CMM 21-51-53 Rev 15 Air Cycle Machine [PDF]

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COMPONENT MAINTENANCE MANUAL 782790



TO ALL HOLDERS OF HAMILTON SUNDSTRAND’S COMPONENT MAINTENANCE MANUAL 21-51-53 APPLICABILITY: DHC8 THIS SHEET TRANSMITS REVISION NO. 15 DATED MAR 01/13 HIGHLIGHTS We recommend that you put this revision into your manual without delay. After you have put the revised pages in your manual, mark the Record of Revisions sheet with the new revision number and date, and write the date that you insert the revised pages into your manual and your initials on the Record of Revisions sheet in the appropriate spaces. This manual has been reissued in its entirety. Please replace these pages of your manual with the pages of this revision. General format and layout changes were made in addition to these technical changes. If you have questions about this manual, you can contact Technical Publications by email at mailto:[email protected] or fax at (860) 660-9014. The changes made to the manual during this revision are described in the table that follows: CHANGE DRIVER REFERENCE



PAGE



DESCRIPTION OF CHANGE



All Affected Pages



Added disclosure restrictions footer to all pages.



Non-technical change; no substantiation data required.



T-1



Changed Export Laws Control statement.



Non-technical change; no substantiation data required.



RR-1



Changed the format of RECORD OF REVISIONS.



Non-technical change; no substantiation data required.



RTR-1



Changed the format of RECORD OF TEMPORARY REVISIONS.



Non-technical change; no substantiation data required.



SBL-1



Changed the format of SERVICE BULLETIN LIST.



Non-technical change; no substantiation data required.



401



Added Sodium-Bicarbonate Blast Media to Table 401.



D2326-AI93040



401



Updated CAGE Code notes for Consumable Materials and Special Tools, Fixtures, and Test Equipment.



Non-technical change; no substantiation data required.



402



Added Cleaning Steel or Aluminum Subassembly Components With Dry Abrasive procedure.



D2326-AI93040



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INFORMATION SUBJECT TO EXPORT CONTROL LAWS Subject to the EAR, ECCN 9E991 This information is subject to the export control laws of the United States, specifically including the Export Administration Regulations (EAR), 15 C.F.R. Part 730 et. seq. Transfer, retransfer, or disclosure of this data by any means to a non-U.S. person (individual or company), whether in the United States or abroad, without any required export license or other approval from the U.S Government is prohibited, including without limitation any diversion to a military end user or use in a military end use application.



AIR CYCLE MACHINE



PART NUMBERS: 782790-6 782790-10 782790-12 782790-16 782790-18 © 1985, 1991, 1993, 1994, 1997, 2002, 2004, 2007-2013 Hamilton Sundstrand Corporation THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION (HSC). RECIPIENT AGREES TO HOLD ALL SUCH INFORMATION IN CONFIDENCE AND AGREES IT SHALL BE USED ONLY FOR RECIPIENT’S INTERNAL PURPOSES TO MAINTAIN RECIPIENT’S EQUIPMENT OR AS MAY OTHERWISE BE PERMITTED IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND HSC. THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN SHALL NOT BE USED FOR ANY OTHER PURPOSE, INCLUDING THE CREATION, MANUFACTURE, DEVELOPMENT, OR DERIVATION OF ANY REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGN, OR CONFIGURATION CHANGES, OR TO OBTAIN FAA OR ANY OTHER GOVERNMENT OR REGULATORY APPROVAL FOR SAME. RECIPIENT AGREES NOT TO DISCLOSE SUCH INFORMATION TO ANY THIRD PARTY, EXCEPT AS MAY OTHERWISE BE PROVIDED FOR IN AN APPLICABLE AGREEMENT BETWEEN RECIPIENT AND HSC. COPYING OR DISCLOSURE OF THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN BY ANYONE WITHOUT HSC’S PRIOR WRITTEN PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY. The data in this document were developed only to maintain systems and/or parts manufactured by or for Hamilton Sundstrand or approved by Hamilton Sundstrand. The data may not be applicable to any other systems and/or parts, regardless of their apparent similarity to systems and/or parts manufactured by or for Hamilton Sundstrand or approved by Hamilton Sundstrand. Do not rely in any way on data in this document to maintain or otherwise support systems and/or parts that were not manufactured by or for Hamilton Sundstrand or approved by Hamilton Sundstrand without evidence that the Federal Aviation Administration or other regulatory agency has determined that the data in this document is valid for such use.



COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST



CAGE Code: 73030



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SAFETY ADVISORY 1. Scope A. This publication describes processes that may require the use of chemicals, solvents, paints, or other materials that can affect a person’s health or safety. It may also cover high energy procedures that can affect a person’s health or safety. Warnings are placed just ahead of these procedures to bring attention to the existence of a procedure or material that can be dangerous. 2. Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS WARNING: BEFORE YOU USE ANY OF THE MATERIALS SPECIFIED IN HAMILTON SUNDSTRAND MAINTENANCE PUBLICATIONS, BE AWARE OF ALL HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH MANUFACTURER’S OR SUPPLIER’S RECOMMENDATIONS MAY RESULT IN PERSONAL INJURY OR DISEASE. THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL SAFETY DATA SHEETS (OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) FORM 20 OR EQUIVALENT) FROM THE MANUFACTURERS OR SUPPLIERS OF MATERIALS TO BE USED. THE USER MUST BECOME COMPLETELY FAMILIAR WITH THE MANUFACTURER OR SUPPLIER INFORMATION AND ADHERE TO THE PROCEDURES, RECOMMENDATIONS, WARNINGS, AND CAUTIONS OF THE MANUFACTURER OR SUPPLIER FOR THE SAFE USE, HANDLING, STORAGE, AND DISPOSAL OF THESE MATERIALS. A. Refer to the materials list at the beginning of each section of this manual for materials used to repair and maintain the covered equipment. B. If you do not have a copy of the manufacturer’s MSDS for the materials covered in the materials list, contact the manufacturer and request that a MSDS be supplied before you use the material. 3. Purpose A. The warnings bring your attention to the existence of a procedure that can affect a person’s health or safety. B. Short warnings are provided in this maintenance publication to alert operating and maintenance personnel of potential hazards that could result in personal injury or health hazards. The warnings do not replace the manufacturer’s recommendations. When there is a reference to the Warnings Registry 341-006, that publication will provide more information about the dangers of the material. The information contained in the Warnings Registry is a summary of the manufacturer’s MSDS. The full-length warnings provide three principle parts of safety: (1) a listing of the known dangers, (2) what is needed to do to protect you from the dangers, and (3) what to do if the dangers occur. C. The detailed warnings in Warnings Registry 341-006 are a summary of the manufacturer’s MSDS and are not intended to replace the material on the sheet, but are intended to supplement them.



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COMPONENT MAINTENANCE MANUAL 782790



D. Cautions are provided in the maintenance publication or service bulletin to alert operating and maintenance personnel to conditions that could result in equipment damage. 4. Definitions Applying to Warnings A. Flammable: a material that can catch fire easily and can be explosive. These materials are labeled according to the flash point of the material. B. Flash Point: the lowest temperature at which a flammable liquid gives off fumes that can burn. C. Ignition Source: includes flames, sparks, or heat. (1) Flames: materials that are burning such as lit matches, propane torches, or pilot lights. (2) Sparks: materials such as lighted cigarettes, electrical motors, or static electricity. (3) Heat: any source of energy that will raise the temperature of a flammable material to its flash point and could include hot parts, heated tools, or direct sunlight. D. Corrosive: acidic or alkaline material that will remove human tissue or create chemical reactions with other materials. E. Toxic: material that is poisonous. F. Reactive: material that will make fumes, burn, or can be explosive when mixed with certain other materials. G. Shock (Electrical): the result of any source of electricity more than 50 volts that causes current to flow through a person and can result in dangerous burns to human tissues or death. H. Exposure: contact with the material or physical process without protection. Contact may be by the eyes, breathing, touch, skin absorption, or swallowing. I. Irritation: any sense of pain, soreness, rash, or general discomfort. 5. Reporting Materials or Processes Not Covered A. Please contact us if you find a material in a Hamilton Sundstrand maintenance document that is known to be covered by a Material Data Safety Sheet (MSDS) but is not covered by a warning in the procedure. • email - mailto:[email protected]



• fax - (860)-660-9014



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COMPONENT MAINTENANCE MANUAL 782790



RECORD OF REVISIONS REVISION NUMBER



ISSUE DATE



DATE INSERTED



BY



1



Feb 15/91



Feb 15/91



S



2



Feb 15/93



Feb 15/93



S



3



Jun 01/93



Jun 01/93



S



4



Apr 15/94



Apr 15/94



S



5



Jul 15/94



Jul 15/94



S



6



Jun 15/97



Jun 15/97



S



7



Sep 15/97



Sep 15/97



S



8



Jan 01/02



Jan 01/02



HS



9



Mar 31/04



Mar 31/04



HS



10



Nov 19/04



Nov 19/04



HS



11



Oct 22/07



Oct 24/07



HS



12



Jun 20/08



Jul 10/08



HS



13



Jun 25/09



Jun 29/09



HS



14



Aug 18/10



Aug 18/10



HS



15



Mar 01/13



0DU+6



REVISION NUMBER



ISSUE DATE



DATE INSERTED



BY



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COMPONENT MAINTENANCE MANUAL 782790



RECORD OF TEMPORARY REVISIONS Table 1



Temporary Revision Number



Issue Date



21-1



Dec 14/87



21-2



Jun 28/90



21-3



Apr 15/92



Date Inserted/ Inserted By



Date Removed/ Removed By



Date Incorporated



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SERVICE BULLETIN LIST Table 1



Service Bulletin/ Revision Number



Issue Date



Date Incorporated or No Effect



Title



21-2039



Dec 15/90



Replacement of the Bearing Cartridge Retention Pin



21-2067



Dec 15/90



Incorporation of New Preform Packing and Compression Spring and Increasing of Rotor Clearances



21-2068



Feb 15/93



Modification of PN 782790-6 to PN 782790-10



21-2110



Jun 15/97



Lubrication System Changes



21-2114



Jun 15/97



Replace the Wicks and Springs



21-2118



Jun 15/97



Change of PN 782790-12 to PN 782790-16 (Rotor Dynamics and Fuseless Turbine Rotor Improvements)



Jan 01/02



Modify 782790-6,-10,-12,-16 to -18



21-2179



Jul 31/99



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LIST OF EFFECTIVE PAGES Subject Title Page



Page



T-1 T-2 Safety Advisory SA-1 SA-1 Record of Revisions RR-1 RR-1 Record of Temporary RTR-1 Revisions RTR-2 Service Bulletin List SBL-1 SBL-1 List of Effective Pages LEP-1 LEP-2 LEP-3 LEP-4 Table of Contents T/C-1 T/C-2 T/C-3 T/C-4 List of Figures LOF-1 LOF-2 LOF-3 LOF-4 List of Tables LOT-1 LOT-2 Introduction INTRO-1 INTRO-2 Description and 1 Operation 2 Testing and 101 Fault Isolation 102 103 104 105 106 107 108 109 110 111 112 113



Date



Subject



Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13



Testing and Fault Isolation (Continued)



Disassembly



Cleaning



Check



Page 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 301 302 303 304 305 306 307 308 401 402 403 404 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516



Date Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13



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COMPONENT MAINTENANCE MANUAL 782790



Subject Check (Continued)



Repair-General



Repair 1-1



Repair 2-1 Repair 2-2



Page 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 601 602 603 604 605 606 607 608 609 610 601 602 603 604 601 602 601 602 603 604 605 606 607 608



Date Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13



Subject Repair 3-1 Repair 3-2 Repair 4-1 Repair 4-2



Repair 4-3 Repair 5-1 Repair 5-2 Repair 5-3



Repair 6-1



Repair 6-2



Repair 7-1



Repair 7-2 Repair 8-1 Repair 8-2 Repair 9-1 Repair 10-1



Page 601 602 601 602 601 602 601 602 603 604 601 602 601 602 601 602 601 602 603 604 605 606 601 602 603 604 601 602 603 604 601 602 603 604 601 602 601 602 601 602 601 602 601 602



Date Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13



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COMPONENT MAINTENANCE MANUAL 782790



Subject Repair 10-2 Repair 11-1



Repair 11-2 Repair 11-3 Assembly



Page 601 602 601 602 603 604 601 602 601 602 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 738 739 740



Date Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13



Subject Assembly (Continued)



Fits and Clearances



Special Tools, Fixtures, and Test Equipment



Illustrated Parts List Introduction



Numerical Index



Detailed Parts List



Page 741 742 743 744 745 746 747 748 749 750 751 752 753 754 755 756 757 758 759 760 761 762 763 764 801 802 803 804 901 902 903 904 905 906 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016



Date Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13



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Subject Detailed Parts List (Continued)



Configuration Change Summary



Page 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044



Date Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13 Mar 01/13



Subject



Page



Date



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TABLE OF CONTENTS Subject



Page



SAFETY ADVISORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-1 1. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-1 2. Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS. SA-1 3. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-1 4. Definitions Applying to Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-2 5. Reporting Materials or Processes Not Covered . . . . . . . . . . . . . . . . . . . . . . . . . . SA-2 RECORD OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RR-1 RECORD OF TEMPORARY REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RTR-1 SERVICE BULLETIN LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SBL-1 LIST OF EFFECTIVE PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEP-1 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T/C-1 LIST OF FIGURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOF-1 LIST OF TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOT-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TESTING AND FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 2. What to do Before the Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 3. Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 4. Leakage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 5. What to do After the Tests are Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 6. Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 2. Drain Oil from Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 3. Removal of Fan Outlet Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 4. Removal of Turbine Outlet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 5. Removal of Turbine Outlet Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 6. Removal of Outlet Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 7. Removal of Containment Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 8. Removal of Identification Plate and Warning Plate. . . . . . . . . . . . . . . . . . . . . . . . . 304 9. Removal of Plugs and Bleeders and Liquid Level Sight Plug . . . . . . . . . . . . . . . . . 304 10. Removal of Lubrication Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 11. Removal of Compressor Housing and Compressor Diffuser . . . . . . . . . . . . . . . . . 305 12. Removal of Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 13. Removal of Rotative Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 14. Disassembly of Rotative Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 15. Disassembly of Containment Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308



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Subject Page CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 2. General Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 3. Cleaning Steel or Aluminum Subassembly Components With Dry Abrasive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 4. Cleaning Nonmetallic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 5. Cleaning Metallic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Specific Check Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Checking Balance of Cooling Fan, Compressor Rotor, and Turbine Rotor . . . . . .



501 501 503 539



REPAIR-GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Specific Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



601 601 606 609



DUCT, TURBINE OUTLET - REPAIR 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Repair of Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 DIFFUSER, COMPRESSOR - REPAIR 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Removal of Minor Scoring or Rotor Rub Marks Up to 0.005 Inch Deep . . . . . . . . 601 DIFFUSER, COMPRESSOR - REPAIR 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Plasma Spray Repair for Scoring Up to 0.032 Inch Deep . . . . . . . . . . . . . . . . . . . 601 FAN, COOLING - REPAIR 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Repair of Tip or Edge Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 FAN, COOLING - REPAIR 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Rebalancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 HOUSING, TURBINE - REPAIR 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Removal of Minor Scoring or Rotor Rub Marks Up to 0.005 Inch Deep . . . . . . . . 601 HOUSING, TURBINE - REPAIR 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Plasma Spray Repair for Scoring Up to 0.032 Inch Deep . . . . . . . . . . . . . . . . . . . 601 HOUSING, TURBINE - REPAIR 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Replacement of Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 ROTOR, COMPRESSOR - REPAIR 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Removal of Minor Nicks, Burrs, and Scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 ROTOR, COMPRESSOR - REPAIR 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Rebalancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 ROTOR, COMPRESSOR - REPAIR 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Replace the Headless Straight Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 PLATE, SEAL - REPAIR 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Replacement of Lead Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 PLATE, SEAL - REPAIR 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Replacement of Vespel Seal (62B, IPL Figure 2) . . . . . . . . . . . . . . . . . . . . . . . . . 601 Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



Subject Page PLATE AND INSULATOR, NOZZLE - REPAIR 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Replacement of Lead Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 NOZZLE PLATE AND INSULATOR - REPAIR 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Replacement of Nozzle Vanes when Worn Beyond Check Limits . . . . . . . . . . . . . 601 ROTOR, TURBINE - REPAIR 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Removal of Minor Nicks, Burrs, and Scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 ROTOR, TURBINE - REPAIR 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Rebalancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 RING, SEAL - REPAIR 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Repair of Sealing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 SHAFT, DRIVE - REPAIR 10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Repair of Minor Damage from Lead-in Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 SHAFT, DRIVE - REPAIR 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Repair of Minor Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 HOUSING, CONTAINMENT - REPAIR 11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Replacement of Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 HOUSING, CONTAINMENT - REPAIR 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Removal of Rust and Replating of Containment Ring . . . . . . . . . . . . . . . . . . . . . . 601 HOUSING, CONTAINMENT - REPAIR 11-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1. Replacement of Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701 2. Preliminary Check for Acceptable Axial Travel of Bearing Cartridge Sleeve in Turbine Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706 3. Assembly of Bearing Cartridge Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709 4. Shimming and Installation of Face Seal -Turbine- End. . . . . . . . . . . . . . . . . . . . . . 719 5. Shimming and Installation of Face Seal -Fan- End. . . . . . . . . . . . . . . . . . . . . . . . . 722 6. Install the Turbine Rotor and Measure the Rotor Clearance . . . . . . . . . . . . . . . . . 725 7. Measure the Runout of the Turbine Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728 8. Install the Bearing Cartridge in the Turbine Housing (Refer to Figure 710) . . . . . . 729 9. Assemble the Remaining Parts of the Rotative Group . . . . . . . . . . . . . . . . . . . . . . 732 10. Compressor Rotor Runout Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734 11. Installation of Fan Spacer and Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736 12. Checking Runouts on Cooling Fan and Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . 738 13. Installation of Lubrication Parts, Liquid Level Sight Plug, and Plugs and Bleeders 740 14. Dynamic Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743 15. Pinning of Seal Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 16. Shimming and Installation of Compressor Diffuser. . . . . . . . . . . . . . . . . . . . . . . . . 753 17. Pinning of Compressor Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756 18. Installation of Compressor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760 19. Installation of Containment Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762 20. Installation of Outlet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762 21. Installation of Warning Plate and Identification Plate . . . . . . . . . . . . . . . . . . . . . . . 763 22. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763 Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



Subject Page 23. Completion of Assembly After Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763 24. Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764 FITS AND CLEARANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801 1. Fits and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801 2. Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802 SPECIAL TOOLS, FIXTURES, AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . 901 1. Special Tools, Fixtures, and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901 ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Detailed Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Configuration Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1001 1001 1007 1011 1035



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



LIST OF FIGURES Figure Figure 1. Figure 101. Figure 102. Figure 103. Figure 104. Figure 105. Figure 106. Figure 107. Figure 108. Figure 109. Figure 110. Figure 111. Figure 112. Figure 113. Figure 114. Figure 501. Figure 502. Figure 503. Figure 504. Figure 505. Figure 506. Figure 507. Figure 508. Figure 509. Figure 510. Figure 511. Figure 512. Figure 513. Figure 514. Figure 515. Figure 516. Figure 517. Figure 518. Figure 519. Figure 601. Figure 601. Figure 601. Figure 602. Figure 603. Figure 604. Figure 601. Figure 601.



Page Air Cycle Machine - Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Preparation of the Speed Pickup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Adapter for the Insulated Mounting Stud . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Installation of the Insulated Mounting Stud and Accelerometer . . . . . . . . 109 Performance Test Equipment Configuration . . . . . . . . . . . . . . . . . . . . . . . 110 Limits for the Compressor Inlet Temperature During the Vibration Survey 111 Locations of the Balance Weights in the Threaded Self-Locking Ring . . . 113 Turbine Performance Curve for PNs 782790-6, -10 and -12. . . . . . . . . . . 117 Turbine Performance Curve for PNs 782790-16 and 782790-18 . . . . . . . 118 Turbine Delta Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Compressor or Fan Corrected Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Compressor Performance Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Fan Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Turbine-Housing External-Leakage Test. . . . . . . . . . . . . . . . . . . . . . . . . . 123 Compressor-Housing External-Leakage Test . . . . . . . . . . . . . . . . . . . . . . 125 Compressor Diffuser Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507 Cooling Fan Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509 Stepped Pin Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 Fan Spacer Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 Turbine Housing Check (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 Lead Seal Plate Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 Vespel Seal Plate Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522 Seal Disk Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523 Nozzle Plate and Insulator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 Turbine Rotor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527 Seal Ring Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528 Drive Shaft Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 Spring Seat Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531 Helical Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533 Bearing Cartridge Sleeve Check (PN 753387-1 and -2) . . . . . . . . . . . . . . 535 Bearing Cartridge Sleeve Check (PN 753387-3). . . . . . . . . . . . . . . . . . . . 536 Bearing Cartridge Sleeve Check (PN 753387-5). . . . . . . . . . . . . . . . . . . . 537 Containment Housing Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538 Turbine Outlet Duct Insulation Repair . . . . . . . . . . . . . . . . . . . . Repair 1-1 603 Compressor Diffuser Repair - Limits for Removal of Minor Scoring or Rotor Rub Marks . . . . . . . . . . . . . . . . . . . . . . Repair 2-1 602 Compressor Diffuser Damage Removal . . . . . . . . . . . . . . . . . . Repair 2-2 602 Compressor Diffuser - Masking for Plasma Spraying . . . . . . . . Repair 2-2 603 Compressor Diffuser-Masking for Plasma Spraying . . . . . . . . . Repair 2-2 603 Compressor Diffuser Finish Dimensions . . . . . . . . . . . . . . . . . . Repair 2-2 605 Cooling Fan Repair Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 3-1 601 Cooling Fan - Rebalancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 3-2 602



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



Subject Figure 601. Figure 601. Figure 602. Figure 603. Figure 601. Figure 601. Figure 601. Figure 602. Figure 603. Figure 604. Figure 605. Figure 601. Figure 601. Figure 601. Figure 601. Figure 601. Figure 601. Figure 601. Figure 601. Figure 701. Figure 702. Figure 703. Figure 704. Figure 705. Figure 706. Figure 707. Figure 708. Figure 709. Figure 710. Figure 711. Figure 712. Figure 713. Figure 714. Figure 715. Figure 716. Figure 717.



Page Turbine Housing - Limits for Removal of Minor Scoring or Rotor Rub Marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 4-1 602 Turbine Housing Damage Removal . . . . . . . . . . . . . . . . . . . . . Repair 4-2 602 Turbine Housing - Masking for Plasma Spraying . . . . . . . . . . . Repair 4-2 603 Turbine Housing Finish Dimensions . . . . . . . . . . . . . . . . . . . . . Repair 4-2 604 Turbine Housing Bushing Replacement . . . . . . . . . . . . . . . . . . Repair 4-3 602 Compressor Rotor - Rebalancing . . . . . . . . . . . . . . . . . . . . . . . Repair 5-2 602 Measure the Diameters of the Holes . . . . . . . . . . . . . . . . . . . . Repair 5-3 602 Install the Headless Straight Pins (Usual Pins). . . . . . . . . . . . . Repair 5-3 603 Make the Oversized Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 5-3 604 Machine the Compressor Rotor for Oversized Pins . . . . . . . . . Repair 5-3 604 Install the Oversized Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 5-3 606 Seal Plate - Lead Seal Replacement . . . . . . . . . . . . . . . . . . . . Repair 6-1 602 Vespel Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 6-2 604 Nozzle Plate and Insulator - Lead Seal Replacement . . . . . . . Repair 7-1 602 Nozzle Plate and Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 7-2 602 Turbine Rotor-Rebalancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 8-2 602 Seal Ring - Repair of Sealing Surface . . . . . . . . . . . . . . . . . . . Repair 9-1 601 Containment Housing - Replacement of Liner . . . . . . . . . . . . Repair 11-1 603 Containment Housing - Replacement of Inlet Screen. . . . . . . Repair 11-3 602 Checking Travel of Bearing Cartridge Sleeve in Turbine Housing . . . . . . . 708 Assembly of Bearing Cartridge Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 Install the Ball Bearing on the Fan (Short) End of the Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 Make a Check of the End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716 Install the Ball Bearing on the Turbine (Long) End of the Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 Installation of Face Seal - Turbine End. . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 Installation of Face Seal - Fan End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 Determination of Turbine Housing to Turbine Rotor Clearence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 Turbine Rotor Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728 Install the Bearing Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 Install the Bearing Cartridge in the Turbine Housing (For PN 782790-16 Units). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731 Compressor Rotor Runout Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735 Installation of Fan Spacer and Cooling Fan and Checking Runouts . . . . . 737 Installation of Lubrication Parts, Liquid Level Sight Plug, and Plugs and Bleeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741 Dynamic Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744 Guide for Placement of Balance Weights in Locking Rings with Unbalance Vector Located on Centering of Holes in Rings (Heavy Side) . 747 Guide for Placement of Balance Weights in Locking Rings with Unbalance Vector Located on Centering of Holes in Rings (Heavy Side) . 748



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Subject Figure 718. Figure 719. Figure 720. Figure 721.



Page Pinning of Seal Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752 Shimming and Installation of Compressor Diffuser . . . . . . . . . . . . . . . . . . 755 Pinning of Compressor Diffuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758 Installation of Compressor Housing, Containment Housing, Outlet Cover, and Turbine Outlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761 IPL Figure 1. Air Cycle Machine (Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1012 IPL Figure 2. Rotative Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1022 IPL Figure 3. Containment Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1032



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LIST OF TABLES Table Table 101. Table 102. Table 103. Table 104. Table 105. Table 106. Table 301. Table 302. Table 401. Table 501. Table 502. Table 503. Table 504. Table 505. Table 506. Table 507. Table 508. Table 509. Table 510. Table 511. Table 512. Table 513. Table 514. Table 515. Table 516. Table 517. Table 518. Table 601. Table 602. Table 701. Table 702. Table 801. Table 802. Table 901. IPL Table 1. IPL Table 2. IPL Table 3. IPL Table 4. IPL Table 5.



Page Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Symbols and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Performance Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Consumable Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Consumable Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 501 General Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 Compressor Diffuser Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 Cooling Fan Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508 Stepped Pin Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 Fan Spacer Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 Turbine Housing Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512 Compressor Rotor Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517 Seal Plate Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 Seal Disk Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523 Nozzle Plate and Insulator Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524 Turbine Rotor Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526 Seal Ring Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528 Drive Shaft Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 Spring Seat Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531 Helical Compression Spring Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532 Bearing Cartridge Sleeve Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534 Containment Housing Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . Repair-General 601 Consumable Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair-General 602 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 702 Consumable Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705 Fits and Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 901 Configuration Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1035 Configuration Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1037 Configuration Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1039 Configuration Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1041 Configuration Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1043



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INTRODUCTION 1. This Component Maintenance Manual gives the maintenance instructions for the Air Cycle Machine PN 782790. The maintenance instructions include tests which show if the Air Cycle Machine is serviceable. There are also procedures to repair or replace parts which are not serviceable. 2. This manual was written by the Commercial Customer Service Department of Hamilton Sundstrand Corporation, a United Technologies Company, One Hamilton Road, Windsor Locks, CT 06096-1010. This manual includes: • Title Page • Safety Advisory • Record of Revisions • Record of Temporary Revisions • Service Bulletin List • List of Effective Pages • Table of Contents • Introduction • Description and Operation • Testing and Fault Isolation Procedures • Disassembly and Assembly Procedures • Cleaning, Check, and Repair Procedures • Fits and Clearances, and Special Tools, Fixtures, and Test Equipment • Ilustrated Parts List 3. Refer to the Table of Contents to find the applicable section. The Repair section includes a list of the repair procedures. 4. The Illustrated Parts List (IPL) shows the parts of the Air Cycle Machine. The Introduction tells how to use the IPL. 5. The Air Cycle Machine has an identification plate which shows the: • Part Name, which identifies the machine with words • Part No., which identifies the machine with a number • Serial No., which identifies each unit • HS Ref, which identifies the parts list used for the initial assembly of the unit • Mod Data, which identifies the engineering changes which were made to the unit. Numbers in this block can be divided by slashes (/) or dashes(-). For example, L5-8/1011 shows that changes L5 thru L8 and L10 and L11 were made. The L9 change was not made. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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6. All measured quantities in this manual are given in English units with metric equivalents in parentheses (). 7. Verification:



Testing and Fault Isolation Disassembly Assembly



Verified 01/17/91 Verified by simulation Verified 01/17/91



8. The Standard Practices Manual M2001 has common maintenance practices that may be applicable for this type of equipment. 9. Abbreviations and Acronyms: A ABR4 ACM CB



-



°C °F °R Delta P HS G N



-



kPaa lb/min Pcal



-



Pcis



-



Pchs



-



Pcos



-



Pfis Pfr



-



ACM self-induced vibration Acetylene Tetrabromide Air cycle machine Corrected Barometer (ambient pressure) Degrees Celsius Degrees Fahrenheit Degrees Rankine Fan static-pressure rise Hamilton Sundstrand Gravity (vibration level) Speed at which the ACM turns Kilopascals absolute Pounds per minute Calibrated flowmeter pressure Compressor inlet static pressure Compressor housing staticpressure Compressor outlet staticpressure Fan inlet static-pressure Flowmeter outlet pressure



psi psia



-



psig



-



Pths



-



Ptis Ptos rpm Tcal



-



Tci



-



Tfi Tfr Tin Tti Tto Wfr



-



Wfrc



-



Wt



-



Pounds per square inch Pounds per square inch (absolute) Pounds per square inch (gage) Turbine housing staticpressure Turbine inlet static-pressure Turbine outlet static-pressure Revolutions per minute Calibrated flowmeter temperature Compressor inlet temperature Fan inlet temperature Flowmeter outlet temperature Inlet air temperature Turbine inlet temperature Turbine outlet temperature Flowmeter leakage indication (lb/min) Corrected flowmeter leakage indication Airflow through the turbine



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DESCRIPTION AND OPERATION 1. Description A. The Air Cycle Machine (ACM) consists of three sections: A compressor section, turbine section, and cooling fan section (Figure 1). The sections are supported by a drive shaft and a bearing cartridge sleeve. The sleeve supports rotative components with ball bearings. (1) The compressor section consists of the compressor rotor, heat shield, compressor diffuser, seal plate, and compressor housing. (2) The turbine section consists of the turbine rotor, seal disk, nozzle plate and insulator, and turbine housing. (3) The cooling fan section consists of a cooling fan, containment housing, and fan outlet diffuser. B. The compressor rotor, seal disk, and turbine rotor are located at one end of the drive shaft, and the cooling fan is located at the opposite end of the shaft. C. The bearing cartridge sleeve, located between the cooling fan and the turbine rotor, supports the rotative components. The sleeve is positioned and retained in the turbine housing by a stepped pin. D. Spring-loaded, nonmetallic wicks extend from the oil sump area of the turbine housing to contact the drive shaft within the bearing cartridge sleeve and provide lubrication of the ball bearings. Carbon face seals in the sleeve prevent air and oil leakage overboard. Lead seals in the seal plate and nozzle plate and insulator prevent pneumatic leakage from the compressor section to the turbine section. 2. Operation A. Engine bleed air from the primary cooling circuit of a heat exchanger (not part of the ACM) increases in pressure and temperature as it passes through the compressor section of the ACM. This compressed air returns to a secondary cooling circuit in the heat exchanger to lose the heat acquired during the compression process. The secondary cooled air flows to the turbine section where it expands, thereby lowering its temperature and pressure to a level suitable for aircraft air conditioning and, in turn, driving the compressor rotor and cooling fan. B. The rotational speed and degree of cooling of the ACM depend on the air supply available at the turbine inlet. C. To moderate air temperature for air conditioning, hot bypass valve bleed air enters the bypass inlet to mix with the cold discharge air. D. The cooling fan assures a cooling ram air flow across the heat exchanger when the aircraft is on the ground.



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Figure 1. Air Cycle Machine - Sectional View



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TESTING AND FAULT ISOLATION 1. General A. Do all of the tests in the sequence shown. B. These conditions are applicable to all tests unless the instructions show differently: (1) Temperature - 80 ±20°F (15.6 to 37.8°C) (2) Barometric Pressure - 28 ±4 inches Hg (710 ± 100 mm Hg). (3) Humidity - 90% relative humidity maximum (with no free moisture). NOTE: A dew point meter will not be required at each ACM rig if the system that provides the air to the test rig has equipment that will: 1) Dry the air to a dew point below that required. 2) Accurately measure the dew point. C. The air must be filtered to 60 microns absolute (40 microns nominal) upstream of the compressor air inlet. D. The special tools, fixtures, and test equipment shown in Table 101 are used to do the tests NOTE: Equivalent tools, fixtures, and equipment can be used if they agree with the requirements of ARINC Report 668. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 101. Special Tools, Fixtures, and Equipment TOOL NO.



NOMENCLATURE



USE



AD32743-1



Test Stand



Supply the inputs and monitor the conditions for the tests.



GS21429-3



Test Diffuser (with speed pickup and displacement probe)



Monitor the ACM speed and fan-end shaft displacement.



GS15632-2



Turbine Inlet-Port Cap (two are necessary)



Seal the two turbine outlet openings during the leakage test.



GS15633-2



Pressure Test Cap



Seal the turbine inlet opening during the leakage test.



GS20137-1



Pressure Test Cap



Seal the compressor outlet during the leakage test.



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Table 101. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.



NOMENCLATURE



USE



GS20138-1



Pressure Test Cap



Seal the compressor inlet during the leakage test.



GS20671-1



Closure Kit



Seal the ACM openings.



GS24306-1



Outlet Duct Assembly



Connects the fan outlet from the test diffuser, GS21429-3, to the test stand during the functional test.



GS22194-1



Turbine Outlet Adapter



Connects the turbine outlet to the test stand during the performance test.



GS22802-1



Compressor Inlet-Duct Assembly



Connect the test stand to the compressor inlet during the performance tests.



2271A



Accelerometer Endevco Corp.



Measure ACM vibration (G).



CAGE Code: 95411 2983B



Insulated Mounting Stud Endevco Corp.



Install the accelerometer on the turbine housing.



CAGE Code: 95411 5-688-04-030-002



Heat Exchanger Power Specialities Co., Inc.



Remove heat from the airflow to the turbine inlet during the tests.



CAGE Code: 0DHL2



E. These items of test equipment are necessary to do the tests: (1) A high pressure air supply - 40 pounds/minute (18.14 kg/minute) flow at 230°F (110°C) and 50 psia (344.7 kPaa). (2) An air supply that can supply air to the cooling fan at a rate of 85 pounds per minute (38.56 kg per minute). (3) A rotation speed monitor - 0 to 75000 rpm, accurate within ±100 rpm between 15000 and 75000 rpm. (4) A flowmeter - accurate within 3% of the total flow. (5) An accelerometer and equipment to monitor vibration. The equipment and accelerometer, together, must be accurate within 10% of full scale. (6) A pressure gage - accurate to 0.5 psi (3.4 kPa).



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(7) Four thermocouples - accurate to 2°F (1°C) with temperature readouts - accurate to 2°F (1°C). (8) Two water manometers - accurate to 0.1 inch (0.02489 kPaa). (9) A heat exchanger to remove heat from the air at the compressor outlet. (10) A probe to measure fan-end shaft displacement. The probe and the spectrum analyzer or oscilloscope used to show the displacement level must be accurate to 0.0001 inch (0.0025 mm). F. Use the materials shown in Table 102 to do the tests. NOTE: Maintenance personnel must use the specified consumable material for the specified task. These consumable materials are known to agree with all of the design and qualification requirements. Only approved materials engineering personnel can make equivalent consumable material decisions. These materials are used at the risk of the organization who makes the decision. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http:// www.bpn.gov/bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 102. Materials Material



Manufacturer or Specification



Use



Chemical Film



AMS2473



Give protection to metal parts.



Elasticized Modeling Clay (Play-Do)



Commercially Available



Seal the turbine weep holes during turbine housing external leakage test.



High-Heat Black Spray-Paint and High-Heat White SprayPaint



Borden, Inc. Dept. HPPG-Krylon 180 E. Broad St. Columbus, OH 43215-3705



Make two color sections on the end of the drive shaft. This is used to monitor the speed at which the drive shaft turns.



Lubricating Oil, BPTO 2380



BP Products North America Inc.



Lubricate the parts.



CAGE Code: 4XLA9



NOTE: If you cannot get BPTO 2380, you can use lubricating oil, MIL-L-23699. Lockwire



MS20995C20



Safety the plug and bleeders.



Masking Tape



Commercially available



Seal the area that do not get paint.



Marking Pen



TT-I-544



Make a reference mark on the threaded self-locking ring during the high speed balance procedure.



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Table 102. Materials (Continued) Material



Manufacturer or Specification



Use



Petroleum Solvent



AMS3160



Clean the parts.



Post-It Note Pad



3M Company



Put a cover on the area on the end of the drive shaft that has the white paint but does not get the black paint.



CAGE Code: 76381 3-Ton Adhesive - No. 750 Liquid Activator and No. 752 Plastic Powder



Davis Instruments



Bond the accelerometer to the turbine housing.



CAGE Code: 58502



G. The symbols and abbreviations used during TESTING are shown in Table 103. Table 103. Symbols and Abbreviations Symbols and Abbreviations



What It Shows



A



ACM self-induced vibration



ABR4



Acetylene Tetrabromide



ACM



Air cycle machine



CB



Corrected Barometer (ambient pressure)



Delta Pi



Fan static-pressure rise



G



Gravity (vibration level)



kPaa



Kilopascals absolute



N



Speed at which the ACM turns



lb/min



Pounds per minute



Pcal



Calibrated flowmeter pressure



Pcis



Compressor inlet static-pressure



Pchs



Compressor housing static-pressure



Pcos



Compressor outlet static-pressure



Pfis



Fan inlet static-pressure



Pfr



Flowmeter outlet pressure



psi



Pounds per square inch



psia



Pounds per square inch (absolute)



psig



Pounds per square inch (gage)



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Table 103. Symbols and Abbreviations (Continued) Symbols and Abbreviations



What It Shows



Pths



Turbine housing static-pressure



Ptis



Turbine inlet static-pressure



Ptos



Turbine outlet static-pressure



rpm



Revolutions per minute



Tcal



Calibrated flowmeter temperature



Tci



Compressor inlet temperature



Tfi



Fan inlet temperature



Tfr



Flowmeter outlet temperature



Tin



Inlet air temperature



Tti



Turbine inlet temperature



Tto



Turbine outlet temperature



Wfr



Flowmeter leakage indication (lb/min)



Wfrc



Corrected flowmeter leakage indication



Wt



Airflow through the turbine



°C



Degrees Celsius



°F



Degrees Fahrenheit



°R



Degrees Rankine



H. Put the covers supplied int he closure kit, GS20671-1, on all of the openings of the ACM. Remove each cover only it is necessary to use the opening. 2. What to do Before the Tests A. Turn the rotative assembly of the ACM manually. Use a light axial pressure in each direction when you turn the rotative assembly. The rotative assembly must turn freely. A light drag from the lead seals is permitted. B. Prepare the speed pickup as follows: (1) Apply masking tape and a cover on the fan-end of the ACM so that only the surface at the end of the drive shaft shows (Figure 101). WARNING: USE GOGGLES AND GLOVES WHEN YOU USE SPRAY PAINT. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (2) Apply the high-heat white spray-paint to the area that shows. Let the paint dry. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(3) Put a Post-it note on one-half of the area that has the white paint. NOTE: We recommend that you use a Post-it note because you can easily remove it from the area that has the paint. When the paint is dry, it does not bond to the Post-it note. You cannot remove masking tape from the paint as easily. (4) Apply the high-heat black spray-paint to the area that shows. C. Fill the oil sump as follows: (1) Fill the oil sump with oil a minimum of 1 hour before you do the tests. (2) Remove the plug and bleeder (220, IPL Figure 1, Sheet 2) from the turbine housing. WARNING: USE GOGGLES AND GLOVES WHEN YOU USE LUBRICATING OIL. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (3) Fill the oil sump with lubricating oil, BPTO 2380, until the level is above the liquid level sight plug (230A). NOTE: We recommend that you use BPTO 2380 oil to lubricate the ACM and its parts. If BPTO 2380 is not available, you can use MIL-L-23699 as an alternative. (4) Install the plug and bleeder (220). Torque 15 to 25 pound-inches (1.7 to 2.8 newtonmeters) more than running torque. The running torque of the plug and bleeder must be 9.5 to 80 pound-inches (1.1 to 9.0 newton-meters). D. Do a prelubrication of the ACM as follows: CAUTION: DO NOT KEEP THE ACM WITH THE SUMP UP FOR MORE THAN 30 SECONDS. THIS WILL KEEP OIL OUT OF THE TURBINE PASSAGES. (1) Turn the ACM so that the oil sump is up. This fills the bearings and seals with oil. (2) Turn the shaft several times while the ACM is in this position. (3) Turn the ACM so that the oil sump is down. This will let oil drain back into the sump.



