-rotation pin is installed using the pin
verification gage 2024496-1.

(e) Align anti-rotation groove of bearing (460) with installed anti-rotation pin (470).

(f) Engage pinion gear (480) with output drive gearshaft assembly (450), then
simultaneously install engaged parts in output housing assembly (580).

(g) Using bearing installation tool 2024477-1, press output drive gearshaft
assembly (450) into previously installed bearing in output housing assembly
(580) using support 2024448-1 to support bearing while pressing gear shaft on
to bearing.

KEY TO FIGURE 503

420. BEARING (IPC FIG. 2) 470. ANTI-ROTATION PIN


450. OUTPUT DRIVE 480. PINION GEAR
GEARSHAFT ASSY 580. OUTPUT HOUSING ASSY
460. BEARING

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Gearcase Assembly (Partial Breakdown)


(Fan Idler Spur Gear, Starter Drive
Cluster Gear, Idler Gear Assembly and Bearings)
Figure 504

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OVERHAUL MANUAL
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1. B. (4) Assemble fan idler spur gar, starter drive cluster gear, idler gear assembly and
bearings as follows. (Refer to Figure 504.)

(a) Press bearings (350) onto fan idler spur gear (360) using 834379-4 bearing
installer, and 834438-1 holder to support gear, then install fan idler spur gear
with bearings in output housing assembly (580).

(b) Press bearings (330) onto starter drive cluster gear (340) as follows:

1 Press one bearing (330) onto starter drive cluster gear (340) at stub
end of shaft using 834379-4 bearing installer, and 834438-8 holder.

2 Place remaining bearing (330) in holder and press splined end of


shaft through bearing using 834379-4 installer.

3 Install pawl drive jaw (320) and nut (310). Hold pawl drive jaw with
285090-1-1 spanner wrench and tighten nut to a torque value of 200
to 225 inch-pounds.

(c) Install starter drive cluster gear (340) with assembled parts in output housing
assembly (580).

(d) Press bearings (290) onto idler gear assemble (300) using 834379-4 bearing
installer. Lift starter drive cluster gear (340) slightly, then install idler gear
assembly with bearings in output housing assembly (580). Make sure starter
drive cluster gear is reseated.

Check Point 40: Make sure bearings are installed on gears.

KEY TO FIGURE 504

290. BEARING (IPC FIG. 2) 340. STARTER DRIVE CLUSTER GEAR


300. IDLER GEAR ASSY 350. BEARING
310. NUT 360. FAN IDLER SPUR GEAR
320. PAWL DRIVE JAW 580. OUTPUT HOUSING ASSY
330. BEARING

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130. BEARING (IPC FIG. 2) 230. BEARING


150. GEARSHAFT 260. MULTI-SPEED GEARSHAFT
190. BEARING 580. OUTPUT HOUSING ASSY
220. GEARSHAFT

Gearcase Assembly (Partial Breakdown)


(Fuel Control Drive Gearshaft Assembly, Multispeed Switch
Gearshaft Assembly, Oil Pump Drive Gearshaft
Assembly and Bearings)
Figure 505

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1. B. (5) Install fuel control drive gearshaft assembly, multispeed switch gearshaft assembly, oil
pump drive gearshaft assembly and bearings as follows. (Refer to Figure 505.)

(a) Press bearing (130) onto stub shaft end of gear (150) using 834379-5 bearing
installer and 834438-9 holder. Press bearing (130) onto splined end of shaft
using 834379-5 bearing installer and 834438-9 holder.

(b) Press bearing (230) onto stub shaft end of gear (260) using 834379-6 bearing
installer and 834438-10 holder. Press bearing (230) onto splined end of shaft
using 834379-6 bearing installer and 834438-9 holder.

(c) Press bearing (190) onto gearshaft (220) using 834438-5 holder.

Check Point 50: Make sure bearings are installed on all gearshafts.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

NOTE: Make sure seal mating surface of gearshaft (150) is coated with oil
(MIL-PRF-7808 or MIL-PRF-23699) prior to installation.

(d) Install gearshafts (150, 220) and multi-speed gearshaft (260) with assembled
bearings (130, 190, 230) onto output housing assembly (580).

