CP23-0-RR-994_Rev_A_Amendment_1_V22_Auxiliary_Power_Unit_System_Test_Section.pdf

debra.m.davis Master Copy

FRC East

FRC Stamp

GTC/PNEUFST/RJW

25 Feb 13

TITLE: Accessory Local Engineering Specification

IDENTIFICATION: CP23-0-RR-994, Revision A, Amendment 1

CLASSIFICATION: Conditional

SYSTEM: V-22 Auxiliary Power Unit

Subj: REPAIR AND TEST CELL CAPABILITY FOR THE HAMILTON SUNDSTRAND T-62T-46-2

AUXILIARY POWER UNIT (APU), BELL BOEING PART NUMBERS (P/N) 901-364-

201-105 AND 901-364-201-107

Ref: None.

Encl: None.

1. Purpose: Supplements Accessory LES CP23-0-RR-994. This amendment incorporates a sealant substitute, adds a clutch input drive shaft inspection and cleaning material, corrects the test procedure for the helical compression spring, P/N 4502471, and adds a new test procedure for the clutch-helical compression spring, P/N 4502215.

2. Cancellation: None.

3. Background Information: None.

4. Application: All T-62T-46-2 Auxiliary Power Units, Bell Boeing P/Ns 901- 364-201-105 and 901-364-201-107, processed at FRC-E Cherry Point.

5. Special Tools and Test Equipment: None

6. Special Materials: None.

7. Effective Date: Immediately upon release.

8. Instructions: Insert the following new paragraphs:

8.13.32 Enclosure (1), SUBTASK 49-21-01-440-001, paragraph F, step (1), sub-step (c), DELETE and REPLACE with the following:

WARNING

ASTM D5363 AN0331 sealants may cause eye and skin irritation. Wear gloves and safety glasses. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

(c) Apply two drops of a retaining compound (PN Loctite 262 or PN TB1363A) 180 degrees apart on the threads of the oil transfer tube (2) (Refer to Figure 1003).

DEPARTMENT OF THE NAVY

NAVAL AIR SYSTEMS COMMAND

RADM WILLIAM MOFFETT BUILDING

47123 BUSE ROAD, BLDG 2272

PATUXENT RIVER, MARYLAND 20670-1547

Accessory LES CP23-0-RR-994, Rev A, Amend 1 Page 2 of 4

8.13.33 Enclosure (1), Subtask 49-26-01-730-001, paragraph C, step (2), INSERT new sub-steps (f) thru (m) as follows:

(f) If the pre-test fails and the calibration fluid is not flowing through the four auxiliary cooling holes, stop test and follow subsequent procedures. If pre-test passed, proceed to Step (3).

(g) Remove Clutch Input Drive Shaft assembly from test fixture.

(h) Use a scribe to manually attempt to push piston in to check for blockage behind the piston.

(i) Disassemble the Clutch Input Drive Shaft per TASK 49-26-01-040-

802, DISASSEMBLY OF THE CLUTCH INPUT DRIVE SHAFT ASSEMBLY.

(j) Visually inspect for blockage or contaminants on the piston, spring, plug and plug threads, and inside of clutch gear.

WARNING

TT-I-735 Isopropyl Alcohol is flammable. Do not use near open flame or other sources of ignition. May irritate skin and eyes. Inhalation may cause dizziness, headaches and irritation to respiratory tract.

Wear chemical splash proof goggles and gloves. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

(k) Remove contaminants with scribe and/or a clean cloth and isopropyl alcohol as required.

(l) Reassemble Input Drive Shaft Assembly IAW TASK 49-26-01-440-802, ASSEMBLY OF THE CLUTCH INPUT DRIVE SHAFT ASSEMBLY.

(m) Redo pre-test IAW ref TASK 49-26-01-730-801, TESTING THE CLUTCH

INPUT DRIVE SHAFT ASSEMBLY.

8.13.34 Enclosure (1), TASK 49-26-01-200-806, SUBTASK 49-26-01-220-005, DELETE and REPLACE with the following:

SUBTASK 49-26-01-220-005

C. VISUAL INSPECTION OF THE HELICAL COMPRESSION SPRING IN THE CLUTCH INPUT

DRIVE SHAFT ASSEMBLY AND THE HELICAL COMPRESSION CLUTCH SPRING IN THE GEARBOX

ASSEMBLY

(1) Do a visual inspection of the helical compression spring (PN 4502471) in the clutch input drive shaft assembly (PN 4502901), and the helical compression clutch spring (PN 4502215) in the gearbox assembly (PN 4503283 Series) as follows:

(a) Examine the helical compression spring and the helical compression clutch spring for nicks, sharp edges, or other stress risers. If nicks, sharp edges, or other stress risers are found, reject the spring.

8.13.35 Enclosure (1), TASK 49-26-01-200-806, Subtask 49-26-01-220-006, DELETE and REPLACE with the following:

SUBTASK 49-26-01-220-006

Accessory LES CP23-0-RR-994, Rev A, Amend 1 Page 3 of 4

D. DIMENSIONAL INSPECTION OF THE HELICAL COMPRESSION SPRING IN THE CLUTCH

INPUT DRIVE SHAFT ASSEMBLY

(1) Do a dimensional inspection of the helical compression spring (PN 4502471) as follows:

NOTE

Load test not required for new springs.

(a) Measure the spring load at 0.717 in (18.21 mm) spring length. If the spring is out of tolerance, reject the spring.

1 If the load is less than 0.95 lb (0.431 kg), reject the spring.

2 If the load is more than 1.05 lb (0.476 kg), reject the spring.

(b) Measure the spring load at 0.617 in (15.67 mm) spring length. If the spring is out of tolerance, reject the spring.

1 If the load is less than 1.23 lb (0.558 kg), reject the spring.

2 If the load is more than 1.35 lb (0.612 kg), reject the spring.

8.13.36 Enclosure (1), TASK 49-26-01-200-806, INSERT new Subtask 49-26-01- 220-007 as follows:

SUBTASK 49-26-01-220-007

E. DIMENSIONAL INSPECTION OF THE HELICAL COMPRESSION CLUTCH SPRING IN THE

GEARBOX ASSEMBLY

(1) Do a dimensional inspection of the helical compression clutch spring (PN 4502215) as follows:

NOTE

Load test not required for new springs.

(a) Measure the spring load at 1.85 in (46.99 mm) spring length. If the spring is out of tolerance, reject the spring.