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Figure 101. Preparation of the Speed Pickup E. Install the insulated mounting stud and accelerometer as follows: (1) Make an adapter as shown in Figure 102. (2) Clean the adapter and the top of the turbine housing as follows (Figure 103), WARNING: KEEP PETROLEUM SOLVENT AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES WHEN YOU USE IT. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT IS FLAMMABLE AND CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (a) Use a brush or swab to apply petroleum solvent. WARNING: USE GOGGLES WHEN YOU USE COMPRESSED AIR. MAKE SURE THE AIR PRESSURE IS NOT MORE THAN (30) PSIG. PARTICLES THAT ARE BLOWN BY COMPRESSED AIR CAN CAUSE DAMAGE TO YOUR EYES AND SKIN. (b) Dry the area with compressed air that is clean, dry, and filtered. WARNING: KEEP NO. 750 LIQUID ACTIVATOR AND NO. 752 PLASTIC POWDER AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES WHEN YOU USE THEM. IF YOU GET THEM ON YOUR SKIN, IMMEDIATELY FLUSH THE AREA WITH WATER. DO NOT BREATHE THEIR FUMES. USE THEM IN AN AREA WITH A GOOD FLOW OF AIR. THEY ARE FLAMMABLE AND CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (3) Mix equal parts (by volume) of No. 750 liquid activator with No. 752 plastic powder. Quickly mix the two parts of the 3-ton adhesive until it is almost the same as toothpaste. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(4) Immediately apply the mixed adhesive to the flat surface of the adapter. Install the adapter on the turbine housing as shown in Figure 103. (5) Install the insulated mounting stud, 2983B, as shown in Figure 103. (6) Install the accelerometer, 2271A, as shown in Figure 103. 3. Performance Tests A. Install the ACM in the test equipment configuration shown in Figure 104. NOTE: The width of the lines that connect the ACM to the test stand must all be the same diameter. B. For all configurations, do the vibration survey test as follows. For PNs 782790-16 and 18, do the fan-end shaft dynamic displacement test together with the vibration survey test as follows: NOTE: This test and the vibration survey test and the fan-end shaft displacement test use the same test conditions. It is important to successfully complete the fanend shaft dynamic displacement test first. If you monitor the vibration of the ACM during this test, you can use the measured vibration from the final run of the fan-end shaft dynamic displacement test for the vibration survey test. (1) During the test make sure that the compressor inlet temperature (Tci) stays in the limit shown in Figure 105. Maximum turbine inlet shall be 250°F (121°C). (2) Slowly increase the ACM speed to 15000 rpm. Keep this speed for a minimum of 1 minute. Measure the fan-end shaft displacement and write it on a record. Monitor the self-induced vibration level. (3) Increase the ACM speed to 65000 rpm, in 5000 rpm increments. Keep the ACM speed stable at each increment for a minimum of 1 minute. Monitor the fan-end shaft displacement continuously. Write the maximum fan-end shaft displacement, the maximum vibration level and the ACM speed at which they occurred on a record. The maximum permitted vibration levels are as follows: • 4.0 G at any stable rpm between 15000 and 65000 • 5.0 G at 65000 rpm • 5.0 G while the rpm increases between increments (15000 to 65000).



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(4) To calculate the maximum fan-end shaft dynamic displacement subtract the displacement measured in step (2) from the displacement measured in step (3). The maximum permitted fan-end shaft dynamic displacement is 0.002 inch.



Figure 102. Adapter for the Insulated Mounting Stud



Figure 103. Installation of the Insulated Mounting Stud and Accelerometer Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 104. Performance Test Equipment Configuration Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 105. Limits for the Compressor Inlet Temperature During the Vibration Survey (5) If the fan end shaft dynamic displacement and/or vibration levels are more than the permitted levels, but less than double the permitted levels, do these steps: (a) Slowly and continuously decrease the compressor inlet pressure (Pci) to zero.



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(b) Do a high speed balance as follows: NOTE: If the lowest speed at which the vibration level is less than 40000 rpm, change the balance weights (155, IPL Figure 1, Sheet 1) at the fan end first. If the vibration level was more than the limit at more than one speed, correct the level at the lowest speed first. This improves the vibration level at all the speeds. 1 Disassemble the ACM as necessary to change the balance weights (155) or (15, IPL Figure 2) as applicable. Refer to DISASSEMBLY. 2 Make a reference mark on the internal retaining ring (150, IPL Figure 1, Sheet 1) or (10, IPL Figure 2) and the threaded self-locking ring (160, IPL Figure 1, Sheet 1) or (20, IPL Figure 2) with a marking pen, TT-I-544, to show where they are aligned. 3 Do a vibration scan at five speed levels each time that you change the balance weights as follows: a Measure the vibration level (A) at 2000 rpm less than the lowest speed (N) at which the vibration was more than the limit. Write the vibration level (A) and the speed (N) on a record. b Increase the speed (N) four times, in increments of 1000 rpm. Write the vibration levels (A) and the speeds (N) on a record. c If the vibration is in the limits given in paragraph (4), do a vibration survey. Refer to paragraphs (1) thru (4). If the vibration is not in the limits, continue at paragraph 4. 4 Remove the internal retaining ring (150, IPL Figure 1, Sheet 1) or (10, IPL Figure 2). 5 Install a teflon weight PN 772427-1 in location 1 of the threaded self-locking ring (160, IPL Figure 1, Sheet 1) or (20, IPL Figure 2). Refer to Figure 106. 6 Install the internal retaining ring (150, IPL Figure 1, Sheet 1) or (10, IPL Figure 2). 7 Do a vibration scan. Refer to paragraph 3. 8 Do the procedures in paragraphs 4 thru 7 but use locations 2 and then 3. Refer to Figure 106. If the vibration scan and vibration survey are in the limits given in paragraph (4), continue at paragraph C. 9 Do the procedures in paragraphs 4 thru 7 but use the location that is between the holes (1, 2, and 3) that had the lowest and next to the lowest vibration levels. Refer to Figure 106. If the vibration scan and vibration survey are in the limits given in paragraph (4), continue at paragraph C. EXAMPLE #1: If location 1 had the lowest vibration level and location 2 had the next lowest vibration level, move the weight to location 1A. EXAMPLE #2: If location 3 had the lowest vibration level and location 2 had the next lowest vibration level, move the weight to location 2C.



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10 If the vibration level is lower, but not in limits, do the procedures in paragraphs 4 thru 7 move the weight one more hole in the direction of the next to the lowest vibration level. Refer to Figure 106. If the vibration scan and vibration survey are in the limits given in paragraph (4), continue at paragraph C. 11 If the vibration level is lower, but not in limits replace the teflon weight with an aluminum weight PN 772427-2 in the same location. Do a vibration scan. Refer to paragraph 3. If the vibration scan and vibration survey are in the limits given in paragraph (4), continue at paragraph C. 12 If the vibration level is lower, but not in limits replace the aluminum weight with a titanium weight PN 772427-3 in the same location. Do a vibration scan. Refer to paragraph 3. If the vibration scan and vibration survey are in the limits given in paragraph (4), continue at paragraph C.



Figure 106. Locations of the Balance Weights in the Threaded Self-Locking Ring 13 If heavier weights increase the vibration level, you can use more than one type of weight in more than one location. 14 If the vibration levels are not in limits after you do the high speed balance procedure, disassemble the ACM. Do balance checks of the cooling fan (170, IPL Figure 1, Sheet 1), compressor rotor (40, IPL Figure 2) and turbine rotor (100). (6) If the vibration levels are more than double the permitted levels, do these steps: (a) Slowly and continuously decrease the compressor inlet pressure (Pci) to zero. (b) Remove the ACM from the test equipment. (c) Remove the compressor housing (90, IPL Figure 1, Sheet 1) and compressor diffuser (115). Refer to DISASSEMBLY.



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(d) Examine the compressor rotor (40, IPL Figure 2) and the inner diameter of the compressor diffuser (115, IPL Figure 1, Sheet 1) to see if they rubbed. If you cannot see that they rubbed continue at step (e). If you can see that they rubbed, do these steps: 1 Remove the cooling fan (170) and rotative group (325, IPL Figure 1, Sheet 2). Refer to DISASSEMBLY. 2 Remove the marks from the compressor rotor (40, IPL Figure 2) where the compressor diffuser (115, IPL Figure 1, Sheet 1) rubbed. Refer to REPAIRGENERAL. 3 Remove the marks from the compressor diffuser (115) where the compressor rotor (40, IPL Figure 2) rubbed. Refer to REPAIR-GENERAL. 4 Assemble, do runout checks, and balance the ACM. Refer to ASSEMBLY. (e) Remove the cooling fan (170, IPL Figure 1, Sheet 1) and rotative group (325, IPL Figure 1, Sheet 2). Refer to DISASSEMBLY. (f) Examine the turbine rotor (100, IPL Figure 2) and the turbine housing (360, IPL Figure 1, Sheet 2) to see if they rubbed. If you cannot see that they rubbed continue at step (g). If you can see that they rubbed, do these steps: 1 Remove the marks from the turbine rotor (100, IPL Figure 2) where the turbine housing (360, IPL Figure 1, Sheet 2) rubbed. Refer to REPAIRGENERAL. 2 Remove the marks from the turbine housing (360) where the turbine rotor (100, IPL Figure 2) rubbed. Refer to REPAIR-GENERAL. 3 Assemble, do runout checks, and balance the ACM. Refer to ASSEMBLY. (g) Disassemble the rotative group (325, IPL Figure 1, Sheet 2). Replace the ball bearings (155, 235, IPL Figure 2). Refer to ASSEMBLY. (h) Assemble, do runout checks, and balance the ACM. Refer to ASSEMBLY. (i) Do the vibration survey again. Refer to paragraph B.



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C. Do a steady-state performance test as follows: (1) Set the conditions shown in Table 104. Keep these conditions for 10 minutes. Table 104. Performance Conditions Quantity



Unit of Measure



Condition



Symbol Minimum



Specified



Maximum



Compressor Inlet StaticPressure



psia



Pcis



33



34



35



Compressor Inlet Temperature



o



F (oC)



Tci



145 (62.8)



165 (73.9)



185 (85)



Turbine Outlet Static-Pressure



psia



Ptos



16.0



16.1



16.2



Turbine Inlet Temperature



o



Tti



185 (85)



190 (87.8)



195 (90.6)



Delta P



inches ABR4



Pcos-Ptis



29



-



-



Fan Inlet Static-Pressure



psia



Pfis



14.2



14.7



15.2



Fan Inlet Temperature



oF



Tfi



60 (15.6)



85 (29.4)



110 (43.3)



F



(oC)



(oC)



(2) After the 10 minutes, write the quantities for the data items shown in Table 105. (3) Find if the performance conditions are satisfactory as follows: (a) Find the intersection of the turbine weight flow (Wt) and the turbine inlet static pressure (Ptis) points on Figure 107 for part numbers 782790-6, 782790-10 and 782790-12, or Figure 108 for part numbers 782790-16 and 782790-18. The test result is satisfactory if the intersection is in the satisfactory area shown in the figure. (b) Turbine Delta Temperature 1 Calculate the turbine delta temperature as follows: Turbine Delta Temperature = (Tti - Tto)/(Tti+460) 2 Find the intersection of the turbine delta temperature and the turbine inlet static pressure (Ptis) points on Figure 109. Find if the point is in the satisfactory area shown on the figure.



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Table 105. Performance Data Data



Symbol



Unit of Measure



ACM self-induced vibration



A



G



Speed



N



rpm



Compressor inlet staticpressure



Pcis



psia



Compressor outlet staticpressure



Pcos



psia



Fan inlet static-pressure



Pfis



psia



Turbine inlet static-pressure



Ptis



psia



Turbine outlet static-pressure



Ptos



psia



Compressor inlet temperature



Tci



°F (°C)



Fan inlet temperature



Tfi



°F (°C)



Turbine inlet temperature



Tti



°F (°C)



Turbine outlet temperature



Tto



°F (°C)



Airflow through the turbine



Wt



lb/min



Fan static-pressure increase



delta Pi



inches H2O



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Figure 107. Turbine Performance Curve for PNs 782790-6, -10 and -12



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Figure 108. Turbine Performance Curve for PNs 782790-16 and 782790-18



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Figure 109. Turbine Delta Temperature



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(c) Compressor Performance 1 Find the compressor corrected speed on Figure 110. 2 Calculate the compressor static-pressure ratio as follows: Ratio = Pcos/Pcis 3 Find the point on Figure 111 where the lines made by the corrected speed and the compressor static-pressure ratio (Pcos/Pcis) are together. Find if the point is in the satisfactory area shown on the figure.



Figure 110. Compressor or Fan Corrected Speed



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Figure 111. Compressor Performance Curve



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(d) Fan Performance 1 Find the fan corrected speed on Figure 110. 2 Calculate the fan differential to static-pressure ratio as follows: Ratio = Delta Pf/Pfis 3 Find the point on Figure 112 where the lines made by the corrected speed and the fan differential to static-pressure ratio (Delta Pf/Pfis) are together. Find if the point is in the satisfactory area shown on the figure.



Figure 112. Fan Performance Curve



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D. Decrease all of the pressures to zero. E. Remove the plug and bleeder (220, IPL Figure 1, Sheet 2) that is at the bottom of the oil sump to drain the sump. F. Install the plug and bleeder (220). Torque 15 to 25 pound-inches (1.7 to 2.8 newtonmeters) more than running torque. The running torque of the plug and bleeder must be 9.5 to 80 pound-inches (1.1 to 9.0 newton-meters). Safety the plug and bleeder with lockwire MS20995C20. 4. Leakage Tests A. Turbine-Housing External-Leakage Test (1) Install the ACM in the test equipment configuration shown in Figure 113. NOTE: For ACM 782790-18, seal the turbine weep holes with elasticized modeling clay (Play-Do) during the test. Make sure to remove it after completion of test. (2) Pressurize the turbine inlet, measured at the flowmeter outlet (Pfr), to 14.5 to 15.5 psig. The temperature of the air must be 65 to 95°F (18.3 to 35°C). (3) Apply a soap and water solution to area around the oil sump openings and the sump cover. Examine the areas with the solution for leakage. If you see any leakage, replace the applicable packings. (4) When you can see that there is no leakage from the oil sump, measure the total leakage with the flowmeter.



Figure 113. Turbine-Housing External-Leakage Test Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(5) Calculate the corrected leakage rate as follows: ( Pfr ) ( Tcal ) Wfrc = Wfr -----------------------------( Pcal ) ( Tfr ) where: Wfrc



= Corrected flowmeter leakage indication (lb/min)



Wfr



= Flowmeter leakage indication (lb/min)



Pfr



= Flowmeter outlet pressure (psia)



Pcal



= Calibrated flowmeter pressure (psia)



Tfr



= Flowmeter outlet temperature (°R)



Tcal



= Calibrated flowmeter temperature (°R) The total leakage must not be more than 0.38 pound per minute (0.17 kg).



(6) Decrease the pressure to zero. Bleed the test stand B. Compressor-Housing External-Leakage Test (1) Install the ACM in the test equipment configuration shown in Figure 114. (2) Pressurize the compressor outlet, measured at the flowmeter outlet (Pfr), to 14.5 to 15.5 psig (100 to 107 kpag). The temperature of the air must be 65 to 95°F (18.3 to 35°C). (3) Measure the total leakage with the flowmeter. (4) Repeat steps A.(5) and (6), above except that the total leakage must not be more than 0.23 ppm (0.10 kg/m) for ACMs 782790-6, -10, and -12, or 0.42 (0.19 kg/m) for ACMs 782790-16 and 18. 5. What to do After the Tests are Completed A. Remove the test fixtures from the ACM. Remove the ACM from the test stand. WARNING: KEEP PETROLEUM SOLVENT AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES WHEN YOU USE IT. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT IS FLAMMABLE AND CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. B. Examine the ACM for contamination from oil or grease. If there is contamination in the air passages, remove the contamination with a clean cloth and petroleum solvent. C. Remove the accelerometer and insulated mounting stud as follows: (1) Remove the accelerometer from the insulated mounting stud. (2) Lightly hit the insulated mounting stud with a small plastic mallet to loosen it from the turbine housing. Remove the stud. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(3) Carefully remove the adhesive from the turbine housing and the insulate mounting stud with a knife.



Figure 114. Compressor-Housing External-Leakage Test (4) Remove the remaining adhesive as follows: WARNING: KEEP PETROLEUM SOLVENT AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES WHEN YOU USE IT. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT IS FLAMMABLE AND CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (a) Apply petroleum solvent with a brush or swab. WARNING: USE GOGGLES WHEN YOU USE COMPRESSED AIR. MAKE SURE THE AIR PRESSURE IS NOT MORE THAN (30) PSIG. PARTICLES THAT ARE BLOWN BY COMPRESSED AIR CAN CAUSE DAMAGE TO YOUR EYES AND SKIN. (b) Dry the parts with compressed air that is clean, dry, and filtered. (5) If the layer of chemical film on the turbine housing gets damage when you remove the insulated mounting stud, apply chemical film, AMS2473, to the areas that have damage. Let the chemical film dry before you move the ACM.



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6. Fault Isolation A. Refer to Table 106 for ACM fault isolation information. Table 106. Fault Isolation Test Result That is not Satisfactory



Possible Cause



How to Correct it



Pre-Test That the Drive Shaft Turns Freely When you turn the rotative assembly in one direction it rubs. It does not rub in the other.



The turbine rotor (100, IPL Figure 2) or compressor rotor (40) rub the housing or diffuser.



Do checks of the end-play of the drive shaft, the runouts of the rotor, and the selection of shims for the rotors. Refer to ASSEMBLY.



Vibration Survey Test The vibration level is more than the limits.



The compressor rotor (40, IPL Figure 2) rubs the compressor diffuser (115, IPL Figure 1, Sheet 1).



Increase the thickness of the solid shims (125, IPL Figure 1, Sheet 1).



The turbine rotor (100, IPL Figure 2) rubs the turbine housing (360, IPL Figure 1, Sheet 2).



Install a sleeve bushing (180, IPL Figure 2) that is longer.



The assembly is incorrectly balanced.



Do the balance procedure.



The cooling fan (170, IPL Figure 1, Sheet 1) runout is incorrect.



Correct the runout.



The compressor rotor (40, IPL Figure 2) or turbine rotor (100) runouts are incorrect.



Correct the runouts.



The compressor diffuser (115, IPL Figure 1, Sheet 1) is not in the center on the compressor rotor (40, IPL Figure 2).



Move the compressor diffuser to the center.



The ball bearings (155 and 235, IPL Figure 2) have damage.



Replace the ball bearings.



Steady-State Performance Test The turbine performance is not satisfactory.



The vanes of the turbine rotor (100, IPL Figure 2) have erosion or damage.



Repair or replace the turbine rotor.



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Table 106. Fault Isolation (Continued) Test Result That is not Satisfactory



Possible Cause



The compressor performance is not satisfactory.



The fan performance is not satisfactory



How to Correct it



The throat area of the turbine housing (360, IPL Figure 1, Sheet 2) has erosion or damage.



Repair or replace the turbine housing.



The vanes of the compressor rotor (40, IPL Figure 2) have erosion or damage.



Repair or replace the turbine rotor.



The throat area of the compressor diffuser (115, IPL Figure 1, Sheet 1) has erosion or damage.



Repair or replace the compressor diffuser.



The blades of the cooling fan (170, IPL Figure 1, Sheet 1) have erosion or damage.



Repair or replace the cooling fan.



The liner or the containment housing (145, IPL Figure 1, Sheet 1) has erosion or damage.



Replace the liner (15, IPL Figure 3).



Turbine-Housing External-Leakage Test The leakage is not in its limits.



The performed packings (265, 330, IPL Figure 1, Sheet 2), (5, 80, IPL Figure 2) are damaged.



Replace the performed packings.



The seals (62, 95, IPL Figure 2) are worn.



Replace the seals.



The sump cover (260, IPL Figure 1, Sheet 2) is damaged.



Repair or replace the sump cover.



The turbine housing (360, IPL Figure 1, Sheet 2) is damaged.



Repair or replace the turbine housing.



Compressor-Housing External-Leakage Test The leakage is not in its limits.



The preformed packings (100, IPL Figure 1, Sheet 1), (45, IPL Figure 2) are damaged.



Replace the preformed packings.



The seals (62, 95, IPL Figure 2) are worn.



Replace the seals.



The compressor housing (90, IPL Figure 1, Sheet 1) is damaged.



Repair or replace the compressor housing.



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THIS IS A BLANK PAGE



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DISASSEMBLY 1. General A. The disassembly procedure is written for complete component maintenance. If partial disassembly is required, use only the applicable sections pertinent to partial component maintenance. NOTE: Refer to TESTING AND FAULT ISOLATION to establish the condition of the component or most probable cause of its malfunction. This is to determine the extent of disassembly required without completely tearing down and rebuilding the component. B. Remove all protective caps and covers prior to disassembly. C. Cut and remove all external lockwire prior to disassembly. Remove warning tag (175, IPL Figure 1, Sheet 2), if present. D. Throughout the disassembly procedure, turbine end refers to the end of the unit which contains the turbine and compressor rotors, and fan end refers to the end in which the cooling fan is located. E. Disassemble generally in numerical sequence of item numbers shown in IPL Figures 1, 2 and 3. F. Where referenced in the disassembly procedures, remove rotors by heating in accordance with the following procedure: WARNING: HANDLING HOT ITEMS PRESENTS SERIOUS BURN POTENTIAL. HEAT RESISTANT GLOVES MUST BE WORN. CAUTION: HEAT ROTOR ONLY AS INDICATED TO PREVENT HOT SPOTS AND LOSS OF ROTOR HARDNESS. (1) Heat rotor using heat gun, Model VT-750B. Maintain a minimum distance of one-half inch between heat gun tip and rotor. (2) Frequently rotate rotor a quarter of a turn to prevent hot spots. (3) After each quarter turn, check rotor surface temperature, in area last heated, using handle and probe set, Model HDX-SET- FSP-T-OST, and digital thermometer, Model HH99A-T1, so that a maximum temperature of 250°F is not exceeded. (4) Frequently check to see if rotor can be removed to minimize amount of heating. (5) Do not heat rotor for more than 1 hour. G. Use a Wilton PowRarm, Model 301, which is a swivel holding tool, to hold and position the ACM during disassembly, as required. The bearing sleeve holder, GS15615-1, and power arm fixture, GS22815-1, which are listed in Table 301, are designed for mounting on the Wilton PowRarm.



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H. Special tools, fixtures, and equipment required for disassembly are listed in Table 301. NOTE: Equivalent tools, fixtures, and equipment can be used if they agree with the requirements of ARINC Report 668. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 301. Special Tools, Fixtures, and Equipment TOOL NO.



NOMENCLATURE



USE



GS15609-1



Carbon Seal Puller



Remove face seals from bearing cartridge sleeve.



GS15610-1



Bearing Sleeve Support



Support bearing cartridge sleeve during removal of turbine end ball bearing, and support fan end ball bearing during removal from removal from drive shaft.



GS15614-1



Seal and Spring Seat Installer Driver



Remove spring seat from bearing cartridge sleeve.



GS15615-1



Bearing Sleeve Holder



Hold rotative group during disassembly. Mounts to Wilton PowRarm, Model 301.



GS15618-1



Check Nut (2 Required)



Hold drive shaft during removal of turbine end threaded self locking ring.



GS15622-1



Turbine Housing Support



Hold ACM during removal of containment housing.



GS22333-2



Spanner Wrench (2 Required)



Remove fan end threaded self locking ring.



GS22529-1



Compressor Housing Extractor (2 required)



Remove compressor housing.



GS22815-1



Power Arm Fixture



Hold turbine housing and rotative group during disassembly. Mounts to Wilton PowRarm, Model 301.



Model HDX-SET-FSP-T-OST, Model HH99A-T1



Handle and Probe Set, Digital Thermometer Omega Engineering Inc. One Omega Dr. P.O. Box 4047 Stamford, CT 06907-0047



Check surface temperature of rotors to prevent overheating during removal.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 301. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.



NOMENCLATURE



USE



Model VT-750B



Heat Gun Master Appliance Corp. 2420 18th St. P.O. Box 68 Racine, WI 53401



Heat rotors for removal.



Model 301



Wilton PowRarm Wilton Corp. 300 S. Hicks Road Palatine, IL 60067



Swivel holding and positioning tool, used with items GS15615-1 and GS22815-1.



CAGE Code: 66080



I. Consumable materials required for disassembly are listed in Table 302. NOTE: Maintenance personnel must use the specified consumable material for the specified task. These consumable materials are known to agree with all of the design and qualification requirements. Only approved materials engineering personnel can make equivalent consumable material decisions. These materials are used at the risk of the organization who makes the decision. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 302. Consumable Materials MATERIAL



MANUFACTURER OR SPECIFICATION



USE



Anti-Seize Thread Lubricant



MIL-T-5544



Protect drive shaft threads during removal of threaded self locking rings.



Petroleum Solvent



AMS3160



Soften adhesive when removing outlet gaskets.



2. Drain Oil from Sump A. Drain oil from sump, if not previously drained, or drain any residual oil by removing plug and bleeder (220, IPL Figure 1, Sheet 2) from sump cover (245). Temporarily replace plug in cover. 3. Removal of Fan Outlet Diffuser A. Remove six screws (5, IPL Figure 1, Sheet 1) and six washers (10) that retain fan outlet diffuser (15) to containment housing (145). B. Remove fan outlet diffuser (15). Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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4. Removal of Turbine Outlet Cover A. Remove six screws (20, IPL Figure 1, Sheet 1), six washers (25), and outlet cover (30). 5. Removal of Turbine Outlet Duct A. Remove six screws (40, IPL Figure 1, Sheet 1), six washers (45), and turbine outlet duct (50). 6. Removal of Outlet Gaskets WARNING: PETROLEUM SOLVENT, AMS3160, IS COMBUSTIBLE AND MODERATELY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. EYE AND SKIN PROTECTION REQUIRED. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. A. Remove outlet gaskets (35 and 55, IPL Figure 1, Sheet 1) from turbine housing (335, IPL Figure 1, Sheet 2) using a plastic scraper and petroleum solvent, AMS3160, to loosen gasket adhesive. Remove any residual adhesive from housing with a clean cloth dampened with solvent. Discard gaskets. 7. Removal of Containment Housing A. Place assembly fan end down on turbine housing support fixture, GS15622-1. B. Remove nine screws (135, IPL Figure 1, Sheet 1) and nine washers (140) that retain containment housing (145) to turbine housing (335, IPL Figure 1, Sheet 2). C. Lift assembly off of containment housing (145, IPL Figure 1, Sheet 1). If necessary, disassemble containment housing (145) in accordance with paragraph 15. D. Install assembly in a horizontal position in power arm fixture, GS22815-1. Fasten assembly to fixture at the fan side flange of turbine housing (335, IPL Figure 1, Sheet 2). 8. Removal of Identification Plate and Warning Plate A. If necessary, remove four screws (180, IPL Figure 1, Sheet 2) and identification plate (185). B. If necessary, remove four screws (190) and warning plate (195). 9. Removal of Plugs and Bleeders and Liquid Level Sight Plug A. Remove pin (200, IPL Figure 1, Sheet 2), spring wire (205), and chain (210). For ACMs incorporating L9, also remove pin (201), spring wire (206), and chain (211). Discard pins (200 and 201). B. Remove two plugs and bleeders (220) and two preformed packings (215). Discard packings. For ACMs incorporating L9, also remove plug and bleeder (221) and preformed packing (216). Discard packing. C. Remove liquid level sight plug (230A) and preformed packing (225). Discard packing. 10. Removal of Lubrication Parts A. Straighten locking tabs on tab washer (240, IPL Figure 1, Sheet 2). Remove internal retaining ring (235) and tab washer (240). Discard tab washer. B. Remove sump cover (245) and preformed packing (265). Discard packing. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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C. Do not remove headless straight pin (250) from cover (260) unless pin is bent or projection exceeds limit of CHECK. See REPAIR-GENERAL. D. Do not remove insert (255) from cover (260) unless insert is loose or damaged. See REPAIR-GENERAL. E. Remove two screws (270), two washers (275), and retaining plate (280). F. Remove two spring retainers (285), two springs (290), two wick bushings (295), and two nonmetallic wicks (300). Discard wicks. 11. Removal of Compressor Housing and Compressor Diffuser A. If necessary, remove plug and bleeder (60, IPL Figure 1, Sheet 1) and preformed packing (65). Discard packing. B. Remove ten nuts (70), ten washers (75), ten screws (85), and ten washers (80). Remove compressor housing (90) by carefully prying off with two compressor housing extractors, GS22529-1, inserted under flange of housing. Remove preformed packing (100) and discard. C. Do not remove insert (95) from compressor housing (90) unless insert is loose or damaged. See REPAIR-GENERAL. CAUTION: REMOVE COMPRESSOR DIFFUSER (115) ONLY IN AN AXIAL DIRECTION TO PREVENT DAMAGING THE BLADES OF COMPRESSOR ROTOR (30, IPL FIGURE 2). D. Remove eight screws (105, IPL Figure 1, Sheet 1) and eight washers (110). Carefully pry off compressor diffuser (115) and heat shield (120). E. Remove the two exposed spiral spring pins (55, IPL Figure 2). Discard pins. F. Remove solid shims (125, IPL Figure 1, Sheet 1). 12. Removal of Cooling Fan A. Remove internal retaining ring (150, IPL Figure 1, Sheet 1) and balance weight(s) (155), if present, from fan end threaded self locking ring (160). NOTE: Balance weights (155) and (15, IPL Figure 2) are reusable. Do not discard. B. Remove internal retaining ring (10) and balance weight(s) (15), if present, from turbine end threaded self locking ring (20). CAUTION: APPLY LUBRICANT TO THREADED ENDS OF DRIVE SHAFT (240), AS INDICATED IN PARAGRAPH C., TO REDUCE THE POSSIBILITY OF THREAD DAMAGE DURING REMOVAL OF THREADED SELF LOCKING RINGS (160, IPL FIGURE 1, SHEET 1) AND (20, IPL FIGURE 2). C. Apply anti-seize thread compound, MIL-T-5544, to threaded ends of drive shaft (240). D. Install spanner wrenches, GS22333-2, in balance weight holes of threaded self locking rings (160, IPL Figure 1, Sheet 1) and (20, IPL Figure 2). E. While holding turbine end threaded self locking ring (20), remove fan end threaded self locking ring (160, IPL Figure 1, Sheet 1). Remove flat washer (165).



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F. Remove cooling fan (170) by heating in accordance with the procedure in paragraph 1.F. G. Remove fan spacer (320, IPL Figure 1, Sheet 2). 13. Removal of Rotative Group A. Remove stepped pin (305, IPL Figure 1, Sheet 2). B. For ACMs not incorporating L9, remove 15 screws (310) and 15 washers (315). For ACMs incorporating L9, remove 11 screws (311) and 11 washers (316). C. Remove assembly from power arm fixture, GS22815-1. CAUTION: DO NOT USE A BANGING MOTION OR IMPACT TYPE FORCE TO REMOVE ROTATIVE GROUP (325) FROM TURBINE HOUSING (335) AS BALL BEARINGS (155 AND 235, IPL FIGURE 2) WILL BE DAMAGED AND REQUIRE REPLACEMENT. REMOVE ASSEMBLY ONLY AS INDICATED IN PARAGRAPH D. D. Place assembly fan end up on an arbor press with turbine housing (335, IPL Figure 1, Sheet 2) resting on support blocks to provide clearance for removal of rotative group (325). Carefully press down on fan end of drive shaft (240, IPL Figure 2), using as little pressure as necessary, to remove rotative group (325, IPL Figure 1, Sheet 2) from turbine housing (335). E. Remove two preformed packings (330) and the fan split ring (332) from fan end bore of turbine housing (335). Discard packings. F. For turbine housing (335 or 335A), do not remove 18 inserts (340), 15 inserts (345), insert (350) or insert (354) from housing (360 or 360A) unless inserts are loose or damaged. See REPAIR-GENERAL. G. For turbine housing (335B), do not remove 18 inserts (340), 11 inserts (346), insert (350) or two inserts (355) from housing (360B) unless inserts are loose or damaged. See REPAIR-GENERAL. H. Do not remove bushing (356) from housing (360A or 360B) unless ID of bushing exceeds limit specified in CHECK. See REPAIR 4-3. 14. Disassembly of Rotative Group A. Remove preformed packing (5, IPL Figure 2) and turbine split ring (6) from bearing cartridge sleeve (275). Discard packing. B. Remove preformed packing (45) from seal plate (60) and preformed packing (80) from nozzle plate and insulator (85). Discard packings. C. Place rotative group in bearing sleeve holder, GS15615-1. D. Install two check nuts, GS15618-1, on fan end of drive shaft (240) and tighten nuts together. While holding inner nut, remove threaded self locking ring (20) with spanner wrench, GS22333-2. Remove flat washer (25) and check nuts.



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CAUTION: IF NECESSARY TO PRY UNDER ROTOR TO ASSIST IN ITS REMOVAL, USE A THIN, WIDE BLADE TOOL TO ENSURE THAT PRESSURE IS DISTRIBUTED OVER THE AREA OF SEVERAL ROTOR VANES TO PREVENT DEFORMATION OF ROTOR. E. Remove compressor rotor (30) by heating in accordance with the procedure in paragraph 1.F. If necessary, removal of rotor may be assisted by carefully prying underneath rotor in two spots. F. Do not remove two headless straight pins (35) from rotor (40). G. Carefully remove seal plate (60), nozzle insulator (70 or 70A), seal disk (75), and nozzle plate and insulator (85). H. Remove the two exposed spiral spring pins (50) and discard. I. Do not remove eight inserts (65) from seal plate (60) unless inserts are loose or damaged. See REPAIR-GENERAL. Lead seal (62) in seal plate (60) must be replaced each time seal plate is removed. See REPAIR 6-1. J. Lead seal (95) in nozzle plate and insulator (85) must be replaced each time nozzle plate and insulator is removed. See REPAIR 7-1. K. Remove turbine rotor (100) by heating in accordance with the procedure in paragraph 1.F. L. Remove aluminum sleeve bushing (180) and record length or dash number of bushing for reference use during assembly. M. Remove internal retaining ring (160) and shims (165). N. Remove face seal (205) using carbon seal puller, GS15609-1. Discard face seal. O. Temporarily position rotative group turbine end down and remove seal ring (230) and shims (210). Discard seal ring. Reposition rotative group with turbine end up and remove internal retaining ring (225). P. Invert rotative group in bearing sleeve holder, GS15615-1, with fan end up. Remove internal retaining ring (105) and shims (110). Q. Remove face seal (125) using carbon seal puller, GS15609-1. Discard face seal. R. Temporarily position rotative group fan end down and remove seal ring (150) and shims (130). Discard seal ring. Reposition rotative group with fan end up and remove internal retaining ring (145). S. Remove rotative group from bearing sleeve holder, GS15615-1. Place assembly on bearing sleeve support, GS15610-1, with fan end of drive shaft (240) facing down. T. Using an arbor press, carefully press on turbine end of drive shaft (240) until ball bearing (235) unseats from shaft. Remove shaft with attached ball bearing (155) from fan end of bearing cartridge sleeve (275). Remove ball bearing (235) from turbine end of sleeve. Discard ball bearing. NOTE: Ball bearings (155 and 235) must be replaced whenever they are removed from drive shaft (240) or whenever the ACM is being disassembled for a complete overhaul. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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U. Place drive shaft (240) turbine end down in bearing sleeve support, GS15610-1, supported by ball bearing (155). Using an arbor press, carefully press on fan end of drive shaft (240) until ball bearing (155) unseats from shaft. Remove bearing from shaft. Discard bearing. V. Insert seal and spring seat installer driver, GS15614-1, into fan end of bearing cartridge sleeve (275). Press tool against spring seat (250) to compress compression spring (270) and remove one headed straight pin (245). Discard pin. W. Remove spring seat (250), compression spring (270), and shims (255) from fan end of bearing cartridge sleeve (275). Record thickness of shims (255) for reference use during assembly. NOTE: If unit being disassembled suffered bearing seizure, compression spring (270) must be replaced. X. Remove remaining headed straight pin (245) and spring seat (250) from turbine end of bearing cartridge sleeve (275). Discard pin. NOTE: Do not disassemble bearing cartridge sleeve (275) as there are no userserviceable parts. 15. Disassembly of Containment Housing A. Remove three screws (5, IPL Figure 3) and three washers (10). Remove liner (15) and containment ring (20) from housing (55). B. Remove preformed packing (25) from housing (55). C. Do not remove three rivets (35) or four rivets (40) unless inlet screen (45) is damaged. See REPAIR 11-3. D. Do not remove 18 inserts (30) from housing (55) unless they are loose or damaged. See REPAIR-GENERAL. E. Do not remove three headless straight pins (50) from housing (55) unless liner (15) is to be replaced. See REPAIR 11-1.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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CLEANING 1. General A. See Table 401 for consumable materials. NOTE: Maintenance personnel must use the specified consumable material for the specified task. These consumable materials are known to agree with all of the design and qualification requirements. Only approved materials engineering personnel can make equivalent consumable material decisions. These materials are used at the risk of the organization who makes the decision. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http:// www.logisticsinformationservice.dla.mil. Other CAGE Code sites are also available on the Web. Table 401. Consumable Materials MANUFACTURER OR SPECIFICATION



MATERIAL



USE



Corrosion Preventive Compound



AMS3078



Corrosion prevention.