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90. PACKING (IPC FIG. 2) 110. NOZZLE


100. TUBE 580. OUTPUT HOUSING ASSY

Gearcase Assembly (Partial Breakdown)


(Tube, Nozzle and Packings)
Figure 506

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OVERHAUL MANUAL
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1. B. (6) Install tube, nozzle and packings as follows: (Refer to Figure 506.)

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

NOTE: Make sure packings (90) are coated with oil (MIL-PRF-7808 or
MIL-PRF-23699).

Check Point 60: 1. Make sure packings and tube are installed.

(a) Install packings (90) on tube (100). Install tube with assembled packings in
output housing assembly (580).

NOTE: Align holes in nozzle (110) to face previously installed cluster gear.

Check Point 60: 2. Make sure packings and nozzle are installed.

(b) Install packings (90) on nozzle (110). Install nozzle with assembled packings
in output housing assembly (580).

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OVERHAUL MANUAL
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10. NUT (IPC FIG. 2) 460. BEARING


20. WASHER 470. ANTI-ROTATION PIN
30. BOLT 490. ALIGNMENT PIN
70. WASHER 570. INPUT HOUSING ASSY
80. BOLT 580. OUTPUT HOUSING ASSY
120. GASKET

Gearcase Assembly (Partial Breakdown)


(Input Side of Matched
Housing Assembly Set)
Figure 507

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OVERHAUL MANUAL
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1. B. (7) Install input side of matched housing assembly set as follows. (Refer to Figure 507.)

(a) Check housing assemblies (570, 580) for cleanliness.

Check Point 70: 1. Make sure both housing assemblies are clean and free
of any foreign matter.

WARNING: USE THE CORRECT PERSONAL PROTECTION. THE HEATED


PARTS WILL CAUSE BURNS.

NOTE: Heat input housing assembly (570) in an oven at 121C (250F) for
approximately five minutes to aid in installation.

Check Point 70: 2. Make sure the gasket is installed.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

(b) Apply a thin film of oil (MIL-PRF-7808 or MIL-PRF-23699) to gasket (120). Place
gasket on output housing assembly (580). Carefully position input housing
assembly (570) over output housing assembly (580) aligning mating surfaces and
bores. Make sure that bearings are seated in their respective bores and that tube
and nozzle is in place before pressing the two sides together.

CAUTION: EXERCISE EXTREME CARE WHEN INSTALLING ALIGNMENT PINS


TO AVOID DISPLACEMENT OF INSTALLED BUSHINGS.

NOTE: Do not invert matched housing assembly set until assembly Step (8), is
completed.

Check Point 70: 3. Make sure three pins (490) are installed in case halves
and dowel pin ends are touched up with primer.

(c) Install alignment pins (490) into respective bores of input housing assembly (570)
using 835669-1 installation fixture. Press pins in until flush to 0.020 inch below
surface. Coat exposed ends of alignment pins with zinc chromate primer (Federal
Specification TT-P-1757).

(d) Install bolts (30, 80), washers (20, 70), and nuts (10). Tighten nuts (10) to a
torque value of 20 inch-pounds. Tighten bolts (30, 80) to a torque value of 25
inch-pounds.

Check Point 70: 4. Make sure the anti-rotation pin is installed.

(e) Align anti-rotation groove of bearing (460) to anti-rotation groove of input housing
assembly (570), then install anti-rotation pin (470).

(f) Rotate gear train and check for freedom of movement and unusual noises.

Check Point 70: 5. Rotate gear train, check for freedom of movement and
unusual noises.

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OVERHAUL MANUAL
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Gearcase Assembly (Partial Breakdown)


(Bearing Retainer and Nozzle Assembly
Figure 508

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

1. B. (8) Install bearing retainer and nozzle assembly. (Refer to Figure 508.)

(a) Install bearing retainer (300) and screws (290) observing the following
instructions.

1 Position guide (330) over face of bearing. Temporarily install 0.030


inch thickness of shims (310). Using a depth gage, measure distance
from top of shims to surface of guide.

2 Adjust thickness of shims (310) to obtain Dimension A (0.062 to 0.082


inch). The result equals thickness of shims required to obtain a 50 to
60 pound bearing preload.