1 If the load is less than 490 lb (222.26 kg), reject the spring.

2 If the load is more than 510 lb (231.33 kg), reject the spring.

Accessory LES CP23-0-RR-994, Rev A, Amend 1 Page 4 of 4

PREPARED BY: APPROVED BY:

R. J. WANSKER D. M. JEFFERSON

Aerospace Engineer Engineering Technician

GTC/PNEU FST GTC/PNEUFST, (AIR 4.4.4.4)

ISSC-Cherry Point, NC ISSC-Cherry Point, NC

T. M. GALLOWAY

Rotary Wing Sub-Team Lead

GTC/PNEU FST, (AIR 4.4.4.4)

ISSC-Cherry Point, NC

J. A. HOUSTON

V-22 Propulsion and Power Systems Engineering Integrator

(AIR 4.4.1.2)

ISSC-Cherry Point, NC

RELEASED BY:

J. N. WITHERS

V-22 Fleet Support Team Lead By Direction Level I Site Lead (AIR-4.0) ISSC Cherry Point, NC

Materials Engineering Division Review: BSH 01/07/2013

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GTC/PNEUFST/TMG

3 December 2012

TITLE: Accessory Local Engineering Specification

IDENTIFICATION: CP23-0-RR-994, Revision A

CLASSIFICATION: Conditional

SYSTEM: V-22 Auxiliary Power Unit

Subj: REPAIR AND TEST CELL CAPABILITY FOR THE HAMILTON SUNDSTRAND T-62T-46-2

AUXILIARY POWER UNIT (APU), BELL BOEING PART NUMBERS (P/N) 901-364-

201-105 AND 901-364-201-107

Ref: (a) A1-V22AB-TIS-000 1V-22(C) B-2-DB1

(b) LPS CP09-0-BB-8064, Eddy Current (ET) Inspection of Components

(c) LPS CP09-2-J-4267, Procedures for Fluorescent Penetrant

Inspection

(d) NA 01-1A-503, Maintenance of Aeronautical Antifriction Bearings

Encl: (1) T-62T-46-2, Hamilton Sundstrand Engine Manual for the V-22 T-62T- 46-2 Auxiliary Power Unit System, P/N 4501859 (BHTI 901-364-201), dtd June 15, 2006

(2) T-62T-46-2-IPC, Hamilton Sundstrand Illustrated Parts Catalog for the V-22 T-62T-46-2 Auxiliary Power Unit System, P/N 4501859 (BHTI 901-364-201), dtd June 15, 2006

(3) 49-32-20, Hamilton Sundstrand Component Maintenance Manual with Illustrated Parts List, Fuel Control Assembly P/N 4502125A, dtd July 1, 2006

(4) 49-32-21, Hamilton Sundstrand Component Maintenance Manual with Illustrated Parts List, Fuel Pump Assembly P/N 4502126A, dtd July 1, 2006

1. Purpose: The purpose of the basic LES is to authorize Fleet Readiness Center East (FRC-E) Cherry Point to repair and test the T-62T-46-2 APU, Bell Boeing Part Numbers 901-364-201-105 and 901-364-201-107 and their subcomponents.

2. Cancellation: CP23-0-RR-994.

3. Background Information:

3.1 FRC-E Cherry Point has developed the capability to repair, test, and make serviceable the T-62T-46-2 APU, Bell Boeing P/Ns 901-364-201-105 and 901-364-201-107.

3.2 The tooling, hardware, and software necessary to accomplish this capability were designed to meet the requirements outlined by the original equipment manufacturer Hamilton Sundstrand in enclosure (1).

3.3 The basic directive incorporates Temporary Engineering Instruction (TEI) 292292 (air inlet housing metal spray), TEI 292293 (oil coolers flush

DEPARTMENT OF THE NAVY

NAVAL AIR SYSTEMS COMMAND

RADM WILLIAM MOFFETT BUILDING

47123 BUSE ROAD, BLDG 2272

PATUXENT RIVER, MARYLAND 20670-1547

debra.m.davis FRC Stamp

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 2 of 19 procedure), TEI 294642 (bearing re-certification), LES CP23-0-NN-550 Amendment 1; adds service intervals for life-limited components;

updates/clarifies various APU assembly and inspection procedures; and adds some P/Ns not illustrated in enclosure (2).

3.4 Revision A updates fluorescent penetrant inspection (FPI) specifications, updates life limit tables, adds tooling P/Ns and procedures, adds a gearbox cover and an exhaust cover, adds repairs for bosses/fittings on the inseparable combustor housing assembly, clarifies removal procedure for retaining ring from quill shaft, corrects the specification for calibrating fluid used in the clutch gear flow-test, and updates the Illustrated Parts Catalog.

4. Application: All T-62T-46-2 Auxiliary Power Units, Bell Boeing P/Ns 901- 364-201-105 and 901-364-201-107, processed at FRC-E Cherry Point.

5. Special Tools and Test Equipment:

5.1 Weetech Model W629 or an equivalent electronic component tester

5.2 CNC Program No. 4504731A_(11), located in Manufacturing Machine Shop, Bldg 137

5.3 Heat Exchanger Leak Test Fixture (96916) 18D9808-3

5.4 Ball Bearing Flange Puller (55820) AID-00212

5.5 Adapter (96919) 18C10455-1

5.6 V-22 APU (Gearbox) Cover (96916) 18D10141-1

6. Special Materials: None.

7. Effective Date: Immediately upon release.

8. Instructions:

8.1 T-62T-46-2 APUs, Bell Boeing P/Ns 901-364-201-105 and 901-364-201-107, that meet the requirements set forth in enclosures (1) and (2) will be considered serviceable.

8.2 Repair and test all T-62T-46-2 APU Fuel Controls, P/N 4502125A, in accordance with enclosures (3) and (4).

8.3 All T-62T-46-2 APU Fuel Controls, P/N 4502125A, which meet the requirements set forth in enclosures (3) and (4), will be considered serviceable.

8.4 Reference (a) is an organizational level Fleet publication maintained and updated by the aircraft original equipment manufacturer. Reference (a) may be used as a supplement for shop and test cell troubleshooting and repair procedures.

8.5 The preferred APU container is P/N 623E001.

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 3 of 19

8.6 An electronic component tester (paragraph 5.1), may be utilized to electrically check the APU harness, sensors, and/or test and reset start and hour meters upon induction and final assembly.

WARNING

MIL-PRF-23699 Lubricating Oil can irritate skin or eyes upon contact. May contain a neurotoxin that can be absorbed through the intact skin. Symptoms of overexposure include tingling or numbness in hands or feet. Wear nitrile gloves, chemical protective goggles. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

NOTE

Engineering has documented the galling of stainless tubing during the removal and assembly of tubing from the APU.

8.7 To ease in the installation of all tubing per enclosure (1), apply a light coat of MIL-PRF-23699 lubricating oil.

8.8 In addition to inspections required by enclosure (1), inspect the Top Mount (P/N 4503203), Side Mount (P/N 4503205), Lifting Eye (P/N 4502524), and Eye Bolt (P/N AN45C4A), as follows:

8.8.1 For APUs inducted for Check and Test, prior to loading APU into test cell, eddy current inspect parts for cracks in the areas identified as per reference (b). Focus on the area around the larger holes in each of the brackets used to mount the APU and lift it in and out of the aircraft.