Isopropyl Alcohol



TT-I-735 Grade A



Cleaning solvent.



Oakite 202 or Aakite 79L Cleaner



Oakite Products, Inc. 50 Valley Road Berkeley Heights, NJ 07922



Rotor cleaning.



CAGE Code: 44389 Petroleum Solvent



AMS3160



Cleaning solvent.



Sodium-Bicarbonate Blast Media (ARMEX blast media maintenance formula or equivalent)



Commercially available



Used for the sodiumbicarbonate dry-abrasive blasting procedure of the steel and the aluminum sub assembly components.



2. General Cleaning Procedures CAUTION: DO NOT USE METAL WOOL, METAL BRUSHES, OR ABRASIVES TO CLEAN PARTS TO AVOID DAMAGING PARTS. A. Clean all parts (except parts requiring replacement) by immersion, swabbing, or spraying with the appropriate solvent. If deposits do not readily wash off, the part may be scrubbed with a natural bristle brush.



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WARNING: COMPRESSED AIR USED FOR CLEANING CAN CREATE AIRBORNE PARTICLES THAT MAY ENTER THE EYES. PRESSURE MUST NOT EXCEED 30 PSIG. EYE PROTECTION REQUIRED. B. Dry parts, including passageways, using clean, dry, filtered, low-pressure, compressed air. 3. Cleaning Steel or Aluminum Subassembly Components With Dry Abrasive A. The steel or the aluminum subassembly components of the ACM can be cleaned by a sodium-bicarbonate dry-abrasive blasting with the procedures that follow: CAUTION: THE SODIUM-BICARBONATE DRY-ABRASIVE BLASTING MUST NOT BE USED TO CLEAN THE BEARING SURFACES SUCH AS BEARING SHAFTS, THRUST BEARING SURFACES, OR RING SEALS. THIS CAN RESULT IN DEGRADATION OF THE SURFACE FINISH. CAUTION: SOME OF THE COMPONENTS CAN CONTAIN SEMI-PERMANENT PART MARKINGS SUCH AS INK MARKINGS. THE PART MARKINGS MUST BE MASKED BEFORE THE SODIUM-BICARBONATE DRYABRASIVE BLASTING PROCEDURE SO THEY ARE NOT DAMAGED. (1) Clean the steel and the aluminum components by sodium-bicarbonate dry-abrasive blasting with a sodium-bicarbonate dry-abrasive blast media. The components must be placed in a applicable blast cabinet or chamber for this procedure. WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER SQUARE INCH (200 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET MEDICAL ATTENTION. (2) Use dry, filtered, compressed air supply 25 pisg (172.4 kPa) maximum to clean the remaining media from the parts after the blast procedure. (3) Immediately after the sodium-bicarbonate dry-abrasive blasting procedure flush the parts in clean water to completely remove the remaining sodium-bicarbonate blast media. NOTE: Parts must be washed 20 minutes after the sodium-bicarbonate dryabrasive blasting procedure. (4) Make sure that the sodium-bicarbonate dry-abrasive blast media has been flushed from the threads, passageways, steel grooves, and concealed areas where the sodium-bicarbonate dry-abrasive blast media can collect. WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS. (5) Put the components in an oven at 220 to 230 °F (104 to 110 °C) for 1 to 2 hours to dry.



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4. Cleaning Nonmetallic Parts WARNING: KEEP ISOPROPYL ALCOHOL, TT-I-735, AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES. USE ISOPROPYL ALCOHOL, TT-I-735, IN AN AREA WITH A GOOD FLOW OF AIR. ISOPROPYL ALCOHOL, TT-I-735, IS FLAMMABLE AND CAN IRRITATE THE EYES, SKIN, AND RESPIRATORY TRACT. A. Nonmetallic parts which contain a rubber or synthetic base may deteriorate from exposure to organic solvents. When necessary, clean these parts with a soft, lint-free cloth moistened with isopropyl alcohol. Immediately after cleaning, wipe the parts dry to remove residual solvent. 5. Cleaning Metallic Parts WARNING: PETROLEUM SOLVENT, AMS3160, IS COMBUSTIBLE AND MODERATELY TOXIC TO SKIN, EYES AND RESPIRATORY TRACT. EYE AND SKIN PROTECTION REQUIRED. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. WARNING: COMPRESSED AIR USED FOR CLEANING CAN CREATE AIRBORNE PARTICLES THAT MAY ENTER THE EYES. PRESSURE MUST NOT EXCEED 30 PSIG. EYE PROTECTION REQUIRED. A. Use petroleum solvent, AMS3160, to clean metallic parts. Use clean, dry, filtered, lowpressure, compressed air to dry the cleaned parts. B. Rotors shall be cleaned prior to inspection by immersing in a tank containing 2 to 5 percent (by volume) Oakite 202 or Oakite 79L. Allow to soak for 15 to 30 minutes. Rinse with cold water until no evidence of cleaner remains. Drain, reinspect for cleanliness, and repeat if necessary. Dry with clean, dry, filtered, low-pressure, compressed air. C. When a delay in the scheduled component maintenance occurs, coat all cleaned, unpainted metallic surfaces with corrosion preventive compound, AMS3078. When the component maintenance procedure has been rescheduled, remove the compound prior to parts inspection by cleaning with petroleum solvent, AMS3160.



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CHECK 1. General A. Special tools, fixtures, and equipment required for check are listed in Table 501. NOTE: Equivalent tools, fixtures, and equipment can be used if they agree with the requirements of ARINC Report 668. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 501. Special Tools, Fixtures, and Equipment TOOL NO. CAB 570 or CAB 690-R



NOMENCLATURE Balance Machine Schenck Trebel Copr. 535 Acorn St. Deer Park, NY 11729



USE Check biplanar balance of cooling fan, compressor rotor, or turbine rotor.



CAGE Code: 30218 GS14773-1



Balance Fixture



Hold cooling fan, compressor rotor, or turbine rotor during balance check on balance machine, CAB 570 or CAB 690-R.



GS15611-1



Arbor Set



Install cooling fan, compressor rotor or turbine rotor in balance fixture, GS14773-1.



GS15800-1



Balancing Accessories Kit



Controls air flow to drive cooling fan, compressor rotor, or turbine rotor during balance check.



GS15801-1



Balance Machine Nozzle Assembly



Direct air flow to cooling fan, compressor rotor, or turbine rotor during balance check.



CAUTION: TO REALIZE PROPER EQUIPMENT OPERATION AND SERVICE LIFE, IT IS ESSENTIAL THAT ALL SUBSEQUENT STEPS BE PERFORMED IN THE CLEANEST, DRIEST ENVIRONMENT POSSIBLE. KEEP ALL PARTS COVERED WHENEVER WORK IS NOT BEING PERFORMED ON THEM. AVOID TOUCHING THE SURFACES OF FINELY MACHINED PARTS. B. Visually check all parts for evidence of wear, galling, metal pickup, cracks, nicks, burrs, and other damage. Refer to Table 502 for specific check procedures. If repairable, refer to REPAIR-GENERAL.



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C. Check all surface treated parts for damage and wear exposing base metal. Repair in accordance with REPAIR-GENERAL or the specific repair referenced. D. Dimensionally inspect parts only when visual inspections indicate wear, unless otherwise specified. It is not necessary to inspect basic profile dimensions shown in figures and charts if wear is not indicated. E. Carefully check the mating surfaces of the parts listed below for burrs, since even extremely small burrs may result in excessive rotor or drive shaft runouts during build-up of the rotative group. Also, check parallelism, perpendicularity, and flatness of mating surfaces of these parts, where specified in Table 502. Threaded self locking rings (160, IPL Figure 1, Sheet 1) and (20, IPL Figure 2) Flat washers (165, IPL Figure 1, Sheet 1) and (25, IPL Figure 2) Cooling fan (170, IPL Figure 1, Sheet 1) Fan spacer (320, IPL Figure 1, Sheet 2) Compressor rotor (30, IPL Figure 2) Seal disk (75, IPL Figure 2) Turbine rotor (100, IPL Figure 2) Seal rings (150 and 230, IPL Figure 2) Aluminum sleeve bushing (180, IPL Figure 2) F. Check passageways for freedom from obstruction. Remove obstruction in accordance with CLEANING. G. Check threads, including inserts, for wear, burrs and nicks. Repair nicks and burrs in accordance with REPAIR-GENERAL. If required, ascertain that threads maintain installation torque. H. If necessary, use a 10-power magnifying glass to confirm reliability of suspected or marginal parts. I. Write the information from the identification plate (185, IPL Figure 1) on a record. Put the information on the plate as specified in ASSEMBLY. If you cannot find the plate, find the necessary information as follows: (1) Look at the records for the unit to find the part number, modification data and serial number. Put the information on the identification plate (185) as specified in ASSEMBLY. If you cannot find this information in the records do steps (2) thru (4), as necessary. (2) Use the applicable detail parts of the unit to identify the unit part number and modification data. The Configuration Change Summary and the Detailed Parts List in the Illustrated Parts List supply the necessary information. (3) Give the unit a new serial number that includes these elements: - Facility identification (e.g. LB) - Month/Year (e.g. 0294) - A sequence-identification for each separate serial number given to each part number by the facility during the identified month (e.g. A). Two examples of serial numbers that include these elements are shown below:



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Example 1:



LB0294A



LB



02



94



A



HSSLB



FEB



1994



The first serial number assigned by HSSLB to this part number during Feb 94



B



MT1194B



Example 2: MT



11



94



MICROTECNICA



NOV



1994



The second serial number assigned by Microtecnica to this part number during Nov 94.



(4) Write the information from steps (2) and (3) on a record that you will keep. Put the information on the identification plate (185) as specified in ASSEMBLY. 2. Specific Check Requirements A. Refer to Table 502 thru Table 518 for items to be specifically checked NOTE: Acceptance or rejection of parts receiving nondestructive inspection shall be determined on service incurred defects only, such as fatigue cracks and overstress cracks. Minor surface irregularities or machine marks are not to be considered cause for rejection. Table 502. General Checks Nomenclature (Item and IPL Figure Number)



Type Check



Procedure



Allowable Limits



Turbine Outlet Duct (50, IPL Figure 1, Sheet 1)



Visual



Check insulation material on duct for damage.



Patch damaged areas in accordance with REPAIR 1-1.



Compressor Housing (90, IPL Figure 1, Sheet 1)



Visual



Check housing and duct ends for deformation and cracks.



Only minor damage from normal use and handling allowed. No cracks allowed.



Fluorescent Penetrant



Check in accordance with AMS 2645.



No service incurred cracks allowed. (See NOTE, above.)



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Table 502. General Checks (Continued) Nomenclature (Item and IPL Figure Number) Threaded Self Locking Ring (160, IPL Figure 1, Sheet 1) and (20, IPL Figure 2)



Type Check Visual



Procedure



Allowable Limits



Check washer contact surface to ensure that surface is free of sharp edges and burrs.



Blend sharp edges and remove burrs in accordance with REPAIR-GENERAL.



Check threads for burrs and for wear.



Remove burrs in accordance with REPAIR-GENERAL. Replace rings if threads are worn.



Liquid Level Sight Plug (230A, IPL Figure 1, Sheet 2)



Visual



Check for adequate retention of lens.



Replace sight plug if lens is loose or there is inadequate metal lip retaining the lens to the plug.



Sump Cover (245, IPL Figure 1, Sheet 2)



Visual and Dimensional



Check straightness and projection of headless straight pin (250). Projection shall be 0.26 inch maximum.



Replace pin in accordance with REPAIR-GENERAL if pin is bent or projection exceeds limit.



Retaining Plate (280, IPL Figure 1, Sheet 2)



Visual



Check for obvious deformation. Check wick contact areas for minute burrs.



No damage allowed. Deburr if necessary.



Nozzle Insulator (70 or 70A, IPL Figure 2)



Visual



Check for cracks, gouges or distortion.



No damage allowed.



Aluminum Sleeve Bushing (180, IPL Figure 2)



Dimensional



Check parallelism of ends of bushing.



Ends of bushing shall be parallel within 0.0002 inch.



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Table 502. General Checks (Continued) Nomenclature (Item and IPL Figure Number) Containment Ring (20, IPL Figure 3)



Type Check Visual



Procedure



Allowable Limits



Check for cracked or broken brazed joints. Check for deformation.



No damage allowed.



Check for rust.



Remove rust and cadmium replate in accordance with REPAIR 11-2.



Magnetic Particle



Check in accordance with AMS2640. Remove cadmium plating if thickness exceeds 0.001 inch. Current application: bar type induced 300 amps, solenoid type induced 3000 amp turns.



No service incurred cracks allowed. (See NOTE, page 503.)



Inlet Screen (45, IPL Figure 3)



Visual



Check inlet screen for damage.



No damage allowed. Replace screen in accordance with REPAIR 11-3.



Housing (55, IPL Figure 3)



Visual



Check housing for cracks, breaks or distortion.



No damage allowed.



Check inserts (30, IPL Figure 3) for damage.



Replace damaged inserts in accordance with REPAIRGENERAL.



Check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503.)



Fluorescent Penetrant



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Table 503. Compressor Diffuser Checks Nomenclature (Item and IPL Figure Number) Compressor Diffuser (115, IPL Figure 1, Sheet 1)



Type Check Visual



Procedure



Allowable Limits



Check for deformation. Inspect vanes for feathering or broken tips.



No damage allowed.



Check for scoring due to rub in throat area, as shown in Figure 501.



No scoring or rub marks allowed. Remove minor scoring or rub marks up to 0.005 inch deep in accordance with REPAIR 2-1. Plasma spray repair scoring exceeding 0.005 inch deep, but less than 0.032 inch deep, in accordance with REPAIR 2-2.



Dimensional



Check per Figure 501.



All dimensional requirements shall be met.



Fluorescent Penetrant



Check in accordance with AMS 2645.



No service incurred cracks allowed. (See NOTE, page 503.)



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



Figure 501. Compressor Diffuser Check



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Table 504. Cooling Fan Checks Nomenclature (Item and IPL Figure Number) Cooling Fan (170, IPL Figure 1, Sheet 1)



Type Check



Procedure



Allowable Limits



Visual



Check fan blades for erosion, feathering, and tip or edge damage.



No damage allowed. See REPAIR 3-1 for repair limits.



Dimensional



Check per Figure 502.



All dimensional requirements shall be met.



Fluorescent Penetrant



Check in accordance with AMS2645.



No service incurred cracks allowed (See NOTE, page 503.).



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



Figure 502. Cooling Fan Check



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 505. Stepped Pin Checks Nomenclature (Item and IPL Figure Number) Stepped Pin (305 and 305A, IPL Figure 1, Sheet 2)



Type Check



Procedure



Allowable Limits



Dimensional



Check per Figure 503.



All dimensional requirements shall be met.



Magnetic Particle



Check in accordance with AMS2640. Current application: 500 ampere coil, solenoid induced at 2500 amp turns.



No service incurred cracks allowed. (See NOTE, page 503.)



* Acceptance or rejection of parts receiving nondestructive inspection shall be determined on service incurred defects only, such as fatigue cracks and overstress cracks. Minor surface irregularities or machine marks are not to be considered cause for rejection.



Figure 503. Stepped Pin Check



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Table 506. Fan Spacer Checks Nomenclature (Item and IPL Figure Number) Fan Spacer (320, IPL Figure 1, Sheet 2)



Type Check Dimensional



Procedure



Allowable Limits



Check per Figure 504.



All dimensional requirements shall be met.



Figure 504. Fan Spacer Check



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 507. Turbine Housing Checks Nomenclature (Item and IPL Figure Number) Turbine Housing (335, 335A, 335B, or 335E, IPL Figure 1, Sheet 2)



Type Check Visual



Procedure



Allowable Limits



Check all flanges and duct ends for nicks and burrs.



Repair small nicks and burrs in accordance with REPAIRGENERAL.



Check all sealing surfaces for damage or wear.



None permitted which could allow air or oil leakage.



Check inserts (340, 345, or 346, 350 and 354 or 355, IPL Figure 1, Sheet 2) for damage.



Replace damaged inserts in accordance with REPAIRGENERAL.



Check oil wick passages for burrs or sharp edges, as shown in Figure 505, Sheet 2.



No burrs or sharp edges allowed. Repair in accordance with REPAIR-GENERAL.



Check oil return passages for obstructions, as shown in Figure 505, Sheet 1.



Remove obstructions using a fine wire.



Check areas for worn surface coating (dichromate treatment) and check surface finish, as sown in Figure 505, Sheets 1 thru 3.



No worn surface coating allowed. Refer to REPAIRGENERAL. Surface finish must be no rougher than requirements shown. Refer to REPAIRGENERAL.



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Table 507. Turbine Housing Checks (Continued) Nomenclature (Item and IPL Figure Number) Turbine Housing (Continued)



Type Check



Procedure



Allowable Limits



Check shroud area for scoring and rotor rub marks, as shown in Figure 505, Sheet 1.



No scoring or rub marks allowed. Remove minor scoring or rub marks up to 0.005 inch deep in accordance with REPAIR 4-1. Plasma spray repair scoring exceeding 0.005 inch deep, but less than 0.032 inch deep, in accordance with REPAIR 4-2.



Check webs beyond throat area for cracks.



None allowed.



Dimensional



Check per Figure 505, Sheets 1 and 2.



All dimensional requirements shall be met. If ID of bushing (356, IPL Figure 1, Sheet 2) exceeds 0.3702 inch, replace bushing in accordance with REPAIR 4-3.



Fluorescent Penetrant



Check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503.)



Visual



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Figure 505. Turbine Housing Check (Sheet 1 of 3)



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Figure 505. Turbine Housing Check (Sheet 2)



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Figure 505. Turbine Housing Check (Sheet 3)



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Table 508. Compressor Rotor Checks Nomenclature (Item and IPL Figure Number) Compressor Rotor (30 or 30A, IPL Figure 2)



Type Check



Procedure



Allowable Limits



Check for deformation and eroded, cracked, or broken blades.



No damage other than superficial erosion, nicks, scoring, and surface scratches allowed. See REPAIR 5-1.



Check seal grooves for damage and cleanliness



No damage allowed. Grooves must be clean and free of lead.



Visual and Dimensional



Check straightness and projection of headless straight pins (35, IPL Figure 2). Projection shall be 0.390 to 0.400 inch.



Replace pins in accordance with REPAIR-GENERAL if pins are bent or projection is not within limits.



Dimensional



Check per Figure 506.



All dimensional requirements shall be met. Rotor profile shall be within limits shown.



Fluorescent Penetrant



Check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503.)



Visual



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Figure 506. Compressor Rotor Check



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Table 509. Seal Plate Checks Nomenclature (Item and IPL Figure Number) Seal Plate (60 or 60A, IPL Figure 2)



Seal Plate (60B)



Type Check Visual



Procedure



Allowable Limits



Check for cracks or distortion.



No cracks or distortion allowed.



Check for nicks or scratches on ID of plate and in dovetail groove for lead seal (62 or 62A, IPL Figure 2)



No damage other than minor nicks or scratches allowed.



Check inserts (65, IPL Figure 2) for damage.



Replace damaged inserts in accordance with REPAIRGENERAL.



Dimensional



Check per Figure 507.



All dimensional requirements shall be met.



Fluorescent Penetrant



If ACM experienced a bearing failure, check plate, with lead seal (62 or 62A, IPL Figure 2) check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503.)



Visual



Check for cracks or distortion.



No cracks or distortion allowed.



Check for nicks or scratches on ID of plate and in area where Vespel seal is located.



No damage other than minor nicks or scratches allowed.



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Table 509. Seal Plate Checks Nomenclature (Item and IPL Figure Number) Seal Plate (60B) (Continued)



Type Check



Procedure



Allowable Limits



Dimensional



Check per Figure 508.



All dimensional requirements shall be met.



Fluorescent Penetrant



If ACM experienced a bearing failure, check plate, with Vespel seal (62B, IPL Figure 2) check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503).



NOTE: Lead seal (62 or 62A, IPL Figure 2) in seal plate (60 or 60A) or Vespel seal (62B) in seal plate(60B). See REPAIR 6-1 for 60 or 60A or REPAIR 6-2 for 60B.



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COMPONENT MAINTENANCE MANUAL 782790



Figure 507. Lead Seal Plate Check



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Figure 508. Vespel Seal Plate Check



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Table 510. Seal Disk Checks Nomenclature (Item and IPL Figure Number) Seal Disk (75, IPL Figure 2)



Type Check



Procedure



Allowable Limits



Visual



Check seal grooves for damage and cleanliness.



No damage allowed. Grooves must be clean and free of lead.



Dimensional



Check for distortion per Figure 509.



No distortion allowed beyond limits shown in Figure 509.



Fluorescent Penetrant



Check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503.)



Figure 509. Seal Disk Check



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Table 511. Nozzle Plate and Insulator Checks Nomenclature (Item and IPL Figure Number) Nozzle Plate and Insulator (85 or 85A, IPL Figure 2)



Type Check



Procedure



Allowable Limits



Check nozzle vanes for erosion and damaged trailing edges per Figure 510.



Erosion that does not extend to trailing edges of nozzle vanes is allowed. Erosion that extends to trailing edges of nozzle vanes, or bent, deformed or irregular trailing edges, are not allowed. The nozzle plate and insulator may be repaired per REPAIR 7-2.



Check for nicks or scratches on ID of plate and in dovetail groove for lead seal (95, IPL Figure 2).



No damage other than minor nicks or scratches allowed.



Check for signs of turbine rotor contact in area shown in Figure 510.



Only minor damage is allowed and may be cleaned up within dimensional limits shown.



Check insulator (90, IPL Figure 2) for cracks, gouges or distortion.



No damage allowed.



Dimensional



Check per Figure 510.



All dimensional requirements shall be met.



Fluorescent Penetrant



Check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE,page 503.)



Visual



NOTE: Lead seal (95, IPL Figure 2) in nozzle plate and insulator (85 or 85A) must be replaced at each overhaul. See REPAIR 7-1.



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Figure 510. Nozzle Plate and Insulator Check



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Table 512. Turbine Rotor Checks Nomenclature (Item and IPL Figure Number) Turbine Rotor (100 or 100A or 100E, IPL Figure 2)



Type Check



Procedure



Allowable Limits



Visual



Check for deformation and eroded, cracked or broken blades.



No damage other than superficial erosion, nicks, scoring, and surface scratches allowed. See REPAIRGENERAL.



Dimensional



Check per Figure 511.



All dimensional requirements shall be met. Rotor profile shall be within limits shown.



Fluorescent Penetrant



Check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503.)



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Figure 511. Turbine Rotor Check



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Table 513. Seal Ring Checks Nomenclature (Item and IPL Figure Number) Seal Ring (150 and 230, IPL Figure 2)



Type Check Visual



Dimensional



Procedure



Allowable Limits



Check large flat surface for flaws using 5X (5 times) magnification.



No flaws (scratches or pits) permissible. Surface shall be mirror like with roughness 2 microinches or better. Surface may be polished in accordance with REPAIR 9-1.



Check ID for wear.



ID shall be within limits shown in Figure 512.



Check per Figure 512.



All dimensional requirements shall be met.



Figure 512. Seal Ring Check



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Table 514. Drive Shaft Checks



Drive Shaft (240, IPL Figure 2)



Visual



Check for deformation and extensive wear including scratches, grooves, and nicks. Check threads for sharp edges and burrs.



No damage allowed. Threads must be completely free of sharp edges or burrs. Remove minor damage to lead-in threads only and remove minor surface scratches in accordance with REPAIR 10-1 and REPAIR 10-2.



Dimensional



Check per Figure 513.



All dimensional requirements shall be met.



Magnetic Particle



Check in accordance with AMS2640. Current application: 500 amp coil, 3500 amp turns.



No service incurred cracks allowed. (See NOTE, page 503.)



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COMPONENT MAINTENANCE MANUAL 782790



Figure 513. Drive Shaft Check



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 515. Spring Seat Checks Nomenclature (Item and IPL Figure Number) Spring Seat (250, IPL Figure 2)



Type Check



Procedure



Allowable Limits



Dimensional



Check per Figure 514.



All dimensional requirements shall be met.



Fluorescent Penetrant



Check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503.)



Figure 514. Spring Seat Check



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 516. Helical Compression Spring Checks Nomenclature (Item and IPL Figure Number) Helical Compression Spring (270 or 270A, IPL Figure 2)



Type Check Dimensional



Procedure



Allowable Limits



Examine the outer diameter of the coils for areas that are polished (show signs of wear). If you see polished areas, measure the diameter of the wire in these areas as shown in Figure 515.



Replace the spring when the dimensions of the coils are not in the limit specified in Figure 515.



If the magnetic particle inspection is satisfactory, measure the load that is necessary to compress the spring to 1.05 inch (26.67 mm).



The load must be 23.75 to 26.25 pounds (10.773 to 11.907 kilograms) for spring (270), or 28.5 to 31.4 pounds (12.9276 to 14.2884 kilograms) for spring (270A).



NOTE: The diameter of the spring wire is 0.0895 to 0.0935 inch (2.2733 to 2.379 mm). Magnetic Particle



If the dimensional check above is satisfactory, do a magnetic particle inspection. Refer to AMS2460. Use a central conductor to supply 500 amps.



No cracks are permitted. (See NOTE,page 503.)



NOTE:If the ball bearings (155, 235) seized during operation, replace the spring.



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Figure 515. Helical Compression Spring



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Table 517. Bearing Cartridge Sleeve Checks Nomenclature (Item and IPL Figure Number) Bearing Cartridge Sleeve (275, 275A, 275B, or 275C, IPL Figure 2)



Type Check Visual



Dimensional



Procedure



Allowable Limits



Check for cracks or deformation.



No cracks or deformation allowed.



Check sleeve spacer and pins for firm retention.



Sleeve spacer and pins must be firmly retained.



Check per Figure 516, Figure 517, and Figure 518.



All dimensional requirement shall be met.



Check for distortion and cracks.



No distortion or cracks allowed.



Check ID for rub.



Rub permitted within dimensional limits of Figure 516. If rub exceeds limits, replace liner (15) in accordance with REPAIR 11-1.



Check in accordance with AMS2645.



No service incurred cracks allowed. (See NOTE, page 503.)



Deleted (Magnetic Particle) Liner (15, IPL Figure 3)



Visual



Fluorescent Penetrant



CAUTION: LINER (15, IPL FIGURE 3), CONTAINMENT RING (20) AND HOUSING (55) ARE MATCHED PARTS OF CONTAINMENT HOUSING (1). DO NOT MIX MATCHED PARTS.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 516. Bearing Cartridge Sleeve Check (PN 753387-1 and -2)



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 517. Bearing Cartridge Sleeve Check (PN 753387-3) Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 518. Bearing Cartridge Sleeve Check (PN 753387-5) Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 518. Containment Housing Checks Nomenclature (Item and IPL Figure Number) Containment Housing (1, IPL Figure 3)



Type Check Dimensional



Procedure



Allowable Limits



Check dimensions per Figure 519.



All dimensional requirements shall be met.



NOTE: Containment housing (1, IPL Figure 3) must be disassembled to check liner (15), containment ring (20), and housing (55).



Figure 519. Containment Housing Check



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3. Checking Balance of Cooling Fan, Compressor Rotor, and Turbine Rotor NOTE: It is not necessary to individually check that balance of cooling fan (170, IPL Figure 1, Sheet 1), compressor rotor (30,IPL Figure 2), or turbine rotor (100) at each overhaul or whenever they are removed from the rotative group. However, balance should be checked, in accordance with the procedure which follows, whenever the initial unbalance requirements for dynamic balance in ASSEMBLY cannot be met and all of the specified corrective measures in that section have been attempted. A. Install balance fixture, GS14773-1, on balance machine, Schenck Model CAB 570 or CAB 690-R. B. Install cooling fan (170, IPL Figure 1, Sheet 1), compressor rotor (30, IPL Figure 2), or turbine rotor (100) in balance fixture, GS14773-1, using arbor set, GS15611-1. C. Using balancing accessories kit, GS15800-1, to drive the cooling fan or rotor, and balance machine nozzle assembly, GS15801-1, to direct air flow to the fan or rotor, apply air pressure and obtain speed of 4400 to 4600 rpm. D. Check biplanar balance and reduce speed to zero. Balance of compressor rotor (30) and turbine rotor (100) must be within 180 micro ounce-inches. Balance of cooling fan (170, IPL Figure 1, Sheet 1) must be within 120 micro ounce-inches. E. If balance is not within specified limit, rebalance rotor or cooling fan in accordance with specific repair procedure in REPAIR-GENERAL. F. Remove cooling fan or rotor from balance fixture. G. Remove balance fixture from balance machine.



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THIS IS A BLANK PAGE



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REPAIR-GENERAL 1. General A. Special tools, fixtures, and equipment required for repairs are listed in Table 601. NOTE: Equivalent tools, fixtures, and equipment can be used if they agree with the requirements of ARINC Report 668. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 601. Special Tools, Fixtures, and Equipment TOOL NO. CAB 570 or CAB 690-R



NOMENCLATURE Balance Machine Schenck Trebel Corp. 535 Acron St. Deer Park, NY 11729



USE Biplanar balance the cooling fan, compressor rotor or turbine rotor.



CAGE Code: 30218 GS14773-1



Balance Fixture



Hold cooling fan, compressor rotor or turbine rotor during balancing on balance machine, CAB 570 or CAB 690-R.



GS15611-1



Arbor Set



Install cooling fan, compressor rotor or turbine rotor in balance fixture, GS14773-1.



GS15800-1



Balancing Accessories Kit



Controls air flow to drive cooling fan, compressor rotor or turbine rotor during balancing.



GS15801-1



Balance Machine Nozzle Assembly



Direct air flow to cooling fan, compressor rotor or turbine rotor during balancing.



GS20649-1



Holding Fixture



Hold seal plate or nozzle plate and insulator in a lathe during replacement of load seal.



GS22826-1



Holding Fixture



Hold compressor diffuser in a lathe during machining to remove damage prior to plasma spray repair.



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Table 601. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.



NOMENCLATURE



USE



GS22827-1



Holding Fixture



Hold turbine housing in a lathe during machining to remove damage prior to plasma spray repair.



GS22828-1



Lead Seal Rolling Tool



Roll new lead seal into seal plate or nozzle plate and insulator.



B. Consumable materials required for repairs are listed in Table 602. NOTE: Maintenance personnel must use the specified consumable material for the specified task. These consumable materials are known to agree with all of the design and qualification requirements. Only approved materials engineering personnel can make equivalent consumable material decisions. These materials are used at the risk of the organization who makes the decision. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 602. Consumable Materials MATERIAL



MANUFACTURER OR SPECIFICATION



USE



Abrasive Cloth



P-C-451



Minor surface repair.



Alodine



MIL-C-5155



Touch up machine surfaces.



Aluminum Alloy Bar



AMS4117



Prepare test specimens (for bond strength test) during plasma spray repair of compressor diffuser.



Aluminum Alloy Sheet



AMS4026



Prepare test specimens (for cup test and microexamination) during plasma spray repair of compressor diffuser.



Anti-seize Thread Compound



MIL-T05544



Thread lubricant for containment housing screws.



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COMPONENT MAINTENANCE MANUAL 782790



Table 602. Consumable Materials (Continued) MANUFACTURER OR SPECIFICATION



MATERIAL AP Armaflex Rubber Insulation Sheet [0.25 inch (6.35 mm) thick]



MIL-P-1528 FORM S



USE Repair damaged insulation on turbine outlet duct.



Armstrong World Industries, Inc., Armstrong Insulation Products, North America P.O. Box 3001, Lancaster, PA 17604 Tel (800)-866-5638 or (717)-376-4127 Website: www.armaflex.com or Armstrong World Industries Canada, LTD. 6911 Decarie Blvd Montreal, Quebec, H3W 3E5 Tel (514) 733-9981



Bushing S788107-1



Hamilton Sundstrand Corporation



Replace bushing in turbine housing.



CAGE Code: 73030 Chemical Film



AMS 2473



Touch up surface coating on aluminum alloys.



Clear Epoxy Polyamide



MIL-C-22750



Seal the ink that identifies that the compressor rotor has oversized pins.



Dry Ice



BB-C-104



Used to cool bushing for installation in turbine housing.



EC 1300 Adhesive



3M Co.



Bond insulation to turbine on left duct.



CAGE Code: 04963 EC2186 Epoxy Cement



3M Co. CAGE Code: 04963



Bond aluminum test specimens for bond strength test during plasma spray repair of compressor diffuser.



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COMPONENT MAINTENANCE MANUAL 782790



Table 602. Consumable Materials (Continued) MATERIAL Epoxy Polyamide (Galvanic) Primer



MANUFACTURER OR SPECIFICATION MIL-PRF-23377, Type I or II, Class C1 or C2, formulated without water.



USE Galvanic insulation film for dissimilar metals.



OR Strontium Chromate Primer



MIL-PRF-85582, Type I or II, Class C1 (Barium Chromate or C2 (Strontium Chromate) primer coatings formulated without water. NOTE: When using either of the above, the admixture of the epoxy resin solution and curing agent shall not be reduced with any thinner.



Glycerin



Commercially available.



Lubricant for containment housing preformed packing.



Isopropyl Alcohol



ASTM D770



General cleaning solvent.



Lead Seal S750493-4



Hamilton Sundstrand Corporation



Replace seal in seal plate.



CAGE Code: 73030 Lead Seal S750493-14



Hamilton Sundstrand Corporation



Replace seal in nozzle plate and insulator.



CAGE Code: 73030 Vespel Seal PN 821246-21



Hamilton Sundstrand Corporation



Replace seal in seal plate.



CAGE Code: 73030 Liner S753453-30



Hamilton Sundstrand Corporation



Replace liner in containment housing.



CAGE Code: 73030 Loctite 290



Metco 52C Plasma Coating



Loctite Corp. CAGE Code: 05972



Sealer for plasma spray coating on compressor diffuser.



Sulzer Metco US Inc.



For repair of turbine housing.



CAGE Code: 01FK3



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Table 602. Consumable Materials (Continued) MATERIAL Metco 404 Plasma Coating (80 Ni-20 Al)



MANUFACTURER OR SPECIFICATION Sulzer Metco US Inc.



USE For repair of compressor diffuser.



CAGE Code: 01FK3 Metco 450 Plasma Coating



Sulzer Metco US Inc.



For repair of turbine housing.



CAGE Code: 01FK3 Methyl Alcohol



O-M-232



General cleaning solvent.



Perchloroethylene



O-T-236



Used to vapor degrease parts.



Petroleum Solvent



AMS3160



Cleaning solvent.



Plasma Coating (Al-Si 12)



Valley Metallurgical Processing Co., Inc. 280 Park Ave. New York, NY 10017



For repair of compressor diffuser.



Sealant Compound, 19-V-5



American Metaseal Co. Div. of Wallace Clark and Co. Inc. 509 Washington Ave. Carlstadt, NJ 07072-2802



Vacuum impregnation sealant after plasma spray repair of turbine housing.



Sealant Compound, 237



Inmont Corp.



Vacuum impregnation sealant after plasma spray repair of turbine housing.



CAGE Code: 30831



C. Carefully remove evidence of galling, corrosion, rust, nicks, burrs, sharp or rough edges from parts using fine abrasive cloth, P-C-451. Remove as little material as possible. In general, this type of repair can be performed if there is no alteration of dimensions, deterioration of surface finish, and parts are cleaned and visually inspected after repair. Significant deformation or faults on sealing surfaces are not repairable and require replacement of the affected part.



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WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MIL-C5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING) LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE, POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0059SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES (BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. D. Repair damaged aluminum alloy surface coating with chemical film, in accordance with AMS2473. E. Repair damaged dichromate treatment on magnesium alloy turbine housing (335, 335A or 335B, IPL Figure 1, Sheet 2) in accordance with AMS2475. F. Refer to paragraph 3 for specific repairs. G. Replace all parts that cannot be repaired to meet requirements of CHECK. 2. Replacement A. Replace damaged inserts (95, IPL Figure 1, Sheet 1), (255, 340, 345 or 346, 350, and 354 or 355, IPL Figure 1, Sheet 2), (65, IPL Figure 2), and (30, IPL Figure 3) in accordance with MS33537 and the following: (1) Remove damaged inserts.



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WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (2) Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it. (3) Apply epoxy polyamide primer to new inserts or tapped holes prior to installation of inserts. (4) Install inserts while primer is wet. For inserts (345 or 346, IPL Figure 1, Sheet 2), (65, IPL Figure 2), and (30, IPL Figure 3), remove tangs. (5) Remove excess primer from inserts, including internal surfaces of inserts and tapped holes. B. Replace damaged headless straight pin (250, IPL Figure 1, Sheet 2) in sump cover (245) as follows: (1) Carefully remove headless straight pin (250) from cover (260). Discard pin. (2) Dimensionally inspect diameter of pinhole in cover (260). Diameter must be 0.1241 to 0.1247 inch (3.1522 to 3.1673 mm). NOTE: If pinhole in cover (260) is out of round or diameter is not within specified limits, sump cover (245) must be replaced.



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COMPONENT MAINTENANCE MANUAL 782790



WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (3) Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it. (4) Apply epoxy polyamide primer to new headless straight pin (250). (5) Install headless straight pin (250) in cover (260), while primer is wet. Projection shall be 0.26 inch (6.6040 mm) maximum. C. Replace damaged headless straight pins (35, IPL Figure 2) in compressor rotor (30 or 30A) as follows: (1) Carefully remove headless straight pins (35) from compressor rotor (30 or 30A). (2) Dimensionally inspect diameter of pinholes in rotor. Diameter must be 0.0773 to 0.0778 inch (1.9635 to 1.9761 mm). NOTE: If pinholes in compressor rotor (30 or 30A) are out of round or diameters are not within specified limits, compressor rotor must be replaced. (3) Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it (4) Apply epoxy polyamide primer to new headless straight pins (35).