Check Point 80: 1. Verify thickness of shims required to obtain a


50 to 60 pound bearing preload.

3 Install thickness of shims (310) determined in Step 2 on guide (330).

NOTE: Free height of spring washer (320) shall be 0.167 to 0.169


inch to obtain specified bearing preload.

4 Install spring washer (320) and bearing retainer (300). Secure


retainer using five screws (290). Tighten screws to a torque value of
15 to 20 inch-pounds.

KEY TO FIGURE 508

290. SCREW (IPC FIG. 1) 380. SCREW


300. BEARING RETAINER 390. WASHER
310. SHIM 400. OIL NOZZLE ASSY
320. SPRING WASHER 410. PACKING
330. GUIDE

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NOTE: Check clearance between oil nozzle assembly (400) and bearing
retainer (300). Use feeler gage to measure clearance between
outer surface of bearing retainer and inner surface of oil nozzle
assembly. If clearance is less than 0.010 inch or if interference
exists between bearing retainer and oil nozzle assembly, rework
surface of nozzle by hand to obtain specified clearance.

1. B. (8) (b) Assemble packing (410) on oil nozzle assembly (400) and install oil nozzle
assembly; secure with screw (380) and washer (390). Tighten screw to a
torque value of 15 to 20 inch-pounds.

Check Point 80: 2. Verify oil jet installation at high speed pinion gear.

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Determining Bearing Pinch and Seal


Length Washer Thickness
Figure 509

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OVERHAUL MANUAL
GTCP85-98DHF/[A]

1. B. (9) Determine bearing pinch and seal length washer thickness as follows: (Refer to
Figure 509.)

(a) Determine thickness of washers (120) required to obtain specified seal length
(Dimension G) and required thickness of shim washers (70) to obtain 0.002 to
0.005 inch pinch on outer raced of bearing as follows:

1 Remove two screws (10) and washers (20) and bearing retainer (30)
temporarily installed in Step (1).

2 Measure Dimensions A and B. Subtract Dimension B from Dimension


A. Record difference as Dimension C.

3 Add 0.002 to 0.005 inch required pinch on outer race of bearing to


Dimension C. Record sum as Dimension D.

4 Dimension D equals thickness of shim washers (70) required to obtain


specified pinch on outer race of bearing.

Check Point 90: 1. Make sure calculations and amount of shim


washers required to obtain 0.002 to 0.005 inch
pinch on outer race of bearing.

5 Measure Dimension E. Add Dimension D to Dimension E. Record


sum as Dimension F.

6 Subtract specified seal length 0.734 to 0.739 inch (Dimension G) from


Dimension F. Record difference as Dimension H.

KEY TO FIGURE 509

10. SCREW (IPC FIG. 1) 80. KEY


20. WASHER 90. NUT
30. BEARING RETAINER 100. SPACER
40. PACKING 110. SEAL ROTOR
60. SEAL STATOR -115. ROTOR (POST SB 49-7173)
70. SHIM WASHER 120. WASHER

- ITEM NOT ILLUSTRATED

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1. B. (9) (a) 7 Dimension H equals thickness of washers (120) required to obtain


specified seal length.

Check Point 90: 2. Verify calculations and washer selection


required to obtain 0.734 to 0.739 inch seal
length.

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE


AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
CHEMICAL IS AN ASPHYXIANT; IT IS POISONOUS AND CAN BE
ABSORBED THROUGH THE SKIN.

NOTE: Make sure seal rotor is coated with oil (MIL-PRF-7808 or


MIL-PRF-23699).

(b) (Pre SB 49-7173) Install thickness of washers (120) determined in Step (a)7
(Dimension H), seal rotor (110), spacer (100) and nut (90).

(Post SB 49-7173) Install thickness of washers (120) determined in Step (a)7


(Dimension H), rotor (-115), spacer (100) and nut (90).

(c) Tighten nut (90) securely and mark nearest key (80) slot on gearshaft, then
remove nut and spacer (100).

NOTE: If slot for key does not align, replace nut; do not add additional shims to
align slot for key.