WARNING

ASTM E 1417 Fluorescent Penetrant materials may cause irritation to skin and eyes. Avoid inhaling powder or vapors, and use only in well-ventilated area. Avoid prolonged or repeated contact with skin. Wear nitrile gloves and safety glasses. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

8.8.2 For APUs inducted for Overhaul, fluorescent penetrant inspect parts in accordance reference (c) using Type I, Method D, Sensitivity Level 4 materials.

8.9 The following Air Inlet Housing, P/N 4504732A, metal-spray procedures shall be used in conjunction with enclosure (1):

8.9.1 Manufacture a bulk supply of Spacer, P/N 18D9515, to be used for the metal spray process repair. Place spacer inside the air inlet housing during processing, and machine out during the finish machine process.

Discard spacer after each use.

8.9.2 Prior to routing of the Air Inlet Housing, P/N 4504732A, wrap in bubble wrap or suitable substitute and place housing in a cardboard box for protection.

8.9.3 Water-strip the abradable coating from the small sealing bore and contour. Prevent damage to the bearing bore, located under the small

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 4 of 19 abradable coated sealing bore, by using the holding fixture and other appropriate materials.

8.9.4 Vapor-degrease housing in accordance with enclosure (1).

8.9.5 Use the holding fixture and the Spacer, P/N 18D9515, to protect the air inlet housing bearing bore, located under the small abradable coated sealing bore, and other non-sprayed surfaces. Use of other appropriate material to accomplish this task is permitted.

8.9.6 Metal-spray the sealing bore and radius per enclosure (1).

8.9.7 Carefully remove material used to protect surfaces from unwanted metal spray, with the exception of the Spacer, P/N 18D9515.

8.9.8 Machine the air inlet housing sealing bore and compressor contour, utilizing the CNC program specified in paragraph 5.2. If any discrepancies with the metal-spray process appear during finish machining, both the sealing bore and compressor contour must be reprocessed.

WARNING

TT-I-735 Isopropyl Alcohol is flammable. Do not use near open flame or other sources of ignition. May irritate skin and eyes.

Inhalation may cause dizziness, headaches and irritation to respiratory tract. Wear chemical splash proof goggles and gloves. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

8.9.9 Route the air inlet housing to the APU assembly shop for flow check and/or cleaning.

8.9.9.1 Flow isopropyl alcohol through the two large oil

passages and bearing bore passage; ensure there is a free flow of alcohol through the bores.

8.9.9.2 Wipe residue with a clean, dry towel and allow housings to completely dry.

8.10 The following flush-cleaning procedures apply to Air/Oil Cooler, P/N 4950929, Heat Exchanger, P/N 4951192, and Oil Cooler, P/N 4951074. This is an on-condition process (as required).

WARNING

MIL-PRF-680 Dry Cleaning Solvent may cause eye and skin irritation. Over exposure may cause dizziness and other central nervous system effects. Wear nitrile gloves and chemical protective goggles. Dry-cleaning solvent is manufactured by several companies, and its composition varies. Therefore, it is very important that you consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

8.10.1 Flush clean air/oil cooler, heat exchanger, and oil cooler with dry cleaning solvent until solvent flow is clear and particle free.

8.10.2 For the Heat Exchanger, P/N 4951192:

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 5 of 19

8.10.2.1 Remove and retain the 5 ea attaching screws, for the shield, from around the oil radiator; retain the screws.

8.10.2.2 Use Heat Exchanger Leak Test Fixture (paragraph 5.3) to pressurize the heat exchanger; do not exceed 20 psig. O-rings for the fixture are M83248-1-012 and M83248-1-019.

8.10.2.3 Once pressurized, place heat exchanger underwater to look for bubbles or signs of leaks. Leaking heat exchangers shall be placed on MRB for disposition.

8.10.2.4 Clean oil radiator coils and underside of the shield.

Re-attach the shield with the 5 ea screws.

8.10.3 Remove excess cleaning solvent from the air/oil cooler using clean, compressed air.

WARNING

MIL-PRF-32033 (formerly VV-L-800) General purpose lubricating oil may irritate skin or eyes. PPE: rubber gloves and safety glasses. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

8.10.4 Apply a protective light coat of lubricating oil to the interior and exterior surfaces of the air/oil cooler, heat exchanger, and oil cooler.

8.10.5 Cap all oil ports and protect each component prior to routing.

8.11 The following bearing re-certification process applies to the APU bearings listed in Table 3. This is an on-condition process (as required).

NOTE

APU bearings are frequently in a supply shortage. The following instructions provide a cleaning and dimensional verification process.

8.11.1 Upon induction, if inspection of the APU reveals signs of metal contamination, bearings are not to be considered for a re-certification.

8.11.2 During disassembly, if it is noticed that the APU bearings have been previously re-certified by markings on individual bearings, those bearings shall not be re-certified.

8.11.3 Individually bag each bearing as referenced in Table 3. Do not route individually bagged bearings through a bulk cleaning process.

8.11.4 Inspect bearings for evidence of thermal discoloration or other damage. If thermal discoloration or other damage has accrued, bearings are not to be considered for re-certification. APU bearings that have been previously re-certified by markings on individual bearings shall not be re-certified.

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 6 of 19

8.11.5 Generate a routing document for each bearing (include P/N on the document). If legible, include the serial number and lot number.

8.11.6 Protect and route bearings to Bearing Shop for cleaning and inspection.

8.11.7 Clean and dimensionally inspect all bearings listed in Table 3 per reference (d) and available drawings.

8.11.8 Scrap all bearings that do not meet reference (d) or print specifications. All scrapped bearings and all paperwork are to be returned to the V-22 APU Production Controller.

8.11.9 The Bearing Shop shall not order new bearings to replace scrapped bearings. Instead, return router document and bearings to V-22 APU Production Controller.

8.11.10 Annotate in the APU final assembly shop database whether or not the APU was made RFI with re-certified bearings.

Table 3. V-22 Auxiliary Power Unit Bearings

Bearing Part Number

Manual Index Number

Units Per Assy

Next Higher Assy 4950821 60 6 Reduction Drive Assembly 4502138 170 1 Turbine Assembly 5908613 455 2 Gearbox Assembly 4950806 475 2 Gearbox Assembly 4951259 565 1 Gearbox Assembly 4950807 620 1 Gearbox Assembly 169640-1 665 2 Gearbox Assembly 4950808 720 1 Gearbox Assembly 4950817 730 / 740 2 Gearbox Assembly

8.12 SM&R codes for parts coded as consumable are provided in Table 4.

Table 4. SM&R Codes

Part Name Part Number SM&R Code Fuel Pump 4502126A PADZZ Fuel Nozzle Assembly 4501970 PAOZZ Start Fuel Nozzle Assembly 4503218 PAOZZ Chamber Assembly, Combustor 4503169 PADZZ Nozzle Assembly, Turbine 4502289C PADZZ Seal Plate Assembly 171762-100 PADZZ Diffuser, Compressor 4502945 PADZZ Impeller Assembly, Compressor 4502085 PADZZ Wheel, Turbine 4502082 PADZZ Shaft Assembly, Input Drive Clutch 4502901 PADZZ Carrier Assembly, Epicyclic Gear 4503479 PADBZ

8.13 Repair and test all T-62T-46-2 APUs, Bell Boeing P/Ns 901-364-201-105 and 901-364-201-107, in accordance with enclosure (1) with the following exceptions:

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 7 of 19

8.13.1 Enclosure (1), AIRWORTHINESS, Page 1, paragraph 1.A, Table 1 (Hard Time Requirements), delete and replace with the following:

Table 1. Hard Time Requirements

Component Age Turbine Wheel 10,000 Cycles Compressor Impeller Wheel 10,000 Cycles

8.13.2 Enclosure (1), AIRWORTHINESS, Page 1, paragraph 1.A, step (1), sub-step (c), delete and replace with the following:

NOTE

The following may be accomplished by utilizing the Weetech Model W629 (paragraph 5.1) or a suitable power supply.