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COMPONENT MAINTENANCE MANUAL 782790



(5) Install headless straight pins (35) in rotor, while primer is wet. Projection shall be 0.390 to 0.400 inch (9.91 to 10.15 mm). 3. Specific Repairs A. Specific repairs are included in separate sections as follows: (1) Repair 1-1:



Turbine Outlet Duct - Repair of Insulation



(2) Repair 2-1:



Compressor Diffuser - Removal of Minor Scoring or Rotor Rub Marks Up to 0.005 Inch Deep



(3) Repair 2-2:



Compressor Diffuser - Plasma Spray Repair for Scoring Up to 0.032 Inch Deep



(4) Repair 3-1:



Cooling Fan - Repair of Tip or Edge Damage



(5) Repair 3-2:



Cooling Fan - Rebalancing



(6) Repair 4-1:



Turbine Housing - Removal of Minor Scoring or Rotor Rub Marks Up to 0.005 Inch Deep



(7) Repair 4-2:



Turbine Housing - Plasma Spray Repair for Scoring Up to 0.032 Inch Deep



(8) Repair 4-3:



Turbine Housing - Replacement of Bushing



(9) Repair 5-1:



Compressor Rotor - Removal of Minor Nicks, Burrs, and Scoring



(10) Repair 5-2:



Compressor Rotor - Rebalancing



(11) Repair 5-3:



Compressor Rotor - Replace the Headless Straight Pins



(12) Repair 6-1:



Seal Plate - Replacement of Lead Seal



(13) Repair 6-2:



Seal Plate - Replacement of Vespel Seal



(14) Repair 7-1:



Nozzle Plate and Insulator - Replacement of Lead Seal



(15) Repair 7-2:



Nozzle Plate and Insulator



(16) Repair 8-1:



Turbine Rotor - Removal of Minor Nicks, Burrs, and Scoring



(17) Repair 8-2:



Turbine Rotor - Rebalancing



(18) Repair 9-1:



Seal Ring - Repair of Sealing Surface



(19) Repair 10-1: Drive Shaft - Removal of Minor Damage from Lead-in Threads (20) Repair 10-2: Drive Shaft - Removal of Minor Scratches (21) Repair 11-1: Containment Housing - Replacement of Liner (22) Repair 11-2: Containment Housing - Removal of Rust and Replating of Containment Ring (23) Repair 11-3: Containment Housing - Replacement of Inlet Screen



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DUCT, TURBINE OUTLET - REPAIR 1-1 1. Repair of Insulation A. Place a piece of AP Armaflex rubber insulation sheet, 0.25 inch thick, over the damaged insulation area on turbine outlet duct (50, IPL Figure 1, Sheet 1). B. Cut through both the new sheet and underlying material to make a patch to fit the damaged area. Refer to Figure 601 for finished dimensional requirements for insulation. Insulation may consist of more than one piece, as shown. C. Remove damaged insulation and adhesive from outlet duct with a plastic scraper. WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. D. Clean with isopropyl alcohol, ASTM D770. WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MIL-C5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING) LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE, POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0059SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES (BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. E. Touch up any damaged surface coating on outlet duct with chemical film, AMS2473.



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WARNING: ADHESIVE, EC1300, IS EXTREMELY FLAMMABLE AND MAY CAUSE EYE, SKIN, AND RESPIRATORY IRRITATION. KEEP AWAY FROM HEAT, SPARKS, AND FLAME. EYE AND SKIN PROTECTION REQUIRED. USE ONLY IN AREAS WITH SUFFICIENT VENTILATION. AVOID BREATHING OF VAPORS. F. Apply a uniform coat of adhesive EC1300 on bonding surfaces of outlet duct and insulation, including butt seam surfaces on insulation. Allow to air dry for 8 to 12 minutes at room temperature. G. Activate adhesive by lightly wiping with a clean solvent dampened lint-free cloth. H. Install insulation patch while adhesive is tacky. I. Apply sufficient pressure to ensure a tight bond. NOTE: Adhesive bonds on contact. Position patch carefully. J. Allow bond to cure for 72 hours minimum at room temperature. Maintain contact pressure on patch during cure.



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COMPONENT MAINTENANCE MANUAL 782790



Figure 601. Turbine Outlet Duct Insulation Repair



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DIFFUSER, COMPRESSOR - REPAIR 2-1 1. Removal of Minor Scoring or Rotor Rub Marks Up to 0.005 Inch Deep A. Remove minor scoring or rotor rub marks from compressor diffuser (115, IPL Figure 1, Sheet 1) using abrasive cloth, P-C-451. Blend to original contour within limits of Figure 601. If scoring cannot be removed within specified limits, repair by plasma spraying in accordance with REPAIR 2-2. B. Coat repaired areas with chemical film, AMS2473.



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Figure 601. Compressor Diffuser Repair - Limits for Removal of Minor Scoring or Rotor Rub Marks Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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DIFFUSER, COMPRESSOR - REPAIR 2-2 1. Plasma Spray Repair for Scoring Up to 0.032 Inch Deep WARNING: PERCHLOROETHYLENE, O-T-236, IS TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. NOTE: A compressor diffuser (115, IPL Figure 1, Sheet 1) with scoring deeper than 0.032 inch is not repairable. If scoring is 0.005 inch deep or less, repair diffuser in accordance with REPAIR 2-1. A. Thoroughly clean compressor diffuser (115) by vapor degreasing in perchloroethylene. B. Fluorescent penetrant inspect compressor diffuser (115) in accordance with Table 502. No cracks allowed. C. Mount and true up holding fixture, GS22826-1, in a lathe. D. Install compressor diffuser (115) in holding fixture, GS22826-1. Check that runout of diameter A and perpendicularity of surface K are within limits of Figure 601. E. Remove 0.012 inch of stock from damaged areas of shroud of compressor diffuser (115, IPL Figure 1, Sheet 1) by machining to dimensions in tabulation on Figure 601. If damaged areas do not clean up, it is permissible to machine up to an additional 0.020 inch of stock (0.032 inch total) to remove damage. CAUTION: AFTER CLEANING AND CONDITIONING SURFACE TO BE COATED, TOUCH SURFACE ONLY WITH CLEAN GLOVES TO AVOID CONTAMINATION THAT WOULD AFFECT INTEGRITY OF PLASMA SPRAY COATING. F. Clean compressor diffuser (115, IPL Figure 1, Sheet 1) per step A. G. Condition the surface to be coated by blasting with the most practicable nonmetallic grit. H. Mask off areas that are not to be plasma sprayed as shown in Figure 602. I. Prepare representative test specimens as follows: (1) Prepare pieces for cup test and micro-examination by cutting aluminum alloy sheet, per AMS4026, into pieces approximately 3.0 x 1.75 x 0.050 inch. (2) Prepare four pieces of aluminum alloy bar, per AMS4117, for bond strength test per Figure 603. Mark two of the pieces for identification. These pieces will not be coated. (3) Clean specimens in same manner as compressor diffuser (115, IPL Figure 1, Sheet 1) and blast with No. 24 nonmetallic grit. NOTE: Specimen pieces shall be coated at the same time and in the same manner as the diffuser area being repaired. They must then withstand the specified tests.



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MACHINING FOR REMOVAL OF 0.012 (0.3048) OF STOCK FROM DIFFUSER SHROUD INCHES MILLIMETERS X BSC Y RAD BSC X BSC Y RAD BSC



0.006 (0.153) 0.010 (0.254) RAD (2 PLACES)



VIEW A ENLARGED



0.032 (0.812) MAX ALLOWABLE STOCK REMOVAL TO CLEAN UP DAMAGE



2.356 (59.843) 2.358 (59.893) DIA DIA



-L-



-A-



(REF)



1.1279 1.0955 0.9954 0.9409 0.8853 0.8287 0.7709 0.7122 0.6525 0.5920 0.5311 0.4705 0.4117 0.3563 0.3057 0.2607 0.2224 0.1909 0.1669 0.1544 0.1491 0.1449 0.1421 0.1402 0.1385 0.1371 0.1317 0.1260*



0.9346 0.9454 0.9501 0.9527 0.9562 0.9615 0.9695 0.9812 0.9973 1.0188 1.0459 1.0790 1.1193 1.1671 1.2225 1.2846 1.3525 1.4254 1.5012 1.5647 1.6037 1.6428 1.6818 1.7213 1.7611 1.8195 1.8895 1.9240*



28.6487 27.8257 25.2832 23.8989 22.4866 21.0490 19.5809 18.0899 16.5735 15.0368 13.4899 11.9507 10.4572 9.0500 7.7648 6.6218 5.6490 4.8489 4.2393 3.9218 3.7871 3.6805 3.6093 3.5611 3.5179 3.4823 3.3452 3.2004*



23.7388 24.0132 24.1325 24.1986 24.2875 24.4221 24.6253 24.9225 25.3314 25.8775 26.5659 27.4066 28.4302 29.6443 31.0515 32.6288 34.3535 36.2052 38.1305 39.7434 40.7340 41.7271 42.7177 43.7210 44.7319 46.2153 47.9933 48.8696*



* REFERENCE POINT FOR BLEND.



A



-KA



X 1.1279 (28.6486) MAX



0.002 (0.0508)



Y RAD 1.9880 (50.4952) MAX DIA



-AL



0.002 (0.0508) TIR



NOTES: 1. DIMENSIONS IN INCHES (MILLIMETERS). FINISHES IN MICROINCHES (MICROMETERS). 2. SYMBOLS PER ANSI Y14.5. 3. MATERIAL: ALUMINUM ALLOY. HARDNESS: 110 BRINELL MIN USING 500 KG LOAD AND 10 MM BALL.



HA-215153-15-25698-A



Figure 601. Compressor Diffuser Damage Removal



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COMPONENT MAINTENANCE MANUAL 782790



Figure 602. Compressor Diffuser - Masking for Plasma Spraying



Figure 603. Compressor Diffuser-Masking for Plasma Spraying



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J. As soon as practicable after surface preparation (preferably within 2 hours), the spraying procedure should be accomplished, making sure the coating material being deposited is dry, free-flowing, and thoroughly blended. NOTE: Gas used in the spraying torch shall consist of argon or helium or mixtures of both. Up to 25% by volume of hydrogen may be added. WARNING: HANDLING HOT ITEMS PRESENTS SERIOUS BURN POTENTIAL. HEAT RESISTANT GLOVES MUST BE WORN. K. Preheat the repair area in the diffuser and the test specimens prior to coating. This will remove moisture and control thermal expansion created by the spraying procedure. Preheating may be accomplished by controlling the torch dwell time immediately prior to spraying or by other suitable means. Maintain an average temperature below 300°F to prevent discoloration, oxidation, and distortion. Routine monitoring of this condition is not essential. L. Apply an even coat of Metco 404 nickel aluminum (80 Ni-20 Al) plasma coating 0.002 to 0.004 inch thick over the entire diffuser repair area surface and one side of half of the cup test and micro-examination specimens. Spray a similar coating 0.008 to 0.010 inch thick on surface A (see Figure 603) of one of the two unmarked bond test specimen. Do not coat the two marked specimens or the second unmarked specimen. M. Following completion of the first coat, spray a second coat of aluminum silicon (Al-Si 12) plasma coating sufficient to ensure that the finish dimensions of Figure 604 can be met after machining. The coating material shall be of the following composition (given in percentages by weight): Silicon Iron Copper Zinc Manganese* Magnesium Other impurities (each)* Other impurities (total)* Aluminum



11.0 to 13.0 0.8 0.30 0.20 0.15 0.10 0.05 0.15 (the remainder)



* If determined. N. Coat the remainder of the cup test and micro-examination specimens with the same coating as in step M. to a thickness of 0.004 to 0.006 inch. Coat surface A of the remaining unmarked bond test specimen to a thickness of 0.008 to 0.010 inch. Mark the specimen for identification. NOTE: Coating on bond test specimens may be ground, if necessary, to meet the thickness requirements. O. Cup test specimens shall be tested on a Detroit or equivalent testing machine using a ball 0.875 inch in diameter and a die with a 1.375 inch diameter opening to form a 0.300 inch depression in the test specimen. Cup shall be drawn so that the coated side of the test piece is on the outside of the cup. NOTE: Chipping or flaking of coating will not be cause for rejection when caused by cracking of the base metal during cup test. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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SHROUD CONTOUR INCHES



X 1.4570 1.3500 1.2720 1.1946 1.0948 0.9949 0.9403 0.8844 0.8273 0.7689 0.7095 0.6489 0.5876 0.5258 0.4642 0.4044 0.3479 0.2964 0.2506 0.2116 0.1797 0.1553 0.1425 0.1372 0.1329 0.1301 0.1282 0.1265 0.1251 0.1198 0.1050*



2.356 (59.843) 2.358 (59.893) DIA DIA



-A-



-L(REF)



MILLIMETERS



Y



X



0.9287 0.9287 0.9287 0.9287 0.9334 0.9381 0.9407 0.9442 0.9496 0.9577 0.9695 0.9859 1.0077 1.0351 1.0688 1.1098 1.1585 1.2149 1.2781 1.3472 1.4212 1.4983 1.5629 1.6023 1.6417 1.6811 1.7208 1.7607 1.8191 1.8877 1.9518*



37.0078 34.2900 32.3088 30.3428 27.8079 25.2705 23.8836 22.4638 21.0134 19.5301 18.0213 16.4821 14.9250 13.3553 11.7907 10.2718 8.8367 7.5286 6.3652 5.3746 4.5644 3.9446 3.6195 3.4849 3.3757 3.3045 3.2563 3.2131 3.1775 3.0429 2.6670 *



Y 23.5890 23.5890 23.5890 23.5890 23.7084 23.8277 23.8938 23.9827 24.1198 24.3256 24.6253 25.0419 25.5956 26.2915 27.1475 28.1889 29.4259 30.8585 32.4637 34.2189 36.0985 38.0568 39.6977 40.6984 41.6992 42.6999 43.7083 44.7218 46.2051 47.9476 49.5757 *



* REFERENCE POINT FOR BLEND.



0.002 (0.0508)



BLEND AS REQUIRED. NO STEP ALLOWED BETWEEN SPRAYED AND NON SPRAYED AREAS.



SEE NOTE 3



-KA



X BSC



0.002 (0.0508)



X RAD BSC DIA



-AL



0.002 (0.0508) TIR



NOTES: 1. DIMENSIONS IN INCHES (MILLIMETERS). FINISHES IN MICROINCHES (MICROMETERS). 2. SYMBOLS PER ANSI Y14.5. 3. PROFILE DESCRIBED BY BSC DIM MAY VARY WITHIN THE SPECIFIED TOLERANCE BAND. PROFILE MUST BE A SMOOTH BLEND. PROFILE AS A WHOLE MAY VARY AN ADDITIONAL ± 0.002 (±0.0508) FROM K.



HA-215153-11-25700-A



Figure 604. Compressor Diffuser Finish Dimensions



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P. Micro-examination of test specimens shall show constituents to be evenly distributed. Coating shall be free of cracks, massive porosity, and excess oxides, and essentially free from inclusion and contaminants at the coating/base metal interface. WARNING: PERCHLOROETHYLENE, O-T-236, IS TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. Q. Thoroughly clean the coated surfaces of the bond test specimens by vapor degreasing in perchloroethylene. Allow to air dry thoroughly. WARNING: EC2186 EPOXY CEMENT CAN CAUSE SKIN IRRITATION. AVOID SKIN CONTACT AND WASH EXPOSED AREAS IMMEDIATELY. R. Apply EC2186 epoxy cement to surface A (see Figure 603) of the two uncoated, marked specimens. Align and join the two uncoated specimens to the two coated specimens at surface A, taking care to avoid entrapment of air bubbles. WARNING: HANDLING HOT ITEMS PRESENTS SERIOUS BURN POTENTIAL. HEAT RESISTANT GLOVES MUST BE WORN. S. Cure bonded specimens in a circulating air oven at 325 to 375°F for 1 to 2 hours. Remove specimens from oven and allow to return to room temperature. T. Trim excess cement from periphery of specimens by hand or belt grinding, taking care to minimize grinding marks. U. Pull specimens apart using a tensile tester with a cross-head speed of approximately 0.050 inch per minute. Bond strength shall be as follows: Nickel aluminum alloy - 5000 psi Aluminum silicon alloy - 300 psi NOTE: If the bond of the test specimens fails to meet requirements because of fracture at the coating/epoxy line, the bond strength test must be repeated using new specimens. V. Immediately following the application of the final aluminum silicon plasma coating on the diffuser, clean and seal the coated surface as follows: (1) Remove masking tape from diffuser. WARNING: KEEP ISOPRPOPYL ALCOHOL, TT-I-735, AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES. USE ISOPROPYL ALCOHOL IN AN AREA WITH GOOD FLOW OF AIR. ISOPROPYL ALCOHOL IS FLAMMABLE AND CAN IRRITATE THE EYES, SKIN, AND RESPIRATORY TRACT. NOTE: Coated surface on diffuser must be sealed again immediately following final machining.



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(2) Clean coated surface with isopropyl alcohol with a clean, lint-free cloth. WARNING: LOCTITE 290 CAN CAUSE SKIN IRRITATION. AVOID SKIN CONTACT AND WASH EXPOSED AREAS IMMEDIATELY. (3) Seal coated surface using Loctite 290 (an anaerobic liquid) as follows: (a) Apply Loctite 290 to coated surface. Do not wipe off excess. WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS. (b) Cure either for 24 hours at room temperature or for 90 minutes at 202 to 222°F (94 to 106°C). (c) Wipe off excess sealant. W. Finish machine the diffuser to the dimensions in tabulation on Figure 604 using the following speed conditions: Roughing



Finishing



Surface speed (rpm)



250 to 300



300 to 350



Feed (per revolution)



0.004 inch (0.1016 mm)



0.002 inch (0.0508 mm)



NOTE: Maintain a flow of coolant during entire machining operation. X. Blend as required to remove step between sprayed and non-sprayed areas. Y. Flush the diffuser to remove chips. Z. Clean and reseal coated surface per step V. WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MIL-C5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING) LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE, POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0059SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES (BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. AA. Coat any exposed parent material with chemical film, AMS2473.



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FAN, COOLING - REPAIR 3-1 1. Repair of Tip or Edge Damage NOTE: A cooling fan (170, IPL Figure 1, Sheet 1) that is deformed or cracked is not repairable. A. Smooth out tip or edge damage, within limits of Figure 601, using either abrasive cloth, P-C-451, or a very fine stone. B. Coat exposed base metal with chemical film, AMS2473.



Figure 601. Cooling Fan Repair Limits



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FAN, COOLING - REPAIR 3-2 1. Rebalancing A. Install balance fixture, GS14773-1, on balance machine, Schenck Model CAB 570 or CAB 690-R. B. Install cooling fan (170, IPL Figure 1, Sheet 1) in balance fixture, GS14773-1, using arbor set, GS15611-1. C. Using balancing accessories kit, GS15800-1, to drive the cooling fan, and balance machine nozzle assembly, GS15801-1, to direct air flow to the fan, apply air pressure and obtain balancing speed of 4400 to 4600 rpm. D. Biplanar balance cooling fan to within 120 micro ounce-inches by removing stock, as necessary, from indicated areas of cooling fan, as shown in Figure 601. Use wheel grinder, part of balancing accessories kit, GS15801-1, to remove stock. Use blow gun, also part of kit, to remove metallic dust. NOTE: To avoid unnecessary stock removal, which will decrease the service life of the cooling fan, do not attempt to improve balance once it is within the specified limit. E. Blend areas, where stock is removed, smoothly in all directions into nominal contour with a minimum radius of 0.062 inch and a maximum surface roughness of 125 microinches. F. Reduce speed to zero. G. Remove cooling fan from balance fixture. H. Remove balance fixture from balance machine. I. Fluorescent penetrant inspect cooling fan in accordance with Table 502. J. Coat areas of cooling fan, where stock has been removed, with chemical film, AMS2473.



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Figure 601. Cooling Fan - Rebalancing



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HOUSING, TURBINE - REPAIR 4-1 1. Removal of Minor Scoring or Rotor Rub Marks Up to 0.005 Inch Deep A. Remove minor scoring or rotor rub marks from turbine housing (335, 335A or 335B, IPL Figure 1, Sheet 2) using abrasive cloth, P-C-451. Blend to original contour within limits of Figure 601. If scoring cannot be removed within specified limits, repair by plasma spraying in accordance with REPAIR 4-2. B. Coat repaired areas with dichromate treatment in accordance with AMS2475.



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Figure 601. Turbine Housing - Limits for Removal of Minor Scoring or Rotor Rub Marks



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HOUSING, TURBINE - REPAIR 4-2 1. Plasma Spray Repair for Scoring Up to 0.032 Inch Deep WARNING: PERCHLOROETHYLENE, O-T-236, IS TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. NOTE: A turbine housing (335, 335A or 335B, IPL Figure 1, Sheet 2) with scoring deeper than 0.032 inch is not repairable. If scoring is 0.005 inch deep or less, repair turbine housing in accordance with REPAIR 4-1. A. Thoroughly clean turbine housing (335, 335A or 335B) by vapor degreasing in perchloroethylene. B. Fluorescent penetrant inspect turbine housing in accordance with Table 502. No cracks allowed. C. Mount and true up holding fixture, GS22827-1, in a lathe. D. Install turbine housing in holding fixture, GS22827-1. Indicate in diameter A to obtain runout of 0.002 inch TIR maximum, and check that perpendicularity of surface Y is within limit of Figure 601. E. Remove 0.032 inch of stock from the damaged area of throat by machining to the dimensions in tabulation on Figure 601. CAUTION: AFTER CLEANING AND CONDITIONING SURFACE TO BE COATED, TOUCH SURFACE ONLY WITH CLEAN GLOVES TO AVOID CONTAMINATION THAT WOULD AFFECT INTEGRITY OF PLASMA SPRAY COATING. F. Reclean turbine housing per step A. G. Mask off areas that are not to be plasma sprayed as shown in Figure 602. H. Apply an even coat of Metco 450 plasma coating, or other plasma spray powder conforming to MIL-P-83348, Type I, Composition H, Class 2, 0.001 to 0.004 inch thick over the repair area. I. Apply a coat of Metco 52C plasma coating, or other plasma spray powder conforming to MIL-P-83348, Type I, Composition E, Class 2, 0.040 inch thick minimum over the repair area. J. Finish machine throat area of turbine housing to the dimensions in tabulation on Figure 603. K. Vacuum impregnate the housing in accordance with MIL-STD-276, Method B, with sealant compound, 19-V-5 or 237, or other impregnant conforming to MIL-I-17563, Class 1.



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Figure 601. Turbine Housing Damage Removal



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Figure 602. Turbine Housing - Masking for Plasma Spraying



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Figure 603. Turbine Housing Finish Dimensions



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HOUSING, TURBINE - REPAIR 4-3 1. Replacement of Bushing A. Remove existing bushing (356, IPL Figure 1, Sheet 2) from turbine housing (335A or 335B) as follows: (1) Heat turbine housing (335A or 335B) to 265 to 285°F. WARNING: HANDLING HOT ITEMS PRESENTS SERIOUS BURN POTENTIAL. HEAT RESISTANT GLOVES MUST BE WORN. (2) Tap bushing (356) out of heated turbine housing from inside of sleeve bore with a plastic punch. NOTE: Bushing (356) has a flanged end and is installed through the bottom of the housing. B. Allow housing to cool to room temperature. Verify that ID of housing bore is within limits of Figure 601. C. If necessary, touch up dichromate treatment in housing bore in accordance with AMS2475. D. Install new semi-finished bushing PN S788107-1 in turbine housing as follows: (1) Heat turbine housing per step A.(1). WARNING: CONTACT WITH DRY ICE, BB-C-104, WILL CAUSE LOW TEMPERATURE BURNS. TEMPERATURE RESISTANT GLOVES AND APRON ARE REQUIRED. DRY ICE (CARBON DIOXIDE) ALSO DISPLACES OXYGEN. USE ONLY IN A WELL VENTILATED AREA. (2) Cool bushing to -100°F minimum with dry ice, BB-C-104. (3) Install bushing in turbine housing until flange of bushing bottoms against housing, as shown in Figure 601. (4) Mask oil passageways and other openings to protect from machining debris, as shown in Figure 601. (5) Drill and line ream ID of bushing to diameter and surface finish shown in Figure 601. (6) Remove masking material. WARNING: PERCHLOROETHYLENE, O-T-236, IS TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. (7) Thoroughly clean turbine housing by vapor degreasing in perchoroethylene, O-T236.



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Figure 601. Turbine Housing Bushing Replacement



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ROTOR, COMPRESSOR - REPAIR 5-1 1. Removal of Minor Nicks, Burrs, and Scoring NOTE: A compressor rotor (30 or 30A, IPL Figure 2) that is deformed or has cracked or broken blades is not repairable. A. Remove minor nicks, burrs, and scoring, within limits of Figure 506, using either abrasive cloth, P-C-451, or a very fine stone. B. Coat exposed base metal with chemical film, AMS2473.



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ROTOR, COMPRESSOR - REPAIR 5-2 1. Rebalancing A. Install balance fixture, GS14773-1, on balance machine, Schenck Model CAB 570 or CAB 690-R. B. Install compressor rotor (30 or 30A, IPL Figure 2) in balance fixture, GS14773-1, using arbor set, GS15611-1. C. Using balancing accessories kit, GS15800-1, to drive the compressor rotor, and balance machine nozzle assembly, GS15801-1, to direct air flow to the rotor, apply air pressure and obtain balancing speed of 4400 to 4600 rpm. D. Biplanar balance the compressor rotor to within 180 micro ounce-inches by removing stock, as necessary, from indicated areas of compressor rotor, as shown in Figure 601. Use wheel grinder, part of balancing accessories kit, GS15800-1, to remove stock. Use blow gun, also part of kit, to remove metallic dust. NOTE: To avoid unnecessary stock removal, which will decrease the service life of the compressor rotor, do not attempt to improve balance once it is within the specified limit. E. Blend areas, where stock is removed, smoothly in all directions into nominal contour with a minimum radius of 0.18 inch and a maximum surface roughness of 80 microinches. F. Reduce air pressure to zero. G. Remove compressor rotor from balance fixture. H. Remove balance fixture from balance machine. I. Fluorescent penetrant inspect compressor rotor in accordance with Table 502. J. Coat areas of compressor rotor, where stock has been removed, with chemical film, AMS2473.



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Figure 601. Compressor Rotor - Rebalancing



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ROTOR, COMPRESSOR - REPAIR 5-3 1. Replace the Headless Straight Pins CAUTION: BE CAREFUL WHEN YOU REMOVE THE HEADLESS STRAIGHT PINS. DO NOT CAUSE DAMAGE TO THE HOLES IN THE ROTOR. A. Remove bent or damaged headless straight pins (35, IPL Figure 2) from the rotor (40). B. Examine the holes in the rotor to find if they are worn. Measure the inside diameters of the holes. Refer to Figure 601. C. If the holes are not worn and the inside diameters are not more than 0.0778 inch (1.976 mm), install new headless straight pins (35). Refer to step D. If the holes are worn or the inside diameters are more than 0.0778 inch (1.976 mm) but less than 0.0928 inch (2.3571 mm), replace the headless straight pins (35) with oversized pins. Refer to step E. If the inside diameters of the holes are more than 0.0928 inch (2.3571 mm), replace the compressor rotor (30). D. Install new headless straight pins (35) as follows: WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (1) Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it. (2) Apply a thin coat of primer on the new headless straight pins (35) and in the holes in the rotor (40). Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 601. Measure the Diameters of the Holes (3) Install the pins (35), while the primer is wet, into the rotor. Push the pins in until they are at the dimension shown in Figure 602. (4) Remove the unwanted primer. E. Replace headless straight pins (35, IPL Figure 2) with oversized pins as follows: (1) Make two oversized pins as shown in Figure 603. NOTE: You can machine headless straight pins PN 69522-6H18 to the necessary dimensions. This pin has the correct large outside diameter and length. WARNING: PERCHLOROETHYLENE (TETRACHLOROETHYLENE) IS TOXIC. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. (2) Vapor degrease the pins in perchloroethylene. (3) Use the two holes as pilots to drill and ream the rotor (40) to the dimensions shown in Figure 604. (4) Break the edges on the holes to 0.025 inch (0.635 mm). (5) Remove all of the metal contamination from the holes.



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WARNING: PERCHLOROETHYLENE (TETRACHLOROETHYLENE) IS TOXIC. DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER. (6) Vapor degrease the rotor (40, IPL Figure 2) in perchloro-ethylene.



Figure 602. Install the Headless Straight Pins (Usual Pins)



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Figure 603. Make the Oversized Pins



Figure 604. Machine the Compressor Rotor for Oversized Pins



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WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MILC-5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING) LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE, POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0059SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES (BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (7) Apply a thin layer of chemical film, AMS2473, in the holes. WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (8) Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it. (9) Apply a thin coat of primer on the pins and in the holes in the rotor (40). (10) Install the pins, while the primer is wet, into the rotor. Push the pins in until they are at the dimension shown in Figure 605.



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(11) Remove the unwanted primer. (12) Examine the areas near the holes for cracks. Use a 10-power (10X) scope. No cracks are permitted. (13) Write "S.R.-2" next to the part number on the rotor with ink. This shows that the rotor has the oversized pins. WARNING: KEEP CLEAR EPOXY POLYAMIDE (MIL-C-22750) AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES WHEN YOU USE IT. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT IS FLAMMABLE AND CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (14) Apply a thin layer of clear epoxy polyamide, MIL-C-22750, on the identification that you wrote. To prepare it, refer to MIL-C-22751. Apply two layers minimum. Let it dry for 30 minutes between layers. Let the rotor dry for 12 hours before you touch it.



Figure 605. Install the Oversized Pins



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PLATE, SEAL - REPAIR 6-1 1. Replacement of Lead Seal A. Pull existing lead seal (62 or 62A, IPL Figure 2) out of dovetail groove in seal plate (60 or 60A) using a metal pick or other suitable tool. Discard seal. Inspect groove to ensure that seal has been completely removed. WARNING: KEEP ISOPROPYL ALCOHOL, TT-I-735, AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES. USE ISOPROPYL ALCOHOL IN AN AREA WITH GOOD FLOW OF AIR. ISOPROPYL ALCOHOL IS FLAMMABLE AND CAN IRRITATE THE EYES, SKIN, AND RESPIRATORY TRACT. B. Clean seal groove with a clean cloth moistened with isopropyl alcohol. Allow to air dry. C. Install holding fixture, GS20649-1, in a lathe chuck. D. Mount seal plate on holding fixture, GS20649-1, using screws provided with fixture. Hand tighten screws. E. Indicate on diameter A, the OD of the seal plate, as shown in Figure 601, to center the plate. Runout of OD must not exceed 0.0005 inch TIR. F. Tighten fixture screws. Verify that runout of seal plate is still within limits. G. Mount lead seal rolling tool, GS22828-1, on lathe. Adjust tool so that ID of seal plate is centered in the roller of the tool. H. Back off lead seal rolling tool, GS22828-1. Insert either semi-finished lead seal PN S750493-4 or commercially pure lead per QQ-L-171, Grade A, over tool. Engage lead in seal plate groove by hand. CAUTION: FOLLOW THE SPECIFIED ROLLING AND MACHINING PROCEDURES PRECISELY. DEVIATION FROM THESE PROCEDURES MAY RESULT IN IMPROPER INSTALLATION OF THE SEAL. I. Roll lead seal to a 1.220 to 1.230 inch diameter at specified rpm, as shown in Figure 601. Roll seal slowly with an even feed. Increased resistance must be felt during rolling of seal, indicating proper installation of seal. When required diameter is reached, keep lead seal rolling tool in place for 15 seconds minimum before disengaging tool. J. Visually inspect seal to ensure that no seams are visible. K. Reindicate on OD of seal plate to meet requirements of step E. L. Machine ID of seal to a 1.300 to 1.301 inch diameter at specified rpm, feed rate, and number of cuts as shown in Figure 601. M. Machine outer face of seal to meet the 0.279 to 0.289 inch dimension at specified rpm, feed rate, and number of cuts as shown in Figure 601. Deburr machined area. N. Reverse position of seal plate in holding fixture. O. Reindicate on OD of seal plate to meet requirements of step E. P. Machine inner face of seal to meet the 0.049 to 0.059 inch dimension at specified rpm, feed rate, and number of cuts as shown in Figure 601. Deburr machined area. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 601. Seal Plate - Lead Seal Replacement



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Q. Verify that any gaps around circumference of seal do not exceed limits specified in Figure 601. R. Apply chemical film, AMS2473, to any areas of seal plate where base metal may have become exposed during machining of seal.



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PLATE, SEAL - REPAIR 6-2 1. Replacement of Vespel Seal (62B, IPL Figure 2) CAUTION: AN OVERSIZED HOLE CAN COMPROMISE RIVET AND SEAL RETENTION. THE MAXIMUM DIAMETER OF THE HOLE MUST NOT EXCEED 0.100 INCH (2.54 MILLIMETERS). A. Drill out riviets (66, IPL Figure 2) while holding the old vespel seal in place. B. Remove the old backing plate (66). C. Pull existing vespel seal (62B, IPL Figure 2) out of groove in seal plate (60B, IPL Figure 2) and discard seal. WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. D. Clean seal plate groove with a clean cloth moistened with isopropyl alcohol. Allow to air dry. E. Measure ID of seal plate (60B) and record. Refer to Figure 601. F. Machine the new vespel seal (62B) if necessary per Figure 601. WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS. G. Heat seal plate at 290 to 310° F (143 to 154 C°) to install new vespel seal. H. Cool vespel seal with liquid nitrogen for 5 minutes minimum. I. Press vespel seal in place within seal plate J. Drill holes in vespel seal using a 0.98 inch (24.89 mm) bit. Use existing holes in plate to transfer the 4 holes through vespel seal.



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WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MIL-C5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING) LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE, POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0059SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES (BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. K. Deburr machined areas to 0.015 (0.381 mm) maximum. Touch up machined areas with alodine. L. Install the backing plate as shown in Figure 601. WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENTRESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. M. Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it.



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WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENTRESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. N. Apply epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer to the 4 rivet holes and assemble as shown. O. Install the 4 rivets (66) as shown in Figure 601. Clean off excess primer.



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Figure 601. Vespel Seal Replacement



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PLATE AND INSULATOR, NOZZLE - REPAIR 7-1 1. Replacement of Lead Seal A. Pull existing lead seal (95, IPL Figure 2) out of dovetail groove in nozzle plate and insulator (85 or 85A) using a metal pick or other suitable tool. Discard seal. Inspect groove to ensure that seal has been completely removed. WARNING: KEEP ISOPROPYL ALCOHOL, TT-I-735, AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES. USE ISOPROPYL ALCOHOL IN AN AREA WITH GOOD FLOW OF AIR. ISOPROPYL ALCOHOL IS FLAMMABLE AND CAN IRRITATE THE EYES, SKIN, AND RESPIRATORY TRACT. B. Clean seal groove with a clean cloth moistened with isopropyl alcohol. Allow to air dry. C. Install holding fixture, GS20649-1, in a lathe chuck. D. Mount nozzle plate and insulator on holding fixture, GS20649-1, using screws provided with fixture. Hand tighten screws. E. Indicate on diameter E, the OD of the nozzle plate, as shown in Figure 601, to center the plate. Runout of OD must not exceed 0.0005 inch TIR. F. Tighten fixture screws. Verify that runout of nozzle plate is still within limits. G. Mount lead seal rolling tool, GS22828-1, on lathe. Adjust tool so that ID of nozzle plate is centered in the roller of the tool. H. Back off lead seal rolling tool, GS22828-1. Insert either semi-finished lead seal PN S750493-14 or commercially pure lead per QQ-L-171, Grade A, over tool. Engage lead in nozzle plate groove by hand. CAUTION: FOLLOW THE SPECIFIED ROLLING AND MACHINING PROCEDURES PRECISELY. DEVIATION FROM THESE PROCEDURES MAY RESULT IN IMPROPER INSTALLATION OF THE SEAL. I. Roll lead seal to a 2.055 to 2.065 inch diameter at specified rpm, as shown in Figure 601. Roll seal slowly with an even feed. Increased resistance must be felt during rolling of seal, indicating proper installation of seal. When required diameter is reached, keep lead seal rolling tool in place for 15 seconds minimum before disengaging tool. J. Visually inspect seal to ensure that no seams are visible. K. Reindicate on OD of nozzle plate to meet requirements of step E. L. Machine ID of seal to a 2.132 to 2.133 inch diameter at specified rpm, feed rate, and number of cuts as shown in Figure 601. M. Machine outer face of seal to blend with nozzle plate surface at specified rpm, feed rate, and number of cuts as shown in Figure 601. Deburr machined area. N. Reverse position of nozzle plate and insulator in holding fixture. O. Reindicate on OD of nozzle plate to meet requirements of step E. P. Machine inner face of seal to blend with nozzle plate surface at specified rpm, feed rate, and number of cuts as shown in Figure 601. Deburr machined area. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 601. Nozzle Plate and Insulator - Lead Seal Replacement



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Q. Verify that any gaps around circumference of seal do not exceed limits specified in Figure 601. R. Apply chemical film, AMS2473, to any areas of nozzle plate where base metal may have become exposed during machining of seal.



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NOZZLE PLATE AND INSULATOR - REPAIR 7-2 1. Replacement of Nozzle Vanes when Worn Beyond Check Limits NOTE: This repair removes the nozzle vanes from the nozzle plate and insulator and incorporates a replaceable steel nozzle ring with nozzle vanes, PN 1002315-1. Replacement of the steel nozzle ring can be performed multiple times on the same plate. No changes to the assembly of the ACM are required when incorporating this repair. A. Separate the insulator (90, IPL Figure 2) from the nozzle (85, IPL Figure 2) plate and store for later use. B. Machine the nozzle plate per Figure 601. Use a locally manufactured holding fixture or locally modify holding fixture GS20649-1. C. Flourescent penetrant inspect nozzle plate in accordance with Table 510. WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MIL-C5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING) LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE, POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0059SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES (BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. D. Alodine touch up machine surfaces per AMS 2473. E. Reidentify ACM after incorporating this change by marking “SK1000094” on or near the ACM nameplate and adding “SK1000094” near the existing part marking on the nozzle and insulator plate assembly.



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Figure 601. Nozzle Plate and Insulator



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ROTOR, TURBINE - REPAIR 8-1 1. Removal of Minor Nicks, Burrs, and Scoring NOTE: A turbine rotor (100 or 100A, IPL Figure 2) that is deformed or has cracked or broken blades is not repairable. A. Remove minor nicks, burrs, and scoring, within limits of Figure 510, using either abrasive cloth, P-C-451, or a very fine stone. B. Coat exposed base metal with chemical film, AMS2473.



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ROTOR, TURBINE - REPAIR 8-2 1. Rebalancing A. Install balance fixture, GS14773-1, on balance machine, Schenck Model CAB 570 or CAB 690-R. B. Install turbine rotor (100 or 100A, IPL Figure 2) in balance fixture, GS14773-1, using arbor set, GS15611-1. C. Using balancing accessories kit, GS15800-1, to drive the turbine rotor, and balance machine nozzle assembly, GS15801-1, to direct air flow to the rotor, apply air pressure and obtain balancing speed of 4400 to 4600 rpm. D. Biplanar balance the turbine rotor to within 180 micro ounce-inches by removing stock, as necessary, from indicated areas of turbine rotor, as shown in Figure 601. Use wheel grinder, part of balancing accessories kit, GS15800-1, to remove stock. Use blow gun, also part of kit, to remove metallic dust. NOTE: To avoid unnecessary stock removal, which will decrease the service life of the turbine rotor, do not attempt to improve balance once it is within the specified limit. E. Blend areas, where stock is removed, smoothly in all directions into nominal contour with a minimum radius of 0.18 inch and a maximum surface roughness of 80 microinches. F. Reduce air pressure to zero. G. Remove turbine rotor from balance fixture. H. Remove balance fixture from balance machine. I. Fluorescent penetrant inspect turbine rotor in accordance with Table 502. J. Coat areas of turbine rotor, where stock has been removed, with chemical film, AMS2473.



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Figure 601. Turbine Rotor-Rebalancing



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RING, SEAL - REPAIR 9-1 1. Repair of Sealing Surface A. Machine sealing surface of seal ring (150 and 230, IPL Figure 2) as necessary, within dimensional limits of Figure 601, to remove flaws such as scratches or pits. B. Surface must meet flatness and finish requirements as shown in Figure 601.