(d) Coat nut (90) with compound (ASTM D 5363, AN0111 through AN0171), then
install key (80) in slot marked in Step (c), spacer (100) and nut. Hold gearshaft
from rotating with 285418-1 adapter, then tighten nut to a torque value of 145 to
155 inch-pounds using 253562-1 spanner wrench and a standard torque
wrench. Bend tab of key up into slot of nut.

Check Point 90: 3. Make sure output shaft nut is torqued 145 to 155 inch-
pounds and key is properly installed and bent over.

CAUTION: PROTECT CARBON FACE OF SEAL STATOR FROM DAMAGE AND


FOREIGN MATTER. DO NOT USE EXCESSIVE PRESSURE AFTER
SEAL IS BOTTOMED IN RETAINER.

(e) (Pre SB 49-7173) Coat mating surfaces of seal stator (60) and bearing
retainer (30) with adhesive, then install seal stator in bearing retainer using
835535-1 seal driver.

(Post SB 49-7173) Coat mating surfaces of seal stator (60) and bearing
retainer (30) with adhesive, then install seal stator in bearing retainer using
259560 seal installation driver.

NOTE: Use of excessive adhesive will channel into carbon-stator


assembly and cause seal malfunction during engine operation.

Make sure sealing surface of seal stator is coated with oil


(MIL-PRF-7808 or MIL-PRF-23699).

(f) Install required thickness of shim washers (70) determined in Step (a)3
(Dimension D), packing (40) and bearing retainer (30) assembled with seal
stator (60). Attach with screws (10) and washers (20). Tighten screws to a
torque value of 15 to 20 inch-pounds.

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Installation of Pressure Test Caps and Plugs


Figure 510

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OVERHAUL MANUAL
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1. B. (10) Check accessory drive gearcase assembly for leakage as follows: (Refer to Figure
510.)

(a) Install pressure test caps and plugs as follows:

1 Install 284521-1-1 pressure test cap on accessory drive gearcase


assembly input flange.

2 Install 284522-1-1 pressure test cap on accessory drive gearcase


assembly starter drive pad.

3 Install 289165-1 pressure test plug in bore of centrifugal switch pad


and 289166-1 pressure test plugs in bores of cooling air fan and oil
pump drive pads.

4 Cover plug and bleeder with masking tape.

(b) Perform leakage check on assembled accessory drive gearcase assembly as


follows:

1 Connect vacuum pump having a capacity of approximately 2.1 cubic


feet per minute, manometer or vacuum gage to fitting on 284521-1-1
pressure test cap. Cap fitting on 284522-1-1 pressure test cap. Apply
negative pressure.

2 With vacuum pump operating, observe negative pressure reading. If


negative pressure stabilizes at 22 inches Hg or higher, seals are
satisfactory.

Check Point 100: Verify vacuum check of 22 inches Hg minimum.

3 Relieve negative pressure, then disconnect vacuum pump,


manometer or vacuum gage from fitting of 284521-1-1 pressure test
cap.

(c) Remove pressure test caps, plugs and masking tape.

(d) Perform final assembly check for completeness, freedom of rotation, and
identification of gearcase assembly part number.

Check Point 110: Check assembly for completeness, freedom of rotation,


and proper identification.

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ACCESSORY DRIVE GEARCASE ASSEMBLY

1. Fits and Clearances

A. Fits and Clearances Instructions

(1) All Assembly Fits and Clearances are called out in the text of Assembly procedures.
Fits and Clearances are listed in Table 601 and referenced to item and figure number
and may be used as an aid in determining overhaul requirements. Torque values are
listed in Table 602.

NOTE: Whenever non-standard torque values are required for individual parts, the
parts are identified and the torque requirements are listed in the applicable
assembly procedures covering the part. These specified torque values do
not include frictional torques developed by self locking devices or "run-
down" resistance. The frictional resistance or "run-down" torque must be
added to the specified torque. Torque tolerances are not provided for nuts
and bolts since this tolerance is assumed to be the nominal tolerance of a
properly calibrated torque wrench. Where two torque values are included,
the lower value shall be used when torque is applied to the nut and the bolt
is held stationary. When torque is applied to the bolt and the nut is held
stationary, the higher value shall be used. When torque values are not
specified, confirm to standard shop practice or sources such as FAA
Manual AC65-9, Airframe and Powerplant Mechan