(c) When the APU or one of the listed components in the Hard Time Requirements table is replaced, the Assembly Service Record (ASR) card assigned to that particular APU S/N shall be updated, along with the APU shop electronic database. In addition, the APU start and hour meters must accurately reflect the time and cycles on the rotor assembly before the APU enters the test cell and/or is made serviceable.

8.13.3 Enclosure (1), AIRWORTHINESS, Page 1, paragraph 1.A, step (2), delete and replace with the following:

(2) Service Time Limits

(a) At each overhaul, the maximum cycles allowed for re-installing a used wheel is defined in Table 2.

Table 2. Service Time Limits

Component Age Turbine Wheel 6,700 Cycles Compressor Impeller Wheel 6,700 Cycles

8.13.4 Enclosure (1), add (Engine Harness Assembly) P/N 4506365A to the following sections:

Installation: Task 49-15-01-430-801, paragraph 1 (INSTALLATION OF THE ENGINE HARNESS ASSEMBLY), step A, sub-step 1.

Disassembly: Task 49-15-01-000-801, paragraph 1 (DISASSEMBLY THE ENGINE HARNESS ASSEMBLY CONNECTORS), step A, sub-step 1; Task 49-15-01-000-801, paragraph 1 (DISASSEMBLY THE ENGINE HARNESS ASSEMBLY CONNECTORS), step C, sub-step 1, sub-sub-step d.

Cleaning: Task 49-15-01-140-801, paragraph 1 (CLEANING OF THE ENGINE HARNESS ASSEMBLY), step A, sub-step 1.

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 8 of 19

Inspection/Check: Task 49-15-01-220-801, paragraph 1 (INSPECTION/CHECK OF THE ENGINE HARNESS ASSEMBLY), step A, sub-steps 1 and 2.

Repair: Task 49-15-01-350-801, paragraph 1 (REPAIR OF THE ENGINE HARNESS ASSEMBLY), step A, sub-steps 1, 2, and 3.

Assembly: Task 49-15-01-440-801, paragraph 1 (ASSEMBLY OF THE ENGINE HARNESS ASSEMBLY), step A, sub-step 1; Task 49-15-01-440-801, paragraph 1 (ASSEMBLY OF THE ENGINE HARNESS ASSEMBLY), step C, sub-step 1(d).

Testing: Task 49-15-01-750-801, paragraph 1 (TESTING OF THE ENGINE HARNESS ASSEMBLY), step A, sub-steps 1 and 2.

8.13.5 Enclosure (1), TASK 49-24-01-220-801 paragraph 1 (INSPECTION OF THE INSEPARABLE COMBUSTOR HOUSING ASSEMBLY), SUBTASK 49-24-01-220-010, step C

(VISUAL/DIMENSIONAL INSPECTION OF THE INSEPARABLE COMBUSTOR HOUSING

ASSEMBLY), insert sub-step (7) as follows:

(7) Examine the bosses and drain pan tee for damage as follows:

(a) Cracks: None allowed. (Refer to REPAIR)

(b) Nicks and Dents: Minor nicks and dents on the body (not the threads) are permitted, provided they do not distort the fitting relative to the combustor housing nor interfere with the mating part. Otherwise, replacement of the fitting is required. (Refer to REPAIR)

(c) Threads: To the extent feasible, minor thread damage may be chased with an appropriate tap. Otherwise, replacement of the fitting is required. (Refer to REPAIR)

(d) Looseness/Lack of Braze or Tack Weld: Re-tack/re-braze or replace fitting. (Refer to REPAIR)

8.13.6 Enclosure (1), TASK 49-24-01-230-801, paragraph 1.C

(PROCEDURE), step (2), sub-steps (a) and (b), delete and replace with the following:

WARNING

ASTM E 1417 Fluorescent penetrant materials may cause irritation to skin and eyes. Avoid inhaling powder or vapors, and use only in well-ventilated area. Avoid prolonged or repeated contact with skin. Wear nitrile gloves and safety glasses. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

(a) Fluorescent penetrant inspect parts with reduced backgrounds on castings, weldments, and machined non-critical details (such as bearing supports, forward seal plate, labyrinth seal, anti-rotation ring) using Type I, Sensitivity Level 1 (or greater) materials as per reference (c).

WARNING

ASTM E 1417 Fluorescent penetrant materials may cause irritation to skin and eyes. Avoid inhaling powder or vapors, and use only in well-ventilated area. Avoid prolonged or repeated contact with skin. Wear nitrile gloves and safety glasses. Consult the

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 9 of 19 applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for additional information.

(b) Fluorescent penetrant inspect machined, highly stressed parts (such as tie bolt nuts and rotor shaft spacers) using Type I, Sensitivity Level 3 materials as per reference (c).

8.13.7 Enclosure (1), TASK 49-24-01-310-802, paragraph 1, delete and replace with the following:

1. REPAIR OF THE INSEPARABLE COMBUSTOR HOUSING ASSEMBLY: FUEL DISCHARGE PORT

BOSS, GEARBOX VENT BOSS, AND FUEL-DRAIN PAN TEE (REFER TO FIGURES 1 AND 2 FOR

LOCATION).

A. PREREQUISITES

(1) The inseparable combustor housing assembly must be inspected IAW enclosure (1). (Refer to Task 49024-01-220-801, INSPECTION OF THE

INSEPARABLE COMBUSTOR HOUSING ASSEMBLY).

B. CONSUMABLES, TOOLS, AND EQUIPMENT

(1) Consumables

NOTE: Equivalent substitutes may be used for the items listed except when noted otherwise.

Table 1. Consumables

CONSUMABLE SOURCE (CAGE)

AMS 4777 Nickel Brazing Alloy Commercially Available AMS 5798 Welding Wire Commercially Available NICROBRAZ WHITE Stopoff Brazing Coating

Wall Colmonoy Corporation (63585)

ASTM D770 Isopropyl Alcohol Commercially Available

(2) Tools: Common hand tools as required.

(3) Equipment

NOTE: Equivalent substitutes may be used for the items listed except when noted otherwise.