Figure 601. Seal Ring - Repair of Sealing Surface



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SHAFT, DRIVE - REPAIR 10-1 1. Repair of Minor Damage from Lead-in Threads NOTE: If there is any damage along the working length of threads, do not attempt repair. Replace drive shaft (240, IPL Figure 2). A. Remove minor damage to lead-in threads only using a fine thread file.



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SHAFT, DRIVE - REPAIR 10-2 1. Repair of Minor Scratches A. Remove minor scratches, using abrasive cloth, P-C-451, provided that dimensional and surface finish requirements, shown in Figure 512, are maintained.



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HOUSING, CONTAINMENT - REPAIR 11-1 1. Replacement of Liner NOTE: Liner (15, IPL Figure 3) may be replaced only one time. The next replacement will require a new containment housing (1). A. Drill out three headless straight pins (50) from housing (55) using a 0.120 inch diameter drill. B. Remove three screws (5), three washers (10), and liner (15). Discard liner. C. Coat three pinholes in housing (55) with chemical film, AMS2473. D. Install new semi-finished liner PN S753453-30 in housing (55). E. Apply a light coat of anti-seize thread compound, MIL-T-5544, to threads and under heads of three screws (5). F. Secure liner (15) with three washers (10) and three screws (5). Tighten screws (5) to 25 to 30 pound-inches above running torque. NOTE: Running torque is the amount of torque required to thread a fastener before tightening. It may vary depending on the individual fastener. G. Simultaneously drill and ream three new pinholes, located as shown in Figure 601, Section C-C, through liner (15, IPL Figure 3), containment ring (20), and housing (55), using a 0.145 inch maximum diameter drill. H. Remove three screws (5), three washers (10), liner (15), and containment ring (20). I. Remachine the three drilled holes in housing (55) to a 0.1552 to 0.1558 inch diameter and to a depth of 0.250 to 0.280 inch, as shown in Figure 601, Section C-C. J. Remachine the three drilled holes in containment ring (20, IPL Figure 3) to a 0.1572 to 0.1710 inch diameter. K. Remachine the three drilled holes in liner (15) to a 0.1572 to 0.1592 inch diameter. L. Coat machined holes in liner (15) and housing (55) with chemical film, AMS2473.



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WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENTRESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. M. Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it. N. Coat three new headless straight pins (50) with primer. O. Install headless straight pins (50), while primer is wet, in drilled holes in housing (55) so that pins project 0.075 to 0.105 inch from housing, as shown in Figure 601, Section C-C. P. Remove preformed packing (25, IPL Figure 3) from housing (55). Discard packing. Q. Apply a thin film of glycerin to a new preformed packing (25). Install packing in housing (55). R. Install containment ring (20) and liner (15) in housing (55). Secure with three washers (10) and three screws (5). Tighten screws (5) to 25 to 30 pound-inches above running torque.



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Figure 601. Containment Housing - Replacement of Liner



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S. Locate centerline of diameter D of housing (55) and machine ID of liner (15) to a 3.657 to 3.663 inch diameter, as shown in Figure 601. T. Remove metal chips from assembly. WARNING: PERCHLOROETHYLENE, O-T-236, IS TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. U. Clean assembly by vapor degreasing in perchloroethylene. V. Remove liner (15, IPL Figure 3). W. Mark the same set serial number, which is marked on containment ring (20) and housing (55), on liner (15). Mark characters less than 0.003 inch deep using either electrolytic etch or vibration peen method per the following example: SET SER NO. XXXX X. Anodize liner (15) in accordance with MIL-A-8625, Type I. Y. Reidentify reworked containment housing (1) by adding "(SK105317)" below the existing part number. Mark characters less than 0.003 inch deep using either electrolytic etch or vibration peen method per the following example: 753453-1 (SK105317)



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HOUSING, CONTAINMENT - REPAIR 11-2 1. Removal of Rust and Replating of Containment Ring A. Remove rust, as required, from containment ring (20, IPL Figure 3) using glass bead peen. B. Inspect containment ring (20) for cracks in accordance with Table 502. No cracks allowed. C. Apply electrodeposited cadmium plating, as required, to containment ring per QQ-P-416, Type II (supplementary chromate treatment) to a thickness of 0.0005 to 0.0008 inch.



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HOUSING, CONTAINMENT - REPAIR 11-3 1. Replacement of Inlet Screen A. Disassemble containment housing (1, IPL Figure 3) in accordance with DISASSEMBLY. B. Remove three rivets (35) and four rivets (40) securing inlet screen (45) to housing (55). C. Remove inlet screen (45) and discard. D. Coat three new rivets (35) and four new rivets (40) with chemical film, AMS2473. E. Touch up any exposed base metal in rivet holes in housing (55) with chemical film, AMS2473. F. Align through holes in new inlet screen (45) with holes in housing (55) and install screen on housing. WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENTRESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. G. Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it. NOTE: The primer mixture must be used within 8 hours. H. Brush or swab a thin coat of primer to three new rivets (35), four new rivets (40), and to rivet holes in housing (55). I. Install rivets (35 and 40), while primer is wet, through aligned holes in inlet screen (45) and housing (55) in required directions for forming of heads, as shown in Figure 601. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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J. Form heads to meet minimum dimensional requirements shown in Figure 601.



Figure 601. Containment Housing - Replacement of Inlet Screen



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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ASSEMBLY 1. General A. Due to the critical nature of the ACM parts, reinspect parts for burrs and other damage which may have developed during handling or storage. Repair, reclean, or replace, as required. CAUTION: ALL PARTS OF THE ACM MUST BE ABSOLUTELY CLEAN AND UNDAMAGED. THEREFORE, PERFORM ALL ASSEMBLY OPERATIONS ON CLEAN BENCHES IN A WELL-LIGHTED, LIMITED TRAFFIC AREA. CAUTION: DO NOT REMOVE NEW BALL BEARINGS (155 AND 235, IPL FIGURE 2) FROM THEIR SEALED PACKAGES UNTIL INSTALLATION IS REQUIRED TO AVOID CONTAMINATION OF BEARINGS. B. Throughout the assembly procedures, reference to the turbine end shall mean that end of the unit in which the turbine and compressor rotors are located. Reference to the fan end shall mean that end of the unit in which the cooling fan is located. C. The assembly torque values for some fasteners are specified as above running torque. Running torque is the amount of torque required to thread a fastener before tightening. It may vary depending on the individual fastener. The running torque must be added to the specified torque value given in the assembly procedures. D. The running torque of threaded self locking rings (160, IPL Figure 1, Sheet 1) and (20, IPL Figure 2) must be between 30 to 120 pound-inches (3 to 14 N•m) to ensure proper securing of rotating parts. The running torque of the rings decreases with repeated use. If the running torque is not within limits, replace the rings. If the running torque still is not within limits, check the threads of drive shaft (240) for damage in accordance with CHECK. NOTE: Drive shaft PN 753385-3 can be used in place of drive shaft PN 753385-2. E. The recommended lubricating oil for the ACM is BPTO 2380 (refer to Table 702). This is the oil that is referenced throughout the assembly procedures. However, where BPTO 2380 is not available, lubricating oils per MIL-L-23699 are suitable when operating in hotter and temperate climates, and MIL-L-7808 is suitable when operating in colder environments. MIL-L-23699 is suitable when ambient temperatures are -10 to +120°F (-23 to +49°C), and MIL-L-7808 is suitable when ambient temperatures are -60 to +32°F (-51 to 0°C). F. Nonmetallic wicks (300, IPL Figure 1, Sheet 2) and face seals (125 and 205, IPL Figure 2) must be soaked in clean, filtered, lubricating oil, BPTO 2380, prior to installation. Nonmetallic wicks (300, IPL Figure 1, Sheet 2) must be soaked for 3 hours minimum and drained, and carbon nose of face seals (125 and 205, IPL Figure 2) must be soaked for 2 hours minimum and drained before installation. These parts may be presoaked prior to build-up of the ACM to facilitate assembly. G. Use a Wilton PowRarm, Model 301, which is a swivel holding tool, to hold and position the ACM during assembly, as required. The bearing sleeve holder, GS15615-1, and power arm fixture, GS22815-1, which are listed in Table 701, are designed for mounting on the Wilton PowRarm.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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H. Special tools, fixtures, and equipment required for assembly are listed in Table 701. NOTE: Equivalent tools, fixtures, and equipment can be used if they agree with the requirements of ARINC Report 668. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 701. Special Tools, Fixtures, and Equipment TOOL NO. CAB 570 or CAB 690-R



NOMENCLATURE Balance Machine Schenck Trebel Corp. 535 Acron St. Deer Park, NY 11729



USE Dynamic balance the rotative group.



CAGE Code: 30218 GS15614-1



Seal and Spring Seat Installer Driver



Install spring seat and face seals in bearing cartridge sleeve.



GS15615-1



Bearing Sleeve Holder



Hold rotative group during build-up. Mounts to Wilton PowRarm, Model 301.



GS15616-1



Dummy Bearing



Used in place of turbine end ball bearing during shimming of bearing cartridge sleeve.



GS15617-1 GS15617-2



End Play Spacers



Used in place of components on short and long ends of drive shaft during shimming of bearing cartridge sleeve.



GS15618-1



Check Nut (3 Required)



Used in place of threaded self locking rings during build-up of bearing cartridge sleeve.



GS15619-1



Bearing Shaft Support



Hold drive shaft during installation of ball bearings.



GS15620-1



Bearing Driver



Install ball bearings on drive shaft.



GS15622-1



Turbine Housing Support Fixture



Hold ACM during pinning and shimming procedures.



GS15623-1



Compressor Rotor Spacer



Simulates compressor rotor during build-up of rotative group.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 701. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.



NOMENCLATURE



USE



GS15626-1



Balance Fixture Kit



Hold turbine housing and rotative group on balance machine, CAB 570 or CAB 690-R, during dynamic balance.



GS15627-1



Pin Installer



Install spiral spring pins for pinning of seal plate and compressor diffuser.



GS15800-1



Balancing Accessories Kit



Controls air flow to drive rotative group during dynamic balance. Includes wheel grinder for balance stock removal and blow gun for cleaning.



GS15801-1



Balance Machine Nozzle Assembly



Direct air flow to rotative group during dynamic balance.



GS20670-1



Torque Adapter



Torque threaded self locking ring.



GS20671-1



Closure Kit



Cap all ports on ACM for storage.



GS20649-1



Holding Fixture



Hold seal plate or nozzle plate and insulator in a lathe during replacement of lead seal.



GS22333-2



Spanner Wrench (2 Required)



Install turbine and fan end threaded self locking rings.



GS22815-1



Power Arm Fixture



Hold Turbine housing and rotative group during build-up. Mounts to Wilton PowRarm, Model 301.



Model 260



Groove Micrometer The L S Starrett Co. 121 Crescent St. Athol, MA 01331-1913



Used to measure grooves in bearing cartridge sleeve during shimming of face seals.



CAGE Code: 57163 Model 301



Wilton PowRarm Wilton Corp. 300 S. Hicks Road Palatine, IL 60067 CAGE Code: 66080



Swivel holding and positioning tool, used with items GS15615-1 and GS22815-1.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 701. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.



NOMENCLATURE



USE



GS15610-1



Bearing Sleeve Support



Hold the bearing cartridge sleeve during assembly of seals.



Model HDX-SET-FSP-T-OST Model HH99A-T1



Handle and Probe Set



Monitor the temperature of the compressor rotor and the cooling fan during installation.



Model VT-750B



Heat Gun Available from: Master Appliance Corp. 2420 18th St. P.O. Box 68 Racine, WI 53401



Digital Thermometer Available from: Omega Engineering Inc. One Omega Dr. P.O. Box 4047 Stamford, CT 06907-4047



Increase the temperature of the compressor rotor and cooling fan to install them on the drive shaft.



CAGE Code: 83284 792790-T-11



Pin Alignment Tool



Align hole for stepped pin in bearing cartridge sleeve with pin hole in turbine housing prior to installing pin.



782790-T-14



Cartridge Installer



Push the cartridge into the turbine housing. This tool is necessary only for PN 782790-16 units.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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I. Consumable materials required for assembly are listed in Table 702. NOTE: Maintenance personnel must use the specified consumable material for the specified task. These consumable materials are known to agree with all of the design and qualification requirements. Only approved materials engineering personnel can make equivalent consumable material decisions. These materials are used at the risk of the organization who makes the decision. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 702. Consumable Materials MATERIAL



MANUFACTURER OR SPECIFICATION



Molybdenum DisulfidePetrolatum Anti-seize Thread Compound



MIL-T-83483



Dow Corning No. 44 Silicone Lubricant



Dow Corning Corporation



USE Thread lubricant



EM Lubricant CP-116 E.M. Corporation Sub of Great Lakes Chemicals P.O. Box 2400 W. Lafayette, IN 47906 Lubricant for preformed packings.



CAGE Code: 71984 Glycerin



Commercially available.



Lubricant for containment housing preformed packing.



Glyptal 1202 Clear Insulating Varnish, Glyptal 1500 Thinner



Glyptal Inc.



Protective coating for identification plate.



Isopropyl Alcohol



ASTM D770



General cleaning solvent.



Lockwire



MS20995C20



Safety wire plugs and bleeders, liquid level sight plug, and warning tag.



Lubricating Oil, BPTO 2380



BP Products North America Inc.



Required lubricating oil for ACM.



CAGE Code: 65313



CAGE Code: 4XLA9



NOTE: Refer to paragraph 1.E. for alternate lubricating oils where BPTO 2380 is not available. Marking Pen



TT-I-544



Mark reference points on parts during shimming and balancing procedures.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



Table 702. Consumable Materials (Continued) MATERIAL Mo-lith No. 2 Thread Lubricant



MANUFACTURER OR SPECIFICATION Fiske Bros. Refining Co.



USE Anti-seize thread lubricant.



CAGE Code: 73219 Epoxy Polyamide (Galvanic) Primer



MIL-PRF-23377, Type I or II, Class C1 or C2, formulated without water.



Galvanic insulation film for dissimilar metals.



OR Strontium Chromate Primer



MIL-PRF-85582, Type I or II, Class C1 (Barium Chromate or C2 (Strontium Chromate) primer coatings formulated without water. NOTE: When using either of the above, the admixture of the epoxy resin solution and curing agent shall not be reduced with any thinner.



Clear Epoxy Polymide Coating



MIL-C-22750



Give protection for the information on the identification plate



Ultrachem Assembly Fluid #1



Ultrachem Inc.



Lubricate the fan and turbine split (vespel) rings to make it easier to install the bearing cartridge.



CAGE Code: 56385



2. Preliminary Check for Acceptable Axial Travel of Bearing Cartridge Sleeve in Turbine Housing NOTE: This procedure is recommended, not necessary. This test can be done during disassembly or by dimensional checks of all of the detail parts. A. Check for acceptable axial travel of bearing cartridge sleeve (275, IPL Figure 2) in turbine housing (335, IPL Figure 1, Sheet 2) with stepped pin (305) installed, in accordance with Figure 701, as follows: (1) Align hole for stepped pin (305, IPL Figure 1, Sheet 2) in bearing cartridge sleeve (275, IPL Figure 2) with pinhole or bushing (356, IPL Figure 1, Sheet 2) in turbine housing (335). (2) Insert bearing cartridge sleeve (275, IPL Figure 2), without preformed packings, into turbine housing (335, IPL Figure 1, Sheet 2).



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(3) Insert stepped pin (305), large end in first, into pinhole in turbine housing (335). Large end must engage pinhole in bearing cartridge sleeve (275, IPL Figure 2), as shown. (4) Align holes in retaining plate (280, IPL Figure 1, Sheet 2) with holes in turbine housing (335) and install plate to retain stepped pin (305). (5) Apply a thin film of clean, filtered, lubricating oil, BPTO 2380, to threads and under heads of two screws (270). (6) Secure retaining plate (280) with two screws (270) and two washers (275). Tighten screws to 20 to 25 pound-inches (2 to 3 N•m) above running torque. (7) Clamp turbine housing (335) to prevent movement.Press stepped pin (305) in against bearing cartridge sleeve (275, IPL Figure 2). Move bearing cartridge sleeve (275) axially in turbine housing (335, IPL Figure 1, Sheet 2) in both directions and measure and record total axial travel using a dial indicator. Total travel shall not exceed 0.005 inch. (8) Repeat step (8) with stepped pin (305) pulled out against retaining plate (280). (9) Remove screws (270), washers (275), retaining plate (280), and stepped pin (305). Remove bearing cartridge sleeve (275, IPL Figure 2) from turbine housing (335, IPL Figure 1, Sheet 2). (10) If total axial travel recorded in steps (8) and (9) exceeds 0.005 inch, dimensionally inspect stepped pin (305), pinhole or bushing (356) in turbine housing (335), and pinhole in bearing cartridge sleeve (275, IPL Figure 2) in accordance with CHECK. Repair or replace parts, as required.



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Figure 701. Checking Travel of Bearing Cartridge Sleeve in Turbine Housing



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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3. Assembly of Bearing Cartridge Sleeve A. Insert one of two spring seats (250, IPL Figure 2), with seat facing inward, into turbine end of bearing cartridge sleeve (275), as shown in Figure 702. Align slot in spring seat with pinhole in sleeve and insert one of two headed straight pins (245, IPL Figure 2). Apply a small piece of masking tape to temporarily hold pin in place. Do not remove tape until indicated. NOTE: Turbine end of bearing cartridge sleeve (275) is the end with two grooves for preformed packings (5). B. Install either shims (255) removed during disassembly, or a 0.042 inch trial thickness of shims, into fan end of bearing cartridge sleeve (275) and seat on spacer in sleeve, as shown in Figure 702, View F. Use a maximum of two shims (255, IPL Figure 2). C. Insert compression spring (270) into fan end of bearing cartridge sleeve (275) and locate in seat of spring seat (250). D. Insert remaining spring seat (250), with seat facing inward, into fan end of bearing cartridge sleeve (275), as shown in Figure 702. Align slot in spring seat with remaining pinhole in sleeve. Insert seal and spring seat installer driver, GS15614-1, into fan end of sleeve. Press tool against spring seat to compress compression spring (270, IPL Figure 2) and insert remaining headed straight pin (245). Apply a small piece of masking tape to temporarily hold pin in place. Do not remove tape until indicated. NOTE: There are two procedures which follow that give instructions on how to complete the bearing cartridge sleeve assembly. The procedure in paragraph E. gives instructions on how to do this with end play spacers, GS15617-1 and GS15617-2, installed on the ends of the drive shaft and tightened in position with special torque nuts, GS15618-1. An alternative procedure that you may find easier to use, and which does not use the end play spacers and special torque nuts, is given in paragraph F. E. Procedure to Complete the Bearing Cartridge Sleeve Assembly With End Play Spacers: (1) Install new ball bearing (155) on drive shaft (240) as follows: (a) Install drive shaft (240), with long end of shaft facing down, in bearing shaft support, GS15619-1. CAUTION: AFTER YOU OPEN THE PLASTIC BAG THAT SEALS THE BALL BEARING, HOLD THE BEARING ONLY BY THE BAG WHEN YOU MOVE OR INSTALL THE BEARING. IF YOU TOUCH THE BEARING WITH YOUR BARE HANDS, YOU WILL REMOVE LUBRICATION OIL FROM THE BEARING AND POSSIBLY CAUSE CONTAMINATION THAT WILL DAMAGE IT. (b) Slide new ball bearing (155) over short end of drive shaft (240) with side of bearing marked THRUST facing down towards wide land of shaft, as shown in Figure 702. (c) Slide tapered end of bearing driver, GS15620-1, over short end of drive shaft (240, IPL Figure 2) and seat against inner race of ball bearing (155). (d) Place assembly on an arbor press. Press down on bearing driver, GS15620-1, and seat ball bearing (155) against wide land of drive shaft (240).. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 702. Assembly of Bearing Cartridge Sleeve (e) Remove bearing driver, GS15620-1, and remove drive shaft (240) with ball bearing (155) from bearing shaft support, GS15619-1 (2) Insert long end of drive shaft (240) through fan end of bearing cartridge sleeve (275) until ball bearing (155) is seated against spring seat (250), as shown in Figure 702. (3) Slide dummy bearing, GS15616-1, over long end of drive shaft (240, IPL Figure 2), until seated against narrow land of shaft, as shown in Figure 702. (4) Install end play spacers, GS15617-1 and GS15617-2, over short and long ends, respectively, of drive shaft (240, IPL Figure 6), as shown in Figure 702. (5) Apply a light coat of thread lubricant, Mo-Lith No. 2, to threads and on contact surface of two check nuts, GS15618-1. Install one nut on each end of drive shaft (240, IPL Figure 2) and hand tighten. (6) Insert fan end of bearing cartridge sleeve assembly into bearing sleeve holder, GS15615-1, and place holder in a horizontal position.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(7) Tighten special torque nut, GS20581-1, at long end of drive shaft (240) to 330 to 350 pound-inches (37.2 to 39.4 newton-meters) more than running torque. Tighten nut at short end of shaft to 285 to 300 pound-inches (32.1 to 33.8 newton-meters) more than running torque. (8) Put a load (8- to 15-pounds reference) to short end of drive shaft (240), then to long end of shaft, and measure total end play of shaft, with respect to bearing cartridge sleeve (275), using dial indicator of bearing sleeve holder, GS15615-1. End play shall be 0.003 to 0.005 inch (0.076 to 0.127 mm). If end play is within limits, proceed to step (9). If end play is not within limits, proceed as follows: (a) Remove two check nuts, GS15618-1, and end play spacers, GS15617-1 and GS15617-2. (b) Remove bearing cartridge sleeve assembly from bearing sleeve holder, GS15615-1. (c) Remove drive shaft (240) with ball bearing (155) from fan end of bearing cartridge sleeve (275). Remove dummy bearing, GS15616-1, from turbine end of sleeve. (d) Remove masking tape from headed straight pin (245). (e) Insert seal and spring seat installer/driver, GS15614-1, into fan end of bearing cartridge sleeve (275). Press tool against spring seat (250) to compress helical compression spring (270) and remove headed straight pin (245). (f) Remove spring seat (250), helical compression spring (270), and solid shims (255). (g) Adjust thickness of solid shims (255) as necessary to obtain required end play. Increasing thickness of shims will decrease end play. Decreasing thickness of shims will increase end play. (h) Reinstall solid shims (255) in bearing cartridge sleeve (275). (i) Reinstall helical compression spring (270), spring seat (250), and headed straight pin (245) in accordance with steps C. and D. (j) Reinstall drive shaft (240), dummy bearing, GS15616-1, end play spacers, GS15617-1 and GS15617-2, and recheck end play of drive shaft (240) in accordance with steps (2) thru (8). (9) Remove check nut, GS15618-1, and end play spacer, GS15617-2, from long end of drive shaft (240). (10) Remove bearing cartridge sleeve assembly from bearing sleeve holder, GS15615-1. (11) Remove drive shaft (240) with ball bearing (155) from fan end of bearing cartridge sleeve (275). Remove dummy bearing, GS15616-1, from turbine end of sleeve. Replace drive shaft in sleeve. (12) Install bearing cartridge sleeve assembly on bearing shaft support, GS15619-1, with short end of drive shaft (240) facing down. (13) Slide new ball bearing (235) over long end of drive shaft (240) with side of bearing marked THRUST facing down towards narrow land of shaft, as shown in Figure 702. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(14) Slide tapered end of bearing driver, GS15620-1, over long end of drive shaft (240, IPL Figure 2) and seat against inner race of ball bearing (235). (15) Place assembly on an arbor press. Press down on bearing driver, GS15620-1, and seat ball bearing (235) against narrow land of drive shaft (240). (16) Remove bearing driver, GS15620-1. Remove bearing cartridge sleeve assembly from bearing shaft support, GS15619-1, and replace in bearing sleeve holder, GS15615-1. (17) Reinstall end play spacer, GS15617-2, and check nut, GS15618-1, on long end of drive shaft (240). Tighten nut to 330 to 350 pound-inches (37.2 to 39.4 newtonmeters) more than running torque. (18) Recheck drive shaft (240) end play in accordance with step (8). NOTE: If end play of drive shaft (240) is not within limits, ball bearing (235) must be replaced after removal from shaft when disassembling bearing cartridge sleeve assembly to adjust thickness of solid shims (255). (19) Remove check nuts, GS15618-1, and end play spacers, GS15617-1 and GS156172, from drive shaft (240).



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



F. Alternative Procedure to Complete the Bearing Cartridge Sleeve Assembly Without End Play Spacers: CAUTION: AFTER YOU OPEN THE PLASTIC BAG THAT SEALS THE BALL BEARING, HOLD THE BEARING ONLY BY THE BAG WHEN YOU MOVE OR INSTALL THE BEARING. IF YOU TOUCH THE BEARING WITH YOUR BARE HANDS, YOU WILL REMOVE LUBRICATION OIL FROM THE BEARING AND POSSIBLY CAUSE CONTAMINATION THAT WILL DAMAGE IT. (1) Install new ball bearing (155) on the short end of the drive shaft (240) with the side of the bearing identified as “THRUST” against the wide land of the shaft, as shown in Figure 703. Leave the bearing loose on the shaft. It will be permanently installed against the wide land of the shaft in a subsequent step. (2) While you hold the ball bearing on the shaft, install the shaft on bearing shaft support, GS15619-1, with the short end of the shaft in the support and the inner race of the bearing on the nose of the support. (3) Put the drive shaft, ball bearing, and bearing shaft support, GS15619-1, on an arbor press. (4) Install the bearing cartridge sleeve (275, IPL Figure 2) assembly on the drive shaft with the fan end of the sleeve down, as shown in Figure 703. (5) Install dummy bearing, GS15616-1, on the long end of the drive shaft. Push the bearing down so that it is against the narrow land of the shaft, as shown in Figure 703. NOTE: Dummy bearing, GS14767-1, has a larger inside diameter than bearing (235, IPL Figure 2) so that it installs without an interference fit on the shaft. (6) Install bearing driver, GS15620-1, on the long end of the drive shaft with the nose of the driver on the inner race of the dummy bearing, as shown in Figure 703. (7) Slowly push down on the bearing driver, GS15620-1, with the arbor press to push ball bearing (155, IPL Figure 2) against the wide land of the drive shaft at the fan end. Push until the movement of the arbor press stops, which shows that the ball bearing is correctly installed.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Figure 703. Install the Ball Bearing on the Fan (Short) End of the Drive Shaft Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(8) Make a check of the end play of the drive shaft as follows: CAUTION: KEEP THE LOAD ON THE BEARING DRIVER, GS15620-1, CONSTANT WHEN YOU MAKE A CHECK OF THE END PLAY OF THE DRIVE SHAFT. IF THE LOAD CHANGES, THE END PLAY THAT YOU MEASURE WILL NOT BE ACCURATE. (a) Keep a load (8- to 15-pounds reference) on the bearing driver, GS15620-1, with the arbor press. (b) With one hand, gently move the bearing cartridge sleeve up and down and measure the total end play of the sleeve. This movement is the equivalent of drive shaft end play. Use a dial indicator to measure the end play. The end play must be 0.003 to 0.005 inch (0.076 to 0.127 mm). Refer to Figure 704. (c) Release the load on the bearing driver, GS15620-1. (d) If the end play is in the limits of step (b), continue with step (9). If the end play is not in the limits, continue as follows: 1 Remove the bearing driver, GS15620-1, from the long end of the drive shaft. 2 Remove the bearing cartridge sleeve assembly from the drive shaft (240, IPL Figure 2) and ball bearing (155). Let the drive shaft and ball bearing stay in the bearing shaft support, GS15619-1. 3 Remove the dummy bearing, GS15616-1, from the turbine end of the bearing cartridge sleeve. 4 Remove the masking tape from the headed straight pin (245). 5 Install the seal and spring seat installer/driver, GS15614-1, in the fan end of the bearing cartridge sleeve. Push the tool against spring seat (250) to compress helical compression spring (270) and remove headed straight pin (245). 6 Remove spring seat (250), helical compression spring (270), and solid shims (255). 7 Change the total thickness of solid shims (255), as necessary, to get the specified end play of the drive shaft. Refer to Figure 704. If you increase the thickness of the shims you will decrease the end play. If you decrease the thickness of the shims you will increase the end play. 8 Install the new thickness of solid shims (255, IPL Figure 2) in the bearing cartridge sleeve.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



Figure 704. Make a Check of the End Play



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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9 Install helical compression spring (270), spring seat (250), and headed straight pin (245) as specified in steps C. and D. 10 Install the bearing cartridge sleeve assembly, dummy bearing, GS15616-1, and bearing driver, GS15620-1, as specified in steps (4) thru (6). 11 Check the end play of the drive shaft again as specified in step (8). (9) Remove the bearing driver, GS15620-1, from the long end of the drive shaft. (10) Remove the bearing cartridge sleeve assembly from the drive shaft (240, IPL Figure 2) and ball bearing (155). Let the drive shaft and ball bearing stay in the bearing shaft support, GS15619-1. (11) Remove the dummy bearing, GS15615-1, from the turbine end of the bearing cartridge sleeve. (12) Install the bearing cartridge sleeve assembly on the drive shaft with the fan end of the sleeve down. CAUTION: AFTER YOU OPEN THE PLASTIC BAG THAT SEALS THE BALL BEARING, HOLD THE BEARING ONLY BY THE BAG WHEN YOU MOVE OR INSTALL THE BEARING. IF YOU TOUCH THE BEARING WITH YOUR BARE HANDS, YOU WILL REMOVE LUBRICATION OIL FROM THE BEARING AND POSSIBLY CAUSE CONTAMINATION THAT WILL DAMAGE IT. (13) Install new ball bearing (235) on the long end of the drive shaft (240) with the side of the bearing identified as “THRUST” against the narrow land of the shaft, as shown in Figure 705. (14) Install bearing driver, GS5620-1, on the long end of the drive shaft with the nose of the driver on the inner race of bearing (235, IPL Figure 2), as shown in Figure 705. (15) Slowly push down on the bearing driver, GS15620-1, with the arbor press to push the ball bearing against the narrow land of the drive shaft. Push until the movement of the arbor press stops, which shows that the ball bearing is correctly installed. (16) Make a check of the end play of the drive shaft again as specified in step (8). NOTE: If the end play of the drive shaft is not in the specified limits, you must replace ball bearing (235, IPL Figure 2) with a new bearing after you disassemble the bearing cartridge sleeve to change the thickness of solid shims (255). Do not use the removed bearing again. (17) Remove bearing driver, GS15620-1. (18) Remove the bearing cartridge assembly from the bearing shaft support, GS15619-1



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Figure 705. Install the Ball Bearing on the Turbine (Long) End of the Drive Shaft Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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4. Shimming and Installation of Face Seal -Turbine- End A. Soak carbon nose of face seal (205, IPL Figure 2) in clean, filtered, lubricating oil, BPTO 2380, for 2 hours minimum and drain. B. Place bearing cartridge sleeve (275) and drive shaft (240) assembly in bearing sleeve holder, GS15615-1, with turbine end facing up. C. Install internal retaining ring (225) in its groove in bearing cartridge sleeve (275), as shown in Figure 706. D. With internal retaining ring (225, IPL Figure 2) loaded down against groove, measure and record dimension S, the distance from the top of the sleeve to the top of the retaining ring, as shown in Figure 706, using a depth micrometer. E. Install seal ring (230, IPL Figure 2), with scalloped side facing down, over drive shaft (240) and seat against ball bearing (235), as shown in Figure 706. F. Measure and record dimension R, the distance from the top of bearing cartridge sleeve (275, IPL Figure 2) to the top of seal ring (230), as shown in Figure 706, using a depth micrometer. NOTE: Due to dimensional differences in parts within their design tolerances, dimension R may be either greater than, less than or equal to dimension S. G. Find the difference between dimensions R and S by subtracting the smaller dimension from the larger dimension (R-S or S-R, as applicable) and record as dimension T. If dimension R equals dimension S, then dimension T equals zero. H. Measure and record dimension U, the thickness of the metal ring of face seal (205 IPL Figure 2), as shown in Figure 706, using a micrometer. Obtain dimension by taking a reading at three places, equally spaced, and obtaining an average value. I. Determine required thickness of shims (210, IPL Figure 2) in accordance with the applicable formula which follows: NOTE: In the following formulas, 0.413 (10.490 mm) is the nominal value for the required 0.411 to 0.415 inch (10.439 to 10.541 mm) distance from the top of face seal (205) to the top of seal ring (230) after shimming and installation of seal, as shown in Figure 706. Shimming to obtain this dimension provides for proper preload on seal. (1) If dimension R is greater than dimension S: Required shim thickness = 0.413 - (U + T) (2) If dimension R is less than dimension S: Required shim thickness = (0.413 - U) + T (3) If dimension R equals dimension S: Required shim thickness = 0.413 - U



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Figure 706. Installation of Face Seal - Turbine End J. Select shims (210, IPL Figure 2) equal to required thickness in step I. ±0.001 inch (0.025 mm). K. Install shims (210) in bearing cartridge sleeve (275), as shown in Figure 706. L. Install face seal (205, IPL Figure 2) as follows: (1) Drain excess lubricating oil, BPTO 2380, from face seal (205). (2) Slide face seal (205), with carbon nose facing down, over drive shaft (240) and into fan end of bearing cartridge sleeve (275). Verify that seal is level and centered in sleeve.



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CAUTION: DO NOT SUPPORT BEARING CARTRIDGE SLEEVE AND DRIVE SHAFT ASSEMBLY ON DRIVE SHAFT WHEN PRESSING FACE SEAL INTO SLEEVE AS BALL BEARINGS WILL BE DAMAGED. (3) Remove bearing cartridge sleeve and shaft assembly from bearing sleeve holder, GS15615-1. Place assembly on an arbor press and support on fan end of sleeve with drive shaft free. (4) Slide seal and spring seat installer driver, GS15614-1, over drive shaft (240) and against face seal (205). Press on driver until face seal (205) is seated in bearing cartridge sleeve (275). Remove driver and remove assembly from arbor press. Verify that drive shaft (240) rotates freely, indicating proper installation of face seal (205). (5) Replace bearing cartridge sleeve and shaft assembly in bearing sleeve holder, GS15615-1, with turbine end up. (6) Do these at the same time (Refer to Figure 706): • Put a 15- to 20-pound (reference) load on the drive shaft in the direction shown. • Measure dimension V, the dimension from the top of the bearing cartridge sleeve (275, IPL Figure 2) to the top of the face seal (205), with a depth micrometer. Write the dimension on a record. (7) Subtract dimension V from dimension R. The difference must be 0.411 to 0.415 inch, indicating correct shimming of face seal (205, IPL Figure 2). If difference is not within limits, remove face seal (205) per DISASSEMBLY and adjust thickness of shims (210), as necessary, to obtain the 0.411 to 0.415 inch dimension. Replace face seal (205) if damaged during removal. M. Measure and record dimension X, the thickness of internal retaining ring (160), as shown in Figure 706, using a micrometer. Take reading opposite open end of ring. N. Measure and record dimension Y, the distance from the top of bearing cartridge sleeve (275, IPL Figure 2) to the top of the groove where internal retaining ring (160) will be installed, as shown in Figure 706, using groove micrometer, Model 260. O. Determine required thickness of shims (165, IPL Figure 2) as follows: Required shim thickness = V - (X + Y) P. Select shims (165) equal to required thickness in step O. ±0.001 inch. Q. Install shims (165) and internal retaining ring (160) in bearing cartridge sleeve (275), as shown in Figure 706.



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5. Shimming and Installation of Face Seal -Fan- End A. Soak carbon nose of face seal (125, IPL Figure 2) in clean, filtered, lubricating oil, BPTO 2380, for 2 hours minimum and drain. B. Place bearing cartridge sleeve (275) and drive shaft (240) assembly in bearing sleeve holder, GS15615-1, with fan end facing up. C. Install internal retaining ring (145) in its groove in bearing cartridge sleeve (275), as shown in Figure 707. D. With internal retaining ring (145, IPL Figure 2) loaded down against groove, measure and record dimension S, the distance from the top of the sleeve to the top of the retaining ring, as shown in Figure 707, using a depth micrometer. E. Install seal ring (150, IPL Figure 2), with scalloped side facing down, over drive shaft (240) and seat against ball bearing (155), as shown in Figure 707. F. Measure and record dimension R, the distance from the top of bearing cartridge sleeve (275, IPL Figure 2) to the top of seal ring (150), as shown in Figure 707, using a depth micrometer. NOTE: Due to dimensional differences in parts within their design tolerances, dimension R may be either greater than, less than or equal to dimension S. G. Find the difference between dimensions R and S by subtracting the smaller dimension from the larger dimension (R-S or S-R, as applicable) and record as dimension T. If dimension R equals dimension S, then dimension T equals zero. H. Measure and record dimension U, the thickness of the metal ring of face seal (125, IPL Figure 2), as shown in Figure 707, using a micrometer. Obtain dimension by taking a reading at three places, equally spaced, and obtaining an average value. I. Determine required thickness of shims (130, IPL Figure 2) in accordance with the applicable formula which follows: NOTE: In the following formulas, 0.413 (10.490 mm) is the nominal value for the required 0.411 to 0.415 inch (10.439 to 10.541 mm) distance from the top of face seal (125) to the top of seal ring (150) after shimming and installation of seal, as shown in Figure 707. Shimming to obtain this dimension provides for proper preload on seal. (1) If dimension R is greater than dimension S: Required shim thickness = 0.413 - (U + T) (2) If dimension R is less than dimension S: Required shim thickness = (0.413 - U) + T (3) If dimension R equals dimension S: Required shim thickness = 0.413 J. Select shims (130, IPL Figure 2) equal to required thickness in step I. ±0.001 inch (0.025 mm).



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K. Install shims (130) in bearing cartridge sleeve (275), as shown in Figure 707. L. Install face seal (125, IPL Figure 2) as follows: (1) Drain excess lubricating oil, BPTO 2380, from face seal (125). (2) Slide face seal (125), with carbon nose facing down, over drive shaft (240) and into fan end of bearing cartridge sleeve (275). Verify that seal is level and centered in sleeve. CAUTION: DO NOT SUPPORT BEARING CARTRIDGE SLEEVE AND DRIVE SHAFT ASSEMBLY ON DRIVE SHAFT WHEN PRESSING FACE SEAL INTO SLEEVE AS BALL BEARINGS WILL BE DAMAGED. (3) Remove bearing cartridge sleeve and shaft assembly from bearing sleeve holder, GS15615-1. Place assembly on an arbor press and support on turbine end of sleeve with drive shaft free.