Table 2. Equipment

EQUIPMENT SOURCE (CAGE)

Pocket Magnifier 10 X Commercially Available Abrasive Wheel Commercially Available

(4) Expendable Parts

Table 3. Expendable Parts

PART NO. NOMENCLATURE SOURCE (CAGE) THRU-HOLE

4502324 Boss, Fuel Discharge Port Local Fabrication 0.3280 IN. MAX 4502325 Boss, Gearbox Vent Local Fabrication 0.6720 IN. MAX 4502990 Tee, Fuel-Drain Pan Hamilton Sundstrand 0.3280 IN. MAX

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 10 of 19

(55820)

C. PROCEDURE

(1) Repair the boss(s) or drain pan tee on the inseparable combustor housing assembly as follows:

(a) Remove damaged fitting per the following:

CAUTION

DO NOT CUT OR GRIND INTO THE PARENT MATERIAL OF THE INSEPARABLE

COMBUSTOR HOUSING ASSEMBLY MORE THAN 0.010 INCH (0.254 MM) OR THE

HOUSING ASSEMBLY WILL BE DAMAGED.

1. Machine or hand-grind the boss(s) or drain pan tee from the inseparable combustor housing assembly. Thru-hole diameter on the combustor housing (for removing the damaged fitting) shall be per Table 3. Grind locally to remove any residual braze alloy.

NOTE

Heating the housing assembly in a furnace may result in the melting/removal of all nickel alloys on the housing. This will require re-brazing of the entire assembly.

2. In lieu of machining/grinding, if desired, heat the inseparable combustor housing assembly in a vacuum furnace at 2000°F for 5 to 7 minutes to remove damaged fitting.

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

SUE 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.

(b) Use isopropyl alcohol and a clean cloth to wipe clean the machined/grinded area.

(c) Position the replacement fitting on the inseparable combustor housing assembly as follows:

NOTE

Average tack shall be 0.03-0.12 inch (0.762-3.048 mm) long.

Penetration shall not exceed 0.100 inch (2.54 mm) diameter.

Maximum gap prior to brazing is 0.006 in. (0.152 mm).

1. Position the boss(s) onto the inseparable combustor housing assembly in the original location of the removed fitting (refer to Figure 1).

Hold in place with ARC tack welds.

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 11 of 19

CAUTION

DRAIN PAN TEE SHALL NOT BE POSITIONED PARALLEL TO THE COMBUSTOR

HOUSING CENTERLINE. FAILURE TO POSITION TEE AT THE REQUIRED

ANGLE WILL RESULT IN INABILITY TO CONNECT THE AIRCRAFT DRAIN HOST

FITTING.

2. Position the drain pan tee onto the drain pan in the original location of the removed fitting (refer to Figure 2). Hold in place with ARC tack welds.

(d) Apply stopoff within 0.25 in. (6.3 mm) of the joints on the fitting.

(e) Vacuum furnace braze in accordance with AMS 2675 and the following:

1. Apply braze (AMS 4777) to the outer edges of the boss(s) or drain pan tee as required.

2. Vacuum furnace braze at 1925 to 1975°F (1052 to 1079°C) for 5 to 7 minutes.

(f) Clean the stopoff from the inseparable combustor housing assembly.

(g) Do an inspection of the repaired areas of the inseparable combustor housing assembly (refer to INSPECTION).

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 12 of 19

Figure 1. Combustor Housing Assembly Fuel Discharge Port Boss and Gearbox Vent Boss Repair

Figure 2. Combustor Housing Assembly Fuel-Drain Pan Tee Repair

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 13 of 19

8.13.8 Enclosure (1), Subtask 49-25-01-030-001, paragraph C, step 1, sub-step (f), delete and replace with the following:

(f) Remove the retaining ring (2) that secures the pinion (3) to the quill shaft (7) by inserting a 7/8-inch socket to fit around the quill shaft.

Use a press to push down the socket. Once pinion (3) and retaining ring (2) are pushed down the quill shaft (7), remove retaining ring (2).

8.13.9 Enclosure (1), TASK 49-25-01-030-801, paragraph 1, sub-paragraph B, step (2), Table 501 (Tools), add the following entries:

TOOL SOURCE (CAGE)

AID-00212 Ball Bearing Flange Puller Hamilton Sundstrand (55820) 18C10455-1 Adapter FRCE Cherry Point (96916)

8.13.10 Enclosure (1), TASK 49-25-01-030-801, paragraph 1, sub-paragraph B, step (4), add the following illustration to Figure 501 (Illustrated Tools and Equipment):

AID-00212

Ball Bearing Flange Puller

8.13.11 Enclosure (1), SUBTASK 49-25-01-030-005, paragraph D, step (1), sub-step (d), delete and replace with the following:

(d) Use ball bearing flange puller (AID-00212) to remove outer race of the thrust ball bearing (17) from the inseparable air inlet housing assembly (30).

8.13.12 Enclosure (1), TASK 49-25-01-160-801, paragraph 1.A

(PREREQUISITES), step (1), delete and replace with the following:

(1) The compressor diffuser (PN 4502945 or 4507140) must be removed from the turbine assembly (PN 4502240D) (Refer to SUBTASK 49-25-01-030-007-0, REMOVE THE COMPRESSOR DIFFUSER).

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 14 of 19

8.13.13 Enclosure (1), TASK 49-25-01-160-801, paragraph 1.C

(PROCEDURE), step (1), delete and replace with the following:

(1) Clean the compressor diffuser (PN 4502945 or 4507140) (Refer to

TASK 49-25-01-100-801, CLEANING OF ALUMINUM PARTS).

8.13.14 Enclosure (1), SUBTASK 49-22-01-220-002, paragraph E

(DIMENSIONAL INSPECTION), step (1), sub-step (d), insert new sub-sub-step 5A after sub-sub-step 5 as follows:

5A Air Inlet Housings which show a wear pattern through the abradable coating shall not exceed 30% of the contour diameter. Housings exceeding this limit shall be placed on the Material Review Board.

8.13.15 Enclosure (1), TASK 49-25-01-300-801, paragraph 1.C

(PROCEDURE), step (1), sub-step (c), delete and replace with the following:

(c) Repair a compressor diffuser (PN 4502945 or 4507140) (Refer to TASK 49-25-01-300-802, REPAIR OF THE COMPRESSOR DIFFUSER).

8.13.16 Enclosure (1), TASK 49-25-01-300-802, paragraph 1.A

(PREREQUISITES), steps (1), (2), and (3), delete and replace with the following:

(1) The compressor diffuser (PN 4502945 or 4507140) must be removed from the turbine assembly (PN 4502240) (Refer to TASK 49-25-01-030-801, DISASSEMBLY OF THE TURBINE ASSEMBLY).

(2) The compressor diffuser (PN 4502945 or 4507140) must be clean (Refer to TASK 49-25-01-160-801, CLEANING OF THE COMPRESSOR DIFFUSER).