Figure 707. Installation of Face Seal - Fan End



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(4) Slide seal and spring seat installer driver, GS15614-1, over drive shaft (240) and against face seal (125). Press on driver until face seal (125) is seated in bearing cartridge sleeve (275). Remove driver and remove assembly from arbor press. Verify that drive shaft (240) rotates freely, indicating proper installation of face seal (125). (5) Replace bearing cartridge sleeve and shaft assembly in bearing sleeve holder, GS15615-1, with fan end up. (6) Do these at the same time (Refer to Figure 707): • Put a 15- to 20-pound (reference) load on the drive shaft in the direction shown. • Measure dimension V, the dimension from the top of the bearing cartridge sleeve (275, IPL Figure 2) to the top of the face seal (125), with a depth micrometer. Write the dimension on a record. (7) Subtract dimension V from dimension R. The difference must be 0.411 to 0.415 inch, indicating correct shimming of face seal (125, IPL Figure 2). If difference is not within limits, remove face seal (125) per DISASSEMBLY and adjust thickness of shims (130), as necessary, to obtain the 0.411 to 0.415 inch dimension. Replace face seal (125) if damaged during removal. M. Measure and record dimension X, the thickness of internal retaining ring (105), as shown in Figure 707, using a micrometer. Take reading opposite open end of ring. N. Measure and record dimension Y, the distance from the top of bearing cartridge sleeve (275, IPL Figure 2) to the top of the groove where internal retaining ring (105) will be installed, as shown in Figure 707, using groove micrometer, Model 260. O. Determine required thickness of shims (110, IPL Figure 2) as follows: Required shim thickness = V - (X + Y) P. Select shims (110) equal to required thickness in step O. ±0.001 inch. Q. Install shims (110) and internal retaining ring (105) in bearing cartridge sleeve (275), as shown in Figure 707.



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6. Install the Turbine Rotor and Measure the Rotor Clearance A. Install two check nuts, GS15618-1, on the fan end of the drive shaft (240, IPL Figure 2). Tighten the two nuts into each other. B. Install the assembly in the bearing sleeve holder, GS15615-1, with the turbine end up. C. Install an aluminum sleeve bushing (180) onto the long end of the drive shaft (240). Use a PN 732160-13 or -14 as a test piece. WARNING: USE HEAT-RESISTANT GLOVES WHEN YOU TOUCH HOT PARTS. IF YOU TOUCH HOT PARTS WITHOUT PROTECTIVE GLOVES YOU CAN CAUSE INJURY TO YOUR HANDS. D. Apply heat to the turbine rotor (100), in an oven at 250 °F (121 °C) for no more than 1 hour. CAUTION: THE TURBINE ROTOR (100) HAS AN INTERFERENCE FIT ON THE DRIVE SHAFT (240). TO PREVENT DAMAGE TO THE FIT, INSTALL THE TURBINE ROTOR THE LEAST NUMBER OF TIMES POSSIBLE. E. Install the hot rotor (100) on the drive shaft (240). F. Install the compressor rotor spacer, GS15623-1, and a check nut, GS15618-1, on the long end of the drive shaft (240). Torque the check nut, GS15618-1, 330 to 350 poundinches (37.2 to 39.4 newton-meters). Each minute, while the temperature of the turbine rotor (100) decreases to ambient, torque the check nut, GS15618-1, again. Torque the check nut, GS15618-1, when the temperature becomes stable. G. Put the turbine housing (360, IPL Figure 1, Sheet 2) on the turbine-housing support fixture, GS15622-1, with the turbine end up, as shown in Figure 708 H. Align the hole in the bearing cartridge sleeve (270, IPL Figure 2) with the hole in the turbine housing (360, IPL Figure 1, Sheet 2). I. Push the assembly into the turbine housing (360) until the turbine rotor (100, IPL Figure 2) touches the turbine housing. J. Measure the distance from the back face of the turbine rotor (100) to the face of the turbine housing (360, IPL Figure 1, Sheet 2) at three positions with a depth micrometer. Calculate the average of the three dimensions. Write this dimension on a record. K. Align the holes for the stepped pin (305, IPL Figure 1, Sheet 2). Insert the stepped pin into the turbine housing (360). L. Apply a 15 to 20 pound (6.8 to 9.1 kilogram) load to the long end of the drive shaft (240, IPL Figure 2) in direction G. Measure the distance from the back face of the turbine rotor (100) to the face of the turbine housing (360, IPL Figure 1, Sheet 2) with a depth micrometer. Calculate the average of the three dimensions. Write this dimension on a record. Remove the load. M. Subtract the dimension measured in step L. from dimension measured in step N. Write this dimension on a record as dimension E. The difference is the clearance between the turbine housing (360) and the turbine rotor (100, IPL Figure 2).



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Figure 708. Determination of Turbine Housing to Turbine Rotor Clearence Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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N. The clearance must be 0.009 to 0.011 inch (0.229 to 0.279 mm). If the clearance is in the limits, then continue at step 7. If the clearance is not in the limits, then continue as follows: (1) Make a selection of a new aluminum sleeve bushing (180) to change the clearance to the necessary dimension. A longer bushing will increase the clearance, and a shorter bushing will decrease the clearance. (2) Remove the stepped pin (305, IPL Figure 1, Sheet 2). (3) Remove the assembly from the turbine housing (360). Install the assembly in the bearing sleeve holder, GS15615-1, with the turbine end up. (4) While you hold the inner check nut, GS15618-1, at the short end of the drive shaft (240, IPL Figure 2), remove the check nut, GS15618-1, at the long end of the drive shaft (190). (5) Remove the compressor rotor spacer, GS15623-1. (6) Remove the turbine rotor (100) as shown in DISASSEMBLY. (7) Remove the aluminum sleeve bushing (180). (8) Install the new aluminum sleeve bushing (180), turbine rotor (100), and the compressor rotor spacer, GS15623-1. (9) Do a check of the turbine rotor to turbine housing clearance again. Refer to steps D. thru M.



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7. Measure the Runout of the Turbine Rotor A. Install the assembly into the bearing sleeve holder, GS15615-1, with the turbine-end up. B. Do a runout-check on the turbine rotor (100, IPL Figure 2) as shown in Figure 709. The maximum permitted runout is 0.002 inch (0.050 mm) at the points shown. C. Do a runout-check on the turbine-end of the drive shaft (240, IPL Figure 2) as shown in Figure 713. The maximum permitted runout is 0.0015 inch (0.0381 mm) at the points shown.



Figure 709. Turbine Rotor Runout



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8. Install the Bearing Cartridge in the Turbine Housing (Refer to Figure 710) A. For PN 782790-6, -10 and -12, install the bearing cartridge in the turbine housing as follows: WARNING: USE GOGGLES AND GLOVES WHEN YOU USE LUBRICATING OIL. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (1) Lubricate the preformed packings (330, IPL Figure 1, Sheet 2) with lubricating oil, BPTO 2380.



Figure 710. Install the Bearing Cartridge (2) Install the preformed packings (330) in the turbine housing (360) and the preformed packing (5, IPL Figure 2) on the bearing cartridge sleeve (275).



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(3) Align the hole in the bearing cartridge sleeve (275) for the stepped pin (305, IPL Figure 1, Sheet 2) before you push the sleeve in its bore. Push the bearing cartridge in the the turbine housing (360) until the holes for the stepped pin are aligned. You can use an alignment tool, 792790-T-11 to help align the holes. After the holes are aligned, install the pin. B. For PN 782790-16, install the bearing cartridge in the turbine housing as follows: (1) Remove the turbine rotor (100, IPL Figure 2). Refer to DISASSEMBLY. WARNING: USE GOGGLES AND GLOVES WHEN YOU USE LUBRICATING OIL. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (2) Lubricate the preformed packing (5) with lubricating oil, BPTO 2380. (3) Install the preformed packings (330, IPL Figure 1, Sheet 2) in the turbine housing (360) and the preformed packing (5) on the bearing cartridge sleeve (275, IPL Figure 2). (4) Apply a thin layer of Ultrachem Assembly Fluid #1 to the fan split ring (332, IPL Figure 1, Sheet 2) and turbine split ring (6, IPL Figure 2). NOTE: NOTE: You can apply the Ultrachem Assembly Fluid #1 before you install the split rings or you can apply it after the turbine housing is hot (immediately before you install the bearing cartridge). (5) Install the fan split ring (332, IPL Figure 1, Sheet 2) in the turbine housing (360). Install the turbine split ring (6, IPL Figure 2) on the bearing cartridge sleeve (275). (6) Remove all of the Ultrachem Assembly Fluid #1 that is not on the split rings or the packings. WARNING: USE GLOVES WITH INSULATION WHEN YOU TOUCH THE HOT HOUSING. THE HEAT CAN CAUSE DAMAGE TO YOUR SKIN. (7) Increase the temperature of the turbine housing (360, IPL Figure 1, Sheet 2) to 300 to 325 5F (148.9 to 162.8 5C) for 30 to 60 minutes before you install the bearing cartridge in the turbine housing. (8) Lubricate the outside of the bearing cartridge sleeve (275, IPL Figure 2) with lubricating oil, BPTO 2380. (9) Radially align the hole in the bearing cartridge sleeve (275) for the stepped pin (305, IPL Figure 1, Sheet 2) with the hole in the turbine housing (360) before you push the sleeve in its bore. (10) Use a press and the cartridge installer, 7827900-T-14, to install the bearing cartridge in the the turbine housing (360). Make sure that the load is on the bearing cartridge sleeve (275, IPL Figure 2) only and not on the shaft or the seals. Push the cartridge only until the holes for the stepped pin (305, IPL Figure 1, Sheet 2) are aligned. You can use an alignment tool, 792790-T-11 to help align the holes. After the holes are aligned, install the pin. Refer to Figure 711 (11) Install the turbine rotor (100, IPL Figure 2).



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Figure 711. Install the Bearing Cartridge in the Turbine Housing (For PN 782790-16 Units)



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9. Assemble the Remaining Parts of the Rotative Group WARNING: USE GOGGLES AND GLOVES WHEN YOU USE LUBRICATING OIL. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. A. Lubricate the preformed packing (80, IPL Figure 2) with lubricating oil, BPTO 2380. Install the packing on the nozzle plate and insulator (85). CAUTION: INSTALL THE NOZZLE PLATE AND INSULATOR CAREFULLY SO YOU DO NOT CAUSE DAMAGE TO THE SEAL. B. Install the seal disc (75) in the nozzle plate and insulator (85). Install the assembly on the drive shaft (240, IPL Figure 2) with the vanes pointed toward the turbine rotor (100). NOTE: If the nozzle plate and insulator (85) has been modified to incorporate a replaceable steel nozzle ring (REPAIR 7-2), install the new nozzle ring with the altered nozzle plate (85). Align the bolt holes in the nozzle ring with the bolt holes in the nozzle plate. All other assembly instructions remain the same. C. Align the holes in the disc with the holes in the turbine rotor for the headless straight pins (35). Align the holes in the nozzle plate with the holes in the turbine housing (360, IPL Figure 1, Sheet 2) for the screws (310). D. Install the nozzle insulator (70, IPL Figure 2) on the nozzle plate and insulator (85) with the flat side down. Align the holes in the nozzle insulator with the holes in the nozzle plate and insulator and the turbine housing (360, IPL Figure 1, Sheet 2) for the screws (310). E. Install the compressor rotor (40, IPL Figure 2) and seal plate (60) as follows: CAUTION: INSTALL THE COMPRESSOR ROTOR CAREFULLY SO YOU DO NOT CAUSE DAMAGE TO THE SEAL. (1) Install the compressor rotor (40) in the seal plate (60). The bore sections of the holes for the screws must point in the direction of the compressor rotor. WARNING: USE GLOVES WITH INSULATION WHEN YOU TOUCH THE ROTOR. THE HEAT CAN CAUSE DAMAGE TO YOUR SKIN. WARNING: DO NOT TOUCH THE NOZZLE OF A HEAT GUN WHILE IT OPERATES, OR FOR AT LEAST 10 MINUTES AFTER IT GOES OFF. DO NOT PUT ANY PART OF YOUR BODY IN FRONT OF THE HEAT GUN WHILE IT OPERATES. THE HEAT CAN CAUSE DAMAGE TO YOUR SKIN. CAUTION: DO NOT KEEP THE HEAT GUN POINTED AT ANY ONE AREA OF THE ROTOR FOR VERY MUCH TIME. DO NOT LET THE ROTOR BE AT THE INCREASED TEMPERATURE FOR MORE THAN 1 HOUR. (2) Increase the temperature of the rotor to 225 ° F (107.2 ° C) maximum with a heat gun, Model VT-750B, as follows: (a) Keep a minimum distance of 0.5 inch (13 mm) between the tip of the heat gun and the rotor. (b) Frequently turn the rotor approximately 90° . This will help to prevent hot spots.



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CAUTION: DO NOT PUT HEAT ON THE ROTOR FOR MORE THAN 1 HOUR. IF IT IS AT A HIGH TEMPERATURE FOR VERY MUCH TIME, IT CAN BECOME DAMAGED. (c) After each time that you turn the rotor, do a check of the surface temperature in the area where the heat gun was just pointed. Use the handle and probe set, Model HDX-SET-FSP-T-OST, and digital thermometer, Model HH99A-T1, to do the check. Make sure that the temperature is less than 225 ° F (107.2 ° C). WARNING: USE GLOVES AND AN APRON WITH INSULATION IN THEM WHEN YOU TOUCH DRY ICE. USE DRY ICE IN AN AREA WITH A GOOD FLOW OF AIR. DRY ICE IS SOLID CARBON DIOXIDE (C02) THAT HAS A TEMPERATURE BELOW -112 ° F (-80 ° C). IF YOU TOUCH IT, IT WILL CAUSE BAD LOW TEMPERATURE BURNS. DRY ICE WILL BECOME CARBON DIOXIDE GAS, AND DECREASE THE CONCENTRATION OF OXYGEN IN THE AIR AROUND IT. (3) Decrease the temperature of the compressor rotor section of the drive shaft (240) with dry ice. CAUTION: INSTALL THE SEAL PLATE CAREFULLY SO THE SEAL DOES NOT BECOME DAMAGED. (4) Install the compressor rotor (40) and seal plate (60) on the drive shaft (240). Make sure that the headless straight pins (35) go through the seal disc (75) and into the turbine rotor (100). (5) Align the holes in the seal plate (60) with the holes in the nozzle insulator (70), nozzle plate and insulator (85) and turbine housing (360, IPL Figure 1, Sheet 2) for the screws (310). (6) Apply a thin layer of molybdenum disulfide-petrolatum antiseize thread compound, MIL-T-83483, on the threads and the flange surface of the self-locking threaded ring (20, IPL Figure 2). Install the flat washer (25) and the ring. (7) Do these at the same time: • Hold the check nuts, GS15618-1, that are at the fan-end of the drive shaft (240). • Torque the self-locking threaded ring (20) 330 to 350 pound-inches (37.3 to 39.6 newton-meters) above a running torque of 60 to 120 pound-inches (6.8 to 13.5 newton-meters). Use torque adapter, GS20670-1. • Final assembly torque, including running torque, shall be 390 to 470 poundinches (44.1 to 53.1 newton-meters). Continue to tighten locking ring every minute until rotor cools to approximately 10°F above room temperature. Retighten nut after rotor stabilizes at room temperaure. (8) Align the seal plate (60) so the drag from the two seals (62, 95) is the minimum possible.



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WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. (8a) Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it. (9) Apply a thin layer of epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer on 11 screws (310, IPL Figure 1, Sheet 2) and on the surfaces of the washers (315) that will touch the seal plate (60, IPL Figure 2). (10) Install the 11 screws (310, IPL Figure 1, Sheet 2) and washers (315). Torque 10 to 15 pound-inches (1.2 to 1.6 newton-meters) more than running torque. The running torque must be 1.5 to 9 pound-inches (0.2 to 1.0 newton-meters). 10. Compressor Rotor Runout Checks . A. Measure the compressor rotor (40, IPL Figure 2) runouts at the points shown in Figure 712. The runouts must not be more than 0.002 inch (0.050 mm). If the runout is satisfactory, continue at step B. If the runout is not satisfactory, do these steps: (1) Identify the radial position of the compressor rotor (40) in relation to the turbine rotor (210). (2) Remove the self-locking threaded ring (20), flat washer (25), seal plate (60), and compressor rotor (40). Refer to DISASSEMBLY. (3) Install the compressor rotor (40) and seal plate (60) so that the headless straight pins (35) engage the opposite holes in the turbine rotor (100). Refer to steps 9. D. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(4) Do the runout checks again. B. Remove the two check nuts, GS15618-1 from the fan-end of the drive shaft (240, IPL Figure 2).



Figure 712. Compressor Rotor Runout Checks Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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11. Installation of Fan Spacer and Cooling Fan A. Place power arm fixture, GS22815-1, supporting turbine housing and rotative group, in a horizontal position. B. Install fan spacer (320, IPL Figure 1, Sheet 2) on short end of drive shaft (240, IPL Figure 2) with small end of spacer seated against seal ring (150), as shown in Figure 713. C. Heat cooling fan (170, IPL Figure 1, Sheet 1) in an oven at 250°F (121°C) for 1 hour maximum. WARNING: HANDLING HOT ITEMS PRESENTS SERIOUS BURN POTENTIAL. HEAT RESISTANT GLOVES MUST BE WORN. D. Install heated cooling fan (170) on short end of drive shaft (240, IPL Figure 2), as shown in Figure 713 E. Apply a light coat of molybdenum disulfide-petrolatum anti-seize thread compound, MILT-83483, to threads on short end of drive shaft (240, IPL Figure 2). F. Install flat washer (165, IPL Figure 1, Sheet 1) and threaded self locking ring (160) on short end of drive shaft (240, IPL Figure 2). While holding threaded self locking ring (20, IPL Figure 2) at long end of shaft with a spanner wrench, GS22333-2, tighten threaded self locking ring (160, IPL Figure 1, Sheet 1) to 285 to 300 pound-inches (32.3 to 33.8 newton-meters) above a running torque of 60 to 120 pound-inches (6.8 to 13.5 newtonmeters), using a second spanner wrench, GS22333-2. Final assembly torque, including running torque, shall be 345 to 420 pound-inches (39.0 to 47.4 newton-meters). Continue to tighten locking ring every minute until cooling fan (170) cools to approximately 10°F above room temperature. Retighten nut after cooling fan stabilizes at room temperature. NOTE: Running torque of threaded self locking ring (160) must be 60 to 120 poundinches (6.8 to 13.5 newton-meters). If running torque is not within limits, replace locking ring. If running torque still is not within limits, check threads on drive shaft (240, IPL Figure 2) for damage.



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Figure 713. Installation of Fan Spacer and Cooling Fan and Checking Runouts



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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12. Checking Runouts on Cooling Fan and Drive Shaft A. Check runouts on cooling fan (170, IPL Figure 1, Sheet 1) and on drive shaft (240, IPL Figure 2) at points A and B, as shown in Figure 713. Rotate drive shaft (240, IPL Figure 2) slowly through 360° while checking runout at each point. Runout at point A shall not exceed 0.002 inch TIR. Runout at point B shall not exceed 0.0015 inch TIR. If runouts are within limits, proceed to paragraph 12. If runout limit at either point is exceeded, proceed as follows: (1) While holding threaded self locking ring (20) at long end of drive shaft (240) using a spanner wrench, GS22333-2, remove threaded self locking ring (160, IPL Figure 1, Sheet 1) on short end of shaft using a second spanner wrench, GS22333-2. (2) Recheck runout that exceeded limit. If runout still is not within limit, proceed to step (3). If runout is within limit, proceed as follows: (a) Either rotate flat washer (165) 180° or replace washer. (b) Reinstall threaded self locking ring (160). While holding threaded self locking ring (20, IPL Figure 2) at long end of drive shaft (240), tighten threaded self locking ring (160, IPL Figure 1, Sheet 1) at short end of shaft to 285 to 300 pound-inches above a running torque of 30 to 120 pound-inches. Final assembly torque, including running torque, shall be 315 to 420 pound-inches. (c) Recheck runout. If runout is within limit, verify that runouts at both points (cooling fan and drive shaft) are within limits, and proceed to paragraph 12. If runout still is not within limit, replace threaded self locking ring (160), verify that both runouts are within limits, and proceed to paragraph 12. (3) Remove flat washer (165). (4) If a shaft zero location was not previously marked at the long end of drive shaft (240, IPL Figure 2), scribe a small line at the short end of the shaft using a fine file. (5) Mark a line on cooling fan (170, IPL Figure 1, Sheet 1), in line with the shaft zero location, using marking pen, TT-I-544. A line also should be marked on fan spacer (320, IPL Figure 1, Sheet 2). However, this cannot be done until cooling fan (170, IPL Figure 1, Sheet 1) is heated and reoriented on shaft in steps (7) through (9), during which fan spacer (320, IPL Figure 1, Sheet 2) can be accessed for marking. (6) Recheck runout that is out-of-limit and note angle, in relation to shaft zero location, at which highest runout occurs. Record angle and high point. (7) Heat cooling fan (170, IPL Figure 1, Sheet 1), in accordance with DISASSEMBLY, paragraph 1.F., to allow fan to be reindexed. (8) Slide cooling fan (170) slightly away from fan spacer (320, IPL Figure 1, Sheet 2) and mark a line on spacer, in line with the shaft zero location, using marking pen, TTI-544. (9) Rotate cooling fan (170, IPL Figure 1, Sheet 1) 180° while maintaining position of fan spacer (320, IPL Figure 1, Sheet 2) in line with shaft zero location. Seat fan against spacer. (10) Reinstall flat washer (165, IPL Figure 1, Sheet 1) and threaded self locking ring (160) in accordance with paragraph 10.F. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(11) Recheck runout that is out-of-limit and record angle and high point. If runout is now within limit, verify that runouts at both points are within limits, and proceed to paragraph 12. If runout still is not within limit, compare runout obtained before rotation of cooling fan (170) with runout obtained after rotation of cooling fan. (12) If runout changed significantly, remove cooling fan (170) and dimensionally inspect in accordance with CHECK. Replace cooling fan, if necessary. (13) If change in runout was small, repeat the reorientation procedure with fan spacer (320, IPL Figure 1, Sheet 2) rotated 180°. Dimensionally inspect and replace fan spacer, if necessary. If problem persists, inspect drive shaft (240, IPL Figure 2) and replace, if necessary.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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13. Installation of Lubrication Parts, Liquid Level Sight Plug, and Plugs and Bleeders A. Soak nonmetallic wicks (300, IPL Figure 1, Sheet 2) in clean, filtered, lubricating oil, BPTO 2380, for 3 hours minimum and drain. CAUTION: WICK BUSHINGS (295) HAVE A LONG END (0.84 INCH (21.34 MM) NOMINAL) AND A SHORT END (0.33 INCH (8.38 MM) NOMINAL). BUSHINGS MUST BE INSTALLED WITH SHORT ENDS LOCATED UNDER HEADS OF NONMETALLIC WICKS (300) TO ENSURE PROPER SPRING TENSION OF WICKS AGAINST DRIVE SHAFT (240, IPL FIGURE 2). ACCIDENTAL INVERSION OF THE WICK BUSHINGS WILL RESULT IN EXCESSIVE HEATING/WICK WEAR AND OTHER POSSIBLE DAMAGE TO THE ACM. B. Assemble two wick assemblies by installing wick bushing (295, IPL Figure 1, Sheet 2) on nonmetallic wick (300), with short end of bushing located under head of wick, followed by spring (290) and spring retainer (285), as shown in Figure 714. C. Install two wick assemblies in turbine housing (335, IPL Figure 1, Sheet 2), as shown in Figure 714. D. Verify that stepped pin (305, IPL Figure 1, Sheet 2) is properly installed in turbine housing (335). E. Install retaining plate (280). F. Apply a thin film of clean, filtered, lubricating oil, BPTO 2380, to threads and under heads of two screws (270). G. Secure retaining plate (280) with two washers (275) and two screws (270). Tighten screws (270) to 20 to 25 pound-inches above running torque. H. Gently pull nonmetallic wicks (300) away from drive shaft (240, IPL Figure 2), against their spring loads, and release. Wicks must return freely to their normal positions with no evidence of binding. I. Apply a thin film of clean, filtered, lubricating oil, BPTO 2380, to preformed packing (265, IPL Figure 1, Sheet 2). Install packing in its groove in turbine housing (335).



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Figure 714. Installation of Lubrication Parts, Liquid Level Sight Plug, and Plugs and Bleeders Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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CAUTION: USE CARE WHEN INSTALLING SUMP COVER (245) NOT TO CATCH THE NONMETALLIC WICKS (300) ON THE INNER LIP OF THE COVER, AS THIS WILL CAUSE BENDING AND ADDITIONAL LOADING ON THE WICKS, RESULTING IN EXCESSIVE HEATING/WICK WEAR AND OTHER POSSIBLE DAMAGE TO THE ACM. J. Install sump cover (245), with headless straight pin (250) located in specified slot in turbine housing (335), as shown in Figure 714, View L-L. Keep sump cover (245, IPL Figure 1, Sheet 2) level during installation and ensure that ends of nonmetallic wicks (300) are located inside the inner lip of the cover to prevent wicks from being caught on the lip. K. Install tab washer (240) and internal retaining ring (235) to retain sump cover (245). Bend tabs on tab washer (240) in three places, as shown in Figure 714, to secure internal retaining ring (235, IPL Figure 1, Sheet 2). L. Apply a thin film of clean, filtered, lubricating oil, BPTO 2380, to preformed packing (225) and to threads and under head of liquid level sight plug (230A). Install packing on sight plug. Install sight plug in turbine housing (335), as shown in Figure 714, View L-L, and tighten plug to 15 to 25 pound-inches. M. Apply a thin film of clean, filtered, lubricating oil, BPTO 2380, to two preformed packings (215, IPL Figure 1, Sheet 2) and to threads and under heads of two plugs and bleeders (220). Install packings on plugs and bleeders. Install one plug and bleeder (220) in turbine housing (335) and install other plug and bleeder (220) in sump cover (245), as shown in Figure 714, View L-L. Tighten plugs to 15 to 25 pound-inches. N. For ACMs incorporating L9, apply a thin film of clean, filtered, lubricating oil, BPTO 2380, to preformed packing (216, IPL Figure 1, Sheet 2) and to threads and under head of plug and bleeder (221). Install plug and bleeder in turbine housing (335), as shown in Figure 714, View L-L. Tighten plug to 15 to 25 pound- inches. O. Install spring wire (205, IPL Figure 1, Sheet 2) through ring of chain (210). Install spring wire (205) in plug and bleeder (220), as shown in Figure 714, View L-L. Attach free end of chain (210, IPL Figure 1, Sheet 2) to turbine housing (335) using pin (200), as shown. Install pin (200) in accordance with AS567. P. For ACMs incorporating L9, install spring wire (206) through ring of chain (211). Install spring wire (206) in plug and bleeder (221), as shown in Figure 714, View L-L. Attach free end of chain (211, IPL Figure 1, Sheet 2) to turbine housing (335) using pin (201). Install pin (201) in accordance with AS567. Q. Do not lockwire plugs and bleeders (220 and 221), liquid level sight plug (230A), and warning tag (175) until indicated after testing of the ACM.



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14. Dynamic Balance. A. Prepare the assembly for the balance procedure as follows: (1) Prepare the speed pickup. Refer to the instructions for the photoelectric cell with your balance machine. (2) Remove the assembly from the turbine-housing support fixture, GS15622-1. Install it on the balance fixture, GS15626-1. Refer to Figure 715. (3) Install the balance fixture on the balance machine, CAB 570 or CAB 690-R. B. Make the balance planes Y and Z, as shown in Figure 715. C. Do an initial balance check of the rotative assembly as follows: (1) Supply air pressure to turn the rotative assembly with the accessories kit, GS158001. Point the flow of air at the vanes of the compressor rotor (40, IPL Figure 2) with the balance nozzle assembly, GS15801-1. WARNING: USE EAR PROTECTION DURING BALANCE OPERATIONS. BALANCE OPERATIONS MAKE HIGH-FREQUENCY NOISE THAT CAN DAMAGE YOUR EARS. (2) Make the balance speed 4400 to 4600 rpm. NOTE: The 4400 to 4600 rpm balance speed is applicable only when you use the Schenck balance machine. If you use a different balance machine, use the balance speed that the machine manufacturer recommends. (3) Make a check to find if the rotative assembly is balanced in 5000 micro ounceinches in planes Y and Z. Refer to Figure 715. If the assembly is not balanced in these limits in plane Z, continue at step D. If the assembly is not balanced in these limits in plane Y, continue at step E. If the assembly is balanced in these limits, continue at step F. D. If the unbalance is more than 5000 micro ounce-inches in plane Z, do these steps: (1) Remove the assembly from the balance fixtures, GS15626-1. Install it on the power arm fixture, GS22815-1. (2) Identify the radial location of the cooling fan (170, IPL Figure 1, Sheet 1) on the drive shaft (240, IPL Figure 2) with small marks on each of them. You can use a marking pen, TT-I-544, to make the mark on the fan, and a fine file to make the mark on the shaft. (3) Remove the cooling fan (170, IPL Figure 1, Sheet 1). Refer to DISASSEMBLY.



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Figure 715. Dynamic Balance



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(4) Make a mark on the fan spacer (320) that is radially aligned with the marks that you made on the cooling fan (170) and drive shaft (240, IPL Figure 2). You can use a marking pen, TT-I-544, to make the mark. (5) Install the cooling fan (170, IPL Figure 1, Sheet 1) 180° from the position from which you removed it. Refer to paragraph (2) Keep the mark on the fan spacer (320) aligned with the mark on the shaft. (6) Measure the fan-end runouts and do a balance check. (7) If the unbalance vector moves in relation to the movement of the cooling fan (170), replace the fan, then do runout and balance checks. NOTE: You can balance the cooling fan (170). Refer to REPAIR 3-2. (8) If the unbalance vector does not move in relation to the movement of the cooling fan, do steps (1) and (3), turn the fan spacer (320) 180°, then do steps (5) and (6). E. If the unbalance is more than 5000 micro ounce-inches in plane Y (turbine-end), do these steps: (1) Remove the assembly from the balance fixtures, GS15626-1. Install it on the power arm fixture, GS22815-1. (2) Identify the radial location of the compressor rotor (40, IPL Figure 2) on the drive shaft (240) with small marks on each of them. You can use a marking pen, TT-I-544, to make the marks. (3) Remove the compressor-end self-locking threaded ring (20) with the torque adapter, GS20670-1. (4) Remove the flat washer (25). (5) Remove the compressor rotor (20) and seal plate (60). Refer to DISASSEMBLY. (6) Make a mark on the seal disc (75) that is radially aligned with the mark on the drive shaft (240). You can use a marking pen, TT-I-544, to make the mark. (7) Turn the compressor rotor (40) 180° in relation to the mark on the drive shaft (240). Keep the mark on the seal disc (75) aligned with the mark on the shaft. (8) Install the compressor rotor (40) on the drive shaft (240). Make sure that the headless straight pins (35) go through the seal disc (75) and into the turbine rotor (100). Refer to paragraph 8. D. (9) Do a check of the compressor rotor runout. Refer to paragraph 9. (10) Do a balance check. Refer to steps 13. A. thru C. (11) If the unbalance vector moves in relation to the movement of the compressor rotor (40), replace the rotor, then do runout and balance checks. NOTE: NOTE: You can balance the compressor rotor (40). Refer to REPAIR 5-2. (12) If the unbalance vector does not move in relation to the movement of the compressor rotor (30), do steps (1) thru (6), turn the seal disc (75) 180° , then do steps (8) thru (10).



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(13) If the unbalance vector moves in relation to the movement of the seal disc (75), do steps (1) thru (6), replace the disk, then do steps (8) thru (10). (14) If the unbalance vector does not move in relation to the movement of the seal disc (75), remove the compressor rotor (40), seal plate (60), nozzle insulator (70), seal disc (75) and nozzle plate and insulator (85). Refer to DISASSEMBLY. (15) Make a mark on the turbine rotor (100) that is radially aligned with the mark on the drive shaft (240). You can use a marking pen, TT-I-544, to make the mark. (16) Remove the turbine rotor (100) and the sleeve bushing (180). Refer to DISASSEMBLY. (17) Do dimensional checks to the sleeve bushing (180). Refer to CHECK. (18) If the sleeve bushing (180) is not in limits, replace it, assemble and install the compressor rotor (40), seal plate (60), nozzle insulator (70), seal disc (75) and nozzle plate and insulator (85), and do the runout and balance checks. Refer to paragraphs 9. thru 13. C. (19) If the sleeve bushing (180) is in limits, turn the turbine rotor (100) 180°, assemble and install the compressor rotor (40), seal plate (60), nozzle insulator (70), seal disc (75) and nozzle plate and insulator (85), and do the runout and balance checks. Refer to paragraphs 9. thru 13. C. (20) If the unbalance vector moves in relation to the movement of the turbine rotor (100), replace the rotor, then do runout and balance checks. Refer to paragraphs 9. thru 13. C. NOTE: You can balance the turbine rotor (100). Refer to REPAIR 8-2. F. Balance the assembly as follows: NOTE: Do not add balance weights to the fan-end at this time. Add these weights during the fan-end shaft dynamic displacement test during TESTING. (1) Balance the assembly to 600 micro ounce-inches in plane Y only, as follows. (a) Add balance weights (15, IPL Figure 2) to the self-locking threaded ring (20). Figure 716 and Figure 717 (from existing 21-51-53) show where, in relation to the unbalance vector, to add the balance weights. You can use these Figures, or you can make the selections from what you know was satisfactory on previous units. NOTE: Balance weights PN 772427-1 (15, IPL Figure 2) are the lightest weights. They are made of Teflon. Balance weights PN 772427-2 (16) are heavier. They are made of aluminum. Balance weights PN 7724273 (17) are the heaviest weights. They are made of steel.



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Figure 716. Guide for Placement of Balance Weights in Locking Rings with Unbalance Vector Located on Centering of Holes in Rings (Heavy Side)



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Figure 717. Guide for Placement of Balance Weights in Locking Rings with Unbalance Vector Located on Centering of Holes in Rings (Heavy Side)



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(b) After you add the balance weights (15), do these steps: 1 Install the internal retaining ring (10) into the self-locking threaded ring (20) to keep the balance weights (15) in position. Identify the radial position of the internal retaining ring on the self-locking threaded ring. You can use a marking pen, TT-I-544, to make the marks. If it is necessary to change the balance weights again during this procedure make sure that the marks are aligned when you install the internal retaining ring. 2 Make the balance speed 4400 to 4600 rpm. 3 Make a check to find if the assembly is balanced to 600 micro ounce-inches in plane Y. (2) Do steps (1) (a) and (b) again until the assembly is balanced to 600 micro ounceinches in plane Y. G. Remove the balance fixture and the assembly from the balance machine. Remove the assembly from the balance fixtures, GS15626-1.



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15. Pinning of Seal Plate A. Install turbine housing and rotative group on turbine housing support fixture, GS15622-1, fan end down. B. Cover area around compressor rotor (30, IPL Figure 2) and outer edge of seal plate (60 or 60A) to nozzle plate and insulator (85 or 85A) with masking tape, as shown in Figure 718, to prevent metal chips from entering rotative group during drilling. Also, cover all holes in seal plate (60 or 60A, IPL Figure 2) except pilot hole to be drilled. C. Drill two 0.092 to 0.097 inch (2.337 to 2.463 mm) diameter holes to depth shown in Figure 718, Section M-M, using two unused 0.059 to 0.067 inch (1.499 to 1.702 mm) diameter pilot holes in seal plate (60 or 60A, IPL Figure 2). Drill holes on opposite sides of seal plate, as shown in Figure 718, Section P-P. Six pilot holes are provided in a new seal plate for drilling and pinning of the plate. Two new holes and two new spiral spring pins (50, IPL Figure 2) must be used each time the plate is pinned. NOTE: After all holes in seal plate (60 or 60A) have been enlarged once, they may be enlarged one more time to a 0.107 to 0.120 inch (2.718 to 3.048 mm) diameter to accommodate oversize spiral spring pins PN 69917-109M500C (refer to NOTE 1 in IPL Figure 2). After all holes have been enlarged a second time, the seal plate (60 or 60A), nozzle insulator (70 or 70A), and nozzle plate and insulator (85 or 85A) must be replaced. WARNING: COMPRESSED AIR USED FOR CLEANING CAN CREATE AIRBORNE PARTICLES THAT MAY ENTER THE EYES. PRESSURE MUST NOT EXCEED 30 PSIG. EYE PROTECTION REQUIRED. D. Blow away metal chips from assembly using compressed air. E. Remove masking tape.



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WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENTRESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. F. Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it. G. Coat two new spiral spring pins (50) with epoxy polyamide primer. H. Press spiral spring pins (50), while primer is wet, into drilled holes and bottom in holes, using pin installer, GS15627-1. I. Stake each hole in two places 180° apart. Ensure that stake marks are close enough to each hole to deform top of hole to retain spiral spring pin (50). J. Remove turbine housing and rotative group from turbine housing support fixture, GS15622-1.



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Figure 718. Pinning of Seal Plate Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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16. Shimming and Installation of Compressor Diffuser A. Install turbine housing and rotative group on power arm fixture, GS22815-1, turbine end up. CAUTION: USE CARE WHEN INSTALLING COMPRESSOR DIFFUSER (115, IPL FIGURE 1, SHEET 1) TO AVOID DAMAGING BLADES OF COMPRESSOR ROTOR (30, IPL FIGURE 2). B. Place compressor diffuser (115, IPL Figure 1, Sheet 1) over compressor rotor (30, IPL Figure 2) so that diffuser is resting on rotor. Align through holes in diffuser with holes in seal plate (60 or 60A). Center diffuser with respect to compressor rotor. NOTE: Use of two threaded studs, installed through two outer threaded holes approximately 180° apart in seal plate (60 or 60A), are helpful for maintaining alignment of compressor diffuser (115, IPL Figure 1, Sheet 1), heat shield (120), and solid shims (125) during installation of diffuser. Threaded studs should be approximately 3 inches long and have 0.1640-32UNJC-3A threads over approximately a 1/2-inch length. C. Place a parallel bar across compressor diffuser (115), as shown in Figure 719. D. Measure and record distance from top of parallel bar to center of end of drive shaft (240, IPL Figure 2) using a depth micrometer, as shown in Figure 719. E. Remove compressor diffuser (115, IPL Figure 1, Sheet 1). F. Install a trial stack of solid shims (125) 0.110 inch thick on seal plate (60 or 60A, IPL Figure 2). Align holes in shims with holes in plate. G. Position heat shield (120, IPL Figure 1, Sheet 1) with curved inner lip facing downward. Align holes in shield with holes in solid shims (125) and install shield on shims, as shown in Figure 719. H. Align through holes in compressor diffuser (115, IPL Figure 1, Sheet 1) with holes in heat shield (120). Install compressor diffuser (115) over compressor rotor (30, IPL Figure 2) and against heat shield (120, IPL Figure 1, Sheet 1). I. Center compressor diffuser (115) with respect to compressor rotor (30, IPL Figure 2) within 0.005 inch total by inserting shim stock in three equally spaced places between rotor and ID of diffuser. Do not remove shim stock until indicated. WARNING: USE GLOVES AND GOGGLES WHEN YOU USE MO-LITH NO. 2. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN IRRITATE YOUR EYES, SKIN, AND RESPIRATORY TRACT. J. Apply a light coat of thread lubricant, Mo-lith No. 2, to threads and under heads of three screws (105, IPL Figure 1, Sheet 1). K. Secure compressor diffuser (115), heat shield (120), and solid shims (125) to seal plate (60 or 60A, IPL Figure 2) with three washers (110, IPL Figure 1, Sheet 1) and three screws (105). Install screws (105) in approximately equally spaced holes in diffuser (115). Tighten screws to 10 to 15 pound-inches above running torque. Remove shim stock from between compressor rotor (30, IPL Figure 2) and compressor diffuser (115, IPL Figure 1, Sheet 1).



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L. Using a force gauge, apply a 15- to 20-pound load to short end of drive shaft (240, IPL Figure 2) in direction H, as shown in Figure 719. M. Repeat measurement per step D. Remove load. N. Subtract dimension recorded in step D. from dimension recorded in step M. The difference is the clearance between compressor diffuser (115, IPL Figure 1, Sheet 1) and compressor rotor (30, IPL Figure 2), shown as dimension J, Figure 719, View K. O. Remove parallel bar. P. For ACMs not incorporating L13, clearance must be 0.011 to 0.013 inch. For ACMs incorporating L13, clearance must be 0.017 to 0.019 inch. If clearance is within limits, proceed to step Q. If clearance is not within limits, proceed as follows: (1) Disassemble as required to access solid shims (125, IPL Figure 1, Sheet 1). Adjust thickness of solid shims (125), as required, to provide applicable clearance.



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Figure 719. Shimming and Installation of Compressor Diffuser



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(2) Reassemble and recenter compressor diffuser (115) with shim stock in accordance with step I. Remove shim stock after securing diffuser with three screws (105). (3) Reapply load to drive shaft (240, IPL Figure 2) and recheck clearance in accordance with steps L. through P. Q. Coat threads of remaining five screws (105, IPL Figure 1, Sheet 1) with thread lubricant in accordance with step J. R. Remove two threaded studs, if used. S. Complete securing of compressor diffuser (115) with remaining five washers (110) and five screws (105). Tighten screws to 10 to 15 pound-inches above running torque. T. Remove turbine housing and rotative group from power arm fixture, GS22815-1. 17. Pinning of Compressor Diffuser A. Install turbine housing and rotative group on turbine housing support fixture, GS15622-1, turbine end up. B. Insert shim stock in three equally spaced places between compressor rotor (30, IPL Figure 2) and ID of compressor diffuser (115, IPL Figure 1, Sheet 1) to keep diffuser properly centered with rotor during pinning of diffuser. Do not remove shim stock until indicated. C. Cover area around compressor diffuser (115) to nozzle plate and insulator (85 or 85A, IPL Figure 2) with masking tape, as shown in Figure 720, to prevent metal chips from entering rotative group during drilling. Also, cover all holes in compressor diffuser (115, IPL Figure 1, Sheet 1) except pilot hole to be drilled. D. Drill two 0.092 to 0.097 inch (2.337 to 2.463 mm) diameter holes to depth shown in Figure 720, Section N-N, using two unused 0.059 to 0.067 inch (1.499 to 1.702 mm) diameter pilot holes in compressor diffuser (115, IPL Figure 1, Sheet 1). Drill holes on opposite sides of compressor diffuser, as shown in Figure 720, Section P-P. Six pilot holes are provided in a new diffuser for drilling and pinning of the diffuser. Two new holes and two new spiral spring pins (55, IPL Figure 2) must be used each time the plate is pinned. NOTE: After all holes in compressor diffuser (115, IPL Figure 1, Sheet 1) have been enlarged once, they may be enlarged one more time to a 0.107 to 0.120 inch (2.718 to 3.048 mm) diameter to accommodate oversize spiral spring pins PN 69917-109M625C (refer to NOTE 2 in IPL Figure 2). After all holes have been enlarged a second time, the compressor diffuser (115, IPL Figure 1, Sheet 1), heat shield (120), solid shims (125), and seal plate (60 or 60A, IPL Figure 2) must be replaced. WARNING: COMPRESSED AIR USED FOR CLEANING CAN CREATE AIRBORNE PARTICLES THAT MAY ENTER THE EYES. PRESSURE MUST NOT EXCEED 30 PSIG (207 KPAG). EYE PROTECTION REQUIRED. E. Blow away metal chips from assembly using compressed air. F. Remove masking tape.



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WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENTRESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. G. Prepare the epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer, which are formulated without water. Do not add thinner to the mixture. Do not use the mixture for 1 hour after you mix it.



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Figure 720. Pinning of Compressor Diffuser



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WARNING: USE HIGH-SOLIDS EPOXY PRIMER COATING, MIL-PRF-23377 (STRONTIUM CHROMATE) CORRECTLY. IT IS FLAMMABLE AND EXPLOSIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0134SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT ON CHEMICAL-SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. WARNING: USE EPOXY COATING, MIL-PRF-85582, TYPE I, CLASS 2, (ALSO KNOWN AS STRONTIUM CHROMATE PRIMER) CORRECTLY. THE COATING AND ITS FUMES ARE FLAMMABLE, EXPLOSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE EPOXY COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING, W0205SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE EPOXY COATING, PUT ON THE RESPIRATOR, CHEMICAL-SPLASH GOGGLES, SOLVENTRESISTANT GLOVES, AND LONG SLEEVE AND LONG LEG CLOTHING. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE EPOXY COATING FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. H. Coat two new spiral spring pins (55) with epoxy polyamide (galvanic) MIL-PRF-23377, Type I or II, Class CI or C2 primer, barium chromate MIL-PRF-85582, Type I or II, Class C1 primer or strontium chromate, Class C2 primer. I. Press spiral spring pins (55), while primer is wet, into drilled holes and bottom in holes, using pin installer, GS15627-1. J. Stake each hole in two places 180° apart. Ensure that stake marks are close enough to each hole to deform top of hole to retain spiral spring pin (55). K. Remove shim stock from between compressor rotor (30) and compressor diffuser (115, IPL Figure 1, Sheet 1). L. Recheck clearance between compressor rotor (30, IPL Figure 2) and compressor diffuser (115, IPL Figure 1, Sheet 1) using feeler wires. Verify that clearance is within applicable dimension J limits on Figure 719. M. Remove assembly from turbine housing support fixture, GS15622-1. Install assembly on power arm fixture, GS22815-1.



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18. Installation of Compressor Housing A. Apply a light coat of Dow Corning No. 44 silicone lubricant to preformed packings (100, IPL Figure 1, Sheet 1) and (45, IPL Figure 2). B. Install preformed packing (100, IPL Figure 1, Sheet 1) in its groove on compressor diffuser (115). Install preformed packing (45, IPL Figure 2) in its groove on seal plate (60 or 60A). C. Install compressor housing (90, IPL Figure 1, Sheet 1), with outlet duct positioned with respect to turbine inlet duct, as shown in Figure 721, on insulator of nozzle plate and insulator (85 or 85A, IPL Figure 2). WARNING: USE GLOVES AND GOGGLES WHEN YOU USE MO-LITH NO. 2. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN IRRITATE YOUR EYES, SKIN, AND RESPIRATORY TRACT D. Apply a light coat of thread lubricant, Mo-lith No. 2, to threads and under heads of ten screws (85, IPL Figure 1, Sheet 1). E. Secure compressor housing (90) with ten screws (85), ten washers (80), ten washers (75), and ten nuts (70). Install nine screws (85) with heads facing out, as shown in Figure 721. Install remaining screw (85, IPL Figure 1, Sheet 1), located under the compressor outlet duct, in the opposite direction with nut (70) facing out, as shown. Install one washer (80) under head of each screw (85). Install one washer (75) under each nut (70). Tighten screws to 20 to 25 pound-inches above running torque. F. If necessary, install plug and bleeder (60) as follows: (1) Apply a light coat of Dow Corning No. 44 silicone lubricant to preformed packing (65). Install packing on plug and bleeder (60). (2) Install plug and bleeder (60) in compressor housing (90). Tighten plug and bleeder to 15 to 25 pound-inches. Secure plug and bleeder to adjacent hole in compressor housing using lockwire, MS20995C20, in accordance with AS567. G. Remove assembly from power arm fixture, GS22815-1.



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Figure 721. Installation of Compressor Housing, Containment Housing, Outlet Cover, and Turbine Outlet Duct



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19. Installation of Containment Housing A. If necessary, assemble containment housing (145, IPL Figure 1, Sheet 1) as follows: (1) Apply a thin film of glycerin to preformed packing (25, IPL Figure 3). Install packing (25) in its groove in housing (55). (2) Align holes in flanges of containment ring (20) and liner (15) with threaded holes and three headless straight pins (50) in housing (55). Install containment ring (20) and liner (15) in housing (55). (3) Apply a light coat of molybdenum disulfide-petrolatum anti-seize thread compound, MIL-T-83483, to threads and under heads of three screws (5). (4) Secure containment ring (20) and liner (15) in housing (55) with three washers (10) and three screws (5). Install screws in holes closest to headless straight pins (50). Tighten screws to 25 to 30 pound-inches above running torque. B. Place containment housing (145, IPL Figure 1, Sheet 1) on turbine housing support fixture, GS15622-1, fan inlet screen side down. C. Install assembly on containment housing (145) so that the two flat areas on the housing are located as shown in Figure 721. WARNING: USE GLOVES AND GOGGLES WHEN YOU USE MOLITH NO. 2. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN IRRITATE YOUR EYES, SKIN, AND RESPIRATORY TRACT D. Apply a light coat of thread lubricant, Mo-lith No. 2, to threads and under heads of nine screws (135, IPL Figure 1, Sheet 1). E. Secure containment housing (145) with nine washers (140) and nine screws (135). Tighten screws to 20 to 25 pound-inches above running torque. 20. Installation of Outlet Cover WARNING: KEEP ISOPROPYL ALCOHOL, TT-I-735, AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES. USE ISOPROPYL ALCOHOL, TT-I-735, IN AN AREA WITH A GOOD FLOW OF AIR. ISOPROPYL ALCOHOL, TT-I-735, IS FLAMMABLE AND CAN IRRITATE THE EYES, SKIN, AND RESPIRATORY TRACT A. Clean surface of turbine housing (335, IPL Figure 1, Sheet 2), where adhesive-backed outlet gasket (35, IPL Figure 1, Sheet 1) and outlet cover (30) will be installed, as shown in Figure 721, with isopropyl alcohol. Allow surface to air dry. B. Remove protective backing from outlet gasket (35, IPL Figure 1, Sheet 1). Install gasket (35) on turbine housing (335, IPL Figure 1, Sheet 2) with adhesive side against housing. Press gasket in place. WARNING: USE GLOVES AND GOGGLES WHEN YOU USE MO-LITH NO. 2. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN IRRITATE YOUR EYES, SKIN, AND RESPIRATORY TRACT C. Apply a light coat of thread lubricant, Mo-lith No. 2, to threads and under heads of six screws (20, IPL Figure 1, Sheet 1).



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D. Install outlet cover (30) on outlet gasket (35). E. Secure outlet cover (30) with six washers (25) and six screws (20). Tighten screws to 8 to 12 pound-inches above running torque. NOTE: Do not install turbine outlet duct (50) and fan outlet diffuser (15) until after testing of the ACM. 21. Installation of Warning Plate and Identification Plate A. If necessary, install new warning plate (195, IPL Figure 1, Sheet 2) and secure with four drive screws (190). B. If necessary, install a new identification plate (185) as follows: (1) Put the necessary information on a new identification plate (185). You can use a typewriter, without the ribbon, or other tool to put the information on the plate. WARNING: KEEP ISOPROPYL ALCOHOL AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES WHEN YOU USE IT. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT IS FLAMMABLE AND CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT. (2) Clean the surface of the turbine housing for the identification plate (185) with isopropyl alcohol. (3) Remove the protective backing from the identification plate (185) and push the plate on to the surface of the turbine housing. Use a hard rubber roller to push all of the areas of the plate against the housing. Make sure that the corners and edges are bonded. (4) Prepare the clear epoxy-polyamide coating, MIL-C-22750. Refer to MIL-C-22751. Seal the identification plate (185) and the area that is 0.125 inch (3.175 mm) around it with the coating. Apply a minimum of two layers. Let each layer dry for a minimum of 30 minutes before you apply the next layer. After you apply the last layer, let it dry for a minimum of 12 hours before you touch it. 22. Testing A. Test the ACM in accordance with TESTING AND FAULT ISOLATION. B. After testing, proceed to paragraph 22 for completion of assembly. 23. Completion of Assembly After Testing A. Install fan outlet diffuser (15, IPL Figure 1, Sheet 1) as follows: WARNING: USE GLOVES AND GOGGLES WHEN YOU USE MO-LITH NO. 2. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN IRRITATE YOUR EYES, SKIN, AND RESPIRATORY TRACT (1) Apply a light coat of thread lubricant, Mo-lith No. 2, to threads and under heads of six screws (5). (2) Align six screw through holes and three screw clearance holes in mounting flange of fan outlet diffuser (15) with threaded holes and heads of three screws in containment housing (145). Install diffuser on containment housing. Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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(3) Secure fan outlet diffuser (15) with six washers (10) and six screws (5). Tighten screws to 20 to 25 pound-inches above running torque. B. Install turbine outlet duct (50) as follows: WARNING: KEEP ISOPROPYL ALCOHOL, TT-I-735, AWAY FROM SPARKS OR FLAMES. USE GOGGLES AND RUBBER GLOVES. USE ISOPROPYL ALCOHOL, TT-I-735, IN AN AREA WITH A GOOD FLOW OF AIR. ISOPROPYL ALCOHOL, TT-I-735, IS FLAMMABLE AND CAN IRRITATE THE EYES, SKIN, AND RESPIRATORY TRACT.. (1) Clean surface of turbine housing (335, IPL Figure 1, Sheet 2), where adhesivebacked outlet gasket (55, IPL Figure 1, Sheet 1) and turbine outlet duct (50) will be installed, as shown in Figure 721, with isopropyl alcohol. Allow surface to air dry. (2) Remove protective backing from outlet gasket (55, IPL Figure 1, Sheet 1). Install gasket (55) on turbine housing (335, IPL Figure 1, Sheet 2) with adhesive side against housing. Press gasket in place. WARNING: USE GLOVES AND GOGGLES WHEN YOU USE MO-LITH NO. 2. USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN IRRITATE YOUR EYES, SKIN, AND RESPIRATORY TRACT (3) Apply a light coat of thread lubricant, Mo-lith No. 2, to threads and under heads of six screws (40, IPL Figure 1, Sheet 1). (4) Install turbine outlet duct (50) on outlet gasket (55). (5) Secure turbine outlet duct (50) with six washers (45) and six screws (40). Tighten screws to 8 to 12 pound-inches above running torque. C. Secure plugs and bleeders (220, IPL Figure 1, Sheet 2), liquid level sight plug (230A), and plug and bleeder (221), if applicable, as shown in Figure 714, with lockwire, MS20995C20, in accordance with AS567. D. Attach either warning tag (175, IPL Figure 1, Sheet 2), or a suitable locally manufactured tag, between indicated plugs and bleeders, as shown in Figure 714, Section C-C, with lockwire, MS20995C20, in accordance with AS567. When locally manufacturing a tag, mark it with the following statement: WARNING: DO NOT ATTEMPT TO RUN UNIT BEFORE FILLING OIL SUMP WITH OIL PER MANUFACTURER'S INSTRUCTIONS. 24. Storage A. Drain oil from sump. B. Cap all ports using closure kit, GS20671-1. C. Install ACM on a suitable support tray with oil sump facing down. Do not enclose unit in a plastic bag.



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FITS AND CLEARANCES 1. Fits and Clearances A. Refer to Table 801 for assembly fits and clearances. Table 801. Fits and Clearances Item and IPL Figure Number



Nomenclature



Requirement



115 - Figure 1, Sheet 1



Compressor Diffuser



Center to compressor rotor (30, IPL Figure 2) within 0.005 inch total.



125 - Figure 1, Sheet 1



Solid Shim



Set compressor rotor clearance of 0.011 to 0.013 inch for ACMs not incorporating L13, or 0.017 to 0.019 inch for ACMs incorporating L13. See Figure 714.



110 - Figure 2



Shim



Shim to fill gap between fan end face seal (125, IPL Figure 2) and internal retaining ring (105). See Figure 704.



130 - Figure 2



Shim



Shim fan end face seal (125, IPL Figure 2) to obtain 0.405 to 0.415 inch dimension from top of seal to top of seal ring (150). See Figure 704.



165 - Figure 2



Shim



Shim to fill gap between turbine end face seal (205, IPL Figure 2) and internal retaining ring (160). See Figure 703.



180 - Figure 2



Aluminum Sleeve Bushing



Set turbine rotor clearance of 0.009 to 0.011 inch for ACMs not incorporating L13, or 0.013 to 0.015 inch for ACMs incorporating L13. See Figure 705.



210 - Figure 2



Shim



Shim turbine end face seal (205, IPL Figure 2) to obtain 0.405 to 0.415 inch dimension from top of seal to top of seal ring (230). See Figure 703.



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Table 801. Fits and Clearances (Continued) Item and IPL Figure Number



Nomenclature



Requirement



255 - Figure 2



Shim



Set end play of drive shaft (240, IPL Figure 2), with respect to bearing cartridge sleeve (275), to 0.003 to 0.005 inch. See Figure 702.



275 - Figure 2



Bearing Cartridge Sleeve



Total axial travel in turbine housing (335, IPL Figure 1, Sheet 2) 0.005 inch maximum. See Figure 701.



2. Torque Requirements A. Refer to Table 802 for assembly torque requirements. Table 802. Torque Requirements Item and IPL Figure Number



Nomenclature



Torque Requirement



5 - Figure 1, Sheet 1



Screw



20 to 25 pound-inches above running torque.



20 - Figure 1, Sheet 1



Screw



8 to 12 pound-inches above running torque.



40 - Figure 1, Sheet 1



Screw



8 to 12 pound-inches above running torque.



60 - Figure 1, Sheet 1



Plug and Bleeder



15 to 25 pound-inches.



85 - Figure 1, Sheet 1



Screw



20 to 25 pound-inches above running torque.



105 - Figure 1, Sheet 1



Screw



10 to 15 pound-inches above running torque.



135 - Figure 1, Sheet 1



Screw



20 to 25 pound0inches above running torque.



160 - Figure 1, Sheet 1



Threaded Self Locking Ring



285 to 300 pound-inches above running torque. Running torque must be 30 to 120 pound-inches.



220 - Figure 1, Sheet 2



Plug and Bleeder



15 to 25 pound-inches.



221 - Figure 1, Sheet 2



Plug and Bleeder



15 to 25 pound-inches.



230A - Figure 1, Sheet 2



Liquid Level Sight Plug



15 to 25 pound-inches.



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Table 802. Torque Requirements (Continued) Item and IPL Figure Number



Nomenclature



Torque Requirement



270 - Figure 1, Sheet 2



Screw



20 to 25 pound-inches above running torque.



310 or 311 - Figure 1, Sheet 2



Screw



10 to 15 pound-inches above running torque.



20 - Figure 2



Threaded Self Locking Ring



330 to 350 pound-inches above running torque. Running torque must be 30 to 120 pound-inches.



5 - Figure 3



Screw



25 to 30 pound-inches above running torque.



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THIS IS A BLANK PAGE



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SPECIAL TOOLS, FIXTURES, AND TEST EQUIPMENT 1. Special Tools, Fixtures, and Equipment A. Special tools, fixtures, and equipment required to overhaul the ACM are listed in Table 901. NOTE: Equivalent tools, fixtures, and equipment can be used if they agree with the requirements of ARINC Report 668. NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. Table 901. Special Tools, Fixtures, and Equipment TOOL NO. CAB 570 or CAB 690-R



NOMENCLATURE Balance Machine Schenck Trebel Corp. CAGE Code: 30218



USE Check biplanar balance or rebalance cooling fan, compressor rotor, or turbine rotor, and dynamic balance the rotative group.



GS14773-1



Balance Fixture



Hold cooling fan, compressor rotor, or turbine rotor on balance machine, CAB 570 or CAB 690-R, during balance check or balancing.



GS15609-1



Carbon Seal Puller



Remove face seals from bearing cartridge sleeve.



GS15610-1



Bearing Sleeve Support



Support bearing cartridge sleeve during removal of turbine end ball bearing, and support fan end ball bearing during removal from drive shaft.



GS15611-1



Arbor Set



Install cooling fan, compressor rotor or turbine rotor in balance fixture, GS14773-1.



GS15614-1



Seal and Spring Seat Installer Driver



Install face seals in bearing cartridge sleeve. Remove and install spring seat in sleeve.



GS15615-1



Bearing Sleeve Holder



Hold rotative group during disassembly and build-up. Mounts to Wilton PowRarm, Model 301.



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Table 901. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.



NOMENCLATURE



USE



GS15616-1



Dummy Bearing



Used in place of turbine end ball bearing during shimming of bearing cartridge sleeve.



GS15617-1 GS15617-2



End Play Spacers



Used in place of components on short and long ends of drive shaft during shimming of bearing cartridge sleeve.



GS15618-1



Check Nut (3 Required)



Hold drive shaft during removal of turbine end threaded self locking ring. Used in place of locking rings during build-up of bearing cartridge sleeve.



GS15619-1



Bearing Shaft Support



Hold drive shaft during installation of ball bearings.



GS15620-1



Bearing Driver



Install ball bearings on drive shaft.



GS15622-1



Turbine Housing Support Fixture



Hold ACM during removal of containment housing and during pinning and shimming procedures.



GS15623-1



Compressor Rotor Spacer



Simulates compressor rotor during build-up of rotative group.



GS15626-1



Balance Fixture Kit



Hold turbine housing and rotative group on balance machine, CAB 570 or CAB 690-R, during dynamic balance.



GS15627-1



Pin Installer



Install spiral spring pins for pinning of seal plate and compressor diffuser.



GS21429-3



Test Diffuser (with speed pickup and displacement probe)



Monitor the ACM speed and fan-end shaft displacement.



GS15632-2



Turbine Outlet Port Cap



Cap outlet port of turbine housing for leakage test.



GS15633-2



Turbine Inlet Port Cap



Cap inlet port of turbine housing for leakage test.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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COMPONENT MAINTENANCE MANUAL 782790



Table 901. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.



NOMENCLATURE



USE



GS15800-1



Balancing Accessories Kit



Controls air flow to dive cooling fan, compressor rotor, or turbine rotor during balance check or balancing, and to drive rotative group during dynamic balance. Includes wheel grinder for balance stock removal and blow gun for cleaning during individual balance of cooling fan or rotors.



GS15801-1



Balance Machine Nozzle Assembly



Direct air flow to cooling fan, compressor rotor, or turbine rotor during balance check or balancing, and to rotative group during dynamic balance.



GS20137-1



Pressure Test Cap Assembly



Cap outlet port of compressor housing for leakage test.



GS20138-1



Pressure Test Cap Assembly



Cap inlet port of compressor housing for leakage test.



GS20649-1



Holding Fixture



Hold seal plate or nozzle plate and insulator in a lathe during replacement of lead seal.



GS20671-1



Closure Kit



Cap all ports on ACM after testing or for storage.



GS21268-1



Compressor Out-Turbine In Testing Duct



Connect from outlet duct of compressor housing to inlet duct of turbine housing.



GS24306-1



Outlet Duct Assembly



Connect from test diffuser, GS21429-3, to fan discharge stack of test facility. Assembly incorporates a restricting orifice required for performance testing.



GS22194-1



Turbine Outlet Adapter



Connect to outlet port of turbine housing. Adapter incorporates a valve to set turbine outlet static pressure.



GS22333-2



Spanner Wrench (2 Required)



Remove and install fan and turbine end threaded self locking rings.



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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Table 901. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.



NOMENCLATURE



USE



GS22529-1



Compressor Housing Extractor (2 Required)



Remove compressor housing.



GS22802-1



Compressor Inlet Adapter



Connect to inlet duct of compressor housing.



GS22815-1



Power Arm Fixture



Hold turbine housing and rotative group during disassembly and build-up. Mounts to Wilton PowRarm, Model 301.



GS22826-1



Holding Fixture



Hold compressor diffuser in a lathe during machining to remove damage prior to plasma spray repair.



GS22827-1



Holding Fixture



Hold turbine housing in a lathe during machining to remove damage prior to plasma spray repair.



GS22828-1



Lead Seal Rolling Tool



Roll new lead seal into seal plate or nozzle plate and insulator.



792790-T-11



Pin Alignment Tool



Align hole for stepped pin in bearing cartridge sleeve with pinhole in turbine housing prior to installing pin.



782790-T-14



Cartridge Installer



Push the cartridge into the turbine housing. This tool is necessary only for PN 782790-16 units.



Model HDX-SET-FSP-T-OST, Mode HH99A-T1



Handle and Probe Set, Digital Thermometer Omega Engineering Inc.



Check surface temperature of rotors to prevent overheating during removal.



CAGE Code: 29907 Model VT-750B



Heat Gun Master Appliance Corp.



Heat rotors for removal.



CAGE Code: 83284 Model 260



Groove Micrometer The L S Starrett Co.



Used to measure grooves in bearing cartridge sleeve during shimming of face seals.



CAGE Code: 57163



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Table 901. Special Tools, Fixtures, and Equipment (Continued) TOOL NO. Model 301



NOMENCLATURE Wilton PowRarm Wilton Corp.



USE Swivel holding and positioning tool, used with items GS15615-1 and GS22815-1.



CAGE Code: 66080 Sleeve FS3-600 Coupling 42167AF-600



V I J Corporation CAGE Code: 94581



2271A



Accelerometer Endevco Corp.



Connect outlet duct assembly, GS24306-1, to test diffuser, GS21429-3. Measure ACM vibration levels.



CAGE Code: 95411 2983B



Insulated Mounting Stud Endevco Corp.



Mount accelerometer on top of turbine housing.



CAGE Code: 95411



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



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ILLUSTRATED PARTS LIST 1. Introduction A. General (1) Purpose - The Illustrated Parts List (IPL) shows the detail parts for each item on the Title Page. The IPL includes all of the parts that can be disassembled, repaired or replaced, and assembled again. (2) Organization - The IPL is divided into: (a) The Introduction, which tells how to use the IPL and includes the Vendor Decoding Table. (b) The Equipment Designator Index (if necessary), which shows all of the electrical components in the sequence of their reference designators. (c) The Numerical Index, which shows all of the parts in the sequence of their part numbers. (d) The Detailed Parts List, which shows all of the parts in their approximate disassembly sequence with illustrations. (e) The Configuration Change Summary, which shows the sequence and causes for the changes in the IPL. (3) Abbreviations and Acronyms - These abbreviations are used in Hamilton Sundstrand’s parts lists. AR -



As Required (necessary)



Be -



Beryllium



CAGE -



Commercial And Government Entity



ESDS -



Electrostatic Discharge Sensitive



HS -



Hamilton Sundstrand Specification/Source Control Drawing



NHA -



Next Higher Assembly



NP -



Non-Procurable



RF -



Reference



(4) The part numbers identified in this Illustrated Parts Catalog / Illustrated Parts List have been shown to comply with the applicable Federal Aviation Regulations and, when purchased from Hamilton Sundstrand, are FAA-approved under a Hamilton Sundstrand FAA Production Certificate (PC), Technical Standard Order (TSO), or Parts Manufacture Approval (PMA) for use in the component listed. (5) This IPC (or IPL) does not constitute a grant of direct-ship authority, or otherwise confer FAA-approval under FAR 21.303 for parts and assemblies purchased directly from a listed vendor. Installation eligibility of all parts and assemblies purchased directly from a listed vendor must be supported by the vendor’s Parts Manufacture Approval (PMA).



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(6) Warnings and Cautions (a) Electrostatic Discharge Sensitive (ESDS) Parts - ESDS parts and assemblies have the letters “ESDS” in the NOMENCLATURE column. They are identified in figures by the ESDS symbol. If an assembly is ESDS, all of its parts are ESDS.



CAUTION: ALL CIRCUIT CARD ASSEMBLIES ARE ESDS. DO NOT REMOVE THEM FROM THEIR CONTAINERS UNTIL IMMEDIATELY BEFORE THEY ARE INSTALLED. OBEY THE ESDS PROCEDURES IN THE MAINTENANCE INSTRUCTIONS. DO NOT KEEP ESDS PARTS NEAR ELECTROSTATIC, ELECTROMAGNETIC, MAGNETIC, OR RADIOACTIVE FIELDS. ESDS PARTS CAN BE DAMAGED IF NOT PROTECTED. (b) Some parts contain beryllium or beryllium oxide. These parts have the letters “Be” in the NOMENCLATURE column of the Detailed Parts List. WARNING: USE GOGGLES, RUBBER GLOVES, AND A PARTICLE MASK WHEN YOU CUT, DRILL, SAW, FILE, OR MACHINE ANY COMPONENTS THAT CONTAIN BERYLLIUM OR BERYLLIUM OXIDE. WORK IN AN AREA WITH A GOOD FLOW OF AIR. BERYLLIUM OXIDE IS POISONOUS TO THE SKIN, EYES, AND RESPIRATORY TRACT. B. How to Use the IPL (1) Assembly Sequence Indentation - The names of the parts in the “NOMENCLATURE” column of the IPL are indented to show which parts are installed in other parts. The level of indentation is shown by the number of dots at the left edge of the NOMENCLATURE column. For example, the top assembly for a parts list figure is at the left margin. The names of its parts and subassemblies are indented by one dot. Subsequent subassemblies and parts are indented with more dots. Top Assembly .Detail Parts of the Top Assembly .Subassembly of the Top Assembly .Attaching Parts for the Subassembly ..Detail Parts of the Subassembly ..Subassemblies of the Subassembly



(2) Part Numbers - Five types of numbers are used in the PART NUMBER column of the Detailed Parts List. They are: (a) Hamilton Sundstrand Part Numbers - If a part is only available from Hamilton Sundstrand, the Hamilton Sundstrand Part number is shown in the PART NUMBER column.



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(b) Vendor Part Numbers - If a part is not changed by Hamilton Sundstrand, the vendor’s part number is shown in the PART NUMBER column. The vendor’s code is shown in the NOMENCLATURE column after the letter “V”. The equivalent Hamilton Sundstrand part number is shown in the NOMENCLATURE column after the letters “HS”. (c) Industrial Standard and Military Numbers - If a part has an industrial standard number or military standard number, that number is shown in the PART NUMBER column. (d) RFN Numbers - “RFN” numbers refer to groups of parts which are thought of as an assembly. This is done to make the parts list easier to use. You cannot procure parts by their “RFN” numbers. (e) RFL Numbers - Some vendor parts have “RFL” numbers in the PART NUMBER column. “RFL” numbers are used when the correct vendor part number is too long to fit in the PART NUMBER column. The correct vendor part number is in the NOMENCLATURE column after the words “IDENT. AS”. You cannot procure parts by their “RFL” numbers. (3) Item Numbers and Variant Letters (a) Each part has an item number in the FIG&ITEM column. Item numbers are in the approximate sequence of disassembly. (b) A variant letter is a letter after the item number for a part number. Letters A through Z, but not I and O, are used. Variant letters are used for: • Optional parts • Added parts for different configurations • Vendor changes • Editorial changes. (4) Parts Replacement Data - These words, in the NOMENCLATURE column, tell if one part replaces another. Words OPTIONAL SUPSD BY ITEM N SUPSDS ITEM N PRE SB XXXX POST SB XXXX



Definition This part is an optional alternative to other parts in the same item number variant group. The part with item number N replaces (supersedes) this part This part replaces (supersedes) the part with item number N. Use this part if Service Bulletin XXXX was not done. Use this part if Service Bulletin XXXX was done. NOTE: If an existing part is checked, inspected and/ or modified by a Service Bulletin, without resulting in a change to the part number, a note will appear in the nomenclature of that part to "(REFER TO SB XX)".



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COMPONENT MAINTENANCE MANUAL 782790



(5) “PARTIAL BREAKDOWN FOLLOWS” - These words, in the NOMENCLATURE column, tell that two or more detail parts of the subassembly are not listed. (6) “SERVICE USE” - These words, in the NOMENCLATURE column, tell that the part was not used in the original equipment but can be used for in-service units. (7) “SERVICE EVALUATION PART” - These words, in the NOMENCLATURE column, tell that the part is being used on a limited population of units and is not being supplied for the general population of units. (8) Items Not Shown - Some parts are not shown in the illustrations. These parts have a dash (-) in front of their item numbers in the FIG&ITEM column. (9) Change Codes (a) Numbers in the CHG CODE column show the sequence in which changes were made. The Configuration Change Summary, at the end of the IPL, tells about each change code number used. (b) If an asterisk follows a change code, all of the parts that have that change code must be replaced at the same time. (c) The Configuration Change Summary tells about the change codes. It identifies each change by its change code number, and tells you: • Which assemblies changed • About the change • Which engineering change caused the change, and which Service Bulletin has the change procedures. (10) Effectivity Codes - If there is more than one top assembly in a parts list figure, each top assembly can have an effectivity code in the EFF CODE column. Effectivity codes are letters A through Z, but not I and O. A part shown with an effectivity code is only used in the top assembly that has the same effectivity code. Parts which do not have effectivity codes are used in all of the top assemblies in the parts list figure. Note that each parts list figure can have a set of effectivity codes. (11) Units per Assembly - The UPA column tells you the total number of each part that is installed in the next higher assembly. (12) All solid shim thicknesses are given in inches. An example is (0.010 THK) which represents a 0.010 inch thick solid shim. Metric equivalents are also given in millimeters (mm). Metric equivalents are given in [ ] throughout the IPL.



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COMPONENT MAINTENANCE MANUAL 782790



C. Vendors NOTE: You can get the full address and other information for vendors or suppliers listed in this table from the World Wide Web (www) at URL http://www.bpn.gov/ bincs/begin_search.asp. Other CAGE Code sites are also available on the Web. V00287 Spirol International Corporation 30 Rock Avenue P.O. Box 179 Danielson, CT 06239-0179



V80756 Spirolox Division of Kaydon Corporation 29 Cassens Court Fenton, MO 63026-2542



V01556 Emhart Fastening Systems Group Heli-Coil Division 510 River Road Shelton, CT 06484



V83086 New Hampshire Ball Bearings Inc. Route 202 Peterborough, NH 03458



V70854 The Barden Corporation Precision Bearings Division 200 Park Avenue Danbury, CT 06810-7505



V97484 Vickers Inc. Tedeco Division 24 East Glenolden Avenue Glenolden, PA 19036-2107



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2. Numerical Index _______________________________________________________________________________ Airline Total Airline Total Part Number Part Number Fig - Item Req. Part Number Part Number Fig - Item Req. _______________________________________________________________________________ 094-0500MCP 094-0625MCP 1191-10CNX0312 1191-6CN0-375



1191-8CN0-375 540628 570057-6 570057-8 5-83BZ 69253B4 69255A4 69295-4-8 69415-0-3 69415-8-6 69494J111 69494J139 69494J154 69494J262 69494K11 69494K113 69494K129 69494K151 69494K29 69692A63 727455-11 727463-11 730449-11 732021-7 732110-81



732110-82



732110-83



2 2 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 3 2 2 1 1 1 1 1 2 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2



-



50 55 350 255 354 355 95 205 206 245 245A 230 185A 185 250 190A 180A 65 100 25 45 80 215 216 225 330 265 5 270 295 285 300 165 25 110 130 165 210 255 111 131 166 211 256 112 132



2 2 1 1 1 2 1 1 1 2 2 1 1 1 1 4 4 1 1 1 1 1 2 1 1 2 1 2 2 2 2 2 1 1 AR AR AR AR AR AR AR AR AR AR AR AR



732110-83



732110-84



732110-85



732110-86



732110-87



732110-88



732110-89



732110-90



732110-91



732144-2 732160-1 732160-10



2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 2 2



-



167 212 257 113 133 168 213 258 114 134 169 214 259 115 135 170 215 260 116 136 171 216 261 117 137 172 217 262 118 138 173 218 263 119 139 174 219 264 120 140 175 220 265 50 180 189



AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 3 AR AR



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COMPONENT MAINTENANCE MANUAL 782790



_______________________________________________________________________________ Airline Total Airline Total Part Number Part Number Fig - Item Req. Part Number Part Number Fig - Item Req. _______________________________________________________________________________ 732160-11 732160-12 732160-13 732160-14 732160-15 732160-16 732160-17 732160-18 732160-19 732160-2 732160-20 732160-21 732160-22 732160-25 732160-3 732160-4 732160-5 732160-6 732160-7 732160-8 732160-9 738612-3 740707-1 740707-3 748933-2 753385-2 753385-3 753387-1 753387-2 753387-3 753387-5 753388-1 753388-2 753389-3 753389-4 753391-1 753392-1 753393-1 753398-2 753398-4 753399-1 753438-1 753443-2 753452-3 753453-1



2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 3



-



190 191 192 193 194 195 196 197 198 181 199 200 201 202 182 183 184 185 186 187 188 240 290 290A 305 240 240A 275 275A 275B 275C 250 250A 270 270A 150 230 320 280 195 195A 175 30 35 55 15 145 1



AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 RF



753453-10 753453-20 753453-30 753453-40 753602-1 753602-2 758073-100 758073-104 758073-105 758073-107 758073-109 758073-111 758073-19 758073-23 758073-24 758073-26 758073-28 758073-30 762049-1 772427-1 772427-2 772427-3 782058-1 782078-1 782078-3 782080-1 782101-1 782101-10 782101-11 782101-2 782101-20 782122-1 782147-1 782148-1 782166-1 782166-10 782195-1 782195-2 782195-3 782195-4 782195-5 782195-6



3 3 3 3 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 2 2 2 2 2 2 1 1 2 1 1 1 1 1 1 1 1 1



-



55 20 15 45 125 205 125A 205A 335 335A 335B 335C 335D 335E 360 360A 360B 360C 360D 360E 170 155 15 156 16 157 17 115 90 90A 75 30 40 40A 30A 35 120 160 20 50 245 260 125 126 127 128 129 130



1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 AR AR AR AR AR AR 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 AR AR AR AR AR AR



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COMPONENT MAINTENANCE MANUAL 782790



_______________________________________________________________________________ Airline Total Airline Total Part Number Part Number Fig - Item Req. Part Number Part Number Fig - Item Req. _______________________________________________________________________________ 782195-7 782790-10 782790-12 782790-16 782790-18 782790-6 785733-2 785733-3 785733-4 785733-5 785733-6 785796-1 785796-2 785796-20 785796-30 785812-1 785812-20 785813-1 788066-1 788077-1 788078-1 788078-20 797619-1 808519-3 816661-1 816662-1 816663-1 821246-1 821246-11 821246-21 821246-31 AN814-3DL AN814-5DL AN960PD10 M202HX67 M202HX67REVC M83485-1-029 M83485-1-129 MS2042AD3-4A MS20426AD3-4A-5 MS20470AD4-12 MS20470AD4-9 MS21042-3 MS21043-3



1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2 1 1 2 2 1 2 2 2 2 1 1 1 1 2 2 2 2 2 1 2 2 3 3 1 1



-



131 1A 1B 1C 1D 1 100 100A 100D 100B 100E 100C 85 85A 95 90 60 62 70 305A 70A 60A 62A 90B 300A 5B 6 332B 60B 63 62B 64 220 221 60 275 155 235 155B 235B 5A 330A 66 66A 35 40 70 70A



AR RF RF RF RF RF 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 2 2 4 3 4 10 10



MS21209C0810 MS21209C0815 MS21209F1-10 MS21209F1-15 MS21318-8 MS9245-28 NAS1201B6A6A NAS1802-08-16



NAS1802-3-10 NAS1802-3-12 NAS1802-3-18 NAS1802-3-9 NAS5903-10 NAS5903-12 NAS5903-14 NAS5903-16 NAS5903-18 NAS5903-9 NAS6002-16



NAS6003U12 NAS620-10L



NAS620C10L



NAS620C8L



1 1 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 3 1 1 1 1 1 1 3 1 1 1 1 1 1 3 1 1 1



-



345 346 65 30 340 180 190 200 201 210 211 105A 310A 311A 20A 40A 5A 85C 135A 20 40 5 5 85 85A 85B 135 105 310 311 5A 10 25 45 75 80 140 10 10A 25A 45A 75A 80A 140A 10A 110 315 316



15 11 8 18 18 4 4 1 1 1 1 8 15 11 6 6 6 10 9 6 6 6 3 10 10 10 9 8 15 11 3 6 6 6 10 10 9 3 6 6 6 10 10 9 3 8 15 11



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COMPONENT MAINTENANCE MANUAL 782790



_______________________________________________________________________________ Airline Total Airline Total Part Number Part Number Fig - Item Req. Part Number Part Number Fig - Item Req. _______________________________________________________________________________ R202B39C3 RFL1518 RFN2115 RFN3738 RFN4426 RFN5970 RFN6035



2 2 2 2 1 2 1 2 1 2 1 2 1



-



155A 235A 155C 235C 325 1 325A 1A 325C 1C 325D 1D 325B



1 1 1 1 1 RF 1 RF 1 RF 1 1 1



RR137S



RR325S RR87S S788107-1 S83BZ S83BZ1 S83BZ-2



2 2 2 2 2 1 1 2 1 1 1 1



-



1B 105 145 160 225 235 150 10 356 230A 230B 230C



RF 1 1 1 1 1 1 1 1 1 1 1



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COMPONENT MAINTENANCE MANUAL 782790



3. Detailed Parts List NOTE: The items in this list are made/or supplied by Hamilton Sundstrand Corporation, a United Technologies Company, or by the suppliers shown in this list. Hamilton Sundstrand does not give approval for items that you get from suppliers who are not shown in this list. Approval from Hamilton Sundstrand is not necessary for government and industry standard parts.