(3) The compressor diffuser (PN 4502945 or 4507140) must be inspected (Refer to TASK 49-25-01-220-802, INSPECTION OF THE COMPRESSOR DIFFUSER).

8.13.17 Enclosure (1), TASK 49-25-01-530-801, paragraph 1, sub-paragraph B, step (1), Table 1201 (Consumables), add the following entry:

CONSUMABLE SOURCE (CAGE)

4952958 Exhaust Cover Commercially Available

8.13.18 Enclosure (1), TASK 49-25-01-530-801, paragraph 1.C

(PROCEDURE), step (1), sub-step (c), delete and replace with the following:

(c) Install the air inlet cover (PN 4952213) around the air inlet screen assembly (PN 4502296 or 4506558 or 4507530).

8.13.19 Enclosure (1), SUBTASK 49-25-02-000-001, paragraph C

(DISASSEMBLE THE ROTOR ASSEMBLY), step (1), sub-step (a), delete and replace with the following:

(a) Use the rotor tie rod nut wrench aid (P/N TM90338) and the rotor stretch tool (P/N TM90285) to remove the tie bolt (2) from the rotor assembly (1). Apply 7,360 to 7,500 lb-in (831.68 to 847.50 N.m or 2,666 to 2,717 psi) to turn the tie bolt.

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 15 of 19

8.13.20 Enclosure (1), SUBTASK 49-25-02-000-002, paragraph D (REMOVAL MARKING OF TIME AND CYCLES), step (1), sub-steps (d) and (e), delete and replace with the following:

(d) The turbine wheel should be evaluated at each removal of the rotor from the APU unless it has accumulated fewer than 1,000 cycles or accumulated fewer than 1,000 cycles since the last time it was checked at depot.

(e) The compressor wheel should be evaluated at each removal from the APU unless it has accumulated fewer than 1,000 cycles or accumulated fewer than 1,000 cycles since the last time it was checked at depot.

8.13.21 Enclosure (1), SUBTASK 49-25-02-280-250, paragraph D

(FREQUENCY INSPECTION), step (1), sub-step (a), delete and replace with the following:

(a) Measure the first mode frequency of the long compressor impeller blade. Each compressor impeller blade shall have a first mode frequency between 2,950 Hz and 3,550 Hz. If any blade is out of tolerance, discard the compressor impeller.

8.13.22 Enclosure (1), SUBTASK 49-25-02-440-001, paragraph C (PARTIAL ASSEMBLY OF THE ROTOR ASSEMBLY), step (1), sub-step (f), sub-sub-step 4, delete and replace with the following:

4 Use the rotor stretch tool (P/N TM90285) and the rotor tie rod nut wrench aid (P/N TM90338) to stretch the tie bolt with 7,350 to 7,490 lb-in (831.68 to 847.50 N.m) of force or 2,663 to 2,714 psi.

8.13.23 Enclosure (1), SUBTASK 49-25-02-040-001, paragraph D

(DISASSEMBLE THE ROTOR ASSEMBLY), step (1), sub-step (b), sub-sub-step 2, delete and replace with the following:

2 Use the rotor stretch tool (PN TM90285) and the rotor tie rod nut wrench aid (PN TM90338) to stretch the tie bolt with 7,360 to 7,500 lb-in (831.68 to 847.50 N.m) or 2,666 to 2,717 psi of force.

8.13.24 Enclosure (1), SUBTASK 49-25-02-440-002, paragraph E (FINAL ASSEMBLY OF THE ROTOR ASSEMBLY), step (1), sub-step (e), sub-sub-step 2, delete and replace with the following:

2 Use rotor tie rod nut wrench aid (P/N TM90338) and the rotor stretch tool (P/N TM90285) to pre-stretch the tie bolt with 4,000 lbs-in (1,814.37 kg) of force or 1,449 psi.

8.13.25 Enclosure (1), SUBTASK 49-25-02-440-002, paragraph E (FINAL ASSEMBLY OF THE ROTOR ASSEMBLY), step (1), sub-step (g), sub-sub-step 2, delete and replace with the following:

2 Use the rotor tie rod nut wrench aid (P/N TM90338) and the rotor stretch tool (P/N TM90285) to stretch the tie bolt with 7,360 to 7,500 lb-in (831.68 to 847.50 N.m) or 2,666 to 2,717 psi.

8.13.26 Enclosure (1), TASK 49-26-01-030-801, paragraph 1, sub-paragraph B, step (2), Table 502 (Tools), add the following entry:

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 16 of 19

TOOL SOURCE (CAGE)

AID-00212 Ball Bearing Flange Puller

Hamilton Sundstrand (55820)

18C10455-1 Adapter FRCE Cherry Point (96916)

8.13.27 Enclosure (1), SUBTASK 49-26-01-030-024, paragraph AD, step (1), sub-step (b), delete and replace with the following:

(b) Use ball bearing flange puller (AID-00212) to remove the inseparable starter flange assembly (60) from the gearbox housing assembly (110).

8.13.28 Enclosure (1), SUBTASK 49-26-01-030-029, paragraph AI, step (1), sub-step (b), delete and replace with the following:

(b) Use ball bearing flange puller (AID-00212) and adapter (18C10455-1) to remove the inseparable fuel pump adapter assembly (31) from the gearbox housing assembly (110).

8.13.29 Enclosure (1), SUBTASK 49-26-01-550-801, paragraph B, step (2), Tools, add the following entry:

TOOL SOURCE (CAGE)

18D10141-1 V-22 APU (Gearbox) Cover

FRCE Cherry Point (96916)

8.13.30 Enclosure (1), SUBTASK 49-26-01-730-801, paragraph B, step (1), Table 1301 (Consumables), correct from “MIL-C-7024 Type II Calibrating Fluid” to “MIL-PRF-7024 Type II Calibrating Fluid”.

8.13.31 Enclosure (1), SUBTASK 49-26-01-730-801, paragraph C, step (2), sub-step (a), delete and replace with the following:

(a) Turn on the supply line to the calibration fluid (PN MIL-PRF- 7024 Type II).

8.14 Comply with the Illustrated Parts Catalog (IPC), enclosure (2), with the following exceptions:

8.14.1 Enclosure (2), ALPHANUMERICAL INDEX, Pages 1-13, add the following in numerical order:

PART NUMBER AIRLINE

PART NO.

CH-SECT-UNIT FIG ITEM TTL

REQ

4505700 49-24-01 1 150 2 4507140 49-25-01 1 240A 1 4507530 49-20-01 1 988B 1

8.14.2 Enclosure (2), NUMERICAL INDEX, Pages 6-8, add the following in numerical order:

PART NUMBER AIRLINE

PART NO.

CH-SECT-UNIT FIG ITEM TTL

REQ

4502349C 49-20-01 1 365C 1

4506365A 49-15-01 1 1B RF

49-20-01 1 175B 1

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 17 of 19

8.14.3 Enclosure (2), section 49-15-01, Fig. 1, Page 3, delete FIG.

ITEM -1A and replace with the following:

FIG.

ITEM

PART

NUMBER

AIRLINE

PART

NUMBER 1 2 3 4 5 6 7 NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

-1B 4506365A HARNESS ASSEMBLY, ENGINE

(FOR NHA SEE IPC 49-20-01

FIG. 1, ITEM 175B)

B RF

8.14.4 Enclosure (2), section 49-20-01, Fig. 1, Page 19, delete FIG.

ITEM -810 and replace with the following (add NOTE 1 at the end of Fig. 1):

FIG.

ITEM

PART

NUMBER

AIRLINE

PART

NUMBER NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

810NOTE 1 4506522 . TOOL, RETAINING – PLASTIC SEAL 1

NOTE 1

Retaining Tool (810) is an integral part of the gearbox assembly.

Its purpose is to prevent damage to the Ring Seal (805) during assembly.

8.14.5 Enclosure (2), section 49-20-01, Fig. 1, Pages 11-21, delete FIG. ITEM’s -175A, -365B, -988A, and replace with the following:

FIG.

ITEM

PART

NUMBER

AIRLINE

PART

NUMBER NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

-175A 4506365 HARNESS ASSEMBLY, ENGINE

(FOR DETAILS SEE IPC 49-15-01

FIG. 1, ITEM 1A)

B,C,D,E 1

-175B 4506365A HARNESS ASSEMBLY, ENGINE

(FOR DETAILS SEE IPC 49-15-01

FIG. 1, ITEM 1B)

E 1

-365B 4502349B . TUBE ASSEMBLY, AIR – GEARBOX

VENT TO FLAME ARRESTOR

(SUPSD BY ITEM 365C)

D,E 1

-365C 4502349C . TUBE ASSEMBLY, AIR – GEARBOX

VENT TO FLAME ARRESTOR

(SUPSDS ITEM 365B)

E 1

-988A 4506558 . SCREEN ASSEMBLY, AIR INLET

(SUPSD BY ITEM 988B)

B,C,D,E 1

-988B 4507530

MS9556-07

. SCREEN ASSEMBLY, AIR INLET

(SUPSDS ITEM 988A)

. BOLT, MACHINE

B,C,D,E

B,C,D,E

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 18 of 19

8.14.6 Enclosure (2), section 49-24-01, Fig. 1, Page 4, delete FIG. ITEMS 150 and 170, and replace with the following:

FIG.

ITEM

PART

NUMBER

AIRLINE

PART

NUMBER NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

150 4500145 . GASKET, MANIFOLD – START FUEL

(SUPSD BY ITEM 150A)

-150A 4505700 . GASKET, MANIFOLD – START FUEL

(SUPSDS ITEM 150)

170 4500145 . GASKET, MANIFOLD – START FUEL

(SUPSD BY ITEM 170A)

-170A 4505700 . GASKET, MANIFOLD – START FUEL

(SUPSDS ITEM 170)

8.14.7 Enclosure (2), section 49-25-01, Fig. 1, Page 4, delete FIG.

ITEM 240 and replace with the following:

FIG.

ITEM

PART

NUMBER

AIRLINE

PART

NUMBER NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

240 4502945

NAS561C5-8

. DIFFUSER, COMPRESSOR –

MACHINED (SUPSD BY ITEM 240A)

.. PIN, SPRING

-240A 4507140

NAS561C5-8

. DIFFUSER, COMPRESSOR –

MACHINED (SUPSDS ITEM 240)

.. PIN, SPRING

8.14.8 Enclosure (2), section 49-26-01, Fig. 1, Page 10, delete FIG.

ITEM 110 and replace with the following:

FIG.

ITEM PART NUMBER

AIRLINE

PART

NUMBER NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

110 4951073

AS3209-218

. OIL FILL ASSEMBLY

.. O-RING

8.14.9 Enclosure (2), Section 49-26-01, Fig. 1, Page 15, FIG. ITEM 685, delete P/N MS9489-13 and replace with MS9489-14.

Accessory Local Engineering Specification, CP23-0-RR-994, Rev. A Page 19 of 19

PREPARED BY: APPROVED BY:

T. M. GALLOWAY T. M. GALLOWAY

Aerospace Engineer Rotary Wing Sub-Team Lead

GTC/PNEU FST GTC/PNEU FST

ISSC-Cherry Point, NC ISSC-Cherry Point, NC

R. D. ATENCIO

GTC/PNEU Fleet Support Team Leader ISSC-Cherry Point, NC

RELEASED BY:

H. L. TUCKER

By Direction Level I Site Lead AIR-4.0 ISSC Cherry Point NC

Materials Engineering Division Review: BSH 02/09/2012

To assist us in measuring our performance, please provide feedback on the quality of this product by accessing https://cpws4.navair.navy.mil/custsatsurvey/custsatsurvey.cfm

GALLOWAY.THOM

AS.M.1249710640

Digitally signed by

GALLOWAY.THOMAS.M.1249710640

DN: c=US, o=U.S. Government, ou=DoD, ou=PKI, ou=USN, cn=GALLOWAY.THOMAS.M.1249710640 Date: 2012.12.03 13:18:42 -05'00'

GALLOWAY.THOM

AS.M.1249710640

Digitally signed by

GALLOWAY.THOMAS.M.1249710640

DN: c=US, o=U.S. Government, ou=DoD, ou=PKI, ou=USN, cn=GALLOWAY.THOMAS.M.1249710640 Date: 2012.12.03 13:18:53 -05'00'

Digitally signed by

ATENCIO.ROBBIE.D.1231449155

DN: c=US, o=U.S. Government, ou=DoD, ou=PKI, ou=USN, cn=ATENCIO.ROBBIE.D.1231449155

TUCKER.HENRY.L

ANSING.III.1056713

Digitally signed by

TUCKER.HENRY.LANSING.III.1056713235

DN: c=US, o=U.S. Government, ou=DoD, ou=PKI, ou=USN, cn=TUCKER.HENRY.LANSING.III.1056713235 Date: 2012.12.03 18:53:56 -05'00'

TESTING

TASK 49-20-01-760-801

1. TESTING OF THE AUXILIARY POWER UNIT ENGINE ASSEMBLY

A. PREREQUISITES

None

B. CONSUMABLES, TOOLS, AND EQUIPMENT

(1) Consumables

NOTE: Equivalent substitutes may be used for the items listed except when noted otherwise.

Table 1301 Consumables

CONSUMABLE SOURCE (CAGE)

MIL-T-5624 Grade JP-5 Fuel or MIL-T-83133 Grade JP-8 Fuel

Commercially Available

MIL-L-23699 Lubricating Oil or MIL-PRF-7808 Lubricating Oil

Commercially Available

MIL-PRF-32033 Preservation Oil Commercially Available

(2) Tools

None

(3) Equipment

NOTE: Equivalent substitutes may be used for the items listed except when noted otherwise.