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COMPONENT MAINTENANCE MANUAL 782790



IPL Figure 1. Air Cycle Machine (Sheet 1)



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COMPONENT MAINTENANCE MANUAL 782790



Figure 1.



Air Cycle Machine (Sheet 2)



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COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 1 1



Part Number 782790-6



-



1A 782790-10



-



1B 782790-12



-



1C 782790-16



-



1D 782790-18



5 -



5A NAS1802-3-12 10



-



NAS620-10L



25A NAS620C10L 30 35 40



-



753452-3 NAS5903-10



20A NAS1802-3-10 25



-



NAS620-10L



10A NAS620C10L 15 20



-



NAS5903-12



753438-1 753443-2 NAS5903-10



40A NAS1802-3-10



Airline Part Number 1234567Nomenclature MACHINE,AIR CYCLE SUPSD BY ITEM 1A PRE SB 21-2068 SUPSD BY ITEM 1D MACHINE,AIR CYCLE SUPSDS ITEM 1 POST SB 21-2068 SUPSD BY ITEM 1B PRE SB 21-2110 SUPSD BY ITEM 1D PRE SB 21-2179 MACHINE,AIR CYCLE SUPSDS ITEM 1A POST SB 21-2110 SUPSD BY ITEM 1C PRE SB 21-2118 SUPSD BY ITEM 1D PRE SB 21-2179 MACHINE,AIR CYCLE SUPSDS ITEM 1B POST SB 21-2118 SUPSD BY ITEM 1D PRE SB 21-2179 MACHINE,AIR CYCLE SUPSDS ITEMS 1, 1A, 1B, 1C POST SB 21-2179 .SCREW SUPSD BY ITEM 5A .SCREW SUPSDS ITEM 5 .WASHER SUPSD BY ITEM 10A .WASHER SUPSDS ITEM 10 .DIFFUSER,FAN OUTLET .SCREW SUPSD BY ITEM 20A .SCREW SUPSDS ITEM 20 .WASHER SUPSD BY ITEM 25A .WASHER SUPSDS ITEM 25 .COVER,OUTLET .GASKET,OUTLET .SCREW SUPSD BY ITEM 40A .SCREW SUPSDS ITEM 40



Chg Eff Code Code UPA A RF



8*



B



RF



12*



C



RF



14*



D



RF



16*



E



RF



6 17*



6 6



17*



6 1 6



17*



6 6



17*



6 1 1 6



17*



6



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COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 1 45 -



45A NAS620C10L 50 55 60 65 70



-



NAS620-10L



75A NAS620C10L 80



-



782148-1 753443-2 AN814-5DL 69494J111 MS21042-3



70A MS21043-3 75



-



Part Number NAS620-10L



NAS620-10L



80A NAS620C10L 85



NAS5903-14



-



85A NAS5903-16



-



85B NAS5903-18



-



85C NAS1802-3-18 90



782078-1



-



90A 782078-3



-



90B 797619-1



95 100 105



1191-8CN0-375 69494J139 NAS6002-16



- 105A NAS1802-08-16 110 115



NAS620C8L 782058-1



Airline Part Number 1234567Nomenclature .WASHER SUPSD BY ITEM 45A .WASHER SUPSDS ITEM 45 .DUCT,TURBINE OUTLET .GASKET,OUTLET .PLUG AND BLEEDER .PACKING,PREFORMED .NUT SUPSD BY ITEM 70A .NUT SUPSDS ITEM 70 .WASHER SUPSD BY ITEM 75A .WASHER SUPSDS ITEM 75 .WASHER SUPSD BY ITEM 80A .WASHER SUPSDS ITEM 80 .SCREW SUPSD BY ITEM 85A SUPSD BY ITEM 85C .SCREW SUPSDS ITEM 85 SUPSD BY ITEM 85B .SCREW SUPSDS ITEM 85A SUPSD BY ITEM 85C .SCREW SUPSDS ITEMS 85 AND 85B .HOUSING,COMPRESSOR SUPSD BY ITEM 90A .HOUSING,COMPRESSOR SUPSDS ITEM 90 SUPSD BY ITEM 90B .HOUSING,COMPRESSOR SUPSDS ITEM 90A PARTIAL BREAKDOWN FOLLOWS ..INSERT,SCREW THREAD V01556, HS69473-3 .PACKING .SCREW SUPSD BY ITEM 105A .SCREW SUPSDS ITEM 105 .WASHER .DIFFUSER,COMPRESSOR



Chg Eff Code Code UPA 6 17*



6 1 1 1 1 10



17*



10 10



17*



10 10



17*



10 10



5*



A



10



6



10



17*



10



2



5*



A



1



A



1



1



1 1 8 17*



8 8 1



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



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COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 1 120 125



Part Number 782122-1 782195-1



-



782195-2 782195-3 782195-4 782195-5 782195-6 782195-7 NAS5903-9



126 127 128 129 130 131 135



- 135A NAS1802-3-9 140



NAS620-10L



- 140A NAS620C10L 145



753453-1



150



RR87S



155



772427-1



- 156 - 157 160 165 170 175 180



772427-2 772427-3 782147-1 732021-7 762049-1 753399-1 MS21318-8



- 180A 69415-8-6



185



69255A4



- 185A 69253B4 190



MS21318-8



- 190A 69415-0-3 195



753398-2



Airline Part Number 1234567Nomenclature .SHIELD,HEAT .SHIM,SOLID (0.010 THK) SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .SHIM,SOLID (0.012 THK) .SHIM,SOLID (0.014 THK) .SHIM,SOLID (0.016 THK) .SHIM,SOLID (0.018 THK) .SHIM,SOLID (0.030 THK) .SHIM,SOLID (0.060 THK) .SCREW SUPSD BY ITEM 135A .SCREW SUPSDS ITEM 135 .WASHER SUPSD BY ITEM 140A .WASHER SUPSDS ITEM 140 .HOUSING,CONTAINMENT SEE FIG. 3 FOR DETAILS CONTAINS MATCHED PARTS .RING,RETAINER-INTERNAL V80756, HS69983S87 .WEIGHT,BALANCE SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .WEIGHT,BALANCE .WEIGHT,BALANCE .RING,THREADED-SELF LOCKING .WASHER,FLAT .FAN,COOLING .TAG,WARNING .SCREW USED WITH ITEM 185 SUPSD BY ITEM 180A .SCREW USED WITH ITEM 185 SUPSDS ITEM 180 .PLATE,IDENTIFICATION SUPSD BY ITEM 185A .PLATE,IDENTIFICATION SUPSDS ITEM 185 .SCREW SUPSD BY ITEM 190A .SCREW SUPSDS ITEM 190 .PLATE,WARNING SUPSD BY ITEM 195A



Chg Eff Code Code UPA 1 AR



AR AR AR AR AR AR 9 17*



9 9



17*



9 1



1 AR



AR AR 1 1 1 1 4



17*



4



1 13*



1 4



17*



4 A



1



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1017 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & Item Part Number 1 - 195A 753398-4 200



MS9245-28



201



MS9245-28



205



540628



206



540628



210



NAS1201B6A6A



211



NAS1201B6A6A



215



69494K11



216



69494K11



220



AN814-3DL



221



AN814-3DL



225 - 230 230A - 230B - 230C



69494K113 5-83BZ S83BZ S83BZ1 S83BZ-2



235 240 - 245 250 255 260 265 270 275 280 285



RR325S 738612-3 782166-1 69295-4-8 1191-6CN0-375 782166-10 69494K151 69692A63 AN960PD10 753393-1 727463-11



Airline Part Number 1234567Nomenclature .PLATE,WARNING SUPSDS ITEM 195 .PIN USED WITH ITEMS 335, 335A OR 335B .PIN USED WITH ITEM 335B .WIRE,SPRING USED WITH ITEMS 335, 335A OR 335B .WIRE,SPRING USED WITH ITEM 335B .CHAIN USED WITH ITEMS 335, 335A OR 335B .CHAIN USED WITH ITEM 335B .PACKING,PREFORMED USED WITH ITEMS 335, 335A OR 335B .PACKING,PREFORMED USED WITH ITEM 335B .PLUG AND BLEEDER USED WITH ITEMS 335, 335A OR 335B .PLUG AND BLEEDER USED WITH ITEM 335B .PACKING,PREFORMED DELETED DELETED DELETED .PLUG,SIGHT-LIQUID LEVEL V97484, HS749042-1 .RING,RETAINER-INTERNAL V80756, HS69983S325 .WASHER,TAB .COVER,SUMP ..PIN,STRAIGHT,HEADLESS ..INSERT,SCREW THREAD V01556, HS69473-53 ..COVER (NP) .PACKING,PREFORMED .SCREW,MACHINE .WASHER .PLATE,RETAINING .RETAINER,SPRING



Chg Eff Code Code UPA 4 1 1



3*



1 1



3*



1 1



3*



1 2



3*



1 2



3*



1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1018 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 1 290



Part Number 740707-1



- 290A 740707-3



295 300



727455-11 730449-11



- 300A 808519-3



305



748933-2



- 305A 788066-1



310



NAS6002-16



- 310A NAS1802-08-16 - 311



NAS6002-16



- 311A NAS1802-08-16 315



NAS620C8L



- 316



NAS620C8L



320 325



753392-1 RFN2115



- 325A RFN3738



Airline Part Number 1234567Nomenclature .SPRING SUPSD BY ITEM 290A PRE SB 21-2114 .SPRING,HELICAL COMPRESSION SUPSDS ITEM 290 POST SB 21-2114 .BUSHING,WICK .WICK,NONMETALLIC SUPSD BY ITEM 300A PRE SB 21-2114 .WICK,NONMETALLIC SUPSDS ITEM 300 POST SB 21-2114 .PIN,STEPPED SUPSD BY ITEM 305A PRE SB 21-2039 .PIN,STEPPED SUPSDS ITEM 305 POST SB 21-2039 .SCREW USED WITH ITEMS 335 OR 335A SUPSD BY ITEM 310A .SCREW SUPSDS ITEM 310 .SCREW USED WITH ITEM 335B SUPSD BY ITEM 311A .SCREW SUPSDS ITEM 311 .WASHER USED WITH ITEMS 335 OR 335A .WASHER USED WITH ITEM 335B .SPACER,FAN .ROTATIVE GROUP (NP) SEE FIG. 2 FOR DETAILS SUPSD BY ITEM 325A PRE SB 21-2068 .ROTATIVE GROUP (NP) SEE FIG. 2 FOR DETAILS SUPSDS ITEM 325 POST SB 21-2068 SUPSD BY ITEM 325B PRE SB 21-2110 SUPSD BY ITEM 325D PRE SB 21-2179



Chg Eff Code Code UPA 2



9*



BC



2



2 2



9*



BCD



2



A



1



1*



17*



1



A



15



A



15



3*



11



17*



11 A



3*



8*



15 11



A



1 1



B



1



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1019 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & Item Part Number 1 - 325B RFN6035



- 325C RFN4426



- 325D RFN5970



330



69494K129



- 330A M83485-1-129



332B 816663-1 - 335



758073-100



- 335A 758073-104



- 335B 758073-105



- 335C 758073-107



- 335D 758073-109



Airline Part Number 1234567Nomenclature .ROTATIVE GROUP (NP) SEE FIG. 2 FOR DETAILS SUPSDS ITEM 325A POST SB 21-2110 SUPSD BY ITEM 325C PRE SB 21-2118 SUPSD BY ITEM 325D PRE SB 21-2179 .ROTATIVE GROUP (NP) SEE FIG. 2 FOR DETAILS SUPSDS ITEM 325B POST SB 21-2118 SUPSD BY ITEM 325D PRE SB 21-2179 .ROTATIVE GROUP(NP) SEE FIG. 2 FOR DETAILS SUPSDS ITEMS 325A, 325B, 325C POST SB 21-2179 .PACKING,PREFORMED SUPSD BY ITEM 330A PRE SB 21-2067 .PACKING SUPSDS ITEM 330 POST SB 21-2067 .SEAL POST SB 21-2118 .HOUSING,TURBINE SUPSD BY ITEM 335A PRE SB 21-2039 .HOUSING,TURBINE SUPSDS ITEM 335 POST SB 21-2039 SUPSD BY ITEM 335B .HOUSING,TURBINE SUPSDS ITEM 335A SUPSD BY ITEM 335C PRE SB 21-2110 SUPSD BY ITEM 325D PRE SB 21-2179 .HOUSING,TURBINE SUPSDS ITEM 335B POST SB 21-2110 SUPSD BY ITEM 335D PRE SB 21-2118 SUPSD BY ITEM 335D PRE SB 21-2179 .HOUSING,TURBINE SUPSDS ITEM 335C POST SB 21-2118 SUPSD BY ITEM 335E PRE SB 21-2179



Chg Eff Code Code UPA 12* C 1



14*



D



1



16*



E



1



A



2



7*



14*



2



D



1



A



1



1*



A



1



3*



AB



1



12*



C



1



14*



D



1



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1020 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & Item Part Number 1 - 335E 758073-111



340 345



MS21209F1-15 MS21209C0810



- 346



MS21209C0815



350



1191-10CNX0312



354



1191-6CN0-375



- 355



1191-6CN0-375



356



S788107-1



360



758073-19



- 360A 758073-23



- 360B 758073-24



- 360C 758073-26



- 360D 758073-28



- 360E 758073-30



Airline Part Number 1234567Nomenclature .HOUSING,TURBINE SUPSDS ITEMS 335B, 335C, 335D POST SB 21-2179 ..INSERT ..INSERT USED WITH ITEMS 335 OR 335A ..INSERT USED WITH ITEM 335B ..INSERT,HELICAL COIL-SPECIAL V01556, HS753394-1 ..INSERT,SCREW THREAD V01556, HS69473-53 USED WITH ITEMS 335 OR 335A ..INSERT,SCREW THREAD V01556, HS69473-53 USED WITH ITEM 335B ..BUSHING USED WITH ITEMS 335A AND 335B POST SB 21-2039 ..HOUSING (NP) SUPSD BY ITEM 360A PRE SB 21-2039 ..HOUSING (NP) SUPSDS ITEM 360 POST SB 21-2039 SUPSD BY ITEM 360B SUPSD BY ITEM 360D PRE SB 21-2179 ..HOUSING (NP) SUPSDS ITEM 360A SUPSD BY ITEM 360C PRE SB 21-2110 SUPSD BY ITEM 360D PRE SB 21-2179 ..HOUSING (NP) SUPSDS ITEM 360B POST SB 21-2110 SUPSD BY ITEM 360D PRE SB 21-2179 ..HOUSING (NP) SUPSDS ITEM 360A, 360B, 360C POST SB 21-2179 .HOUSING (NP) SUPSDS ITEMS 360C, 360D



Chg Eff Code Code UPA 16* E 1



A



3*



18 15



11 1 A



1



3*



2



1*



1



A



1



1*



A



1



3*



AB



1



12*



CD



1



16*



E



1



17*



B



1



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1021 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



IPL Figure 2. Rotative Group Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



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COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 2 1



Part Number RFN2115



-



1A RFN3738



-



1B RFN6035



-



1C RFN4426



-



1D RFN5970



-



5



69494K29



5A M83485-1-029



-



5B 816661-1



6



-



816662-1



10



RR87S



15



772427-1



16 17 20



772427-2 772427-3 782147-1



Airline Part Number 1234567Nomenclature ROTATIVE GROUP SEE FIG. 1 FOR NHA SUPSD BY ITEM 1A PRE SB 21-2068 ROTATIVE GROUP SEE FIG. 1 FOR NHA SUPSDS ITEM 1 POST SB 21-2068 SUPSD BY ITEM 1B PRE SB 21-2110 SUPSD BY ITE4M 1D PRE SB 21-2179 ROTATIVE GROUP SEE FIG. 1 FOR NHA SUPSDS ITEM 1A POST SB 21-2110 SUPSD BY ITEM 1C PRE SB 21-2118 SUPSD BY ITEM 1D PRE SB 21-2179 ROTATIVE GROUP SEE FIG. 1 FOR NHA SUPSDS ITEM 1B POST SB 21-2118 SUPSD BY ITEM 1D PRE SB 21-2179 ROTATIVE GROUP SUPSDS ITEMS 1A, 1B, AND 1C POST SB 21-2179 .PACKING,PREFORMED SUPSD BY ITEM 5A PRE SB 21-2067 .PACKING SUPSDS ITEM 5 POST SB 21-2067 SUPSD BY ITEMS 5B AND 6 PRE SB 21-2118 .PACKING SUPSDS ITEM 5A POST SB 21-2118 .RING, SPLIT, TURBINE SUPSDS ITEM 5A POST SB 21-2118 .RING,RETAINER-INTERNAL V80756, HS69983S87 .WEIGHT,BALANCE (6 AVG) SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .WEIGHT,BALANCE (3 AVG) .WEIGHT,BALANCE (2 AVG) .RING,THREADED-SELF LOCKING



Chg Eff Code Code UPA A RF



8*



B



RF



12*



C



RF



14*



D



RF



16*



E



1



A



2



7*



ABCE



2



14*



D



1



14*



D



1



1 AR



AR AR 1



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1023 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 2 25 - 30



-



30A 782101-2



35 40



-



Part Number 732021-7 782101-1



782101-20 782101-10



40A 782101-11



45 50



69494J262 094-0500MCP



55



094-0625MCP



60



785812-1



-



60A 788078-1



-



60B 821246-1



62



785812-20



-



62A 788078-20



-



62B 821246-21



-



63



821246-11



-



64



821246-31



-



65 MS21209C0815 66 MS2042AD3-4A 66A MS20426AD3-4A-5



Airline Part Number 1234567Nomenclature .WASHER,FLAT .ROTOR,COMPRESSOR SUPSD BY ITEM 30A PRE SB 21-2068 .ROTOR,COMPRESSOR SUPSDS ITEM 30 POST SB 21-2068 ..PIN,STRAIGHT,HEADLESS ..ROTOR (NP) SUPSD BY ITEM 40A PRE SB 21-2068 ..ROTOR (NP) SUPSDS ITEM 40 POST SB 21-2068 .PACKING,PREFORMED .PIN,SPRING-SPIRAL V00287, HS69917-094M500C SEE NOTE 1 .PIN,SPRING-SPIRAL V00287, HS69917-094M625C SEE NOTE 2 .PLATE,SEAL SUPSD BY ITEM 60A .PLATE,SEAL SUPSDS ITEM 60 SUPSD BY ITEM 60B PRE SB 21-2179 .PLATE,SEAL SUPSDS ITEM 60A POST SB 21-2179 PARTIAL BREAKDOWN FOLLOWS ..SEAL MAKE FROM S750493-4 SUPSD BY ITEM 62A ..SEAL MAKE FROM S750493-4 SUPSD BY ITEM 62B PRE SB 21-2179 ..SEAL SUPSDS ITEM 62A POST SB 21-2179 ..PLATE POST SB 21-2179 ..PLATE, BACKING POST SB 21-2179 ..INSERT DELETED ..RIVET, SOLID



Chg Eff Code Code UPA 1 A 1



8*



BCD E



A



8*



BCD E



1



2 1



1



1 2



2



A



1



3*



BCD



1



16*



E



1



A



1



3*



1



18*



E



1



18*



E



1



18*



E



1 8 4



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1024 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 2 70 -



70A 788077-1 75 80 85



-



Part Number 785813-1



782080-1 69494J262 785796-1



85A 785796-2



90 95



785796-30 785796-20



100



785733-2



- 100A 785733-3



- 100B 785733-5 - 100C 785733-6 - 100D 785733-4



- 100E 785733-5



-



105



RR137S



110



732110-81



111 112 113 114 115 116 117



732110-82 732110-83 732110-84 732110-85 732110-86 732110-87 732110-88



Airline Part Number 1234567Nomenclature .INSULATOR,NOZZLE SUPSD BY ITEM 70A .INSULATOR,NOZZLE SUPSDS ITEM 70 .DISK,SEAL .PACKING,PREFORMED .PLATE AND INSULATOR,NOZZLE SUPSD BY ITEM 85A .PLATE AND INSULATOR,NOZZLE SUPSDS ITEM 85 SEE NOTE 3 PARTIAL BREAKDOWN FOLLOWS ..INSULATOR ..SEAL MAKE FROM S750493-14 .ROTOR,TURBINE SUPSD BY ITEM 100A PRE SB 21-2068 .ROTOR,TURBINE SUPSDS ITEM 100 POST SB 21-2068 SUPSD BY ITEM 100B PRE SB 21-2118 SUPSD BY ITEM 100E PRE SB 21-2179 .DELETED .DELETED .ROTOR,TURBINE SUPSDS ITEM 100A POST SB 21-2118 SUPSD BY ITEM 100E .ROTOR,TURBINE SUPSDS ITEM 100D POST SB 21-2118 SUPSDS ITEM 100A POST SB 21-2179 .RING,RETAINER-INTERNAL V80756, HS69983S137 SUPSD BY ITEM 100C .SHIM (0.020 THK) SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .SHIM (0.022 THK) .SHIM (0.024 THK) .SHIM (0.026 THK) .SHIM (0.028 THK) .SHIM (0.030 THK) .SHIM (0.032 THK) .SHIM (0.034 THK)



Chg Eff Code Code UPA A 1 3*



1



A 3*



1 1 1 1



1 1 A



1



BC



1



14*



D



1 1 1



15



DE



1



8*



1



AR



AR AR AR AR AR AR AR



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1025 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & 2 -



Item 118 119 120 125



Part Number 732110-89 732110-90 732110-91 753602-1



- 125A 753602-2



-



130



732110-81



131 132 133 134 135 136 137 138 139 140 145



732110-82 732110-83 732110-84 732110-85 732110-86 732110-87 732110-88 732110-89 732110-90 732110-91 RR137S



150 155 - 155A - 155B



753391-1 M202HX67 R202B39C3 M202HX67REVC



- 155C RFL1518



-



160



RR137S



165



732110-81



166 167 168 169 170



732110-82 732110-83 732110-84 732110-85 732110-86



Airline Part Number 1234567Nomenclature .SHIM (0.036 THK) .SHIM (0.038 THK) .SHIM (0.040 THK) .SEAL,FACE SUPSD BY ITEM 125A PRE SB 21-2068 SUPSDS ITEM 125A POST SB 21-2179 .SEAL,FACE SUPSDS ITEM 125 POST SB 21-2068 SUPSD BY ITEM 125 PRE SB 21-2179 .SHIM (0.020 THK) SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .SHIM (0.022 THK) .SHIM (0.024 THK) .SHIM (0.026 THK) .SHIM (0.028 THK) .SHIM (0.030 THK) .SHIM (0.032 THK) .SHIM (0.034 THK) .SHIM (0.036 THK) .SHIM (0.038 THK) .SHIM (0.040 THK) .RING,RETAINER-INTERNAL V80756, HS69983S137 .RING,SEAL DELETED DELETED .BEARING,BALL V70854, HS753601-3 .BEARING,BALL V83086, HS753601-3 IDENT. AS MTMER202SD600REVC SUPSDS ITEM 155A .RING,RETAINER-INTERNAL V80756, HS69983S137 .SHIM (0.020 THK) SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .SHIM (0.022 THK) .SHIM (0.024 THK) .SHIM (0.026 THK) .SHIM (0.028 THK) .SHIM (0.030 THK)



Chg Eff Code Code UPA AR AR AR 16* AE 1



8*



BCD



1



AR



AR AR AR AR AR AR AR AR AR AR 1 1 1 1 1 10



1



1 AR



AR AR AR AR AR



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1026 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & 2 -



Item 171 172 173 174 175 180



Part Number 732110-87 732110-88 732110-89 732110-90 732110-91 732160-1



- 181



732160-2



- 182



732160-3



- 183



732160-4



- 184



732160-5



- 185



732160-6



- 186



732160-7



- 187



732160-8



- 188



732160-9



- 189



732160-10



- 190



732160-11



- 191



732160-12



- 192



732160-13



- 193



732160-14



- 194



732160-15



- 195



732160-16



- 196



732160-17



- 197



732160-18



- 198



732160-19



- 199



732160-20



Airline Part Number 1234567Nomenclature .SHIM (0.032 THK) .SHIM (0.034 THK) .SHIM (0.036 THK) .SHIM (0.038 THK) .SHIM (0.040 THK) .BUSHING,SLEEVE,ALUMINUM (0.443 LG) SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .BUSHING,SLEEVE,ALUMINUM (0.446 LG) .BUSHING,SLEEVE,ALUMINUM (0.449 LG) .BUSHING,SLEEVE,ALUMINUM (0.452 LG) .BUSHING,SLEEVE,ALUMINUM (0.455 LG) .BUSHING,SLEEVE,ALUMINUM (0.458 LG) .BUSHING,SLEEVE,ALUMINUM (0.461 LG) .BUSHING,SLEEVE,ALUMINUM (0.464 LG) .BUSHING,SLEEVE,ALUMINUM (0.467 LG) .BUSHING,SLEEVE,ALUMINUM (0.470 LG) .BUSHING,SLEEVE,ALUMINUM (0.473 LG) .BUSHING,SLEEVE,ALUMINUM (0.476 LG) .BUSHING,SLEEVE,ALUMINUM (0.479 LG) .BUSHING,SLEEVE,ALUMINUM (0.482 LG) .BUSHING,SLEEVE,ALUMINUM (0.485 LG) .BUSHING,SLEEVE,ALUMINUM (0.488 LG) .BUSHING,SLEEVE,ALUMINUM (0.491 LG) .BUSHING,SLEEVE,ALUMINUM (0.494 LG) .BUSHING,SLEEVE,ALUMINUM (0.497 LG) .BUSHING,SLEEVE,ALUMINUM (0.500 LG)



Chg Eff Code Code UPA AR AR AR AR AR AR



AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



Page 1027 Mar 01/13



COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 2 - 200



Part Number 732160-21



- 201



732160-22



- 202



732160-25



205



753602-1



- 205A 753602-2



-



210



732110-81



211 212 213 214 215 216 217 218 219 220 225



732110-82 732110-83 732110-84 732110-85 732110-86 732110-87 732110-88 732110-89 732110-90 732110-91 RR137S



230 235 - 235A - 235B



753391-1 M202HX67 R202B39C3 M202HX67REVC



- 235C RFL1518



240



753385-2



- 240A 753385-3 245



570057-6



Airline Part Number 1234567Nomenclature .BUSHING,SLEEVE,ALUMINUM (0.503 LG) .BUSHING,SLEEVE,ALUMINUM (0.506 LG) .BUSHING,SLEEVE,ALUMINUM (0.472 LG) .SEAL,FACE SUPSD BY ITEM 205A PRE SB 21-2068 SUPSDS ITEM 205A POST SB 21-2179 .SEAL,FACE SUPSDS ITEM 205 POST SB 21-2068 SUPSD BY ITEM 205 PRE SB 21-2179 .SHIM (0.020 THK) SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .SHIM (0.022 THK) .SHIM (0.024 THK) .SHIM (0.026 THK) .SHIM (0.028 THK) .SHIM (0.030 THK) .SHIM (0.032 THK) .SHIM (0.034 THK) .SHIM (0.036 THK) .SHIM (0.038 THK) .SHIM (0.040 THK) .RING,RETAINER-INTERNAL V80756, HS69983S137 .RING,SEAL DELETED DELETED .BEARING,BALL V70854, HS753601-3 .BEARING,BALL V83086, HS753601-3 IDENT. AS MTMER202SD600REVC SUPSDS ITEM 235A .SHAFT,DRIVE OPTIONAL TO ITEM 240A .SHAFT,DRIVE OPTIONAL TO ITEM 240 .PIN,STRAIGHT,HEADED SUPSD BY ITEM 245A PRE SB 21-2110



Chg Eff Code Code UPA AR AR AR 16*



AE



1



8*



BCD



1



AR



AR AR AR AR AR AR AR AR AR AR 1 1 1 1 1 10



1



1 19



1 2



Use or disclosure of this data is subject to restrictions on the Title Page of this document.



21-51-53



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COMPONENT MAINTENANCE MANUAL 782790



Fig & Item Part Number 2 - 245A 570057-8



250



753388-1



- 250A 753388-2



-



255



732110-81



256 257 258 259 260 261 262 263 264 265 270



732110-82 732110-83 732110-84 732110-85 732110-86 732110-87 732110-88 732110-89 732110-90 732110-91 753389-3



- 270A 753389-4



275



753387-1



- 275A 753387-2



- 275B 753387-3



- 275C 753387-5



Airline Part Number 1234567Nomenclature .PIN,STRAIGHT,HEADED SUPSDS ITEM 245 POST SB-2110 .SEAT,SPRING SUPSD BY ITEM 250A PRE SB-2110 .SEAT,SPRING SUPSDS ITEM 250 POST SB-2110 .SHIM (0.020 THK) SELECT FROM THIS AND THE FOLLOWING AT ASSEMBLY .SHIM (0.022 THK) .SHIM (0.024 THK) .SHIM (0.026 THK) .SHIM (0.028 THK) .SHIM (0.030 THK) .SHIM (0.032 THK) .SHIM (0.034 THK) .SHIM (0.036 THK) .SHIM (0.038 THK) .SHIM (0.040 THK) .SPRING,COMPRESSION SUPSD BY ITEM 270A PRE SB 21-2067 .SPRING,COMPRESSION SUPSDS ITEM 270 POST SB 21-2067 .SLEEVE,BEARING CARTRIDGE SUPSD BY ITEM 275A PRE SB 21-2068 .SLEEVE,BEARING CARTRIDGE SUPSDS ITEM 275 POST SB 21-2068 SUPSD BY ITEM 275B PRE SB 21-2110 .SLEEVE,BEARING CARTRIDGE SUPSDS ITEM 275A POST SB 21-2110 SUPSD BY ITEM 275C PRE SB 21-2179 .SLEEVE,BEARING CARTRIDGE SUPSDS ITEM 275B POST SB 21-2179



Chg Eff Code Code UPA 11* 2



2



11*



2



AR



A



7*



AR AR AR AR AR AR AR AR AR AR 1



1



A



1



8*



B



1



12*



CD



1



16*



E



1



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COMPONENT MAINTENANCE MANUAL 782790



Fig & Item 2



Part Number



Airline Chg Eff Part Number 1234567Nomenclature Code Code UPA NOTE 1: THE FOLLOWING PART IS AVAILABLE IN ACCORDANCE WITH INSTRUCTIONS IN ASSEMBLY: PN 69917-109M500C SPIRAL SPRING PIN (0.015 OVERSIZE). PN NAS51923-454 SPIRAL SPRING PIN IS OPTIONAL TO PN 69917-109M500C. NOTE 2: THE FOLLOWING PART IS AVAILABLE IN ACCORDANCE WITH INSTRUCTIONS IN ASSEMBLY: PN 69917-109M625C SPIRAL SPRING PIN (0.015 OVERSIZE). PN NAS51923-456 SPIRAL SPRING PIN IS OPTIONAL TO PN 69917-109M625C.



NOTE 3: THE FOLLOWING PART IS AVAILABLE TO SUPPORT REPAIR 7-2: PN 1002315 PLATE, NOZZE (FOR USE WITH A MODIFIED PN 785796-2, PLATE, NOZZLE AND INSULATOR.



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IPL Figure 3. Containment Housing



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Fig & Item 3 1



Part Number 753453-1



5



NAS5903-12



-



5A NAS6003U12 10



-



NAS620-10L



10A NAS620C10L 15



753453-30



20



753453-20



25 30 35 40 45 50 55



69494J154 MS21209F1-10 MS20470AD4-12 MS20470AD4-9 753453-40 732144-2 753453-10



Airline Part Number 1234567Nomenclature HOUSING,CONTAINMENT SEE FIG. 1 FOR NHA CONTAINS MATCHED PARTS .SCREW SUPSD BY ITEM 5A .SCREW SUPSDS ITEM 5 .WASHER SUPSD BY ITEM 10A .WASHER SUPSDS ITEM 10 .LINER MATCHED PART MAKE FROM S753453-30 .RING,CONTAINMENT MATCHED PART .PACKING,PREFORMED .INSERT .RIVET .RIVET .SCREEN,INLET .PIN,STRAIGHT,HEADLESS .HOUSING (NP) MATCHED PART



Chg Eff Code Code UPA RF



3 17*



3 3



17*



3 1



1 1 18 3 4 1 3 1



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4. Configuration Change Summary IPL Table 1. Configuration Change Summary Chg Code



Item Configuration



Service Bulletin



HS Internal Reference



Description



L6



Not Required



145294-1



Basic coverage.



1



L7



21-2039



148771-6



Provided a new stepped pin with a larger OD and a new turbine housing incorporating a stellite bushing to reduce the possibility of wear between the pin and housing.



2



L8



Not Required



155952-3



Relocated the boss for overtemperature switch on compressor housing.



3



L9



Not Required



148154-8



Improved the service life of the turbine rotor by incorporating a new nozzle plate and insulator, nozzle insulator, seal plate, and turbine housing. Added an additional plug and bleeder, preformed packing, chain, spring wire, and cotter pin for the new turbine housing. Reduced the quantity of seal plate screws and washers.



4



L10



Not Required



154711-3



Provided a new warning plate with revised oil maintenance data.



5



L11



Not Required



159751-3



Incorporated a new compressor housing that facilitates manufacturing.



6



L12



Not Required



190632



Incorporated a longer screw to secure the compressor housing to the turbine housing to accommodate a thicker flange of the new cast compressor housing (L11 configuration).



-



782790-6



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IPL Table 1. Configuration Change Summary (Continued) Chg Code



Item Configuration



Service Bulletin



HS Internal Reference



Description



L13



21-2067



197230



Extended the service life of the air cycle machine by (1) incorporating new, more resilient, preformed packings to minimize the chance of bearing cartridge sleeve fretting; (2) incorporating a new compression spring to increase preload on the ball bearings and enhance bearing tracking, and (3) increasing the axial clearance of the turbine and compressor rotors to reduce the possibility of rotor rub.



9



L14



21-2114



221288-1



Changed the nonmetallic wicks to ones that have contoured heads. Changed the springs for the wicks to ones that have a smaller load and length.



11



L15



21-2110



228774



Changed the spring seat and the pins that hold them. The initial pins rubbed the turbine housing.



13



-



Not Required



235058



Replaces a drive screw identification plate with an adhesive backed identification plate.



17



-



Not Required



247819 247819-1



Replaces cadmium plated parts.



19



-



Not Required



239742



Adds an alternate drive shaft part number.



7



782790-6



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IPL Table 2. Configuration Change Summary Chg Code



Item Configuration



Service Bulletin



HS Internal Reference



Description



-



21-2068



197230-1



Improved the damping characteristics of the air cycle machine to increase its service life by (1) incorporating a new bearing cartridge sleeve with reduced OD and increased ID; (2) incorporating new face seals with increased OD to accommodate the increase ID of the sleeve, and (3) incorporating new compressor and turbine rotors with reduced contours to increase clearances and reduce the chance of rotor rub.



9



L14



21-2114



221288-1



Changed the nonmetallic wicks to ones that have contoured heads. Changed the springs for the wicks to ones that have a smaller load and length.



10



-



Not Required



219073



The vendor changed the part number.



11



L15



21-2110



228774



Changed the spring seat and the pins that hold them. The initial pins rubbed the turbine housing.



13



-



Not Required



235058



Replaces a drive screw identification plate with an adhesive backed identification plate.



17



-



Not Required



247819 247819-1



Replaces cadmium plated parts.



19



-



Not Required



239742



Adds an alternate drive shaft part number.



8



782790-10



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IPL Table 3. Configuration Change Summary Chg Code 12



Item Configuration 782790-12



L15



Service Bulletin



HS Internal Reference



Description



21-2110



228774



Changed the drain hole configuration of the bearing cartridge sleeve to make sure that a small quantity of oil stays in the sleeve. Changed the oil sump vent configuration in the turbine housing to prevent a reverse flow condition that was possible in the initial configuration.



13



-



Not Required



235058



Replaces a drive screw identification plate with an adhesive backed identification plate.



17



-



Not Required



247819 247819-1



Replaces cadmium plated parts.



19



-



Not Required



239742



Adds an alternate drive shaft part number.



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IPL Table 4. Configuration Change Summary Chg Code 14



Item Configuration 782790-16



-



Service Bulletin



HS Internal Reference



Description



21-2118



-



Air Cycle Machine PN 782790-16 supersedes Air Cycle Machine PN 782790-12 (rotor dynamics and fuseless turbine rotor improvements).



15



L16



Not Required



238733



Replaces the turbine rotor with one that is made from a forging



17



-



Not Required



247819 247819-1



Replaces cadmium plated parts.



19



-



Not Required



239742



Adds an alternate drive shaft part number.



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IPL Table 5. Configuration Change Summary Chg Code



Item Configuration



Service Bulletin



HS Internal Reference



Description



-



21-2179



245647-1



Air Cycle Machine PN 782790-18 supersedes Air Cycle Machine PN 782790-16 (rotor dynamics and compressor seal plate improvements).



17



-



Not Required



247819 247819-1



Replaces cadmium plated parts.



18



-



21-2179



245647-1



Adds parts for Vespel Seal.



16



782790-18



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