Table 1302 Equipment

EQUIPMENT SOURCE (CAGE)

4501861 Electronic Control Unit (ECU) Slave Test Equipment

Hamilton Sundstrand (55820)

4502081 Built-In-Test (BIT) Display Unit

(BDU)

Slave Test Equipment

Hamilton Sundstrand (55820)

HAMILTON SUNDSTRAND

ENGINE MANUAL

T-62T-46-2

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

49-20-01 Page 1301 Jun 15/06

EQUIPMENT SOURCE (CAGE)

4501863 Engine Interconnect Harness Slave Test Equipment

Hamilton Sundstrand (55820)

Output Shaft Slave Test Equipment

Hamilton Sundstrand (55820)

Model UTR-AS Thermocouples 6 Qty

Kaye Inc GE Infrastructure Sensing Inc.

(27970)

Viatran Model 118 Transducer Viatran Corporation (27385)

Viatran Model 123 Transducer Viatran Corporation (27385)

Robinson Halpern Model 125–K094 Transducer

Robinson Halpern Products

Lambda Model LP-521–Q Power Supply 24 to 28 Vdc

Lambda Americas (89022)

Digital PDP 1123 Computer Commercially Available

Gould Model 2800 Chart Recorder Commercially Available

Micro Motion D12 Mass Flow Meter Micro Motion Inc.

Division of Emerson Electric Co.

(1CJ06)

Rotor Mag Pickup Commercially Available

Airpax Tactrol 3D to A Converter Airpax Acquisition LLC DBA Airpax Corp. LLC (81541)

Gearbox Mag Pickup Commercially Available

Lebow Model 3169–108 Load Cell Dynamometer

Honeywell Sensotec DBA Sensotec Inc.

(51518)

Endevco Model 2221F Accelerometer Endevco Corporation (95411)

Endevco Model 6634 Charge Amplifier Endevco Corporation (95411)

TTE Model AB 135 Bandpass Filter Fc=1070 Hz

TTE Inc.

(07766)

HAMILTON SUNDSTRAND

ENGINE MANUAL

T-62T-46-2

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

49-20-01 Page 1302

SUBTASK 49-20-01-99F-001

C. GENERAL INFORMATION AND REQUIREMENTS

(1) General Information

(a) The acceptance test procedure (ATP) is done on each auxiliary power unit engine. Satisfactory results of this procedure are required to return an engine back to service.

(2) Fuel and Oil Requirements

(a) Fuel and Oil

WARNING: JET FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE

VAPORS. USE IN WELL-VENTILATED AREA FREE FROM

SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH

GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER

PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH

WITH WATER FOR 15 MINUTES AND SEEK MEDICAL

ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP

AND WATER.

1 The fuel used for these tests shall be (PN MIL-T-5624 Grade JP-5) or (PN MIL-T-83133 Grade JP-8).

WARNING: USE SYNTHETIC TURBINE OIL CORRECTLY. IT IS

FLAMMABLE AT HIGH TEMPERATURES AND IS MILDLY

POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH

OR SAFETY. BEFORE YOU USE THE OIL, GET THE MATERIAL

SAFETY DATA SHEET FROM THE MANUFACTURER OR

SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY.

READ THE DETAILED WARNING, W0126SE, IN THE WARNING

REGISTRY 341-006. BEFORE YOU USE THE OIL, PUT ON

CHEMICAL- SPLASH GOGGLES AND OIL-RESISTANT

GLOVES.

2 The lubricating oils used for these tests shall be (PN MIL-L-23699) or (PN

MIL-PRF-7808).

3 The fuel boost pressure shall be 5 to +15 psig ( 34.473 to 103.421 kPag).

(3) Dry Weight

(a) The dry weight of the engine assembly shall not be more than 151.93 lb (68.91 kg). The dry weight of each engine assembly shall be recorded. If the engine assembly dry weight is measured after the engine assembly has been serviced with fuel and oil, and after subsequent draining, the dry weight may be calculated by subtracting the weight of residual fluids from the measured engine assembly weight.

HAMILTON SUNDSTRAND

ENGINE MANUAL

T-62T-46-2

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

49-20-01 Page 1303

(4) A sample ATP raw test data point printout sheet shall be provided upon test completion (Refer to Figure 1301). Formatting of the actual data sheet used may differ from what is shown, however the recorded parameters shall be the same.

Sample ATP Raw Test Data Point Printout Figure 1301

HAMILTON SUNDSTRAND

ENGINE MANUAL

T-62T-46-2

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

49-20-01 Page 1304

SUBTASK 49-20-01-410-001

D. TEST CELL FACILITY

(1) Test Cell

(a) A test cell is necessary to test the performance and operational capabilities of the APU after repairs.

(b) The test cell should have the necessary equipment and controls to operate and monitor the performance of the APU (Refer to Figure 1302, Sheet 1 of 2).

(2) Slave Equipment

(a) Slave test equipment shall be used in the test cell facility.

(b) Slave test equipment is defined as non-deliverable test hardware that meets the same functional requirements as the deliverable components.

(c) The slave test equipment are as follows:

Electronic Control Unit (ECU) with the latest version of software.

Bit Display Unit (BDU)

Engine Interconnect Harness

Output Shaft

(3) Power Source

(a) A 24 to 28 Vdc power source shall be used to supply electrical energy to the starter motor. To simulate the V-22 aircraft regulated converter, the starter power source shall provide the starter terminal voltage within low and high limit ranges (Refer to Figure 1303).

(4) Exhaust System

(a) The APU exhaust will be ducted from the cell through the facility system (Refer to Figure 1302, Sheet 1 of 2). An instrumented exhaust duct shall be used (Refer to Figure 1302, Sheet 2 of 2).

(b) Six exhaust thermocouple rakes shall be clocked in a circumferential direction (Refer to Figure 1304).

(5) Mounting System

(a) The APU shall be mounted by the attachment points used in the aircraft.

(b) The natural frequencies of the test stand, with the APU installed, shall be less than 50 % of the APU maximum rotor speed.

HAMILTON SUNDSTRAND

ENGINE MANUAL

T-62T-46-2

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

49-20-01 Page 1305

Acceptance Test Procedure (ATP) Test Cell Facility Set Up Figure 1302 (Sheet 1 of 2)

Acceptance Test Procedure (ATP) Test Cell Facility Set Up — Exhaust Duct Configuration Figure 1302 (Sheet 2 of 2)

HAMILTON SUNDSTRAND

ENGINE MANUAL

T-62T-46-2

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

49-20-01 Page 1306

Starter Power Source Figure 1303

HAMILTON SUNDSTRAND

ENGINE MANUAL

T-62T-46-2

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

49-20-01 Page 1307

Exhaust Thermocouple Clocking Figure 1304

HAMILTON SUNDSTRAND

ENGINE MANUAL

T-62T-46-2

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

49-20-01 Page 1308

SUBTASK 49-20-01-480-001

E. TEST INSTRUMENTATION/DATA RECORDING

(1) Engine Assembly Instrumentation

(a)…